Manuel de Maintenance TEREX

TEREX Equipment Limited Maintenance Manual
TA35 - TA40 G7
MAINTENANCE MANUAL
15503431
CLICK HERE FOR TABLE OF CONTENTS
SM917/865
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TEREX Equipment Limited Maintenance Manual Re-Order
Issued by;
Customer Support Department
Terex Equipment Limited
Newhouse Industrial Estate
TA35 - 40 G7
Motherwell, ML1 5RY

Scotland
Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210
www.terex.com
MAINTENANCE MANUAL
Technical Assistance:
http://constructionsupport.terex.com
SM917/865
Re-Order Part Number

15503431
revision July 2007

TEREX Equipment Limited Maintenance Manual - Introduction
For further information on the subject matter detailed within this Maintenance Manual,
TA35 - TA40 G7
please refer to Terex Equipment Limited Operator Handbooks and Product Parts
Books.
Alternatively, please contact;
Customer Support Department

Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210
MAINTENANCE MANUAL
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.
No part of this publication may be reproduced, transmitted in any form - electronic,

mechanical, photocopying, recording, translating or by any other means without prior
permission of Customer Support Department - Terex Equipment Limited.
Please refer to TEREX Specification Sheets or consult Factory Representatives to

ensure that information is current.
IMPORTANT SAFETY NOTICE
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.
Safety Alert Symbol

The safety alert symbol is used to alert you to a potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
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.
DANGER indicates an imminently hazardous situation which, if not avoided, will

DANGER result in death or serious injury.
WARNING indicates an potentially hazardous situation which, if not avoided, could

WARNING result in death or serious injury.
CAUTION indicates an potentially hazardous situation which, if not avoided, may

CAUTION result in minor or moderate injury.
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.

000 GENERAL INFORMATION
0000 Technical Data - TA35 2498
0000 Technical Data - TA40 2436 Rev2
0010 Welding Procedure 2172
100 CHASSIS
0010 Frames 2403
0020 Articulation and Oscillation Pivot 2438
0040 Hood and Mounting 2383 Rev1
110 ENGINE
0030 Engine and Mounting 2384
0050 Air Cleaner 2404
120 TRANSMISSION
0010 Transmission and Mounting 2416 Rev1
0090 Transmission PTO 2371
125 DROPBOX
0010 Dropbox and Mounting 2367 Rev4
0020 Emergency Steering Pump 2369
130 DRIVELINES
0010 Front Drivelines 2385
0020 Rear Drivelines 2386
140 FRONT AXLE GROUP
0020 Axle Group (Hub) (Refer to Section 160-0030) -
0040 Wheel Rim and Tyre (Refer to Section 160-0050) -
0060 Differential Drive Head (Refer to Section 160-0020) -
150 CENTRE AXLE
0020 Differential Drive Head 2249
160 REAR AXLE GROUP
0020 Differential Drive Head 2248
0030 Axle Group (Hub) 2408 Rev1
0050 Wheel Rim and Tyre 2389 Rev1
165 BRAKE ASSEMBLY
0015 Oil Cooled Disc Brakes 2390
170 PARKING BRAKE
0010 Parking Brake and Mounting 2428
180 SUSPENSION SYSTEM
0020 Front Suspension 2391
0040 Rear Suspension 2392
190 ELECTRICAL SYSTEM

0000 Circuit Diagrams (DDEC V, 4000Series transmission) 2439 Rev1
0085 Hydraulic System ECU 2443 Rev1
0270 Switches and Sensors 2368 Rev2
200 FUEL SYSTEM
0040 Fuel System 2394
0051 Electronic Foot Pedal 2395
SM 2497 Rev01 07-07 1
TABLE OF CONTENTS
Section No. Description SM No.

210 COOLING SYSTEM
0000 Cooling System (Series 60 Engine) 2260
0005 Cooling System Schematic 2397
0010 Cooling Fan and Motor 2458 Rev 1
0040 Radiators and Mounting 2445 Rev1
0044 Fan Disconnect Valve 2457
0050 Disc Brake Oil Cooler 2153
0060 Transmission Oil Coolers 2433 Rev1
0065 Dropbox Oil Cooler 2432
0100 Hydraulic Oil Cooler 2459
215 MAIN HYDRAULIC VALVE
0050 Main Hydraulic Valve Assembly 2442 Rev2
220 STEERING SYSTEM

0000 Steering System Schematic 2423 Rev1
0090 Steering Valve 2364
0120 Steering Cylinder 2399
230 BODY SYSTEM

0000 Body System Schematic 2441 Rev1
0040 Hydraulic Tank (Refer to Section 250-0025) -
0050 Main Hydraulic Pump 2370 Rev 2
0081 Body Control Lever 2418
0130 Body Cylinder 2402
250 BRAKING SYSTEM

0000 Braking System Schematic 2430 Rev1
0025 Brake Coolant / Hydraulic Tank 2447 Rev2
0045 Motor/Triple Pump Assembly 2422
0050 Brake Manifold Valve 2456
0060 Accumulator 2431
0070 Treadle Valve 2427
0075 OCDB Relief Unloader Valve 2426
260 OPERATORS COMPARTMENT

0010 Cab and Mounting 2388
0090 Driver Seat and Mounting 2400
0130 Air Conditioning 2460 Rev1
270 BODY
0010 Body and Mounting 2429
300 MISCELLANEOUS
0020 Lubrication System 2435 Rev4
0070 Service Tools 2437
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239
* * * *
2 SM 2497 Rev01 07-07
General Information - Technical Data TA35
Section 000-0000
SM - 3528
3 315
(10-11)
Max 1 495
Body (4-11) 3 130
Depth (10-3)
6 930
(22-9)
66˚
3 945
(12-11)
3 740 3 140
(12-3) (10-4)
3 550 2 470
(11-8) (8-1)
905
605 (2-9)
(2-0)
1 840 3 025 1 310 2 990 1 950 1 780
(6-0) (9-11) (4-4) (9-10) (6-5) (5-10)
2 595
(8-6) 11 055
3 360 (36-3)
(11-3)
Dimensions in mm (ft-in)
Fig. 1 - Machine Dimensions
ENGINE Main ................................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

Make/Model ................................... Detroit Diesel Series 60 Temperatures:
Type 6 .... Cylinder, in line , Four cycle diesel, water cooled, Normal ................................... 60° - 135° C (140° - 275° F)
turbocharged with air to air cooling, electronic engine Maximum .................................................. 165° C (329° F)
management. Ratios:
Transmission ..................................... Refer to table below
Gross power at 2 110 rev/min ...... 298 kW (400 hp, 405 PS)
Net power at 2 110 rev/min .......... 389 kW (388 hp, 393 PS) Low Range
Note: Gross power rated to SAE J1995 Jun 90. Engine Forward
emission meets USA EPA Tier 3 /CARB MOH 40 CFR 89 Gear 1 2 3 4 5 6
Tier 3 and proposed EU NRMM (non-road mobile km/h 5.2 11.0 15.9 24.3 31.0 35.2
machinery) Tier 3 directive.
mile/h 3.2 6.8 9.9 15.1 19.3 21.9
Maximum Torque .... 2 000 Nm (1475 lbf ft) at 1 200 rev/min Reverse
Number of cylinders/configuration .......................... 6, in line Gear 1
Bore x Stroke ........................ 133 x 168 mm (5.24 x 6.61 in)
Piston Displacement ................................. 14 litres (855 in³) km/h 4.6
Air cleaner .................................... Dry type, double element mile/h 2.9
Starting ..................................................................... Electric
Maximum Speed (No load) ............................ 2 300 rev/min
Maximum Speed (Full load) ........................... 2 200 rev/min High Range
Idle Speed ........................................................ 700 rev/min Forward
Safe Operating Angle .................................. 43°/94% Grade Gear 1 2 3 4 5 6
km/h 7.9 16.8 24.3 37.1 47.7 53.9
TRANSMISSION
mile/h 4.9 10.4 15.1 23.1 29.6 33.5
Make/Model ................................... Allison 4500 ORS with
integral retarder mounted directly to the engine, fully Reverse
automatic transmission with planetary gearing, lock-up in all Gear 1
gear ranges. Electronic control with six forward and one km/h 7.0
reverse gear.
mile/h 4.3
SM 2498 03-07 1
Section 000-0000
DROPBOX HYDRAULIC SYSTEM
Remote mounted transfer gearbox taking drive from the Braking, steering and body hoist systems are controlled by
transmission and feeding it via a lockable differential to the a main hydraulic valve mounted on frame. Systems are
front and rear wheels. supplied with oil from a common tank by the main hydraulic
pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
AXLES line.
Three axles in permanent all-wheel drive (6 X 6) with Pump:
differential coupling between each axle to prevent driveline Type ......................................................................... Piston
wind-up. Heavy duty axles with fully-floating axle shafts and Capacity at 2 700 rev/min ....... 5.4 litre/s (85.6 US gal/min)
outboard planetary reduction gearing.
Brakes
Automatic limited slip differentials in each axle. Centre axle Full hydraulic braking system with enclosed, forced oil-
incorporates a through-drive differential to transmit drive to cooled multiple discs on each wheel. Independent circuits
the rear axle. This differential and the dropbox output for front and rear brake systems. Warning lights and
differential are locked simultaneously using one switch audible alarm indicate low brake system pressure. Brake
selected by the operator. system conforms to ISO 3450, SAE J1473.
Ratios: Actuating Pressure ................ 48 ± 2.4 bar (700 ± 35 lbf/in²)
Differential ............................................................... 3.70:1 Pump Type ................................................ Triple stage gear
Planetary ................................................................. 6.35:1 Capacity at 1 685 rev/min ..... 8.9 litre/s (2.35 US gal/min)
Total Reduction ..................................................... 23.50:1
SUSPENSION Braking surface (tractor) ....... 590240 mm2 (914.9 in2)/brake

Front: Four trailing links and a panhard rod locate the front Braking surface (trailer) ........ 590240 mm2 (914.9 in2)/brake
axle giving a high roll centre. The optimised front axle
position along with the wide spaced main and rebound Parking: Spring-applied, hydraulic-released disc on
mounts, mounted directly above the axle and long rear driveline.
suspension travel, combine with two heavy duty dampers
each side to give excellent handling and ride. Emergency: Automatic application of driveline brake
should pressure fall in main brake hydraulic
Rear: Each axle is coupled to the frame by three rubber- system. Service brakes may also be applied
bushed links with lateral restraint by a transverse link. using the parking-emergency brake control.
Pivoting inter-axle balance beams equalise load on each
axle. Suspension movement is cushioned by rubber/metal Retardation: Hydraulic retarder integral with transmission.
laminated compression units between each axle and
underside of balance beam ends. Pivot points on rear
suspension linkages are rubber-bushed and maintenance- Steering
free.
Hydrostatic power steering by two single-stage, double-
WHEELS AND TYRES acting, cushioned steering cylinders. Emergency steering
pressure is provided by a ground driven pump mounted on
Wheels: ............ 5-piece earthmover rims with 12 stud fixing
the rear of the transmission. An audible alarm and warning
Size:
light indicates should the emergency system activate.
Standard ....................... 25 x 22.00 in for 26.5 R25** tyres
Conforms to ISO 5010, SAE J53.
Tyres:
System Pressure ............................... 240 bar (3 500 lbf/in²)
Standard .......................................................... 26.5 R25**
Steering Angle to either side .......................................... 45°
Lock to Lock Turns, steering wheel .................................... 4
Inflation Pressures (Bridgestone):
Body Hoist
Front Centre/Rear
Two single-stage, double-acting hoist rams, cushioned at
26.5 R25** ...... 3.73 bar (54 lbf/in²) 4.97 bar (72 lbf/in²)
both ends of stroke. Electro servo assisted hoist control.
Inflation Pressures (Michelin):
System Pressure ................................. 240 bar (3 500 lbf/in²)
Front Centre/Rear
Control Valve ....................... Pilot Operated, Closed Centre
Body Raise Time (loaded) ...................................... 12.5 sec
Body Lower Time (power down) .................................. 8 sec
Inflation Pressures (GoodYear):
Front Centre/Rear
26.5 R25** ...... 4.75 bar (69 lbf/in²) 4.75 bar (69 lbf/in²) ELECTRICAL SYSTEM
Type .............................................. 24 volt, Negative Ground
Note: Tyre pressures should be regarded as nominal only. It Battery ......................................... Two, 12 Volt, 175 Ah each
is recommended that for tyres both listed and unlisted, the Accessories ............................................................... 24 Volt
user should consult the tyre manufacturer and evaluate all Alternator ................................................................ 100 Amp
job conditions in order to make the proper selection.
2 SM 2498 03-07
Section 000-0000
BODY
Of all welded construction, fabricated from high hardness
Vehicle Weights 29.5 R25 Tyres
(min. 360 BHN) 1 000 MPa (145 000 lbf/in²) yield strength Standard Vehicle kg lb
steel. 25° tail chute angle provides good load retention Net Distribution
without tailgate.
Front Axle 15 086 32 258
Centre Axle 7 125 15 707
Plate Thicknesses:
Rear Axle 7 068 15 582
Floor and Tailchute .................................. 15 mm (0.58 in)
Sides ........................................................ 12 mm (0.47 in) Vehicle, Net 29 279 64 547
Front ........................................................... 8 mm (0.39 in) Payload 34 000 74 956
Volume: Gross Distribution
Struck (SAE) .......................................... 15.5 m³ (20.3 yd³) Front Axle 17 279 38 094
Heaped 2:1 (SAE) ................................. 21.0 m³ (27.5 yd³) Centre Axle 23 000 50 705
Rear Axle 23 000 50 705
SERVICE CAPACITIES Vehicle, Gross 63 279 139 506
Fuel tank ........................................... 481 litres (127 US gal) Bare Chassis 23 669 52 177
Hydraulic System ............................. 330 litres (87.2 US gal) Body 4 950 10 915
Cooling System ................................. 80 litres (21.1 US gal) Body Hoists (Pair) 660 1 455
Engine Crankcase (with filters) ........... 37 litres (9.8 US gal)
Transmission (with filters) .................. 61 litres (14.8 US gal)
Differentials - Front & Rear .................. 33 litres (8.9 US gal)
Differentials - Centre ........................... 34 litres (8.7 US gal)
Planetaries (each) ................................. 9 litres (2.4 US gal)
Driveshaft Bearings ............................ 1.5 litres (0.4 US gal)
Air Conditioning Compressor ..... 0.125 litres (0.033 US gal)
TYPICAL NOISE LEVELS

Operator Ear (ISO 6394) ........................................... 76 dbA
*Exterior Sound Rating (ISO 6395) ......................... 109 dbA

* - The above result is for the mode giving the highest
exterior sound level when measured and operated as per
the prescribed procedures of the standard. Results shown
are for the vehicle in base configuration.
Note: Noise Level Exposure to the operator and bystander

personnel may be higher depending upon proximity to
buildings, rock piles, machinery etc.. The actual job site
Noise Level Exposure must be measured and applicable
regulations complied with in respect to Employee Hearing
Protection.
* * * *
SM 2498 03-07 3
Section 000-0000
SM - 3528
3 315
(10-11)
Max 1 495
Body (4-11) 3 130
Depth (10-3)
6 930
(22-9)
66˚
3 945
(12-11)
3 740 3 140
(12-3) (10-4)
3 550 2 470
(11-8) (8-1)
905
605 (2-9)
(2-0)
1 840 3 025 1 310 2 990 1 950 1 780
(6-0) (9-11) (4-4) (9-10) (6-5) (5-10)
2 595
(8-6) 11 055
3 360 (36-3)
(11-3)
Dimensions in mm (ft-in)
Fig. 1 - Machine Dimensions
ENGINE Main ................................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

Make/Model ................................... Detroit Diesel Series 60 Temperatures:
Type 6 .... Cylinder, in line , Four cycle diesel, water cooled, Normal ................................... 60° - 135° C (140° - 275° F)
turbocharged with air to air cooling, electronic engine Maximum .................................................. 165° C (329° F)
management. Ratios:
Transmission ..................................... Refer to table below
Gross power at 2 110 rev/min ...... 338 kW (454 hp, 460 PS)
Net power at 2 110 rev/min .......... 326 kW (437 hp, 443 PS) Low Range
Note: Gross power rated to SAE J1995 Jun 90. Engine Forward
emission meets USA EPA Tier 3 /CARB MOH 40 CFR 89 Gear 1 2 3 4 5 6
Tier 3 and proposed EU NRMM (non-road mobile km/h 5.5 11.7 16.9 25.8 33.0 37.5
machinery) Tier 3 directive.
mile/h 3.4 7.3 10.5 16.0 20.5 23.3
Maximum Torque ..... 2 100 Nm (1548 lbf ft) at 1 350 rev/min Reverse
Number of cylinders/configuration ........................... 6, in line Gear 1
Bore x Stroke ........................ 133 x 168 mm (5.24 x 6.61 in)
Piston Displacement .................................. 14 litres (855 in³) km/h 4.8
Air cleaner ..................................... Dry type, double element mile/h 3.0
Starting ....................................................................... Electric
Maximum Speed (No load) .............................. 2 300 rev/min
Maximum Speed (Full load) ........................... 2 200 rev/min High Range
Idle Speed ........................................................ 700 rev/min Forward
Safe Operating Angle .................................. 43°/94% Grade Gear 1 2 3 4 5 6
km/h 8.4 17.8 25.8 39.5 50.4 60.0
TRANSMISSION
mile/h 5.2 11.0 16.0 24.5 31.3 37.3
Make/Model ................................... Allison 4500 ORS with
integral retarder mounted directly to the engine, fully Reverse
automatic transmission with planetary gearing, lock-up in all Gear 1
gear ranges. Electronic control with six forward and one km/h 7.4
reverse gear.
mile/h 4.6
SM 2436 Rev2 03-07 1

Section 000-0000
DROPBOX HYDRAULIC SYSTEM
Remote mounted transfer gearbox taking drive from the Braking, steering and body hoist systems are controlled by
transmission and feeding it via a lockable differential to the a main hydraulic valve mounted on frame. Systems are
front and rear wheels. supplied with oil from a common tank by the main hydraulic
pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
AXLES line.
Three axles in permanent all-wheel drive (6 X 6) with Pump:
differential coupling between each axle to prevent driveline Type ......................................................................... Piston
wind-up. Heavy duty axles with fully-floating axle shafts and Capacity at 2 700 rev/min ....... 5.4 litre/s (85.6 US gal/min)
outboard planetary reduction gearing.
Brakes
Automatic limited slip differentials in each axle. Centre axle Full hydraulic braking system with enclosed, forced oil-
incorporates a through-drive differential to transmit drive to cooled multiple discs on each wheel. Independent circuits
the rear axle. This differential and the dropbox output for front and rear brake systems. Warning lights and audible
differential are locked simultaneously using one switch alarm indicate low brake system pressure. Brake system
selected by the operator. conforms to ISO 3450, SAE J1473.
Ratios: Actuating Pressure ................ 48 ± 2.4 bar (700 ± 35 lbf/in²)
Differential ............................................................... 3.70:1 Pump Type ................................................. Triple stage gear
Planetary ................................................................. 6.35:1 Capacity at 1 685 rev/min ..... 8.9 litre/s (2.35 US gal/min)
Total Reduction ..................................................... 23.50:1
SUSPENSION Braking surface (tractor) ........ 590240 mm2 (914.9 in2)/brake

Front: Four trailing links and a panhard rod locate the front Braking surface (trailer) ......... 590240 mm2 (914.9 in2)/brake
axle giving a high roll centre. The optimised front axle
position along with the wide spaced main and rebound Parking: Spring-applied, hydraulic-released disc on
mounts, mounted directly above the axle and long rear driveline.
suspension travel, combine with two heavy duty dampers
each side to give excellent handling and ride. Emergency: Automatic application of driveline brake
should pressure fall in main brake hydraulic
Rear: Each axle is coupled to the frame by three rubber- system. Service brakes may also be applied
bushed links with lateral restraint by a transverse link. using the parking-emergency brake control.
Pivoting inter-axle balance beams equalise load on each
axle. Suspension movement is cushioned by rubber/metal
laminated compression units between each axle and Steering
underside of balance beam ends. Pivot points on rear Hydrostatic power steering by two single-stage, double-
suspension linkages are rubber-bushed and maintenance- acting, cushioned steering cylinders. Emergency steering
free. pressure is provided by a ground driven pump mounted on
WHEELS AND TYRES the rear of the transmission. An audible alarm and warning
light indicates should the emergency system activate.
Wheels: ............ 5-piece earthmover rims with 12 stud fixing Conforms to ISO 5010, SAE J53.
Size:
Standard ....................... 25 x 25.00 in for 29.5 R25** tyres System Pressure ................................ 240 bar (3 500 lbf/in²)
Steering Angle to either side ............................................ 45°
Tyres: Lock to Lock Turns, steering wheel .................................... 4
Standard ........................................................... 29.5 R25**
Body Hoist
Two single-stage, double-acting hoist rams, cushioned at
Inflation Pressures (Bridgestone): both ends of stroke. Electro servo assisted hoist control.
Front Centre/Rear
29.5 R25** ........ 4.0 bar (76 lbf/in²) 5.0 bar (73 lbf/in²) System Pressure ................................. 240 bar (3 500 lbf/in²)
Control Valve ....................... Pilot Operated, Closed Centre
Inflation Pressures (Michelin): Body Raise Time (loaded) .......................................... 13 sec
Front Centre/Rear Body Lower Time (power down) ................................ 7.5 sec
Inflation Pressures (GoodYear): ELECTRICAL SYSTEM

Front Centre/Rear Type .............................................. 24 volt, Negative Ground
29.5 R25** ...... 3.24 bar (47 lbf/in²) 4.6 bar (66 lbf/in²) Battery ......................................... Two, 12 Volt, 175 Ah each
Accessories ................................................................ 24 Volt
Note: Tyre pressures should be regarded as nominal only. It Alternator ................................................................ 100 Amp
is recommended that for tyres both listed and unlisted, the
user should consult the tyre manufacturer and evaluate all
job conditions in order to make the proper selection.
2 SM 2436 Rev2 03-07

Section 000-0000
BODY
Vehicle Weights 29.5 R25 Tyres
Of all welded construction, fabricated from high hardness
(min. 360 BHN) 1 000 MPa (145 000 lbf/in²) yield strength Standard Vehicle kg lb
steel. 25° tail chute angle provides good load retention Net Distribution
without tailgate.
Front Axle 15 880 34 936
Plate Thicknesses:
Rear Axle 7 440 16 368
Floor and Tailchute ................................... 15 mm (0.58 in)
Sides ......................................................... 12 mm (0.47 in) Vehicle, Net 30820 67 804
Front ......................................................... 10 mm (0.39 in) Payload 38 000 83 775
Gross Distribution
Volume:
Front Axle 18 320 41 500
Struck (SAE) .......................................... 17.4 m³ (22.8 yd³)
Heaped 2:1 (SAE) ................................. 23.3 m³ (30.3 yd³)
Rear Axle 25 000 55 000
Vehicle, Gross 68 320 151 500
SERVICE CAPACITIES
Bare Chassis 24 760 54 444
Fuel tank ........................................... 481 litres (127 US gal)
Hydraulic System ............................. 330 litres (87.2 US gal) Body 5 400 11 905
Engine Crankcase and filters .............. 32 litres (8.4 US gal) Body Hoists (Pair) 660 1 455
Cooling System ................................. 67 litres (17.7 US gal)
Transmission (including cooler) .......... 61 litres (2.6 US gal)
Dropbox .................................................. 13 litres (8.7 US g
Differentials - Front & Rear (each) ...... 33 litres (8.7 US gal)
Differential - Centre ............................. 34 litres (8.9 US gal)
Planetaries (each) ............................... 9 litres (2.37 US gal)
Hand Pump Tank ................................. 1 litres (0.26 US gal)
Air Conditioning Compressor ..... 0.125 litres (0.033 US gal)
TYPICAL NOISE LEVELS

Operator Ear (ISO 6394) ........................................... 76 dbA
*Exterior Sound Rating (ISO 6395) ......................... 109 dbA

* - The above result is for the mode giving the highest
exterior sound level when measured and operated as per
the prescribed procedures of the standard. Results shown
are for the vehicle in base configuration.
Note: Noise Level Exposure to the operator and bystander

personnel may be higher depending upon proximity to
buildings, rock piles, machinery etc.. The actual job site
Noise Level Exposure must be measured and applicable
regulations complied with in respect to Employee Hearing
Protection.
* * * *
SM 2436 Rev2 03-07 3

GENERAL INFORMATION - Welding Procedure
Section 000-0010
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.
Note: The current from the welding rod always follows

the path of least resistance. If, for example, the ground
Before any welding is done ensure all paint has clamp is attached to the rear frame when welding is
been removed from the area to be welded. performed on the front frame, the current must pass a
Failure to do so may result in hazardous fumes frame connection to return to the welding machine.
being given off from the paint. Since the pivot coupling offers the least resistance but
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
Note: Always fasten the welding machines ground cause welding blotches on their wearing surfaces and
cable to the piece/frame being welded if possible. increase the wear rate of these components.
Electric arc welding is recommended for all welded

frame repairs. Since the nature and extent of damage General Welding Procedure
to the frame cannot be predetermined, no definite The following general procedure should be used for
repair procedure can be established. As a general rule the repair of defects outwith the vicinity of alloy steel
however, if parts are twisted, bent or pulled apart, or a castings.
frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned. 1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
Successfully welded repairs will depend to a great employed, pre-heat area to 100° C (212° F), measure
extent upon the use of the proper equipment, materials 3 - 4" either side of repair prior to gouging. On
and the ability of the welder. The Customer Support completion of gouging grind to remove thin carbon
Department can be consulted regarding the feasibility layer.
of welding repairs.
2. Apply dye-penetrant check to ensure crack has
been completely removed.
SM 2172 11-05 1
General Information - Welding Procedure
Section 000-0010
3. Pre-heat area to 100° C (212° F), measured 3 - 4" 3 - 4" either side of repair prior to gouging. On
either side of repair. Avoid local overheating. completion of gouging grind to remove thin carbon
layer.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from 2. Apply dye-penetrant check to ensure crack has
moisture pick-ups at all times. been completely removed.
5. Allow repair weld to cool slowly. 3. Pre-heat area to 200° C (392° F), measured 3 - 4"
either side of repair. Avoid local overheating.
6. Grind and blend repair to original contour. Paint
heat damaged areas. 4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the 5. On completion of welding, post-heat repair area to
welds joining steel castings. 400° C (752° F), measure 3 - 4" either side of repair.
1. Completely ARC-AIR gouge or grind out the crack 6. If welding has to be interrupted for any reason, e.g.
until sound metal is reached. If ARC-AIR method is overnight, post-heat immediately as in Step 5.
employed, pre-heat area to 200° C (392° F), measure
* * * *
2 SM 2172 11-05
CHASSIS - Frames
Section 100-0010
SM - 3413
Fig. 1 - General Arrangement of Frame Assemblies
DESCRIPTION
The front and rear frames are all-welded high grade Note: For details on the articulation and oscillation
steel fabrications, with rectangular box section beams pivot and procedures for separating the front and rear
forming the main side and cross-members. These frames, refer to Section 100-0020, ARTICULATION
heavy duty structures are designed to withstand the AND OSCILLATION PIVOT.
severe loadings incurred when operating over rough
terrain.
MAINTENANCE
The front frame houses engine, transmission, Note: This section covers maintenance of the front
hydraulic and fuel tanks and carries the cab, front and rear frames only.
suspension and front drive axle. The rear frame
carries the body, body cylinders, rear suspension
system and the rear drive axles. Inspection
Inspect the frames and attached parts at intervals not
Inter-frame oscillation is provided by a robust exceeding 250 hours for cracked or broken welds and
cylindrical coupling, carried on large nylon bushes. bending of the frame. Any defects found should be
Steering is by frame articulation to 45 degrees either repaired before they progress into major failures.
side by two widely spaced vertical pivot pins in taper
roller bearings.
SM 2403 01-06 1
Chassis - Frames
Section 100-0010
Straightening d- Battery supply cables

If the frame is not too badly sprung or twisted, e- Alternator earth cables
hydraulic straightening and aligning equipment can be f- Alternator supply cables
used to straighten the frame without dismantling the g- ECM Vehicle (both 68 pin connectors)
machine. However, if the frame is severely damaged, h- Transmission TCM (80 pin connector)
it will be necessary to disassemble the machine in i- Transmission (4th Gen) connector
order to repair or replace the frame assembly. j- Hydraulic ECU Electronic Controller
k- Body hydraulics joystick
All straightening operations should be performed l- VDU panel CPU (all connectors)
without application of heat if possible. If heat must be
applied, do not heat the metal beyond a dull cherry red After welding, connect all of the above in the reverse
colour, as it will result in serious weakening of the order.
frame by decreasing the tensile strength of the steel.
When it is necessary to apply heat, apply it uniformly Note: Always fasten the welding machines ground
over the area to be straightened until the metal cable to the piece/frame being welded if possible.
reaches a uniform colour. Protect the heated surface
from drafts to prevent sudden cooling of the metal. If Electric arc welding is recommended for all welded
the frame or frame parts cannot be straightened they frame repairs. Since the nature and extent of damage
must be replaced. to the frame cannot be predetermined, no definite
repair procedure can be established. As a general rule
however, if parts are twisted, bent or pulled apart, or a
Welding frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned.
WARNINGS Successfully welded repairs will depend to a great

Before any welding is done on a machine extent upon the use of the proper equipment, materials
equipped with the DDEC system, disconnect and the ability of the welder. The Service Department
wiring harnesses at the ECM, connections at can be consulted regarding the feasibility of welding
body hydraulics joystick, all battery repairs.
connections at both positive and negative
terminals and ground cable to alternator to
avoid damage to electrical components. Turn Reinforcement
battery master switch to the 'Off' position Frame reinforcement can be made with channel, angle
before disconnecting any components. or flat structural stock. Whenever possible, the
Remove battery ground cable first, and reinforcement should extend well beyond the bent,
reconnect last, to avoid damaging electrical broken or cracked area. The reinforcement stock
components. thickness should not exceed that of the frame stock
and the material should be of the same tensile
strength.
Before any welding is done ensure all paint
has been removed from the area to be welded.
Failure to do so may result in hazardous fumes Painting
being given off from the paint. To keep rust and corrosion to a minimum, periodic
painting of abrasions and other exposed metal areas
Note: Prior to welding, switch off/disconnect the on the frames is highly recommended.
following in the order given. Failure to do so may
seriously damage the machines electrical If painting of a frame is required, thoroughly clean the
components. areas to be painted. Apply a primer coat of synthetic
red oxide and then a finish coat of synthetic enamel.
a - Turn keyswitch off
b - Turn battery master switch off
c - Battery earth cables
* * * *
2 SM 2403 01-06
CHASSIS - Articulation and Oscillation Pivot
Section 100-0020
SM - 3533
25 52 56
50 51 29 56
16 5,6 55
19 7
20
14 27 53 54
8,9
56
17 DETAIL A
42 25
41
45,46,49 39
36,49
45,47,49
1
32
26,56 26,53
30
52,55 54,55 10,26
23
56
38 11
2,3,4 2,3,4
33 60
57,58,59
49,61,62 36,49 40 28 51 18
13
15 8,9
51
31 63
17
50 16
19
19 64-68
44,48,49 43 37,49 16
29
31
35 14 24 8,9
29 15
38
30,23 21,22
34 12
25
10,26
45,46,49 37,49 45,47,49
1 - Pivot Assembly 16 - Lockplate 27 - Lube Fitting 41 - Washer 55 - Lube Fitting

2 - Nylon Bush 17 - Front Yoke 28 - Plug 42 - Nut 56 - Elbow
3 - Loctite 648 18 - Brake Yoke 29 - 'O' Ring 43 - Lower Pin 57 - Adaptor
4 - Loc Quick Primer 19 - Bolt 30 - Bearing Assembly 44 - Hardened Washer 58 - Connector
5 - Gasket 20 - Washer 31 - Retaining Ring 45 - Washer 59 - Elbow
6 - Cover Plate 21 - Lockwasher 32 - Seal Housing 46 - Bolt 60 - Pipe Assembly
7 - Bolt 22 - Bolt 33 - Seal Housing 47 - Bolt 61 - Washer
8 - Bearing Assy - Cup 23 - Extreme Pressure 34 - Seal Housing 48 - Bolt 62 - Bolt
9 - Bearing Assy - Cone Lithium No.2 Grease 35 - Seal Housing 49 - Loctite 243 63 - Thrust collar-Rear
10 - 'V' Ring Seal 24 - SAE 80W-90 EP 36 - Seal 50 - Thrustcollar-Front 64 - Shim
11 - Thrust Nut Gear Oil 37 - Seal 51 - 'O' Ring 65 - Shim
12 - Locking Plate 25 - Plug 38 - Shim 52 - Hose Assembly 66 - Shim
13 - Antiseize Comp 26 - Extreme Pressure 39 - Spacer 53 - Hose Assembly 67 - Shim
14 - Driveshaft Multipurpose Grease 40 - Upper Pin 54 - Connector 68 - Shim
15 - Seal
Fig. 1 - Articulation and Oscillation Pivot
DESCRIPTION AND OPERATION connecting the drive between the front and rear frames.
The articulation and oscillation pivot allows the front
and rear frames to rotate horizontally (articulation) and Articulation bearings, oscillation bushes, pivot
tilt laterally (oscillation) with respect to each other. It is driveshaft bearing and associated parts can be
also the main load bearing coupling between the two removed, inspected and replaced or renewed by
frames. The pivot assembly houses the driveshaft following the procedures outlined in this section.
SM 2438 01-06 1
Chassis - Articulation and Oscillation Pivot
Section 100-0020
9. Disconnect mounting hardware securing protective

guard (if fitted), from beneath the parking brake disc, to
THRU-DRIVE DRIVESHAFT
the rear frame.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified. 10. Release the parking brake by turning the hex-head
on the parking brake actuator fully anticlockwise.
Note: The following procedures assume that only
thru-drive components require repair.
WARNING
Note: Tighten all fasteners without special torques Tensioned spring on adjuster.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE 11. Remove mounting hardware securing parking
SPECIFICATIONS. brake assembly to mounting bracket on frame, then
secure parking brake assembly clear of brake disc.
WARNINGS 12. Identify the relationship of the driveline caps to

To prevent personal injury and property brake yoke (18). Remove capscrews, disconnect
damage, be sure wheel blocks are properly driveline and secure clear of brake yoke.
secured and of adequate capacity to do the job
safely. 13. Withdraw driveshaft assembly (14) from housing
by pulling rearwards on parking brake disc/brake
When necessary to drive out or drive on yoke assembly (18). If necessary, tap front end of
components during disassembly/assembly, be driveshaft (14) to ease removal, take care to avoid
sure to use a soft drift to prevent property damaging threads. Place driveshaft (14) assembly on
damage and personal injury. work bench for further disassembly.
14. Prise out and discard seal (15) from front of the
Removal and Disassembly
housing.
1. Position the vehicle on a level work area and apply
parking brake. 15. Lift out front bearing assembly cup (8) from front
of the housing.
2. Raise body and install body safety prop to secure
body in partially raised position. 16. If bearing replacement is required, use a suitable
puller to remove front and rear bearing assembly
3. Shut down engine and block all wheels securely. cups (8) from the housing.
4. Identify the relationship of the driveline caps to the Note: If either bearing assembly cup or cone (8 or 9)
transmission yoke and front yoke (17). Remove need replacing, they must be replaced as a set.
capscrews and remove driveline from vehicle.
17. If retaining rings (31) need replacing, use a
Note: Take extra care when handling drivelines as suitable drift or puller to remove them from the housing.
any deformity on a rotating mass creates vibration
and excessive wear during any operation. 18.Temporarily install front yoke (17) fully onto front of
driveshaft (14) and suitably restrain to resist rotation.
5. Remove wheel blocks, start engine and steer
vehicle into a full left-hand lock. Shut down engine 19. Remove mounting hardware securing parking
and block all wheels securely. brake disc to brake yoke (18) and remove brake disc.
6. Remove Lockplate (16) , 2 0ff Front bolts (19) & 20. Remove Lockplate (16) , 2 off Rear bolts (19) ,
Front thrust collar (50). Rear Thrust collar (63) & Brake yoke (18) from
driveshaft (14). Identify front and rear ends of
7. Remove and discard 'O' rings (29 & 51) from Thrust driveshaft (14).
collar (50).
21. Remove and discard 'O' rings (29 & 51) from Rear
8. Place a suitable container under the front of the Thrust collar (63).
pivot and pull front yoke (17) from driveshaft (14).
2 SM 2438 01-06
Section 100-0020
9 SM - 3143
14
22. Remove and discard seal (15) from driveshaft (14).
23. If bearing replacement is required, use a suitable

puller or drift to remove rear bearing assembly cone (9)
from driveshaft (14).
Inspection
1. Clean all parts with a suitable solvent and let dry.

DO NOT spin bearings with compressed air. Place 55mm
bearings on a clean surface, cover with a lint free
cloth and allow to dry.
Fig. 2 - Pre assembly of bearing
2. Check bearing assemblies cups and cones (8 & 9) 6. Refer to Fig. 2, Maintain end face of cone approximately
for wear or damage. Renew as necessary. 55mm from end of spline face.
Note: If either bearing assembly cup or cone (8 or 9) 7. Insert driveshaft (14) into truck end of pivot casing
need replacing, they must be replaced as a set. until bearing assembly cone (9) seats firmly in the
bearing asembly cup (8).
3. Inspect splines of driveshaft (14) and yokes
(17 & 18) for nicks, burrs or excessive wear. Replace 8. Apply loctite (3) to new seal (15) and fit over the
if wear is excessive or splines are nicked. Burrs may driveshaft (14) with seal 'Lip' to bearing side.Press seal
be removed with a fine file or medium India stone. home using a mandrel.
4. Check yokes (17 & 18) for damage in region 9. Apply grease to splines of Front yoke (17) and slide
polished by oil seal lip; even slight damage in this onto the drive shaft (14).
area can cause leakage. Very slight marks may be
polished out with fine emery cloth but it is essential 10. Fit new 'O'-rings ( 29 & 51) to Front thrust collar
that polishing marks are parallel to the seal lip. (50) and fit collar over stub end of driveshaft (14) (align
mating holes). Fit 2 off front bolts (19).
5. Replace all seals and 'O' rings with new parts.
11. Tighten Front bolts (19) ; alternately 1/4 - 1/2 turns,
drawing driveshaft (14) hard against the inner face of
Assembly and Installation Front thrust collar (50). Shaft will be visible through
1. If removed, use a suitable driver and install retaining inspection hole on the collar.
rings (31) into housing, ensuring that they butt hard
against abutment shoulders. 12. Lock Front yoke (17) from rotation by a suitable
method / bar acting on the ground. Torque front bolts
2. Using a suitable driver, install front bearing cup (8) (19) to 54Nm/39 Ibf ft.
into tractor end of pivot casing. Ensure it is firmly
seated & that a 0.05mm (0.002") feeler gauge cannot 13. Using special mandrel (15270104) home locking
be inserted between cup and mating face. plate (16) onto Bolts (19). Remove the clamping bar.
3. Check rear bearing cup (8) is firmly seated in the 14. Slide Rear bearing asembly cone (9) onto rear end
body end of the pivot casing, again ensuring 0.05mm of drive shaft (14) until it seats in bearing assembly
(0.002") feeler gauge cannot be inserted between cup cup (8).
and mating face.
15. Position clamping bar assembly and screw central
4. Lightly oil both bearing assembly cones (9) with SAE bolt hard against bolts (19) of front thrust collar (50),
80W - 90 E. P. gear oil (24). enabling body end bearing to be fully seated home.
5. Support driveshaft (14) in a suitable fixture & tap one 16. Using mandrel and heavy hammer, drive Rear
Bearing assembly cone (9) onto driveshaft (14) using a bearing assembly cone, fully into cup. Now remove
tubular mandrel. clamp bar assembly from front end.
SM 2438 01-06 3
Section 100-0020
Sm 3144
'A'
'B' 'D' DEPTH
SHAFT MICROMETER
SHIM AREA 'E' ('D' - 'C')

'C'
Fig. 3 - Measurements / various
17. Take remaining seal (15), apply loctite (3) and fit
over drive shaft with seal 'Lip' to bearing side. Press 22. The actual free air space 'E' to be shimmed
seal home using a mandrel. between end of drive shaft (14) and compression face
of Thrust collar (63) equals:
18. Apply grease to splines of brake yoke (18) and
slide onto drive shaft (14). Ensure milled slots of E='D' - 'C'.
driving flanges are aligned with those of brake yoke.
23. Now add 0.6mm (0.024") to dimension 'E' to allow
Note : For Measurment letters- refer to fig. 3, unless for oversize shims. This value is dimension 'F'
otherwise stated. (End float will be determined by subtraction).
19. Before fitting of Rear Thrust collar (63) record 24. Remove Rear bolts (19) and Rear thrust collar (63)
Measurements as stated: from pivot body end and chap drive shaft (14) to free
bearing.
i) Measure total width 'A' of Rear thrust collar (63)
25. Calculate the nominal combination of minimum
ii) Using Depth micrometer, measure inner bore depth number if shims (64) to achieve the size nearest to
'B' of collar (63) and record value. dimension 'F'. Record the appropriate part numbers and
total nominal thickness value.
iii) Subtract 'B' from 'A' to determine recess dimension
'C'. 26. Select the shims (64) and measure the total actual
thickness of the combination. Record this value.
20. Fit Rear thrust collar (63) without 'O'-rings onto
Drive shaft (14) and tighten Rear bolts (19) to a nominal 27. Place the shim pack (64) in the rear thrust collar
torque of 15Nm/11Ibf ft. (63) , lock off the Brake yoke (18) from rotation by
suitable method / bar on ground. Torque bolts (19) to
Note : a gap should be visible between end of shaft full torque.
and inner face of collar.
28. Remove the clamp and spin the yoke (18) to
21. Using a Depth micrometer, measure distance 'D' ensure driveshaft (14) free rotation.
from collar (63) outer face to end face of drive shaft
(14) via the hole in the collar and record the value. 29. Take a magnetic clock gauge located on the flange
of pivot casing, needle acting on rear thrust collar (63)
4 SM 2438 01-06
Section 100-0020
end face. Check Brake yoke (18) float movement.
43. Remove plug (25) from underside of oscillation hub
30. Take reading obtained and subtract a figure to drain the cavity between the oscillation hub and
sufficient to give an end float in the range 0.05mm - pivot assembly (1) of any oil that entered while filling
0.15mm (0.002" - 0.006"), reduce shim pack (64) the driveshaft bearing housing.
accordingly.
44. Install plug (25) into filler/level hole on pivot
31. Remove Rear thrust collar (63) and shims (64) and assembly (1). Install gasket (5) and cover plate (6) on
re-assemble with the apporpriate shims. Ensure 'O'- side of oscillation hub, secure with bolts (7) and
rings (29 & 51) are now fitted. washers (20).
32. Lock Brake yoke (18) flange as before ,applying 45. Install plug (25) into cavity drain port on underside
alternate 1/4 -1/2 turns on bolts (19). Torque to 54 Nm of oscillation hub.
(39 Ibf ft).
46. Install parking brake disc protective guard (if fitted)
33. Remove the locking bar and confirm that the and secure with bolts, washers and nuts. Tighten nuts
driveshaft (14) end float is in the range 0.05mm - to a torque of 73 Nm (54 lbf ft).
0.15mm (0.002" - 0.006") by moving the brake yoke
(18) for and aft against the clock gauge. 47. Start engine, raise body, lower body safety prop
and lower body.
34. Adjust and refit the shim pack (63) as necessary.
48. Remove wheel blocks.
35. Float set correctly; Drive home locking plate (16)
using a mandrel (15270104) . Re-check the end float.
ARTICULATION COMPONENTS
36. Install parking brake disc on brake yoke (18) and Numbers in parentheses refer to Fig. 1, unless
secure with bolts and washers. Tighten bolts to a otherwise specified.
torque of 73 Nm (54 lbf ft).
Note: The following procedures assume that only
37. Install parking brake assembly to mounting components associated with articulation require repair.
brackets and secure with bolts, washers and nuts.
Refer to Section 170-0010, PARKING BRAKE AND Note: It is essential that the grease used for articulation
MOUNTING. components is Extreme Pressure Lithium Complex No. 2
(23), as specified in Section 300-0020, LUBRICATION
38. Apply parking brake by turning the hex-head on the SYSTEM.
parking brake actuator fully clockwise.
Note: Tighten all fasteners without special torques
39. Apply Loctite 638 to the threads of capscrews used specified to torques listed in Section 300-0080,
to mount driveline to brake yoke (18). Align match STANDARD BOLT AND NUT TORQUE
marks and install driveline. Tighten capscrews to a SPECIFICATIONS.
40. Apply Loctite 638 to the threads of capscrews used WARNINGS

to mount driveline between transmission yoke and front To prevent personal injury and property
yoke (17). Align match marks and install driveline. damage, be sure wheel blocks, blocking
Tighten capscrews to a torque of 153 Nm (113 lbf ft). materials and lifting equipment are properly
41. Remove bolts (7), washers (20), gasket (5) and safely.
cover plate (6) from side of oscillation hub to gain
access to filler/level hole plug (25) on pivot assembly When necessary to drive out or drive on
(1). Remove filler/level plug (25). components during disassembly/assembly, be
sure to use a soft drift to prevent property
42. Add SAE 80W - 90 E. P. gear oil (24) through filler/ damage and personal injury.
level hole in pivot assembly (1) until the oil is level with
the bottom of filler/level hole.
SM 2438 01-06 5
Section 100-0020
SM - 008
9. Remove bolt (62), washer (61), large nut (42) and
washer (41) securing upper pin (40).
10. Remove upper pin (40). If necessary tap upper pin

(40) to ease removal taking care to avoid damaging the
threads.
Note: It may be necessary to relieve binding between

the pin and pin bores by raising or lowering the pivot/
rear frame assembly.
11. Remove bolt (48) and hardened washer (44)

securing lower pin (43).
Fig. 4 - Determining Shim Thickness
12. Remove lower pin (43). If necessary tap lower pin
Disconnecting Front and Rear Frames (43) to ease removal taking care to avoid damaging the
Note: The front and rear frames can be separated pin.
sufficiently to permit disassembly/assembly of the
articulation components without disconnecting Note: Only separate the frames sufficiently to permit
hydraulic lines or electrical wiring. removal of the articulation bearings or damage to
hydraulic and electrical connections could result.
parking brake. 13. Remove blocks from rear wheels and use lifting
equipment to pull pivot/rear frame assembly clear of
2. Raise body and install body safety prop to secure the front frame. After moving, block pivot/rear frame
body in partially raised position. assembly and block the wheels.
3. Shut down engine and block all wheels securely. 14. Remove spacer (39) noting orientation to ensure
correct installation.
4. Identify the relationship of the driveline caps to the
transmission yoke and front yoke (17). Remove
capscrews and remove driveline from vehicle. Disassembly
1. Identify seal housings (32, 33, 34 & 35) to ensure
5. Support tractor frame at front and rear with suitably correct location on assembly/installation.
placed stands or timbers so the frame will remain level
during and after pin removal. Note: Seal housings (32, 33, 34 & 35) are not
interchangeable.
6. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of 2. Remove bolts (46 & 47), washers (45), seal housings
pivot. (32, 33, 34 & 35) and upper and lower shims (38).
7. Release the parking brake by turning the hex-head 3. Prise out and discard seals (36 & 37) from the
on the parking brake actuator fully anticlockwise. housings.
4. Remove and tag all bearing assemblies (30) with

WARNING spacers to ensure correct assembly/installation.
Tensioned spring on adjuster.
Note: Bearing assemblies (30) and spacers are a
8. Attach suitable lifting equipment to pivot/rear frame matched set, never interchange cups, cones or
assembly. Lifting equipment must prevent pivot from spacers between sets.
oscillating after separation, and, be capable of pulling
pivot/rear frame assembly clear of front frame. Raise
Inspection
lifting equipment to support pivot/rear frame assembly. 1. Clean all parts with a suitable solvent and let dry.
DO NOT spin bearings with compressed air. Place
bearings on a clean surface, cover with a lint free cloth
6 SM 2438 01-06
Section 100-0020
and allow to dry. Connecting Front and Rear Frames
1. Install spacer (39) in upper outer seal housing (32),
2. Check bearing assemblies (30) and spacers, and as noted on removal.
pins (40 & 43) for wear or damage. Renew as
necessary. 2. Smear bearing and pin bores with Extreme Pressure
Lithium Complex No. 2 grease (23).
Note: Bearing assemblies (30) and spacers must be
renewed as a matched set. 3. Attach suitable lifting equipment to pivot/rear frame
assembly. Lifting equipment must prevent pivot from
3. Replace all seals with new parts. oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame
Assembly pin bores. Raise lifting equipment to support pivot/rear
frame assembly.
1. Apply Loctite 243 (49) sparingly to bore of seal
housings (32, 33, 34 & 35). 4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull
2. Using a suitable driver, install seals (36 & 37) into pivot/rear frame assembly to align pivot bearing bores
seal housings (32, 33, 34 & 35) ensuring that the metal and front frame pin bores. Block wheels and block
ring on inside of the seals are not disturbed, and, that pivot/rear frame assembly to remain level and
they are located towards the inside of seal housing. stationary.
3. Apply Loctite 243 (49) to threads of outer seal 5. Freeze upper and lower pins (40 & 43) to ease
housing bolts (46). installation.
4. Place outer seal housings (32 & 34) in position 6. Smear lower pin (43) with Extreme Pressure Lithium
ensuring that grease relief hole in seal housings are Complex No. 2 grease (23) and install through front
directly opposite bearing grease port on pivot. Secure frame and bearing bores.
with bolts (46) and washers (45). Tighten bolts (46) to a
torque of 94 Nm (68 lbf ft). Note: It may be necessary to relieve binding between
the pin and pin bores by raising or lowering pivot/rear
Note: Bearing assemblies (30) and spacers are a frame assembly.
matched set, never interchange cups, cones or
spacers between sets. 7. Apply Loctite 243 (49) to threads of bolt (48) and
secure lower pin (43) with bolt (48) and hardened
5. Using Extreme Pressure Lithium Complex No. 2 washer (44). Tighten bolt (48) to a torque of 73 Nm
grease (23), pack bearing assemblies (30), including (54 lbf ft).
end faces, and install bearings.
8. Smear upper pin (40) with Extreme Pressure Lithium
6. Place inner seal housings (33 & 35) temporarily in Complex No. 2 grease (23) and install through front
position and secure with bolts (47) and washers (45). frame and bearing bores.
Tighten bolts (47) to a torque of 16 Nm (12 lbf ft).
9. Apply Loctite 243 (49) to threads of bolt (62). Secure
7. Using feeler gauges, as shown in Fig. 4, measure upper pin (40) with bolt (62), washer (61), large nut (42)
the dimension between the inner pivot faces and seal and washer (41). Tighten nut (42) to a torque of 1 425
housings (33 & 35). Measure at 3 positions equally Nm (1 050 lbf ft).
spaced around seal housings and determine average
dimension, this is the size of shims (38) required.
Final Assembly
8. Remove bolts (47), washers (45) and inner seal 1. Apply parking brake by turning the hex-head on the
housings (33 & 35). parking brake actuator fully clockwise.
9. Install shims (38) as calculated at Step 7, reinstall 2. Remove lifting equipment from pivot/rear frame
inner seal housings (33 & 35) and secure with bolts assembly.
(47) and washers (45). Tighten bolts (47) to a torque of
94 Nm (68 lbf ft). 3. Remove stands or timbers from front frame.
SM 2438 01-06 7
Section 100-0020
SM - 038
4. Apply Loctite 270 to the threads of capscrews used
to mount driveline between transmission yoke and front
yoke (17). Align match marks and install driveline.
Tighten capscrews to a torque of 153 Nm (113 lbf ft).
5. Align steering cylinder bores and mounting pin bores

on pivot, install pins and secure with bolts and
washers. Tighten bolts to a torque of 73 Nm (54 lbf ft).
6. Remove plugs (28) from articulation bearing, grease

ports and replace with lube fittings (27).
Note: Lube fittings (27) are stored on pad on side of

pivot assembly (1). Fig. 5 - Preventing Pivot Assembly From Oscillating
7. Fill bearing housings with Extreme Pressure Lithium

lifting equipment are properly secured and of
Complex No. 2 grease (23), through lube fittings (27),
adequate capacity to do the job safely.
until excess grease starts to escape from seal
housings (32 & 34).
When necessary to drive out or drive on
components during disassembly/assembly, be
8. Remove lube fittings (27) and reinstall plugs (28).
sure to use a soft drift to prevent property
Store lube fittings (27) on pad on side of pivot
damage and personal injury.
assembly (1).
Hydraulic fluid pressure will remain
9. Start engine, raise body, lower body safety prop and
within the braking system after engine shut
lower body.
down. Operate the treadle pedal continuously
until the pressure has dissipated before
carrying out any work on the braking system
or serious injury could result.
OSCILLATION COMPONENTS
Disconnecting Front and Rear Frames
Numbers in parentheses refer to Fig. 1.
Note: The following procedure assumes that only parking brake.
components associated with oscillation require repair.
2. Raise body and install body safety prop to secure
Note: It is necessary to disconnect the front and rear body in partially raised position.
frames at the articulation point to service the
oscillation components. 3. Shut down engine and block all wheels securely.
Note: It is essential that the grease used for 4. Depress and release brake pedal continuously to
oscillation components is Extreme Pressure relieve the pressure in the braking system.
Multipurpose Grease (26), as specified in Section 300-
0020, LUBRICATION SYSTEM. 5. Carefully loosen brake lines at base of both
accumulators to check that the pressure has
Note: Tighten all fasteners without special torques released. Re-tighten brake lines.
STANDARD BOLT AND NUT TORQUE 6. Tag all hydraulic lines and electrical wiring between
SPECIFICATIONS. front and rear frames to ensure correct assembly/
installation. Disconnect all hydraulic lines and plug
openings to prevent ingress of dirt. Disconnect
WARNINGS electrical wiring and any other attachments which could
To prevent personal injury and property damage, be damaged on separation of front and rear frames.
be sure wheel blocks, blocking materials and
8 SM 2438 01-06
Section 100-0020
7. Identify the relationship of the driveline caps to the securing guard to the rear frame. Refer to
transmission yoke and front yoke (17). Remove Section 170-0010, PARKING BRAKE AND
capscrews and remove driveline from the vehicle. MOUNTING.
8. Support tractor frame at front and rear with suitably 2. Remove mounting hardware securing parking brake
placed stands or timbers to keep the frame level during assembly to mounting bracket on frame. Remove and
and after pin removal. secure parking brake assembly clear of brake disc.
9. Remove bolts, washers and pins securing steering 3. Identify the relationship of the driveline caps to
cylinders to pivot. Secure steering cylinders clear of brake yoke (18). Remove capscrews, disconnect
pivot. driveline and secure clear of brake yoke (18).
10. Release the parking brake by turning the hex- 4. Remove mounting hardware securing parking brake
head on the parking brake actuator fully anticlockwise. disc to brake yoke (18) and remove brake disc.
5. Place a suitable container under rear brake yoke (18)

WARNING to catch oil released when pulling brake yoke (18) from
Tensioned spring on adjuster. driveshaft (14).
11. Attach suitable lifting equipment to pivot/rear frame 6. Remove Rear bolts (19), Lockplate (16) & Rear
assembly. Lifting equipment must prevent pivot from thrust collar (63). Pull brake yoke (18) from driveshaft
oscillating after separation, and, be capable of pulling (14) .
pivot/rear assembly clear of front frame. Raise lifting
equipment to support pivot/rear frame assembly. 7. Remove adaptor (57), connector (58), elbow (59)
and pipe assembly (60) from oscillation hub.
12. Remove bolt, washer, large nut (42) and washer
(41) securing upper pin (40). 8. Remove bolts (22) and washers (21) securing
locking plate (12). Remove locking plate (12).
13. Remove upper pin (40). If necessary tap upper pin
(40) to ease removal taking care to avoid damaging 9. Restrain pivot assembly (1) to prevent it oscillating,
the threads. by placing a heavy bar between the steering cylinder
mountings. Lock the bar in position using suitable
Note: It may be necessary to relieve binding between trestles or stands. See Fig. 5.
the pin and pin bores by raising or lowering the pivot/
rear frame assembly. 10. Using a suitable tool, remove thrust nut (11). If
wear area of thrust nut (11) is damaged, replace thrust
14. Remove bolt (48) and hardened washer (44) nut (11).
securing lower pin (43). 11. Insert an M20 eyebolt into tapped pad provided on
top of pivot assembly (1) and attach suitable lifting
15. Remove lower pin (43). If necessary tap lower pin equipment.
(43) to ease removal taking care to avoid damaging the 12. Remove pivot restraining bar.
pin.
13. Using lifting equipment, carefully pull pivot
16. Remove blocks from rear wheels and use lifting assembly (1) clear of oscillation hub. Place pivot
equipment to pull pivot/rear frame assembly clear of assembly (1) in a suitable work area for further
the front frame. After moving, block pivot/rear frame disassembly.
assembly and block the wheels.
14. Note position of front 'V' ring (10) to aid in
17. Remove spacer (39) noting orientation to ensure 'Installation'. Remove and discard 'V' ring (10).
correct installation. Cover articulation bearings to
prevent ingress of dirt. 15. Inspect nylon oscillation bushes (2) as described in
'Inspection'. If bushes are to be renewed, proceed with
step 16.
Disassembly
1. Remove protective guard (if fitted) from beneath 16. Remove nylon oscillation bushes (2) with hammer
parking brake disc by removing mounting hardware and chisel.
SM 2438 01-06 9
Section 100-0020
SM - 011 3. Install plug (25) in filler/level hole on pivot assembly

(1). Install gasket (5) and cover plate (6) on side of
PAINT DOT oscillation hub and secure with bolts (7) and washers
(20).
4. Install plug (25) in cavity drain port on underside of

oscillation hub.
5. Install plugs (28) into oscillation bearing grease

ports.
6. Lightly coat 'V' ring (10) and machined surfaces of

pivot with Extreme Pressure Multipurpose Grease (26)
and, install 'V' ring (10), with lip towards rear, on front of
Fig. 6 - Installing Oscillation Bushes
oscillation hub.
Note: The suggested method is to make an axial cut 7. Using suitable lifting equipment, and taking care to
along the bush then to lever the bush in order to prevent damaging bushes (2) or pivot threads, install
collapse it upon itself. pivot assembly (1) into rear frame.
Inspection 8. Lightly coat 'V' ring (10) and machined surfaces of

pivot with Extreme Pressure Multipurpose Grease (26)
1. Clean nylon oscillation bushes with a suitable and, install 'V' ring (10), with lip towards front, on rear of
solvent and allow to dry. oscillation hub.
2. Inspect nylon oscillation bushes for wear, scoring, 9 . a) Restrain pivot assembly (1) to prevent it
erosion and 'out of round'. Pay particular attention to oscillating, by placing a heavy bar between the steering
the thrust faces of the bushes which should also be cylinder mountings. Lock the bar in position using
inspected for cracking/splitting. Renew if required. suitable trestles or stands. See Fig. 5.
3. Replace all seals with new parts. b) Secure a suitable tool to pivot thrust nut (11) and
tighten thrust nut (11) until there is no end float/
Assembly clearance at thrust face of either bush. Slacken thrust
nut (11) until pin of the locking plate (12) can be
Numbers in parentheses refer to Fig. 1. inserted in the first available hole in the thrust nut (11).
Note: Tighten all fasteners without special torques c) Secure locking plate (12) with bolts (22) and
specified to torques listed in Section 300-0080, lockwashers (21). Torque tighten bolts (22) to 94 Nm
STANDARD BOLT AND NUT TORQUE (69 lbf ft).
SPECIFICATIONS.
10. Install adaptor (57), connector (58), elbow (59) and
pipe assembly (60) to oscillation hub.
WARNING
To prevent personal injury and property 11. Install brake yoke (18) on driveshaft (14) until it
damage, be sure wheel blocks are properly butts against bearing assembly cup and cone (8 & 9).
safely. 12. Install parking brake disc on brake yoke (18) and
secure with bolts, washers and nuts. Tighten bolts to a
1. Wipe bush housing clean using a suitable solvent torque of 73 Nm (54 lbf ft).
and allow to dry.
13. Install rear of driveshaft (14).
2. Apply Loctite 648 (3) and Loc Quick Primer (4) and
align new bushes (2) to housing with grease holes 14. install Brake yoke (18) , Rear thrust collar (63)
aligned vertically and identification 'PAINT DOT' at Top ensuring 'O'-rings (29& 51) are in place , shim pack (64)
Dead Centre. Refer to Fig. 6. Drift bushes (2) into and bolts (19).
housing using hammer with soft packing for protection.
10 SM 2438 01-06
Section 100-0020
15. Lock off Brake yoke flange as before (18) with 8. Smear upper pin (40) with Extreme Pressure Lithium
suitable clamping method. Torque bolts (19) to 73 Nm Complex No. 2 grease (23) and install through front
(Ibf ft) frame and bearing bores.
9. Apply Loctite 243 (49) to threads of bolt (62). Secure

16. Take a magnetic clock gauge located on the flange upper pin (40) with bolt (62), washer (61), washer (41)
of pivot casing , needle acting on Rear thrust collar (63) and large nut (42). Tighten nut (42) to a torque of 1 425
end face. Check Brake yoke (18) float movement. Nm (1 050 lbf ft).
Ensure still within range 0.05mm - 0.15mm (0.002" -
0.006").
17. If float is incorrect, alter arrangement of shim pack Final Assembly
(64) to bring within size. 1. Install parking brake assembly to mounting
brackets and secure with bolts, washers and nuts.
18. Using special mandrel (15270104) home locking Refer to Section 170-0010, PARKING BRAKE AND
plate (16) onto bolts (19). Remove clamping bar. MOUNTING.
2. Apply parking brake by turning the hex-head on the

parking brake actuator fully clockwise.
Connecting Front and Rear Frames
1. Install spacer (39) in upper bearing assembly (30) as
noted on removal. WARNING
Tensioned spring on adjuster.
2. Smear bearing assembly (30) and pin bores with
Extreme Pressure Lithium Complex No. 2 grease (23). 3. Remove lifting equipment from pivot/rear frame
assembly.
3. Attach suitable lifting equipment to pivot/rear frame
assembly. Lifting equipment must prevent pivot from 4. Remove stands or timbers from front frame.
oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame 5. Apply Loctite 270 to threads of capscrews used to
pin bores. Raise lifting equipment to support pivot/rear mount driveline between transmission yoke and front
frame assembly. yoke (17). Align match marks and install driveline.
Tighten capscrews to a torque of 153 Nm (113 lbf ft).
4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull 6. Align match marks and reconnect driveline to brake
pivot/rear frame assembly to align pivot bearing bores yoke (18). Tighten capscrews to a torque of
and front frame pin bores. Block wheels and block 153 Nm (113 lbf ft).
pivot/rear frame assembly to remain level and
stationary. Note: Take extra care when handling drivelines as
chips, dents, burrs or deformity on any rotating mass
5. Freeze upper and lower pins (40 & 43) to ease creates vibration and excessive wear during any
installation. operation.
Note: It may be necessary to relieve binding between 7. Align steering cylinder bores and mounting pin bores
the pin and pin bores by raising or lowering pivot/rear on pivot. Install pins and secure with bolts and washers.
frame assembly. Tighten bolts to a torque of 73 Nm (54 lbf ft).
6. Smear lower pin (43) with Extreme Pressure Lithium 8. Connect hydraulic lines and electrical wiring as
Complex No. 2 grease (23) and install through front noted on disassembly.
frame and bearing bores.
9. Remove bolts (7), washers (20), gasket (5) and
7. Apply Loctite 243 (49) to threads of bolt (48). Secure cover plate (6) from side of oscillation hub to gain
lower pin (43) with bolt (48) and hardened washer (44). access to filler/level plug (25) on pivot assembly (1).
Tighten bolt (48) to a torque of 73 Nm Remove filler/level plug (25).
(54 lbf ft).
SM 2438 01-06 11
Section 100-0020
(26) to oscillation bushing lube fittings (55) on top of
10. Add SAE 80W - 90 E. P. gear oil (24) through filler/ oscillation hub. Lube until excess grease in seen.
the bottom of filler/level hole.
WARNING
11. Remove plug (25) from underside of oscillation hub To prevent personal injury and property
to drain the cavity between the oscillation hub and damage, be sure wheel blocks are properly
pivot assembly (1) of any oil that entered while filling secured and of adequate capacity to do the job
the driveshaft bearing housing. safely.
12. Install plug (25) in filler/level hole on pivot Every 250 hours, check the end float/clearance at the
assembly (1). Install gasket (5) and cover plate (6) on thrust face of the oscillation bushes. Any clearance
side of oscillation hub, secure with bolts (7) and found must be removed by adjustment of the thrust
washers (20). nut, as described in step 9 of 'Assembly' procedure.
13. Install plug (25) in cavity drain port on underside of Note: A practical method of establishing the effective
oscillation hub. adjustment of the thrust nut is to use movement of the
machines body in the raised position. Move the body
14. Remove plugs (28) from articulation bearing grease from fully raised to almost fully raised while watching
ports and replace with lube fittings (27). the effect of this action on the frame and pivot
arrangement. Any slackness between the thrust nut
Note: Lube fittings (27) are stored on pad on side of and thrust faces will be clearly visible movement of the
pivot assembly (1). frame.
15. Fill bearing housings with Extreme Pressure Every 1 000 hours (6 months), follow the procedure
Lithium Complex No. 2 grease (23) through lube fittings given below to check the oil level in the driveshaft
(27) until excess grease starts to escape from seal bearing housing, and, lubricate the articulation and
housings (32 & 34). oscillation bearings.
16. Remove lube fittings (27) and reinstall plugs (28). Note: It is essential that the grease used for
Store grease fittings (27) on pad on side of pivot articulation components is Extreme Pressure Lithium
assembly (1). Complex No. 2 grease (23), as specified in Section
300-0020, LUBRICATION SYSTEM.
17. Add Extreme Pressure Multipurpose grease (26) to
oscillation bushing lube fittings (55) on top of oscillation 1. Position the vehicle on a level work area and apply
hub. Lube until excess grease in seen. parking brake.
18. Install parking brake disc protective guard (if fitted) 2. Raise body and install body safety prop to secure
and secure with bolts, washers and nuts. Tighten nuts body in partially raised position.
to a torque of 73 Nm (54 lbf ft).
3. Shut down engine and block all wheels securely.
19. Start engine to charge hydraulic systems, raise
body, lower body safety prop and lower the body. 4. Remove protective guard (if fitted) from beneath
parking brake disc by removing nuts, washers and
20. Bleed the braking system as described in Section bolts securing guard to rear frame.
165-0010, BRAKE PARTS.
5. Remove bolts (7), washers (20), gasket (5) and
21. Remove wheel blocks. cover plate (6) from side of oscillation hub to gain
access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).
MAINTENANCE
Numbers in parentheses refer to Fig. 1. 6. Add SAE 80W - 90 E. P. gear oil (24) through filler/
Every 250 hours, oscillation bushes must be the bottom of filler/level hole.
lubricated. Add Extreme Pressure Multipurpose grease
12 SM 2438 01-06
Section 100-0020
7. Remove plug (25) from underside of oscillation hub

to drain the cavity between the oscillation hub and
pivot assembly (1) of any oil that entered while filling
the driveshaft bearing housing.
8. Install plug (25) into filler/level hole on pivot

assembly (1). Install gasket (5) and cover plate (6) on
side of oscillation hub, secure with bolts (7) and
washers (20).
9. Install plug (25) into cavity drain port on underside of

oscillation hub.
10. Remove plugs (28) from articulation bearing grease

ports and replace with lube fittings (27).
Note: Lube fittings (27) are stored on pad on side of

pivot assembly (1).
11. Fill bearing housings with Extreme Pressure

Lithium Complex No. 2 grease (23) through lube fittings
(27) until excess grease starts to escape from seal
housings (32 & 34).
12. Remove lube fittings (27) and reinstall plugs (28).

Store grease fittings (27) on pad on side of pivot
assembly (1).
13. Add Extreme Pressure Multipurpose grease (26) to

oscillation bushing lube fittings (55) on top of oscillation
hub. Lube until excess grease in seen.
14. Install parking brake disc protective guard (if fitted)

and secure with bolts, washers and nuts. Torque
tighten nuts to 73 Nm (54 lbf ft).
15. Start engine, raise body, lower body safety prop

and lower body.
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the thrust nut tool and general service tools
and adhesives required for procedures outlined in this
section. These tools and adhesives are available from
your dealer.
SM 2438 01-06 13
Section 100-0020
SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. No. ITEM No. ITEM NAME Nm lbf ft
1 19 Nut (to seat bearing only) 250 180
1 22 Bolt 94 69
1 42 Nut 1 425 1 050
1 46 & 47 Bolt 94 68
1 48 Bolt 73 54
- - Parking Brake Disc Bolts 73 54
- - Parking Brake Brkt Mounting Nuts 680 490
- - Driveline Mounting Capscrews 153 113
- - Protective Guard Mounting Nuts 73 54
- - Steering Cylinder Pin Bolts 73 54
* * * *
14 SM 2438 01-06
CHASSIS - Hood andSection
Mounting
100-0040
SM - 3409
1*
9 2
14
6
30 7
31 28
38 22
18 29
24
27
11
39
30 38 17 26
31 21
13 25
22 18
15
32 18
37 22
23
15
17 16 8
13 21
36 10
14
4 20
19 5
3 18
12 22
18
20
14 22 34
35
33
1 - Hood Assembly 11 - RH Grill 21 - Washer 31 - Washer

2 - Hood 12 - Adjustment Rod 22 - Lockwasher 32 - Washer
3 - Front sub-frame 13 - Bolt 23 - Hardened Washer 33 - Bolt
4 - Rear sub-frame 14 - Bolt 24 - Electric Actuator 34 - Nut
5 - LH Bracket assy. 15 - Bolt 25 - Bolt 35 - Washer
6 - RH Bracket assy. 16 - Plate 26 - Hardened Washer 36 - Grille
7 - Plate 17 - Nut 27 - Rubber Cup 37 - Bolt
8 - LH Plate 18 - Nut 28 - Nut 38 - Bolt
9 - RH Plate 19 - Hardened Washer 29 - Hardened washer 39 - Cone
10 - LH Grill 20 - Nut 30 - Nut
Fig 1 - Hood and Mounting
HOOD
SM - 3673
DESCRIPTION AND OPERATION
Numbers in parentheses refer to Fig 1 & 2.
The vehicle is fitted with a electrically powered hood.

The hood is activated from the hood control switch.
The hood control switch is located in the cab on the
under the passenger seat. It is a three position switch;
Centre:off; Up:raise; Down:lower. Operating the hood
control switch will send an electrical signal to the motor
fitted to the actuator. As the motor is powered the
actuator extends outwards to raise the hood or retracts
inwards to lower the hood. Fig 2 - Hood Switch
SM 2383 rev01 06-07 1

Chassis - Hood and Mounting
Section 100-0040
Removal 10. Using suitable lifting equipment, remove the hood

assembly (1) from the vehicle.
11. If necessary, remove bolts (15), washers (22) and
nuts (18) securing front and rear sub-frames (3 & 4) to
WARNING
the hood (2). Remove sub frames and constituent
To prevent personal injury and property
parts.
damage, be sure blocking materials and lifting
equipment are properly secured and of
Installation
1. Position the machine on a level surface, apply the
parking brake.
Note: Tighten all fasteners to torques listed in
2. Remove bolts (37) and washers (32) securing grille
Section 300-0080, STANDARD BOLT AND NUT
(36) to front subframe (3). Remove grille (36) clear of
TORQUE SPECIFICATIONS.
hood (2).
3. Raise the hood enough to insert suitable sling / strap

WARNING
for securing; by activating the appropriate request
button in the cab. This will cause the electric actuator
damage, be sure blocking materials and lifting
(24) to extend outward, raising the hood.
4. Once elevated secure the hood using suitable lifting
equipment and sling, ensure the sling is secured the
1. If removed, secure front and rear sub-frames (3 & 4)
full length of the hood from front to back. before
to hood (2), using bolts (15), lockwashers (22) and nuts
removing the hood from the actuator (24).
(18).
2. Using suitable lifting equipment, lift and position

5. Block all road wheels, switch off the engine. and
hood assembly (1) on the machine and align holes in
place the battery master switch in the 'Off' position.
hinges with mounting holes on frame front sub-frame
(3). Secure hood assembly (1) to hinges using
6. Remove engine sump guard from the front chassis
washers (25) and nuts (20).
frame, to allow access to the electric actuator (24).
3. Taking the actuator (24), in the fully extended
Note: If for any reason, electrical power is disabled
position, locate and secure the base end of the
from the electric actuator (24) , the actuator can be
actuator to the mating holes on the front chassis
raised manually. Taking a suitable ball end allen key
bracket. Secure using bolt (38), washer (31) and nut
(6mm) with extension, remove the cap covering the
(30).
hand wind socket from the base end of the actuator
(24) (refer to Fig. 3)
4. Locate and secure the rod end of actuator (24) to
mating holes on rear sub-frame (4) lugs. Secure using
Using allen key, turning clockwise, screw the actuator
bolt (38), washers (31) and nut (30).
out manually, till sufficiently extended to allow access
to the inside of the hood.
5. Wire the electrical connections of the actuator (24)
to the correct system components to allow the actuator
7. Remove bolt (38), washer (31) and nut (30) securing
to screw down, lower the hood assembly (1) onto the
the base end of actuator (24) to the front chassis
vehicle frame bed.
bracket lugs.
6. Once fully lowered. Install grille (36) to the front sub-
8. Remove bolt (38), washer (31) and nut (30) securing
frame (3). Secure using bolts (37) and washers (32).
the rod end of the actuator (24) to the rear sub-frame
(4).
7. Lower hood assembly and check for correct
alignment between hood (1) and vehicle frame, ensure
9. Remove 2-off nuts (20). The hood assembly (1)
no interference occurs between elements contained
should now be free to be removed from the vehicle.
under the hood and the hood assembly.
2 SM 2383 rev01 06-07

Chassis - Hood and Mounting
Section 100-0040
8. Remove wheel blocks. 9
MAINTENANCE
Periodically check bolts (33), washers (25) and nuts
10 8
(34) and tighten when necessary.
Periodically check actuator (42) mechanism ensuring it

is secure and in working order.
Refer to Fig. 1. unless otherwise stated.

1 2 3 4 5 6 7
If for any reason the electric actuator (24) does not

work, suitable investigation as to the cause of the 1 - Rear Adaptor 6 - Rod
failure should be carried out. 2 - Clutch 7 - Front Adaptor
3 - Brake 8 - Electrical wires
4 - Screw 9 - Motor
If the motor (9, Fig. 4) or sealing elements within the 5 - Nut 10 - Gear
actuator need replacement, these can be replaced
using the applicable service kits. For details of service Fig 4 - Typical Actuator Assembly
kit number, refer to the relevant TEREX Parts book
manual.
SPECIAL TOOLS
For all other detail specific to the electric actuator, There are no special tools required for procedures
consult the relevant manufacturer for detail. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
SM - 3410 tools and adhesives required. These tools and
adhesives are available from your dealer.
Manual
Wind
View on Bottom
of Actuator
Fig 3 - Actuator End Detail
* * * *
SM 2383 rev01 06-07 3

ENGINE - Engine and Mounting
Section 110-0030
SM - 3513
FUEL FILTERS - ENGINE LHS
1 15
11
12
3 4
6
13
7
17
14
FRONT
FRAME REF.
TOP OF ENGINE
16
14
2
8
5 10
18
1 - Engine 6 - Alternator Pulley 11 - Bolt

2 - Oil Filter 7 - Adaptor Plate 12 - Washer
3 - Primary Fuel Filter 8 - Snubbing Washer 13 - Washer
4 - Secondary Fuel Filter 9 - Bolt 14 - Isolation Mount
5 - Coolant Filter 10 - Nut 15 - Alternator/ Air con Belt
16 - Engine Oil Fill
17 - Engine Oil Dipstick
18 - Quick drain
Fig. 1 - Engine and Mounting
washer (8) to the isolator mounting and the entire

DESCRIPTION assembly is secured in place by bolt (9) and nut (10).
Numbers in parentheses refer to Fig. 1. Rubber isolation mounts (14) provide sufficient
flexibility to absorb varying engine vibration and
For engine make, model and specification, refer to torsional loads.
Section 000-0000, GENERAL INFORMATION. For
engine servicing and repair data refer to the engine At its rear, the engine is coupled to the transmission,
manufacturers service manual. which in turn is secured to the frame rails at dedicated
mounting brackets located on either side of the
The engine is mounted to the front of the tractor frame transmission. Refer to section 120-0010,
at the engine isolator mounting point, which is integral TRANSMISSION AND MOUNTING.
to the front frame assembly. Through this, the engine
is secured from its bracket to the adaptor plate (7), via There are two full-flow oil filters (2) mounted on the
bolts and washers (11 & 12). This arrangement right hand side of engine (1) in a downward position.
sandwiches the isolation mounts (14) and snubbing The filters are of the throw away, spin-on type. Oil
supplied by the engine oil pump passes through oil
SM 2384 05-06 1
Engine - Engine and Mounting
Section 110-0030
filters (2) before reaching the various moving parts of The DDEC V system also takes action to prevent
engine (1). The oil is forced by pump pressure through damage to the engine and, provides the serviceman
a passage in the filter adaptor and into the elements. with diagnostic capabilities so that problems can be
Impurities are filtered out as the oil passes through the corrected quickly and easily.
elements and out through another passage in the filter
adaptor. 1. Electronic Control Module (ECM) - Receives
electronic inputs from the driver as well as from
Engine coolant filter (5) and conditioner is a compact mounted sensors that provide information
bypass type unit with a replaceable spin-on type electronically, such as oil pressure and temperature
element mounted on the gear case cover at the front and intake manifold pressure. This information is used
right hand side of engine (1). Refer to Section to control both the quantity of fuel injected and injection
210-0000, COOLING SYSTEM. timing.
There are two spin-on type fuel filters mounted on the 2. Programmable Read Only Memory (PROM) -
left hand side of engine (1). Primary fuel filter (3) is in Located in the ECM and encoded with the operating
the fuel flow and acts as a strainer and secondary fuel software. Additional information is programmed into the
filter (4) filters the fuel after having passed through EEPROM. This information controls the horsepower
primary fuel filter (3). The word 'Primary' or 'Secondary rating, torque curve, maximum engine speed and
is cast into the top of the respective adaptor to prevent engine protection devices. The ECM processes this
mismatching. information and sends electronic signals to the
Electronic Unit Injectors (EUI) where the precise
amount of fuel is injected into the engine.
DETROIT DIESEL ELECTRONIC
CONTROL (DDEC V) 3. 'N3' Electronic Unit Injectors (EUI) - The EUI is a
lightweight, compact unit that injects diesel fuel directly
Description into the combustion chamber. The amount of fuel
Refer to Fig. 2. injected and the beginning of injection timing is
determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.
WARNING
Before any welding is done on a machine The EUI performs four functions:
equipped with the DDEC V system, disconnect
the following in this order: a - Creates the high fuel pressure required for efficient
Battery earth cable, battery supply cable, injection.
alternator earth cables, alternator supply b - Meters and injects the exact amount of fuel required
cables, body hydraulics joystick, hydraulic to handle the load.
ECU, Transmission TCM, Dash Panel (VDU) c - Atomizes the fuel for mixing with the air in the
CPU, ECM engine harness connector (68-pin combustion chamber.
LHS), ECM vehicle interface harness connector d - Permits continuous fuel flow for component cooling.
(68-pin RHS). Turn off battery master switch
before disconnecting any components. Electronic unit injectors are self compensating and
virtually eliminate engine tune-ups.
After welding connect all of the above in the
reverse order. Note: Never apply 12 V directly to terminals on the
injector or engine sensors as they will burn out. Before
removing injectors, the fuel passages must be blown
out to prevent fuel flow from entering the cylinder head.
The engine is equipped with DDEC V which controls
the timing and amount of fuel injection by the electronic 4. Electronic Foot Pedal - The electronic foot pedal
unit injectors (EUI). The system also monitors several provides an electrical signal to the engine's fuel control
engine functions using electrical sensors which send system in proportion to the degree of pedal actuation.
electrical signals to the electronic control module
(ECM). The ECM then computes the incoming data
and determines the correct fuel output and timing for
optimum power, fuel economy and emissions.
2 SM 2384 05-06
Section 110-0030
SM - 3514
5 6
3 2 STOP P
1
8 7
L
1,2
9
1 - Electronic Control Module (ECM) 6 - 'Check' Engine Light

2 - Programmable Read Only Memory (PROM) 7 - Diagnostic Switch
3 - 'N3' Electronic Unit Injectors (EUI) 8 - Diagnostic Test Point
4 - Electronic Foot Pedal 9 - Batteries
5 - 'Stop' Engine Light
Fig. 2 - DDEC components
Note: The DDEC V controlled engine will override the Pressing and releasing the switch will flash out the
electronic foot pedal position until the engine is warmed engine codes. Pressing the switch a second time will
up to the correct operating temperature. The engine stop the engine codes flashing.
MUST be started with foot 'OFF' the electronic foot
pedal. Note: Inactive codes are displayed on Check Engine
Light and active codes are displayed on Stop Engine
5. Stop Engine Light - When the 'Stop Engine' light Light. Code 25 means no codes present.
comes on, the computer has detected a major
malfunction in the engine that requires immediate Operates as a Stop Engine Override Switch when the
attention. It is the operators responsibility to shut down engine is in a rampdown protection mode for any of the
the engine to avoid serious damage. following:
6. Check Engine Light - When the 'Check Engine' light Low Coolant Level WARNING
comes on, the computer has detected a fault in the High Coolant Temperature Overide function only
engine. The fault should be diagnosed and corrected at Low Oil Pressure to be used in a safety
the earliest opportunity. High Oil Temperature critical condition.
7. Diagnostic Switch - Operates as a diagnostic 8. Diagnostic Test Point - Plug in connector for
request switch when: diagnostic data reader (DDR).
a - the engine is not running and ignition is 'On'. 9. Batteries - Two 12 volt maintenance free batteries
b - the engine is idling and not in an engine protection supply the machine with electrical power to operate all
condition. electrical components.
SM 2384 05-06 3
Section 110-0030
Operation can be plugged into the engine computer memory to

Numbers in parentheses refer to Fig. 2. extract information related to the cause of the problem.
Once the malfunction has been corrected, the DDEC
system will return the engine to normal operation. The
The machine is equipped with the DDEC V engine
DDR and DDDL can distinguish between active codes
protection system, which records the stop engine
and those stored in the historic code memory. The
malfunction in ECM (1). The stop engine and check
malfunction code recorded in ECM (1) memory will
engine lights illuminate when the engine protection
remain until it is erased by a technician.
system is initiated. The engine will immediately reduce
to 70% of the available torque. Rampdown then
commences over a 30 second period and reduces the
WARNINGS
engine to 40% of the available torque.
The operator of a DDEC V-equipped vehicle
must not attempt to use or read a DDR of any
To allow for the possibility of the engine protection
kind while the vehicle is operating. Doing so
system being activated while the machine is operating
can result in loss of control, which may cause
in a critical situation, a stop engine override switch (7)
vehicle damage and may result in personal
is provided. If the switch is pressed and released
injury.
during rampdown, the 30 second timer will reset,
restoring torque to the level immediately following
When engine or electronics system
illumination of stop engine (5) and check engine (6)
diagnosis is required on a DDEC-V equipped
lights. The switch must be pressed and released again
vehicle, this must be done by a person other
to obtain a subsequent override.
than the operator. The operator must maintain
control of the moving vehicle while the
Note: The operator must continue to reset the
assistant performs the diagnosis.
automatic engine protection system by pressing and
releasing stop engine override switch (7) at intervals of
When the engine is not running and the ignition is on,
approximately 15 to 20 seconds.
or, the engine is idling and not in an engine protection
condition, engine faults can be diagnosed by the
Note: ECM (1) will record the number of times the
operator. Pressing and releasing diagnostic request
override is activated after the fault occurs. Available
switch (7) will cause check engine light (6) or stop
Torque is the actual torque available from the engine
engine light (5) to flash a code number indicating the
when the fault occurred based on the actual rev/min
fault, e.g. flash twice - pause - flash five times - pause
when the fault occurred.
indicates a code 25. Code 25 indicates all systems are
operating correctly. Pressing the switch a second time
The engine should not be restarted after it has been
will stop the engine codes flashing. Refer to 'DDEC V'
shut down after activation of the engine protection
Diagnostic Codes' table for other code descriptions.
system unless the problem has been diagnosed and
corrected.
Conditions that will cause the Stop Engine Light to

L
come on are; Low Coolant Level, High Coolant
Temperature, Low Oil Pressure and High Oil
Temperature.
Whenever check engine light (6) or stop engine light (5)

comes on, the DDEC computer will determine where
the problem is and will store this information in its
memory. If the malfunction is intermittent, the lights
will come on and go off as the computer senses the
changing engine condition. Fig. 3 - Diagnostic Request/ Override Switch
A special diagnostic data reader (DDR) or laptop based

Detroit Diesel Diagnostic Link (DDDL) are available that
4 SM 2384 05-06
Section 110-0030
DDEC V DIAGNOSTIC CODES

DDEC Code
# (Flashed) PID SID FMI DDEC Description
- 240 - 2 Fram checksum incorrect
- 251 - 10 Clock module abnormal rate
- 251 - 13 Clock module fault/failure
- - 253 13 Incompatible calibration version
- - 254 0 External failed RAM
- - 254 1 Internal failed RAM
- - 254 6 Entered boot via switches
11 187 - 4 VSG sensor voltage low
11 187 - 7 VSG switch system not responding
12 187 - 3 VSG sensor high
13 111 - 4 Coolant level sensor input voltage low
13 111 - 6 Add coolant level sensor input voltage low
14 110 - 3 Coolant temperature sensor input voltage high
14 175 - 3 Oil temperature sensor input voltage high
15 110 - 4 Coolant temperature sensor input voltage low
15 175 - 4 Oil temperature sensor input voltage low
16 111 - 3 Coolant level sensor input voltage high
16 111 - 5 Add coolant level sensor input voltage high
21 91 - 3 TPS input voltage high
22 91 - 4 TPS input voltage low
23 174 - 3 Fuel temperature sensor input voltage high
24 174 - 4 Fuel temperature sensor input voltage low
25 - - - Reserved for 'No Codes'
26 - 25 1 Auxiliary shutdown #1 active
26 - 61 11 Auxiliary shutdown #2 active
27 171 - 3 Ambient air temperature sensor input voltage
high (Release 2.00 or later only)
27 172 - 3 Air temperature sensor input voltage high
27 105 - 3 Intake manifold temperature sensor input voltage
high
28 171 - 4 Ambient air temperature circuit failed low
(Release 2.00 or later only)
28 172 - 4 Air temperature sensor input voltage low
28 105 - 4 Intake manifold temperature sensor input voltage
low
31 - 51 3 Aux. output #3 open circuit (high side) (E-49)
31 - 51 4 Aux. output #3 short to ground (high side)
(E-49)
31 - 51 7 Aux. output #3 mechanical system fail (E-49)
31 - 52 4 Aux. output #4 short to ground (high side) (E-48)
SM 2384 05-06 5
Section 110-0030

DDEC Code
32 - 238 4 SEL open circuit
32 - 238 3 SEL short to battery (+)
32 - 239 3 CEL short to battery (+)
32 - 239 4 CEL open circuit
33 102 - 3 Turbo boost pressure sensor input voltage high
34 102 - 4 Turbo boost pressure sensor input voltage low
35 100 - 3 Oil pressure sensor input voltage high
36 100 - 4 Oil pressure sensor input voltage low
37 94 - 3 Fuel pressure sensor input voltage high
37 95 - 3 Fuel restriction sensor input voltage high
38 94 4 Fuel pressure sensor input voltage low
38 95 - 4 Fuel restriction sensor input voltage low
41 - 21 0 Too many SRS (missing TRS)
42 - 21 1 Too few SRS (missing SRS)
43 111 - 1 Coolant level low
44 110 - 0 Coolant temperature high
44 172 - 0 Air inlet temperature high
44 175 - 0 Oil temperature high
27 105 - 3 Intake manifold temperature sensor input voltage high
28 171 - 4 Ambient air temperature circuit failed low
(Release 2.00 or later only)
28 172 - 4 Air temperature sensor input voltage low
28 105 - 4 Intake manifold temperature sensor input voltage low
32 - 238 4 SEL open circuit
32 - 238 3 SEL short to battery (+)
32 - 239 3 CEL short to battery (+)
32 - 239 4 CEL open circuit
33 102 - 3 Turbo boost pressure sensor input voltage high
34 102 - 4 Turbo boost pressure sensor input voltage low
35 100 - 3 Oil pressure sensor input voltage high
36 100 - 4 Oil pressure sensor input voltage low
37 94 - 3 Fuel pressure sensor input voltage high
37 95 - 3 Fuel restriction sensor input voltage high
38 94 4 Fuel pressure sensor input voltage low
38 95 - 4 Fuel restriction sensor input voltage low
41 - 21 0 Too many SRS (missing TRS)
6 SM 2384 05-06
Section 110-0030

DDEC Code
42 - 21 1 Too few SRS (missing SRS)
43 111 - 1 Coolant level low
44 110 - 0 Coolant temperature high
44 172 - 0 Air inlet temperature high
44 175 - 0 Oil temperature high
44 105 - 0 Intake manifold temperature high
45 100 - 1 Oil pressure low
46 - 155 4 Injector Vreg voltage failed low
46 168 - 1 ECM battery voltage low
46 - 211 1 Vehicle sensor supply voltage low (V-11, V-12)
46 - 212 4 Injector Vslope voltage failed low
46 - 214 1 RTC backup battery voltage low
46 - 221 4 Injector Ipullin voltage failed low
46 - 232 1 Engine sensor supply voltage low (E-12, E-26)
47 94 - 0 Fuel pressure high
47 102 - 0 Turbo boost pressure high
47 106 - 0 Air inlet pressure high
48 94 - 1 Fuel pressure low
48 106 - 1 Air inlet pressure low
52 - 254 12 A/D conversion fail
53 - 253 2 Memory check failed on startup
53 - 253 12 Memory write error - single location
53 - 253 13 Calibration memory error
53 - 253 14 Memory write error - all locations
54 84 - 12 Vehicle speed sensor fault
55 - 216 14 Missing other ECU information
55 - 231 12 J1939 data link fault
56 - 250 12 J1587 data link fault
58 92 - 0 Torque overload
61 - xxx 0 Injector xxx response time long
61 - xxx 6 Injector xxx circuit short to ground
62 - 26 3 Aux. output #1 short to battery (+) (V-04)
62 - 26 4 Aux. output #1 open circuit (V-04)
SM 2384 05-06 7
Section 110-0030

DDEC Code
62 - 259 3 Aux. output #11 short to battery (+) (E-13)
62 - 259 4 Aux. output #11 open circuit (E-13)
62 - 26 7 Aux. output #1 mechanical system failure (V-04)
62 - 258 7 Aux. output #10 mechanical system failure (V-
55)
62 - 259 7 Aux. output #11 mechanical system failure (E-
13)
63 - 57 3 PWM #1 short to battery (+) (V-52)
63 - 57 4 PWM #1 open circuit (V-52)
63 - 58 3 PWM #2 short to battery (+) (V-46)
63 - 58 4 PWM #2 open circuit (V-46)
63 - 59 3 PWM #3 short to battery (+) (E-01)
63 - 59 4 PWM #3 open circuit (E-01)
63 - 60 3 PWM #4 short to battery (+) (E-04)
63 - 60 4 PWM #4 open circuit (E-04)
64 103 - 8 Turbo speed sensor input failure
64 103 - 0 Turbo overspeed
65 107 - 3 Air filter restriction sensor voltage high
65 107 - 4 Air filter restriction sensor voltage low
66 - 99 3 Oil filter restriction sensor voltage high
66 - 99 4 Oil filter restriction sensor voltage low
67 109 - 3 Coolant pressure sensor input voltage high
67 109 - 4 Coolant pressure sensor input voltage low
67 106 - 3 Air inlet pressure sensor input voltage high
67 106 - 4 Air inlet pressure sensor input voltage low
68 - 230 6 TPS idle validation circuit fault (short to ground)
68 - 230 5 TPS idle validation circuit fault (open circuit)
71 - xxx 1 Injector xxx response time short
72 84 - 0 Vehicle overspeed
72 84 - 11 Vehicle overspeed (absolute)
73 107 - 0 Air filter restriction high
8 SM 2384 05-06
Section 110-0030

DDEC Code
74 99 - 0 Oil filter restriction high
75 - 155 3 Injector Vreg voltage failed high
75 168 - 0 ECM battery voltage high
75 - 211 0 Vehicle sensor supply voltage failed high (V-11, V-12)
75 - 212 3 Injector Vslope voltage failed high
75 - 214 0 RTC backup battery voltage high
75 - 221 3 Injector Ipullin voltage failed high
75 - 232 0 Engine sensor supply voltage high (E-12, E-26)
76 121 - 0 Engine overspeed with engine brake
77 21 - 0 ECU temperature above range
77 21 - 1 ECU temperature below range
77 21 - 3 ECU temperature failed high
77 21 - 4 ECU temperature failed low
77 100 - 0 Oil pressure high
77 102 - 1 Turbo boost pressure low
77 108 - 0 Barometric pressure high
77 108 - 1 Barometric pressure low
77 171 - 0 Ambient air temperature high
77 171 - 1 Ambient air temperature low
77 174 - 0 Fuel temp high
77 251 - 10 Clock incorrect
77 251 - 13 Clock failure
77 252 - 10 Date incorrect
77 252 - 13 Clock/Date failure
81 98 - 3 Oil level sensor input voltage high
81 173 - 3 Exhaust temperature sensor input voltage high
82 98 - 4 Oil level sensor input voltage low
82 173 - 4 Exhaust temperature sensor input voltage low
83 173 - 0 Exhaust temperature high
83 173 - 4 Exhaust temperature sensor input voltage low
83 73 - 0 Pump pressure high
84 98 - 1 Oil level low
85 190 - 0 Engine overspeed
86 73 - 3 Pump pressure sensor input voltage high
86 108 - 3 Barometric pressure sensor input voltage high
87 73 - 4 Pump pressure sensor input voltage low
87 108 - 4 Barometric pressure sensor input voltage low
88 109 - 1 Coolant pressure low
89 95 - 0 Fuel restriction high
89 111 - 12 Maintenance alert coolant level fault
SM 2384 05-06 9
Engine - Engine and Mounting Engine - Engine and Mounting
Section 110-0030
Note: Only one light will be flashing at any one time. Note: Radiator header tank will be removed as part of
When code flashing is initiated, the active codes (or the goalpost assembly.
code 25) will be flashed on stop engine light (7), then
the inactive codes (or code 25) will be flashed on 8. Support engine sump guard with suitable blocking
check engine light (6). When all of the inactive codes and remove mounting hardware securing sump guard to
have been flashed, the process of flashing the codes the frame. Remove sump guard from the frame.
will repeat until the conditions for code flashing are no
longer satisfied. 9. Support guard plate under the engine at the front of
the frame with suitable blocking and remove mounting
REMOVAL hardware securing guard plate to the frame. Remove
Numbers in parentheses refer to Fig. 1. guard plate from the frame.
Note: Tag all cables, harnesses, lines and pipes 10. Place a suitable container under the engine drain
disconnected during removal to aid in installation. port, remove drain plug on no drip drain plug (18) and
drain the oil. After draining, reinstall drain plug in engine
sump and tighten securely.
WARNINGS
damage, be sure wheel blocks, blocking WARNING
materials and lifting equipment are properly Before disconnecting any air conditioner lines,
secured and of adequate capacity to do the job refer to Section 260-0130, AIR CONDITIONING.
safely. Refrigerant will rapidly freeze all objects with
which it comes into contact. It can cause
High electrical current can cause sparks serious and permanent damage to the eyes and
and personal injury from burns. Turn battery skin.
master switch to the 'Off' position before
removing any components. Remove battery 11. Evacuate air conditioning system and disconnect
ground cable first, and reconnect last, to avoid air conditioner lines at the engine compressor. Refer to
damaging electrical components. Section 260-0130, AIR CONDITIONING.
1. Position the vehicle in a level work area, ensure the 12. Remove the radiator assembly from the vehicle.
body is fully lowered, apply the parking brake Refer to Section 210-0040, RADIATOR AND
MOUNTING.
2. Remove hood . Refer to Section 100-0040, HOOD
AND MOUNTING. 13. With a suitable container in position, remove drain
cock on the transmission oil cooler flanges and drain
3. Switch off the engine. Turn steering wheel several the coolant. Remove coolant pipes from the engine
times to relieve any pressure in the steering circuit. water pump and engine oil cooler. Refer to Section 210-
0060, TRANSMISSION OIL COOLER.
4. Block all road wheels and place the battery master
switch in the 'Off' position. 14. Remove charge air cooler pipes from engine
turbocharger and engine inlet manifold.
5. Disconnect battery cables from terminal posts (earth
cable first). 15. Disconnect exhaust piping from the engine
turbocharger.
6. Remove mounting hardware securing air cleaner
assembly to right hand fender. Slacken mounting clamp 16. Disconnect air cleaner intake pipe from engine
at air cleaner intake pipe and draw air cleaner, complete turbocharger and remove from the engine.
with rubber hose, away from intake pipe. Cover open ends
to prevent entry of dirt. 17. Identify heater lines for ease of installation and with a
suitable container in position, disconnect heater lines
7. With a suitable container in position, open shut-off from the engine. Cap open line ends and fittings.
valve on the radiator assembly and drain the coolant.
18. Identify fuel lines for ease of installation and with a
suitable container in position, disconnect fuel lines
from the engine. Cap open line ends and fittings.
10 SM 2384 05-06
Section 110-0030
SM - 3570
1 - Engine (Flywheel Housing)

2 - Transmission
3 - Flexplate Adapter
4 - Wear Plate
5 - Flexplate Assembly
6 - Starter Ring Gear
7 - Crankshaft Hub Adapter
8 - Bolt (12-off)
9 - Bolt (12-off)
10 - Bolt (12-off)
Fig. 4 - Engine and Transmission Coupling Components
19. Identify all electrical harnesses and cables for ease DISASSEMBLY
of installation and disconnect from the engine.
Numbers in parentheses refer to Fig. 4 & 5 unless
otherwise stated.
20. Disconnect clips securing items to the engine and
transmission that cannot be removed with the engine /
1. Remove plug from rear rhs of engine, using a 3/4"
transmission sub-assembly.
square drive.
21. Disconnect transmission hoses and lines. Refer to
Section 120-0010 TRANSMISSION AND MOUNTING.
SM - 3569
22. Disconnect all relevant electrical transmission

harness connections necessary prior to removal of
engine / transmission sub-assembly. Refer to Section
120-0010 TRANSMISSION AND MOUNTING.
23. Disconnect driveline from transmission to dropbox.

Refer to Sections 130-0010 DRIVELINES and 125-
0010 DROPBOX AND MOUNTING.
23. Attach suitable lifting equipment to the lifting

brackets on the engine and transmission units and
raise lifting equipment to take up the slack.
24. Carefully support weight of transmission and

remove transmission and engine from the mated
position.
25. Remove engine and transmission to side for further

disassembly as required.
Fig. 5 - Plug On Engine Removed
SM 2384 05-06 11
Section 110-0030
2. Turn crankshaft clockwise until one bolt (10) is Note: Alternator belt tension adjustment is made after
accessible for removal. Remove 1-off bolt (10). installation of engine (1) and the radiator assembly.
3. Continue cranking clockwise until next bolt (10) in 8. Install air conditioner compressor and drive belt to
concession is accessible for removal. Remove bolt engine (1). Refer to Section 260-0130, AIR
(10). CONDITIONING.
4. Repeat step 3 until all 12 bolts (10) have been Note: Position rubber isolation mount (14) to their
removed. mounts as shown in Fig. 1.
5. Remove 12-off bolts (9) and washers securing Numbers in parentheses refer to Fig. 1,4 & 5. unless
transmission outer housing to engine housing. otherwise stated
6. Remove and discard filters (2, 3, 4 & 5) from engine Sub-assembly: Engine & Transmission
(1), as described in 'Maintenance'. Cover engine inlet
ports to prevent entry of dirt. 1. Bolt flexplate assembly (5) onto the engine. Torque
12-off bolts (8) to a value of 68Nm (50Ibf ft), then turn
7. Refer to 'Engine Manufacturers Service Manual' if an additional 120degrees.
engine service or repair is required.
2. If not removed already, remove plug from rear RHS
of engine allowing access as shown in Fig. 5.
INSPECTION
Numbers in parentheses refer to Fig. 1. 2. Align one of the flexplates bolt holses around the
flexplate circumference with the access opening in the
Note: As the engine is installed with the transmission engine flywheel housing.
already assembled to it, it will be necessary to check
for damage on all related transmission mounts and 2. Lubricate the centre pilot boss with molybdenum
brackets. disulfide grease. (molycote G or equivalent).
1. Inspect rubber isolation mounts (14) for damage and 3. Install a headless guide bolt into one of the flexplate
replace if required. bolt holes in the flexplate adapter or torque converter
mounting lug. Align the guide bolt with the flexplate
2. Inspect engine flywheel housing for any damage. hole at the access opening.
3. Inspect crankshaft hub adapter for damage or 4. Push the transmission towards the engine while
cracks. Replace as necessary. guiding the pilot boss on the torque converter into the
flexplate hub adapter and guide the bolt into the hole on
the flexplate (5).
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 5. Seat the transmission squarely against the engine
flywheel housing. Note: no force is required. If
Note: Tighten all fasteners without special torques interference is encountered, move the transmission
specified to standard torques listed in Section away from the engine and investigate the cause.
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 6. Align the bolt holes in the converter housing with
those in the engine flywheel housing.
1. Remove covers from engine filter ports and install
new filters (2, 3, 4 & 5) on engine (1), as described in 7. Install all transmission to engine bolts finger tight.
'Maintenance'.
8. Tighten four bolts at equally spaced intervals around
the convertor housing bolt circle. Use the torque
Note: Replace all belts in a set when one is broken or specified by the engine manufacturer.
replaced.
9. Remove flexplate guide bolt through the engine
7. Install 'V' belts (15) in the grooves of alternator and flywheel housing access opening. Replace with self
accessory drive pulley. locking bolt. Tighten bolt finger tight.
12 SM 2384 05-06
Section 110-0030
10. Install remaining 8-off bolts (9) and washers to the
outer housing. Tighten bolts (9) to 80Nm. 7. Install air cleaner intake pipe and exhaust piping to
engine turbocharger.
11. Rotate the engine crankshaft to install the
remaining self-locking bolts into the flexplate adapter. 8. Remove caps from heater lines and fittings and
After all bolts have been installed finger tight. Tighten connect heater lines to engine (1) as identified at
12-off bolts (10) to 36Nm. (Rotate engine crankshaft as removal.
necessary to access bolts).
9. Remove caps from fuel lines and fittings and
Installation connect fuel lines to engine (1) as identified at removal.
10. Connect all electrical harnesses and cables to
Note: Tighten all fasteners without special torques engine (1) (with the exception of battery connections)
specified to standard torques listed in Section as identified at removal.
SPECIFICATIONS. 11. Connect air conditioner lines at the compressor as
identified at removal. On completion of engine
installation the air conditioning system will require to be
charged. Refer to Section 260-0130, AIR
WARNING
CONDITIONING.
damage, be sure lifting device is properly
12. Install the goalpost and radiator header tank
assembly on the vehicle. Refer to Section 100-0040,
safely.
HOOD AND MOUNTING.
1. Attach suitable lifting equipment to engine (1) and
13. Ensure all cooling lines to radiator assembly,
transmission sub assembly lifting brackets and
engine (1) and radiator header tank are correctly
carefully position assembly over tractor frame.
connected. Refer to Section 210-0040, RADIATOR
AND MOUNTING.
2. As required, assemble mounting for transmission
brackets on either side of the transmission. Refer to
14. Remove covers from air cleaner intake pipe and
Section 120-0010 TRANSMISSION AND MOUNTING.
rubber hose on the air cleaner inlet then slide air
cleaner assembly towards the hood locating the rubber
3. Secure isolation mounts (14) and adaptor plate in place
hose to the inlet pipe.
to front frame location, by means of washer (13), washer
(13), bolt (9) and nut (10). Torque nut (10) to a value of 921
15. Secure air cleaner assembly to the right hand
Nm (680 Ibf ft).
fender and rubber hose to the inlet pipe with mounting
hardware removed during removal.
4.Secure engine (1) to the front frame at adaptor plate (7),
by means of washers (12) and bolts (11). Torque bolts (11)
16. Connect battery positive connections to battery
to a value of 330 Nm (239 Ibf ft).
terminals. Connect battery earth connections to battery
terminals.
3. Connect driveline to the transmission coupling and
Refer to Section 130-0010, FRONT DRIVELINES.
17. Ensure all lines, harnesses and cables are secured
with clips and clamps as removed during removal.
4. Install transmission oil cooler on vehicle. Refer to
Ensure no lines are chaffing on sharp edges or resting
Section 210-0060, TRANSMISSION OIL COOLER.
against areas where heat will be evident.
5. Install radiator assembly on the vehicle. Refer to
18. Ensure shut-off valve at the bottom of the radiator
Section 210-0040, RADIATOR AND MOUNTING.
assembly, drain plugs in transmission oil cooler flanges
and drain cocks on engine (1) water jacket are securely
6. Install air cooler pipes from engine turbocharger and
closed. Ensure shut off cocks at coolant filter (3) are
engine inlet manifold to charge air cooler integral to the
open to allow flow through the filter.
rh combination cooler; radiator assembly. Refer to
19. Fill the cooling system with coolant. Refer to
Section 210-0040, RADIATOR AND MOUNTING.
Section 210-0000, COOLING SYSTEM.
SM 2384 05-06 13
Section 110-0030
20. Fill the engine with lubricant through oil filler to the top Every 250 Hours
mark on dipstick (6). Refer to Section 300-0020,
Engine (1): Drain engine oil and refill. Refer to Section
LUBRICATION SYSTEM for oil specification.
300-0020, LUBRICATION SYSTEM for oil
specification.
21. Check all line and pipe connections for leaks prior
to starting the vehicle. Tighten as required.
Engine Oil Filters (2): Replace oil filters as follows:
22. Switch the battery master switch to the 'On'
1. Using filter wrench, remove and discard both oil
position, start up the engine and check for leaks.
filters (2) from engine (1). Inspect the sealing surface
Tighten lines, pipes and fittings and top up all systems
of the filter to ensure that the seal ring stayed with the
as required.
filter. If not, remove it from the filter adaptor.
23. Install hood assembly on the vehicle. Refer to
2. Clean the filter adaptor with a clean, lint free cloth.
Section 100-0040, HOOD AND MOUNTING.
3. Lightly coat new oil filter (2) seal with clean engine
Note: Check that gap between hood and cowl is correct
oil as specified in Section 300-0020, LUBRICATION
(12 mm (0.5 in) maximum).
SYSTEM.
24. Using suitable lifting equipment position front guard
4. Start a new oil filter (2) on the filter adaptor and
plate under the engine and secure to the frame with
tighten it by hand until the seal touches the adaptor
mounting hardware removed during removal.
filter head. Tighten an additional 2/3 of a turn after
contact.
25. Using suitable lifting equipment position engine
sump guard under the engine and secure to the frame
Note: Mechanical tightening of oil filters (2) is not
with mounting hardware removed during removal.
necessary and will distort or crack the adaptor. Tighten
oil filters by hand only.
26. Remove wheel blocks from all road wheels.
5. Repeat steps 3 and 4 for second oil filter (2).
MAINTENANCE
6. Start and run the engine for a short period and check
for oil leaks. If any leaks are noted, have them
corrected.
Note: Carry out the following maintenance procedures
in conjunction with additional procedures listed in
7. After the engine has been stopped long enough
Section 300-0020, LUBRICATION SYSTEM.
(approximately 20 minutes) for the oil from various
parts of engine (1) to drain back to the crankcase,
Every 10 Hours (Daily) check oil level and add oil to bring it to the proper level
on the dipstick. Refer to Section 300-0020,
Engine (1): Visually check engine for damage, loose or
LUBRICATION SYSTEM for oil specification.
frayed belts and listen for any unusual noises. Check
the turbocharger for leaks.
Fuel Filters (4 & 5): Replace primary fuel filter (4) and
secondary fuel filter (5) as follows:
Engine (1) Oil Level: Check engine oil level and add
Note: There is a fuel system shut off valve on the
oil if low.The dipstick is provided with a 'MIN' and
discharge side of secondary fuel filter (5). Closing this
'MAX' level band which the oil level should be within.
valve will prevent loss of fuel prime at time of filter
replacement.
Note: If checking the oil level after the vehicle has bee
running for any period, ensure the vehicle is parked on
1. Close shut off valve at secondary fuel filter (5) and,
level ground and has been stopped for a minimum of 3
using filter wrench, remove and discard both fuel filters
minutes to allow oil to drain into the sump.
(4 & 5) from engine (1).
2. Fill the replacement filters and coat the gaskets
Every 150 Hours slightly with clean fuel oil as specified in Section
Engine Air cleaner: Visual Check of inlet screen.
Clean. Refer to Section 110-0050, AIR CLEANER for
detail.
14 SM 2384 05-06
Section 110-0030
3. Start new primary fuel filter (4) on the filter adaptor 4. Start coolant filter (3) on the filter adaptor and tighten
and tighten it by hand until the gasket contacts the it by hand until the seal touches the adaptor filter head.
adaptor fully with no side movement of the filter Tighten an additional 2/3 of a turn after contact.
evident. Tighten an additional 1/2 of a turn.
Note: Mechanical tightening of fuel filters (4 & 5) is not Note: Mechanical tightening of coolant filter (3) is not
recommended, and may result in seal and/or cartridge necessary and will distort or crack the adaptor. Tighten
damage. Tighten fuel filters by hand only. coolant filter by hand only.
4. Repeat step 3 for secondary fuel filter (5). 5. Open shut off valves at coolant filter (3) inlet and
outlet lines.
5. Start the engine and check for leaks. If any leaks 6. Start the engine and check for leaks. If any leaks are
are noted, have them corrected. noted, have them corrected. Add coolant as required.
Refer to Section 210-0000, COOLING SYSTEM.
Every 500 Hours Engine Air Cleaner : Replace element. Refer to

Engine Air Cleaner : Visual Check of inlet screen. Section 110-0050, AIR CLEANER for detail.
Clean. Refer to Section 110-0050, AIR CLEANER for
detail.
Every 2000 Hours
Every 1000 Hours Engine (1) Steam Clean: clean engine to help
Coolant Filter (3): Check condition of coolant inhibitor maintain proper working order.
as described in Section 210-0000, COOLING
SYSTEM. Replace coolant filter (3) as follows: Engine Mounting Bolts (X): Check torque. (Torque
seal). Torque value should be 330Nm (239 Ibf ft).
Note: There is a shut off valve at the coolant inlet and
outlet lines of coolant filter (3). Closing these valves Every 3000 Hours
will enable coolant filter (3) to be replaced without an Engine Water Pump: Inspect water pump drain hole
excessive loss of coolant. and clean if required.
1. Close shut off valves at coolant filter (3) inlet and

outlet lines and, using filter wrench, remove and Drive Belt Adjustments
discard coolant filter (3) from engine (1). Every 50 Hours: Check all drive belt tensions and
adjust if required. If vehicle is equipped with air
2. Clean the filter adaptor with a clean, lint free cloth. conditioning, compressor belts should be checked and
adjusted as described in Section 260-0130, AIR
3. Lightly coat new coolant filter (3) seal with clean CONDITIONING.
engine oil as specified in Section 300-0020,
LUBRICATION SYSTEM. Every 2 000 Hours: Replace all drive belts.
Note: Replace all belts in a set when one is worn.
Single belts of similar size should not be used as a
substitute for a matched belt set as premature belt

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Locknut 921 680
1 11 Bolt 330 239
1 38 Bolt 81 - 95 60 - 70
1 41 Locknut 165 122
4 8 Bolt 68 50
4 9 Bolt 80 59
4 10 Bolt 36 26.5
SM 2384 05-06 15
Section 110-0030
wear can result due to belt length variation. All belts in SPECIAL TOOLS
a matched belt set are within 0.81 mm (0.032 in) of
their specified centre distances.
numbers of service tools which should be used in
Using belt tension gauge, adjust the belt tension to the
conjunction with procedures outlined in the engine
following values:
manufacturers service manual, and, general service
tools required. These tools are available from your
Note: A belt is considered 'Used' if it has been in dealer.
service for 10 minutes or longer. If the used belt
tension is less than the minimum value, tighten the belt
to the maximum value.
Belts should be neither too tight nor too loose. Belts

that are too tight impose excess loads on the alternator
bearings, shortening both belt and bearing life. A loose
belt will slip and may cause damage to accessory
components.
* * * *
16 SM 2384 05-06
ENGINE - Air Cleaner
Section 110-0050
SM - 3415
7
8
3
4
1 - Air Cleaner Body 5 - Mounting Band

2 - Primary Element 6 - Cover Assembly
3 - Safety Element 7 - Rain Cap
4 - Vacuator Valve
Fig. 1 - Exploded View of Typical Air Cleaner
DESCRIPTION AND OPERATION An air restriction pressure switch is located in the

Numbers in parentheses refer to Fig. 1. primary filter element, this senses when system air
flow is being restricted, a signal is then sent to the cab
The dual dry element air cleaner is remote mounted mounted Visual display unit displaying a symbol to
horizontally on the right hand side of the tractor frame. indicate to the operator that the filter element should be
The air cleaner prolongs engine life by removing grit, checked and changed if necessary.
dust and water from the air as it enters the engine. Grit
and dust, combined with engine oil, forms a highly While air restriction warning gauge indicates the need
abrasive compound which can destroy the engine in a for servicing, it does not give as precise a
comparatively short period of time. measurement as a water manometer or vacuum gauge.
Refer to 'Measuring Air Restriction'.
A rubber vacuator valve (4) attached to end cover (6) in
a downward position, ejects grit, dust and water while Secondary (safety) element (3) is installed in air
the engine is running. Vacuator valve (4) minimizes the cleaner body (1) inside of primary element (2). This
need for daily servicing. Even though vacuator valve element increases the reliability of the air cleaner’s
(4) is normally under a slight vacuum when the engine protection of the engine from airborne dirt. It protects
is running, pulsing of the vacuum opens and closes the the engine from dirt admitted by a damaged primary
rubber valve, expelling dust and water as they collect. element (2), or dirt that might be dropped into air
When the engine is stopped, vacuator valve (4) opens cleaner assembly while changing primary element (2).
and expels any accumulated grit, dust or water.
SM 2404 01-06 1
Engine - Air Cleaner
Section 110-0050
SM - 3416
15
AIR FILTER ELEMENT
WARNING SYMBOL
12 20 19 18 17
11 9
10
8
14 16 13
7
6
1
2 5
4
3
5
1 - Air Intake Tube 8 - Bolt 15 - Bolt

2 - Hose 9 - Lockwasher 16 - Lockwasher
3 - Clamp 10 - Washer 17 - Bolt
4 - Elbow 11 - Nut 18 - Washer
5 - Clamp 12 - Platform 19 - Spring Washer
6 - Reducer 13 - Bolt 20 - Nut
7 - Clamp 14 - Washer 21 - Air filter / element warning.
Fig. 2 - Exploded View of Typical Air Cleaner Mounting
AIR CLEANER 5. Remove bolts (13) and washers (14) securing

platform (12) to chassis frame brackets.
Removal
Numbers in parentheses refer to Fig. 2. 6. Using suitable lifting equipment, lift platform (12)
assembly clear of air cleaner body (1, Fig.1).
1. Position the vehicle in a level work area, apply the
parking brake. 7. Slacken clamps (3,5 & 7) securing hose (2), air
intake tube (1). elbow (4) and reducer (6).
2.Raise the hood by activating the appropriate request
button in the cab. 8. Remove bolts (8), nuts (11), lockwashers (9) and
2. Block all road wheels, switch off the engine, place washers (10) securing air cleaner to RH fender
the steering lock bar in the 'Locked' position and the brackets.
battery master switch in the 'Off' position.
9. Using suitable lifting equipment, support the air
4. Remove bolts (15) and lockwashers (16) securing cleaner assembly and draw air cleaner away from
platform (12) to top of RH fender. elbow (2).
2 SM 2404 01-06
Section 110-0050
10. Blank off all open ends with tape or cardboard to b. Check that air cleaner is mounted securely to the
prevent entry of dirt. RH fender support brackets.
11. If required, remove clamps ( 5 & 7), securing hose

(2), air intake tube (1), elbow (4) and reducer (6). MAINTENANCE
Remove all components from the vehicle. Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
Disassembly
Numbers in parentheses refer to Fig. 1, unless WARNING
otherwise specified. Always shutdown the engine before servicing
air cleaner.
Note: Air cleaner body (1) should be thoroughly
cleaned twice a year. Do not apply heat in any form to Check Visual display unit for air filter / element warning
air cleaner body (1). symbol. The air cleaner elements should be serviced
when the maximum allowable restriction has been
1. Release latches on cover assembly (6) and remove reached. The elements should not be serviced on the
cover assembly from air cleaner body (1). basis of visual observation as this would lead to over
service. When restriction readings finally indicate a
2. Remove primary element (2) and safety element (3) change, remove primary element (2) carefully and
from air cleaner body (1). clean/replace as required. Refer to 'Primary Element'.
3. Open mounting bands (5) and remove from air Never attempt to clean safety element (3). Change
cleaner body (1). safety element (3) after every third primary element (2)
service.
4. Slacken clamp (8), from the top port on the RH
fender and remove rain cap (8) from the RH fender. Make sure vacuator valve (4) is not damaged or
plugged and that the joint with cover assembly (6) is
5. Blank off air cleaner body (1) outlets with tape or not broken. If vacuator valve (4) is lost or damaged,
cardboard. Reach inside body with a compressed air replace it to maintain pre-cleaner efficiency and normal
nozzle or brush and remove dust from the body. filter element service life.
6. Remove all loose dust from air cleaner body (1) and Check condition of clamp (8), clamps (3,5 & 7, Fig. 2),
remove tape or cardboard from body outlets. elbow (4, Fig. 2) and air intake tube (1 Fig. 2). Tighten/
replace as necessary.
Assembly/Installation
otherwise specified. Primary Element
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT Although a paper primary element (2) is used, it is
TORQUE SPECIFICATIONS. possible to remove excess dirt by tapping element.
Assembly and installation of the air cleaner assembly 1. Release latches on cover assembly (6) and remove
is the reverse of disassembly and removal. Reset air cover assembly from air cleaner body (1).
restriction gauge (17).
2. Remove primary element (2) from air cleaner body (1)
Following installation, but before starting the engine, and clean/replace. It is advised to replace the element
the following system checks should be carried out: rather than attempt to clean thoroughly.
a. Check air intake tube (1), elbow (4) and hose (2) for 3. Using a damp cloth and a suitable solvent, wipe out
defects and that clamps (3,5 & 7) (and those supplied all excess dust from air cleaner body (1) and allow to
with the engine) are securely tightened to ensure that dry.
there are no leaks in the system. 4. Install primary element (2) in air cleaner body (1).
SM 2404 01-06 3
Section 110-0050
MEASURING AIR RESTRICTION

5. Install cover assembly (6) on air cleaner body (1)
and secure with latches.
As a dry air cleaner element becomes loaded with
Secondary Element dust, the vacuum on the engine side of the air cleaner
(air cleaner outlet) increases. This vacuum is generally
measured as 'restriction in mm (inches) of water'.
Since safety element (3) is protected from
The recommended maximum allowable intake
contamination by primary element (2), it needs no
restrictions at rated speed and load are as follows:
periodic cleaning and should be replaced only after
every third primary element (2) service.
a. 380 mm-H2O (15 in-H2O) with clean filter elements.
b. 635 mm-H2O (25 in-H2O) with dirty filter elements.
1. With primary element (2) removed from air cleaner
body (1), remove safety element (3).
While the air restriction gauge sends a signal to
indicate the need for servicing, it does not give as
2. Remove any dust dislodged into air cleaner body (1)
precise a measurement as a water manometer or
outlet and, using a damp cloth and a suitable solvent,
vacuum gauge.
wipe out all excess dust from air cleaner body (1) and
allow to dry.
Water Manometer
3. Install new safety element (3) followed by primary
a. Hold water manometer vertically and fill both legs
element (2) in air cleaner body (1).
approximately half full of water. Connect one of the
upper ends to port by means of a flexible hose.
4. Install cover assembly (6) on air cleaner body (1)
and secure with latches.
b. With the manometer held vertically and the engine
drawing maximum air, the difference in height of the
Recommendations water columns in the two legs is measured as the air
cleaner restriction.
c. If the restriction exceeds the levels indicated, engine
1. Under no condition should the vehicle be operated
performance will be affected. Primary filter element
without both filter elements in each air cleaner
should be cleaned or replaced.
assembly.
Vacuum Gauge
2. It is very important that elbow (4), hose (2) and air
intake tube (1) from the air cleaner assembly to the
a. Connect the hose from the vacuum gauge to
engine be airtight or the purpose of the air cleaner will
port and, with the engine drawing maximum air, take a
be completely defeated. All clamps (3,5 & 7) (and
note of the reading on the gauge.
those supplied with the engine) should be checked
frequently and tightened to prevent leaks.
b. If the restriction exceeds the levels indicated, engine
performance will be affected. Primary filter element
3. Keep new or cleaned filter elements on hand for
should be cleaned or replaced.
replacement to prevent unnecessary downtime of the
vehicle.
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.
* * * *
4 SM 2404 01-06
Transmission - Transmission and Mounting
Section 120-0010
SM - 3486
16 19
20
17 12
18 21
13 22
14 23
15
14
6
6
5
10 5
11 10
3 11
RH 2
LH
8
9 24
9
8
24
1
1
25
4
7 4
26 7
1 - Isolation Mount 8 - Bolt 14 - Clip 20 - Bolt

2 - Mounting Bracket 9 - Lockwasher 15 - Hose 21 - Lockwasher
3 - Mounting Bracket 10 - Bolt 16 - Bolt 22 - Washer
4 - Snubbing Washer 11 - Lockwasher 17 - Washer 23 - Bracket
5 - Washer 12 - Dipstick 18 - Locknut 24 - Boss
6 - Bolt 13 - Tube assembly 19 - Clamp 25 - Drain Plug (non drip)
7 - Nut 26 - Hose adaptor
Fig. 1 - Exploded View of Transmission and Mounting
DESCRIPTION
secured via mounting brackets (2 & 3, Fig. 1) on either
side of the transmission. Isolation mounts (1) provide
sufficient flexibility to absorb varying transmission
For transmission make, model and specification, refer
vibration and torsional loads.
to Section 000-0000, GENERAL INFORMATION. For
transmission servicing and repair data refer to
The transmission consists of a number of major
transmission manufacturer service manual.
assembly 'modules'. Integral with the transmission
assembly are torque converter and planetary gearing
The transmission convertor housing module is close-
modules.There are six forward gears, one reverse gear
coupled to the engine output flywheel housing, as the
and a neutral position, with automatic lockup in all
engine is secured to the chassis frame via isolation
speed ranges. Operation of the transmission is
mounts at it's front, refer to Section 110-0030 ENGINE
signalled by the electronic shift control via the 4th GEN
AND MOUNTING for specific arrangement details, this
CONTROL system.
in turn means that the front of the transmission is
secured in place. At its rear, the transmission is
SM 2416 Rev1 03-07 1

Section 120-0010
SM - 3487
4 5 6 7 10
8 9
1
11
12
2
20
3
13
17
14
x
18
16 15
19
1 -Turbine 7 - C2 Clutch 14- C5 Piston

2 - Stator 8 - C3 Clutch 15- Electro-hydraulic Control Module
3 - Lockup 9 - C4 Clutch 16- Rotating Clutch
4 - Torque Convertor Pump 10 - C5 Clutch 17- Turbine Shaft
5 - Charging Oil Pump 11 - P1 Module 18- Engine Speed Sensor
6 - C1 Clutch 12 - P2 Module 19- Turbine Speed Sensor
13 - P3 Module 20- Output Speed Sensor
Fig. 2 -Sectional View Of Typical 4000 Series Transmission.
A brief description and operation of the main Convertor Housing module

transmission modules follows: The convertor housing module connects the engine and
the gearbox modules. The provision for the Power take
Numbers in parentheses refer to Fig. 2 unless Off (PTO) is on the convertor housing, with the helical
otherwise stated. PTO drive gear contained internal. The turbine shaft
(17) passes through the convertor housing to the
INPUT MODULES transmission gearbox module. PTO gear hub is driven
at engine speed by the torque convertor pump (4) hub
Input modules are required to connect the transmission drive. In turn the PTO gear hub drives the charging
to the engine, an input module is located between the pump (5).
engine and transmission gearbox modules. Input Power takeoff at the left hand side of the transmission
modules include; Torque convertor module, Convertor provides the drive for the main hydraulic pump which
housing and front support/ charging pump module. supplies the braking, steering and body hoist systems.
Refer to SECTION 120-0090 POWER TAKEOFF for
Torque convertor module details.
The torque convertor operates hydraulically and
transfers torque from the engine to transmission. It Front Support/ Charging Pump module
consists of a vaned turbine (1), a vaned stator (2) and The front support is bolted to the transmission main
a lockup clutch/ torsional damper assembly (3). housing and contains the convertor ground sleeve
2 SM 2416 Rev1 03-07

Section 120-0010
through which the turbine shaft passes to the rotating Output Retarder module
clutch assembly. The charging pump pressurizes the The output retarder module is to assist in stopping the
transmission fluid. Charging pump rotates with engine vehicle and controlling the downhill speed of the
to provide a constant flow of pressurised fluid for the vehicle.
transmission hydraulic system.
ELECTRO-HYDRAULIC CONTROL MODULE (15)
GEARBOX MODULES
The basic gearbox modules contain five clutch The control module houses the solenoids, sensors,
assemblies and three planetary gear sets to provide six valves and regulators that control the pressure and flow
forward speeds, neutral and one reverse. of the transmission fluid to the clutches, the torque
convertor and the lubricating/ cooling hydraulic circuits.
Rotating Clutch module The control module also houses the transmission fluid
The rotating clutch (16) hub assembly is spilined to the filters.
turbine shaft (17) and rotates with the turbine (1). The
rotating clutch module contains the turbine shaft
assembly, rotating clutch hub assembly, C1 and C2 (6 TRANSMISSION CONTROL MODULE
& 7) clutch assemblies, rotating clutch drum and sun (TCM).
gear drive hub assembly for the P1 planetary gear set.
Refer to Figures 3 & 4 unless otherwise stated.
Main Housing module SM - 3489
The main housing module consists of the C3, C4 and
C5 clutches (8,9 & 10), ring gear component of the P1
planetary gear set and the transmission main housing.
The clutches in the main housing are stationary clutch
assemblies and do not rotate when hydraulically
applied. The ECU signals solenoid valves in the control
module to apply and release clutches based on power
and speed requirements.
Fig. 3 - Transmission Control Module (TCM).
P1Planetary Gear module (11)
P1 is the first planetary gear set assembly, consisting WARNING
of - sun gear driven by the rotating clutch drum. P1 Heatsink of the TCM must be electrically
carrier assembly containing P1 pinion gears and the P1 isolated from all vehicle electrical systems
ring gear housed in the C3 clutch assembly. including chassis ground!
P2 Planetary Gear module (12)

The transmission control module is the "brain" of the
P2 is the second planetary gear set assembly,
system. The independent controller is configured to run
consisting of a sun gear splined to the main shaft. P2
off 24V. The TCM receives and processes signals from
carrier assembly containing the P2 pinion gears and P2
various switches and sensors. These inputs are
ring gear splined to P1 carrier.
processed and the TCM determines the optimum shift
sequences, timing and clutch apply / release
Main Shaft module 13) pressures. This is done by controlling the transmission
The main shaft module passes through the centre of solenoids and valves.
the transmission gearbox. The P2 and P3 sun gears
are part of or splined to the main shaft, enabling it to SM - 3488
transmit torque to the rotating clutch module. Input SHIFT SELECTOR
torque to the main shaft is received either through

rotating clutch module or the P2 carrier. This main SPEED SENSORS OIL LEVEL SENSOR
shaft provides the primary path for transmitting torque THROTTLE POSITION SENSOR SOLENOIDS
through the various stages of the transmission. RETARDER MODULATION TCM DIAGNOSTIC PRESSURE SWITCH
VEHICLE/ENGINE
TEMPERATURE SENSOR
COMMUNICATION LINKS
(SUMP / RETARDER)
OUTPUT MODULES
The output modules contain components that transmit
power and torque to the vehicle driveline. The output INPUTS OUTPUTS
centerline of the transmission is in line with the SWITCHES,SENSORS & SOLENOIDS

transmission input centreline. Fig. 4 - TCM inputs / Outputs.
SM 2416 Rev1 03-07 3

Section 120-0010
SM - 3490
1 - Engine Speed Sensor

2 - Turbine Speed Sensor
3 - Output Speed Sensor
4 - Electro-hydraulic Control Module
5 - Internal wiring harness location
6 - OLS Oil level sensor
10
7 - OTS Oil temperature sensor
8 - Solenoid Locations
9 - Transmission filters
10 - Transmission retarder
6
9
1
2 8
9
3 4
7
Fig. 5 - Location of transmission switches, sensors and Solenoids.
Numbers in parentheses refer to Fig. 5, unless temperature critical warning to be displayed on the
otherwise specified. VDU screen.
Transmission Oil Temperature Transmission Oil Level

Trans. oil temperature is monitored by the temp. The transmission oil level is constantly monitored by
sensor (7) contained within the internal wiring harness the Oil level sensor (OLS) (6) located within the control
(5) of the transmission, located within the main control module. The oil level can be checked and monitored
module. Oil temperature sensor (7) senses via the display on the gearshift lever. To enter the oil
transmission oil temp. and sends a signal back to the information sequence, pressing the display mode
TCM, which in turn transmits the data on the J1939 button once on the gear shift lever. A two minute
datalink, where it is read by the Instrument panel ECU countdown will begin when the following conditions of
and is displayed on the Instrument panel by the temp the vehicle system are met:
gauge.
1. Engine at idle.
The transmission temp. should read between 60°C and 2. Oil is at operating temp. within range 82-104° C.
135°C during normal operating and may reach 165°C 3. Transmission is in neutral 'N'.
when using the retarder. If the gauge reads above this, 4. Transmission output shaft is stationary.
the transmission shifted to neutral and engine speed
increased to 1 200 - 1 500 rev/min. Under this For further detail on displaying oil levels, refer to
condition, oil temperature should drop to normal values gearshift displaying OLS information detail.
in about 2 - 3 minutes. If oil temperature does not drop,
the cause should be investigated.
Should the transmission reach a critical temperature
condition, this will cause the transmission oil
4 SM 2416 Rev1 03-07

Section 120-0010
SM - 3597
5
4
6
7 3
1 - SS1 (Shift Solenoid) 5 - PS1 (Pressure Switch)

2 - PCS 2 (Proportional Control Solenoid) 6 - MODULATED MAIN Solenoid
3 - PCS1 (Proportional Control Solenoid) 7 - PCS4 (Proportional Control Solenoid)
4 - TCC (Torque Convertor Clutch) 8 - PCS3 (Proportional Control Solenoid)
Fig. 6 - Control Valve Solenoid Designation & Internal wiring harness.
Lockup Clutch Transmission output speed must be below 250RPM

The transmission lockup clutch (3, Fig 2) is in reverse,neutral,1st or 2nd range.
automatically engaged. Engine speed is picked up by PTO input must be off
turbine speed sensor (2) which sends a signal to
energise the normally closed TCC solenoid (3, Fig. 6) A shift must not be in progress.
when turbine speed reaches a predetermined level. Shift Solenoid
Energising TCC (3, Fig. 3).
Normally closed On/Off SS1 (1, Fig. 6) controls fluid
Modulated Main
flow to the top of the latch valves.
4th Gen controls include modulated main pressure for
PCS Solenoids
improved cooler flow and reduced charging pump loses
at low engine and output shaft speeds. The modulated PCS1 through PCS4 produce pressure that is
main solenoid (6 Fig. 6) is a normally closed; On/Off proportional to the current supplied by the TCM.
solenoid.
PCS1 is normally open
The TCM (Fig. 3) commands the modulated main
solenoid on when all of the following conditions are PCS2 is normally open
met- PCS3 is normally closed
• Sump temperature must be between 35 & 145°C. PCS4 is normally closed.
Engine RPM must be less than 1200RMP in all Diagnostic Pressure Switch
ranges (except neutral- no restriction).
PS1 (5, Fig. 6) is a normally closed switch which
Throttle position must be less than 18% in all ranges
monitors the C3 clutch pressure, verifying the position
(except neutral-no restriction)
of C1 and C2 latch valves.
SM 2416 Rev1 03-07 5
Section 120-0010
OPERATION SM - 3491
4th Gen Automatic Shift Control 1
Numbers in parentheses refer to Fig. 7 unless

otherwise stated.
The 4000 series transmission is equipped with 4th
1
2
3
DE
4
CT
Generation controls and shift selector lever. The shift
MO
5
LE
D
SE
N
R
selector communicates with the transmission TCM via
OR
NIT
the J1939 datalink. The shift selector is a remote
MO
mounted lever type. The selector has a 2-digit LED 2
display, that during normal operation will display the 3
range selected and range attained.
4
5
There is a hold override button (1) that must be
pressed when shifting between R,N and D. The hold
override button (1) is released when the desired 1 - Hold/Override Button 4 - Range Attained
2 - Mode Button 5 - Display Mode Button
selector position is reached. The selector can move 3 - Range Selected
freely between D and the number ranges without
pressing the override button.
Fig. 7 - 4th Gen Gear Shift Lever
The transmission upshifts and downshifts
automatically between first range and the highest range
Failure to meet any of the conditions 1-4 previously
selected on the selector in direct response to throttle
listed, will stop the 2 minute countdown and the shift
position and transmission output speed. When reverse
lever will display one of the following codes-
range is selected, the reverse alarm sounds and the
reverse light illuminates at the rear of the truck.
oL0X Setting time too short.
oL50 Engine RPM too low.
The shift selector can be used to display a number of
oL59 Engine RPM too high.
parameters, including oil level information and
oL65 Neutral not selected.
transmission fault code information.
oL70 Sump fluid temperature too low.
oL79 Sump fluid temperature too high.
Displaying Oil Level Information (OLS) oL89 Output shaft rotation detected.
oL95 Oil level sensor failed.
To enter the oil information sequence, press the
display mode (5) button once on the gear shift lever. A Displaying Diagnostic Fault codes
2 minute countdown begins when the following Should there be a transmission fault, the check
conditions are met - 1.Engine at idle, 2. Oil at operating transmission warning light will illuminate at the top of
temp 82-104°C, 3. transmission in neutral and 4. the instrument panel bank of warning symbols,
transmission output shaft stationary. indicating that the TCM has registered a diagnostic
code. As many as five codes may be recorded in
The oil level will be displayed at the end of the 2
memory, listed in order of newest to oldest. In which
minute countdown (to facilitate constant oil drain back).
case, fault codes can be retrieved through the 4th Gen
During the countdown, the display flashes out a
shift selector lever.
numerical value starting at '8' in 15 second intervals,
decreasing in value by 1 each time in sequence i.e. To enter the diagnostic code sequence, press the
8,7,6,5,4,3,2 & 1. After the number sequence the display mode button (5), twice on the shift lever. Each
display will then sequentially flash the oil level code consists of 4 sequential elements; each being 1
information, 2 characters at a time; the following may or 2 characters. The display for each code will repeat
be displayed: continuously until the next code is displayed (if
oL ; oK Oil level OK present). To display the next code if present, press the
oL ; Lo Oil level low 1 quart- or as many as req. mode button (2). The following cycle illustrates the
oL ; HI Oil level high 1 quart- or as many as req. display cycle:
(1 US quart = 0.95Litre = 0.2 gallon).
6 SM 2416 Rev1 03-07

Section 120-0010
d1 Code list position (d1 newest, d5 oldest). The retarder may be used at any time to slow the
P vehicle down. If additional braking is required apply the
service brakes.
25
34 Note: The retarder is not meant for bringing the vehicle
Code repeats until the next code (d2) is accessed by to a stop, service brakes should be used for stopping.
pressing the mode button (5)
The retarder consists of a stator, rotor, housing and
Clearing Diagnostic Fault codes control valve body assembly. The rotor is splined to
the transmission output shaft and is driven at output
To clear active codes, press and hold the mode button
shaft speed. The retarder stator, rotor and housing all
(2) for 3 to five seconds. Similarly to clear inactive fault
have integral vanes. The rotor rotates between the
codes, press and hold the mode button (2) for 8 to 10
stationary stator and retarder housing.
seconds.
Exiting Diagnostic mode Retardation occurs when the retarder housing is filled
with transmission fluid and pressurized, thus impeding
Any of the following methods may be used to exit the and slowing the rotor, output shaft and vehicle.
diagnostic display mode -
\ Momentarily press the display mode button (5). For the retarder to engage, certain conditions must be
satisfied:
Move the gearshift lever to any other position that the
one selected when the diagnostic display mode was 1. Accelerator released.
activated. 2. Transmission 'STOP' warning light must be out.
4 Wait until time out (approx. 10 minutes). The system 3. Transmission must be in lockup.
automatically returns to normal operating mode.
Turn the vehicle off - Eliminating power to SM - 3492
transmission ECU.
L
Mode selection / Shift Schedule 1

2
The mode button (2) gives the option to select between
'POWER' (primary shift schedule) and 'ECONOMY'
(secondary shift schedule) shift schedules which are
preprogrammed into the TCM memory. The
transmission must be in neutral before the switch will
function. Proper selection of the shift schedules
permits vehicle operation to be tailored towards fuel 1 - Retarder Request Switch.
economy or maximised performance. 2 - Retarder Lever ( 6-position)
The primary shift schedule is the default setting each Fig. 8 - Retarder Req. Sw / Percentage Lever.
time the vehicle is started. This is used for normal
operation. The secondary shift schedule can be
requested by pressing the Mode button. A small red To apply the retarder, the dash mounted retarder
light next to the mode button indicates that the function request switch must be on (1, Fig. 8). A signal is then
has been selected. sent to the TCM to request retarder operation, when all
conditions are met.
Transmission Retarder
The amount of retardation requested, is operator
The transmission retarder is used to assist in stopping dependant. This is done via the six-position lever on
the vehicle and reduce the need for service brake the right hand switch bank (2, Fig. 8). With maximum
applications, thus reducing service brake ware and retardation requested in the lowest position.
preventing overheating.
SM 2416 Rev1 03-07 7

8
Section 120-0010
Gear activation
The following table shows the condition of the individual solenoids, switched and latch valves to attain the full range of gears from the transmission. Note:
Intermediate stages i.e. neutral to reverse, have been ommitted, only the range attained is listed. For where to check pressure setting and measure
pressure values, see following detail.
Range Attained Solenoid Energised Latch Valve Position PS1 position Main Mod Press. Solenoid. SS1 Clutch apply
PCS1 PCS2 PCS3 PCS4 C1 C2 Open Closed Energised De-energized Energized
Neutral X X X Up Up X X C5
1st X X Down Up X X C1 + C5
2nd X X Down Down X X X C1 + C4
3rd X X Down Down X X X C1 + C3
4th Down Down` X X X C1 + C2
5th X X Down Down X X X C2 + C3
6th X X Up Down X X C2 + C4
Reverse X X Up Up X X C3 + C5
Main pressure modulation is checked at idle in Neutral, reverse, 1st convertor and second convertor. Main modulation pressure is checked at high speed
in neutral only. RPM in range 1780 - 1820.
SM 2416 Rev1 03-07
Section 120-0010
SM - 3493
LOCKUP PRESSURE DRAIN PLUG

TAP
MAIN
C4 C5
C3
C1 C2
MAIN
LUBE
OIL FILTER
COVERS
LUBE PRESSURE CLUTCH PRESSURE

TAP TAPS
Fig. 9 - Pressure Check Points
PRESSURE CHECKS
Note: Check to see if there are diagnostic codes 2. Bring the transmission to normal operating
present that are related to the transmission temperature of 71 - 93 Deg. Celcius (160- 200 Deg F).
difficulty which is being experienced. Proceed to Check for fluid leaks in the circuit being checked. Be
make mechanical preparations for checking clutch sure that fluid level is correct.
pressures only after codes have been evaluated
first. 3. Compare clutch pressures recorder with those given
in the table. If clutch pressures are not within
Checking individual clutch pressures helps to specification take corrective action to redeem the fault.
determine if a transmission malfunction is due to a
mechanical or an electrical problem. Properly making 4. Main pressure modulation is checked in neutral,
these pressure checks requires transmission and reverse, 1st and 2nd converter.
vehicle preparation, recording of data and comparing
data against specifications provided. 5. Main pressure modulation is checked at high speed
in neutral only.
1. Remove plug from the pressure tap and install a
suitable hydraulic fitting and pressure gauge at location Refer to the following tables on pages 10 & 11, which
where measurement is desired. Pressure gauge set should be used as reference for checking pressures
J26417-A is available. and troubleshooting the system.
Note: Allison DOC or Pro-link should be used for

measuring engine speed.
Note: Transmission sump fluid temperature can be

measured using Allison DOC or Pro-link.
WARNING
Be sure that the transmission has enough fluid
for cold operation until an operating fluid level
can be set.
SM 2416 Rev1 03-07 9

Section 120-0010
SM - 3562A
Engine Range Clutches Main Press. Range Clutch Conv.Out Lube LU Clutch
RPM Applied Spec. Press. Spec* Press. Spec Press. Spec Press. Spec*
Idle Neutral C5 218 - 319 0 - 5.8 (C5) -
Reverse C3 C5 218 - 319 0 - 5.8 (C3 & C5) 0.5 min
1C C1 C5 189 - 261 0 -10 (C1) 0.5 min
0 - 5.8 (C5)
2C C1 C4 189 - 261 0 - 10 (C1) 0.5 min
0 - 5.8 (C4)
1780 - Neutral C5 261 - 319 0 - 5.8 11 - 44 7 - 28
1820 Reverse C3 C5 261 - 319 0 - 5.8 (C3 & C5) 25 - 44 17 -28
1C C1 C5 225 - 261 0 -10 (C1) 25 - 44 17 - 28
0 - 5.8 (C5)
2C C1 C4 225 - 261 0 -10 (C1) 25 - 44 17 - 28
0 - 5.8 (C4)
2L C1 C4 LU 152 - 203 0 - 10 (C1) 29 - 51 20 - 28 0 - 8.7
0 - 5.8 (C4)
3C C1 C3 225 - 261 0 -10 (C1) 25 - 44 17 - 28
0 - 5.8 (C3)
3L C1 C3 LU 152 - 203 0 -10 (C1) 29 - 51 20 - 28 0 - 8.7
0 - 5.8 (C3)
4C C1 C2 225 - 261 0 -10 (C1) 19 -36 13 - 22
0 -10 (C2)
4L C1 C2 LU 152 - 203 0 -10 (C1) 23 - 44 16 - 22 0 - 8.7
0 -10 (C2)
5C C2 C3 184 - 247 0 -10 (C2) 19 - 36 13 -22
0 - 5.8 (C3)
5L C2 C3 LU 131 - 181 0 -10 (C2) 23 - 44 16 - 22 0 -8.7
0 -5.8 (C3)
6C C2 C4 184 - 247 0 -10 (C2) 19 - 36 13 -22
0 - 5.8 (C3)
6L C2 C4 LU 131 -181 0 -10 (C2) 23 -44 16 -22 0 - 8.7
0 - 5.8 (C4)
Note: Pressure values are given in 'psi'
* Subtract clutch pressure from main pressure; the difference must fall within the specification given.
10 SM 2416 Rev1 03-07

Section 120-0010
SM - 3496
No. COLOUR WIRE# DESCRIPTION
3 W 103 Signal Return

4 S 104 Engine Brake Enable
5 B/S 105 Diff Lock Relay
7 Y 107 Link For Termination Resistor(J1939)
9 B 109 Battery Ground
10 R 110 Battery Supply
11 O 111 PCS4 Modulated Main
12 K 112 Sensor Supply
15 W 115 Retarder Solenoid Supply 61 41 21 1
16 U 116 Oil Level Sensor Signal
19 - - 25 Ohm 3 watt Resistor
20 U 120 Turbine Speed Sensor Low
21 P/R 121 Not Used
61
41
21
1
24 Y/W 124 Retarder Warning Lamp
25 R/W 125 Not Used
28 Y 128 Link For Termination Resistor (J1939)
29 B/N 129 Check Transmission Lamp
30 W/U 130 Mid Axle Diff Lock Relay Enable
31 Y 131 Retarder/Lock Up Solenoid Return
33 Y 133 PCS3 Solenoid Supply
34 W 134 Shift Selector Position Indentifier
36 O 136 PCS1 Solenoid Supply
37 W 137 TCC Solenoid Supply
39 O 139 Engine Speed Sensor Low
40 G 140 Output Speed Sensor Low
41 W/G 141 Neutral Start Relay
42 N/Y 142 Range Inhibit
43 O/B 143 Diff Lock Request
48 U/R 148 CAN 1 Controller , High (+) (J1939)
49 U/Y 149 CAN 1 Controller Shield
51 W 151 SS1 Shift Solenoid
52 G 152 PCS2 Solenoid
54 N 154 Sump Temperature Signal
55 W 155 PCS4 Solenoid
56 Y 156 Retarder Modulation Request
57 K/S 157 Engine Brake Request
58 W/B 158 Analogue Return
59 N 159 Engine Speed Sensor High
60 Y 160 Output Speed Sensor High
61 W/S 161 Retarder Request
62 N 162 Service Brake Status
63 R 163 Ignition Battery Power
64 O/B 164 Sump retarder temp indicator
65 U/Y 165 Reverse Warning Signal
68 G 168 CAN 1 Controller, Low (-) (J1939)
69 B 169 Battery Ground
70 R 170 Battery Supply
71 Y 171 PCS1, PCS2, PCS3 & SS1
80
60
40
20
74 U 174 Modulated Main Solenoid Low

75 O 175 Retarder Temperature
76 Y 176 Trans ID
77 G 177 Diagnostic Pressure Switch
80 O 180 Turbine Speed Sensor High (+) 80 60 40 20
Fig. 11 - Transmission TCM Pin Designations
SM 2416 Rev1 03-07 11

Section 120-0010
TRANSMISSION TCU CONNECTIONS temperature drops to normal operating range. In most

cases, a minor fault triggering the check trans warning
The transmission TCM has one 80-pin connector that light will not prevent normal operation from continuing
provides the inputs and outputs for transmission but, depending on the nature of the problem, the TCM
functions. Refer to Fig. 11 for specific detail. could take action to protect the transmission from damage,
such as preventing operating in high gear ranges. If the
check trans light comes 'On', have the problem
WARNING
diagnosed and corrected at the earliest opportunity.
Before any welding is done on a machine
equipped with a 4th GEN system, disconnect
the following in this order: Battery earth cable, TROUBLE-SHOOTING DIAGNOSTIC
battery supply cable, alternator earth cables,
alternator supply cables and electrical
CODES.
connections at the engine ECM, transmission
TCM and cab bulkhead to avoid damage to Note: Refer to tables on pages 12 - 15 for a full list of
electrical components. Turn off ignition key diagnostic codes and their description.
switch to isolate the batteries before
GENERAL TROUBLESHOOTING
Performance Complaints
Make the following general checks before beginning
For colour designations, refer to 'Wire colours' in specific troubleshooting.
ELECTRICAL SYSTEM -Circuit Diagrams SECTION
190-0000. Colour designations not listed, use the • Are there active diagnostic codes?
following for reference:
• Is the shift lever in N to allow engine start?
GRY - Gray TN - Tan PNK - Pink • Is the battery properly connected and charged?
• Are all fluid levels correct?
• Is the voltage to the TCM correct?
SM - 3494 • Is engine properly tuned?
• Is fuel flow to the engine correct?
1 • Is air flow to the cooler and radiator unrestricted?
• Is the driveline properly connected?
P
• Are there signs of fluid leakage under the vehicle?
•
2 STOP
1
What is the origination point of this leak?
• Are all hydraulic connections leak free?
• Are all electrical connections correct?
Fig. 12 - Warning Light
After making these checks, Some complaints involve
diagnostic codes, so all troubleshooting checks should
Check Trans Warning Light (Fig. 12) - Illuminates to involve checking the system for diagnostic codes.
alert of a minor fault in the transmission control system
or abnormal transmission temperature. The light will
come 'On' when the ignition key switch is turned to
position '1' to provide a bulb and system check and
should go 'Off' a few seconds after the engine is
started and the transmission oil pressure rises.
The check trans warning light will come 'On' during
operation, if the TCM has detected a minor fault in an
electrical component or abnormal transmission oil
temperature. If transmission oil temperature is too high,
stop the vehicle, select neutral 'N', and increase engine
speed to allow a greater flow of oil to the cooler until oil
12 SM 2416 Rev1 03-07

Section 120-0010
Code Meaning of code / Possible Cause of Fault

C1312 Retarder Request Sensor Failed Low
C1313 Retarder Request Sensor Failed High
P0122 Pedal Position Sensor Circuit Low Voltage
P0123 Pedal Position Sensor Circuit High Voltage
P0218 Transmission Fluid Over temperature
P0561 System Voltage Low Performance
P0562 System Voltage Low
P0563 System Voltage High
P0602 TCM Not Programmed
P0610 TCM Vehicle Options Error (Trans ID)
P0613 TCM Processor
P0614 Torque Control Mismatch (ECM/ TCM)
P0634 TCM Internal Temperature Too High
P063E Auto Configuration Throttle Input Not Present
P063F Auto Configuration Engine Coolant Temperature Input Not Present
P0658 Actuator Supply Voltage 1 Low (HSD 1 open/gnd)
P0659 Actuator Supply Voltage 1 High (HSD 1 batt)
P0701 Transmission Control System Performance
P0702 Transmission Control System Electrical (Trans ID)
P0703 Brake Switch Circuit
P0708 Transmission Range Sensor Circuit - High Input
P070C Transmission Fluid Level Sensor Circuit - Low Input
P070D Transmission Fluid Level Sensor Circuit - High Input
P0711 Transmission Fluid Temp. Sensor Circuit Performance
P0712 Transmission Fluid Temperature Sensor Circuit Low Input
P0713 Transmission Fluid Temperature Sensor Circuit High Input
P0716 Turbine Speed Sensor Circuit Performance
P0717 Turbine Speed Sensor Circuit No Signal
P071D General Purpose Input Fault
P071A RELS Input Failed On
P0720 Output Speed Sensor Circuit
P0721 Output Speed Sensor Circuit Performance
P0722 Output Speed Sensor Circuit No Signal
P0726 Engine Speed Input Circuit Performance
P0727 Engine Speed Input Circuit No Signal
P0729 Incorrect 6th Gear Ratio
P0730 Incorrect Gear Ratio
P0731 Incorrect 1st Gear Ratio
P0732 Incorrect 2nd Gear Ratio
P0733 Incorrect 3rd Gear Ratio
P0736 Incorrect Reverse Ratio
P0741 Torque Convertor Clutch System Stuck Off
P0776 Pressure Control Solenoid 2 Controlled Clutch Stuck Off
P0777 Pressure Control Solenoid 2 Controlled Clutch Stuck On
SM 2416 Rev1 03-07 13

Section 120-0010

P0842 Transmission Pressure Switch Solenoid 1 Circuit Low
P0843 Transmission Pressure Switch Solenoid 1 Circuit High
P0880 TCM Power Input Signal
P0881 TCM Power Input Signal Performance (Battery Voltage)
P0882 TCM Power Input Signal Low (Battery Voltage)
P0883 TCM Power Input Signal High (Battery Voltage)
P0960 Main Pressure Modulation Solenoid Control Circuit Open
P0961 Main Pressure Modulation Solenoid System Performance
P0962 Main Pressure Modulation Solenoid Control Circuit Low
P0963 Main Pressure Modulation Solenoid Control Circuit High
P0964 Pressure Control (PC) Solenoid 2 Control Circuit Open
P0965 Pressure Control (PC) Solenoid 2 System Performance
P0966 Pressure Control (PC) Solenoid 2 Control Circuit Low
P0967 Pressure Control (PC) Solenoid 2 Control Circuit High
P0968 Pressure Control (PC) Solenoid 3 Control Circuit Open
P0972 Shift Solenoid (SS) 1 Control Circuit Open
P0973 Shift Solenoid (SS) 1 Control Circuit Low
P0974 Shift Solenoid (SS) 1 Control Circuit High
P0975 Shift Solenoid (SS) 2 Control Circuit Open
P0976 Shift Solenoid (SS) 2 Control Circuit Low
P0977 Shift Solenoid (SS) Control Circuit High
P0989 Retarder Pressure Sensor Failed Low
P0990 Retarder Pressure Sensor Failed High
P1739 Incorrect Low Gear Ratio
P1891 Throttle Position Sensor PWM Signal Low Input
P1892 Throttle Position Sensor PWM Signal High Input
P2184 Engine Coolant Temperature Sensor 2 Circuit Low
P2185 Engine Coolant Temperature Sensor 2 Circuit High
P2637 Torque Management Feedback Signal (SEM)
P2641 Torque Management Feedback Signal (LRTP)
P2670 Actuator Supply Voltage 2 Low (HSD 2 gnd)
P2671 Actuator Supply Voltage 2 High (HSD 2 batt/open)
P2685 Actuator Supply Voltage 3 Low (HSD 2 gnd)
P2686 Actuator Supply Voltage 3 High (HSD 3 batt/open)
P2718 Pressure Control (PC) Solenoid 4 System Open
14 SM 2416 Rev1 03-07

Section 120-0010

P2740 Retarder Oil Temperature Hot
P2742 Retarder Oil Temperature Sensor Circuit - Low Input
P2743 Retarder Oil Temperature Sensor Circuit - High Input
P2761 TCC PCS Control Circuit Open
P2762 TCC PCS Control Circuit Range/ Performance
P2763 TCC PCS Control Ciruit High
P2764 TCC PCS Control Circuit Low
P278A Kickdown Input Switch Circuit
P2793 Gear Shift Direction Circuit
U0001 Hi Speed CAN Bus Reset Counter Overrun (CAN2/IES CAN)
U0010 CAN Bus Reset Counter Overrun (CAN1/J1939)
U0100 Lost Communication with ECM / PCM "A"
U0073 CAN Bus Reset Counter Overrun (CAN2/GMLAN)
U0103 Lost Communication With Gear Shift Module 1
U0115 Lost Communication with ECM / PCM "B"
U0291 Lost Communication with Gear Shift Module 2
U0292 Invalid Data received from Gear Shift Control Module 2
U0304 Software Incompatibility With Gear Shift Control Module 1
U0333 Software Incompatibility With Gear Shift Control Module 2
SM 2416 Rev1 03-07 15

Section 120-0010
REMOVAL 5. Remove blanking cap from remote drain line at the

bottom of the hydraulic tank. Install a length of hose on
Numbers in parentheses refer to Fig. 1. remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
hose and reinstall blanking cap.
Note: Tag all lines, cables and linkages disconnected
during removal to aid in installation.
6. Disconnect transmission harness at the cab floor
and earth strap between rear LH side of the
WARNINGS transmission and the frame.
To prevent personal injury and property damage,
be sure wheel blocks, blocking materials and 7. Remove RH fender from the machine. Refer to
lifting equipment are properly secured and of Section 100-0070 FENDER AND MOUNTING.
8. Remove air filter from the machine. Refer to Section
Hydraulic oil pressure will remain within 110-0050 AIR CLEANER.
the braking system after engine shutdown.
Operate the treadle valve continuously until the 9. Remove cab from the machine. Refer to Section
pressure has dissipated before removing any 260-0010, CAB AND MOUNTING.
brake lines or serious injury could result.
10. Refer to Fig. 13. Remove chassis frame cross-
High electrical current can cause sparks member (1) from the machine. By removal of bolts (2),
and personal injury from burns. Turn battery washers (3) and nuts (4).
master switch to the 'Off' position before
SM - 3499
disconnecting any components.
1 4 3
1. Position the vehicle in a level work area, ensure the
2
body is fully lowered, apply the parking brake and switch
off the engine. Operate steering right and left several
times to relieve any pressure in the steering system.
2. Operate the treadle valve continuously to discharge the

brake accumulators, block all road wheels, place the
steering lock bar in the 'Locked' position and the battery
master switch in the 'Off' position.
3. Disconnect the following cables and connectors in

the order given, to prevent serious damage to the
vehicles electrical components.
a - Battery earth cables Fig. 13 - Chassis Cross-member

b - Battery supply cables
c - Alternator earth cables 11. Taking fabricated engine support bracket tooling
d - Alternator supply cables (refer to details at end of transmission section). Locate
e - Body hydraulics joystick and secure LH bracket and RH bracket to engine
f - Hydraulic ECU mounting holes and to chassis frame. Secure in place
g - Instrument panel (VDU) CPU using suitable bolts.
h - Transmission (4th GEN) connector
i - TCM interface harness connector (80 pin) Note: Height adjustment of RH bracket may be
j - ECM power harness connector (5 pin RHS) necessary to ensure mating to engine is correct.
k - ECM sensor harness connector (30 pin LHS)
l - ECM engine to transmission datalink connector 12. Remove drain plug (25) on base on transmission
(6 pin RHS) control module and drain transmission oil through hose
(26) into a suitable container.
4. Carefully loosen brake pipes at base of both
accumulators to check that brake pressure has been 13. Disconnect retarder and cooler hoses.
discharged. Tighten brake pipes.
16 SM 2416 Rev1 03-07
Section 120-0010
SM - 3502
9 10
8
6 7
4
16
1 3
11
12
13 14
15
(7,9,10 SAME ALL SENSORS)
Fig. 14 - Transmission Disassembly
14. Disconnect driveline connected from transmission and attach a hoist to make sure lifting attachments are
to dropbox and secure clear of the transmission. Refer placed so that the transmission is balanced.
to Section 130-0010, DRIVELINES.
20. Remove bell-housing bolts. Loosen off two engine /
15. Disconnect pressure and suction hoses from main transmission mounts and retract transmission via
hydraulic pump. Identify and tag hydraulic lines holding bracket , approximately 3" to separate.
Note: Access to suction hose is limited; use a suitable 21. Lift transmission Clear of chassis frame and
10mm ball end allen key with extension for removal. engine.
16. Identify and tag all hydraulic lines at the main

hydraulic, brake and emergency steering pumps. DISASSEMBLY
Disconnect hydraulic lines and cap lines and ports to Numbers in parentheses refer to Fig. 14, unless
prevent entry of dirt. otherwise specified.
17. Remove npt plug from engine 3/4" sq. drive, 1. Remove 8-off mounting bolts (1) securing PTO to
situated below starter motor to access 12 bolts holding transmission LHS.
flex plate damper, which connects the engine to
transmission. 2. Remove PTO (2) and gasket (3). Inspect PTO
studs for damage and remove if necessary.
18. Engine crank has to be turned, to allow access to
the 12-off bolts. Use special tool 15502496. 3. Remove bolts (16) retaining oil fill tube hose to
clamp over top of transmission. Remove bracket, fill
19. Mount holding bracket 15502498 to transmission tube, seal and dipstick from transmission.
SM 2416 Rev1 03-07 17

Section 120-0010
4. Remove 6-off bolts retaining remote cooler manifold INSPECTION

to the main housing module.
5. Bend down tabs of locktabs (9) if present, and
Periodic Inspection of the exterior of the transmission
loosen 2-off bolts (10).
is an essential part of preventative maintenance.
Severity of service and operating conditions should be
6. Remove bolt (15), washer (14) and lockwasher (13) .
used to determine the frequency of inspection.
7. Remove yoke (11). Remove 'O'-rings (12).
1. Check mounting brackets assembly (2 & 3), for
cracks and damage. Repair or replace as required.
8. Inspect Journal sealing area for minimum allowed
2. Check condition of engine output flywheel housing
diameter of 85.0mm (3.346").
for general damage before mating the transmission to
the engine.
9. Remove bolt (), retainer (), speed sensor () and 'O'-
ring () from convertor housing module (engine speed 3. Check general condition of transmission assembly
sensor), main housing module (turbine speed sensor) for wear and damage; Loose bolts, fluid leaks,
and rear cover or retarder (output speed sensor). damaged or loose hoses.
4. Check for worn or damaged driveline flanges and

Removal of Control Valve Module excessive wear on mounting holes and isolation
mounts (1).
WARNING 5. Check condition of all electrical harnesses and
Control module weighs approx. 25kg (55Ib). connections and repair/replace as required. Check
Ensure suitable support is in place to aid in condition of all hydraulic lines on the transmission and
removal. replace if damaged.
Note: Control module and / or filters may contain ASSEMBLY

residual transmission fluid. Ensure external part of feed Numbers in parentheses refer to Figs 1 & 14, unless
through harness connector has been disconnected otherwise specified.
from external brackets before removing control module.
Assembly is largely the reverse of disassembly.
1. Remove 43-off bolts ( & ) retaining control module to Replace faulty or damaged components where
the main housing module, including bolts retaining filter applicable.
covers.
2. Loosen control module by applying pressure at the specified to standard torques listed in Section
reinforced tabs, or use jack bolts inserted into the 300-0080, STANDARD BOLT AND NUT TORQUE
control module bolt holes that bottom against the main SPECIFICATIONS.
housing module.
3. Remove covers and filters if a handhold is needed to INSTALLATION

remove the control module. Numbers in parentheses refer to Fig. 1, unless
4. Remove control module assembly and gasket.
5. Refer to transmission manufacturers service manual specified to standard torques listed in Section
if further transmission service or repair is required. 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Note: Tighten all hydraulic lines fitted with ORFS

connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
18 SM 2416 Rev1 03-07

Section 120-0010
SM - 3500
WARNING
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
safely.
1. Install Fender assembly to chassis frame. Refer to

Section 100-0070 FENDERS AND MOUNTING.
HOT
FULL
2. Install the cab assembly on the front frame. Refer to
Section 260-0010, CAB AND MOUNTING.
HOT
ADD
3. Connect all harnesses and electrical connections at
front of the cab. COLD
FULL
4. Fill hydraulic tank with hydraulic oil specified in

COLD
Section 300-0020, LUBRICATION SYSTEM. Refer to ADD
Section 230-0040, HYDRAULIC TANK for fill level and
procedure.
Fig. 15 - Transmission Dipstick Markings
5. Fill transmission with engine oil specified in Section
300-0020, LUBRICATION SYSTEM. Check the oil
level as described under 'Oil Level Check'. 9. Refer to section 110-0030 ENGINE AND
MOUNTING, for details of installation of adaptor plate
6. Connect the following cables and connectors in the and isolation mount installation.
order given to prevent serious damage to the engines
electrical components. 10. Lift engine / transmission assembly into frame and
secure at front mounting plate using 2-off bolts, refer to
a - Battery earth cables section 110-0030 ENGINE AND MOUNTING.
b - Battery supply cables
c - Alternator earth cables 11. Secure rear of transmission at mounting brackets
d - Alternator supply cables (2 & 3), with bolts (6) and washers (5). Secure on
e - Body hydraulics joystick underside using 2-off snubbing washers (4) and nuts
f - Hydraulic ECU (7). Torque bolts (6) and both transmission and engine
g - Instrument panel (VDU) CPU front, to a value of 921Nm (680 Ibf ft).
h - Transmission (4th GEN) connector
i - TCM interface harness connector (80 pin) 12. Connect driveline from transmission to dropbox.
j - ECM power harness connector (5 pin RHS) Refer to section 130-0010 FRONT DRIVELINES for
k - ECM sensor harness connector (30 pin LHS) installation detail.
l - ECM engine to transmission datalink connector
(6 pin RHS) 13. Turn the battery master switch to the 'On' position,
start the engine and make an operational check of all
7. Install 2-off plates (24) to the underside of lines and electrical connections disconnected during
transmission mounting brackets (2 & 3). Secure in removal. Check for leaks and tighten lines and fittings
place using bolts (10) and washers (11). Torque bolts as required. Allow transmission to warm up and
(11) to a value of 40 Nm ( 29.5 Ibf ft). recheck all connections for leaks.
8. Place isolation mounts (1) in 3-off places; either side 14. Ensure parking brake is applied, disconnect
of transmission and at engine crossmember. steering lock bar and secure in the 'Stowed' position.
Remove wheel blocks from all road wheels.
15. Check for correct operation of the transmission,

shift selector and warning lights.
SM 2416 Rev1 03-07 19

Section 120-0010
SM - 3501
MAIN
LUBE MAIN
2 1
LUBE
TRANSMISSION SUMP
3
4
1 - Main Filter
6
2 - Lube Filter
3 - 'O'-ring 5
4 - 'O'-ring
5 - Gasket
6 - Gasket
7 - Filter Covers * (Not Shown)
Fig. 16 - Transmission Oil Filters
MAINTENANCE Section 300-0020, LUBRICATION SYSTEM.

Because the transmission oil cools, lubricates and
Periodic Inspections transmits hydraulic power it is important that the proper
oil level be maintained at all times. If the oil level is too
For easier inspection, the transmission should be kept
low, the converter and clutches will not receive an
clean. Make periodic checks for loose mounting bolts
adequate supply of oil. If the oil level is too high, the oil
and leaking oil lines. Check the condition of electrical
will aerate and the transmission will overheat. It is
harnesses and connections regularly.
absolutely necessary that the oil put into the
transmission is clean.
Transmission breather (8, Fig. 2) should be checked on
a regular basis (every 250 hours), and as frequently as
Oil level can be checked either manually, as described
necessary, depending on operating conditions. A badly
in the following text, or through the 4th GEN gearshift
corroded or plugged breather restricts proper breathing
lever.
and causes a buildup of condensation and subsequent
oil deterioration.
Refer to DISPLAYING OIL LEVEL INFORMATION
(OLS) page 6, for specific detail on using the shift lever
Oil Level Check for this purpose.
Numbers in parentheses refer to Fig. 15. unless

Manual Oil Level Check
otherwise stated.
Note: Clean dirt from around the end of the fluid fill
WARNING tube before removing the dipstick. Do not allow dirt or
foreign matter to enter the transmission. Dirt or foreign
When checking the oil level, be sure that the
matter in the hydraulic system may clog passages and
parking brake is applied and all road wheels are
cause undue transmission part failure or wear.
securely blocked.
Always check the fluid level reading at least twice
using the following procedure. Consistent / repeatable
Check the transmission oil level and add oil if low,
readings are important to maintain proper fluid level.
every 10 hours/daily. Use only oil specified in
20 SM 2416 Rev1 03-07

Section 120-0010
If inconsistent readings persist, check the transmission

breather to ensure it is not clogged. 1. Operate the transmission in D (Drive) range until
Cold Level Check normal operating temperature is reached:
• Sump temperature 71°-93°C (160°- 200°F)

WARNING
Do NOT start the engine until the presence of • Converter-out temperature 82°- 104°C (180°-220°F)
sufficient transmission fluid has been 2. Park the vehicle on a level surface and shift to N
confirmed. Remove the transmission fluid (Neutral). Allow the engine to idle.
dipstick and be sure that static fluid level is
near the HOT FULL mark. 3. With the engine running, remove the dipstick from
the tube and wipe clean.
1. The purpose of the cold level check is to determine
if the transmission has enough fluid to be operated 4. Insert the dipstick into the tube and remove. Check
safely, until a hot check can be made. fluid level. Repeat the check procedure to verify
reading.
2. Park vehicle on a level surface, block all road
wheels and apply the parking brake. 5. If the fluid level is not within the "HOT RUN" band,
add or drain as necessary to bring the fluid level within
3. Run the engine at idle or at least one minute with the the band. Safe operating level is within the "HOT RUN"
transmission in N (neutral). Shift to D (Drive), then shift band on the dipstick.
to R (reverse) to clear the hydraulic system of air. Then
shift to N (Neutral) and allow the engine to idle.
Oil and Filter Change
4. With the engine running, remove the dipstick from
the tube and wipe clean. Numbers in parentheses refer to Fig. 16. unless
otherwise stated.
5. Insert dipstick into tube and remove. Check fluid
level. Repeat the check procedure to verify the reading. The interval for oil filters change is 3000 hours.
6. If the fluid level is within the "COLD RUN" band, the The interval for oil change is 6000 Hours, assuming
transmission can be operated until the fluid is hot that the correct / approved oil type has been put into
enough to perform a "HOT RUN" check. If fluid level is the transmission unit. For details of oil types refer to
not within the "COLD RUN" band, add or drain as section 300-0020 LUBRICATION SYSTEM for
necessary to bring the fluid level to the middle of the recommended lubricant details.
"COLD RUN" band.
1.To replace oil filters, remove 12-off bolts and filter
7. Perform a hot check at the first opportunity after covers (7).
normal operating temperature is reached, 71° - 93°C
(160° - 200°F). 2. Remove and discard gaskets (5 &6), 'o'-rings (3 &4) ,
main oil filter (1) and lube oil filter (2).
Hot Level Check
3. Lubricate and reinstall new 'o'-rings (3 & 4) on each
cover (7). Lubricate 'o'-ring inside filter (1 & 2) and push
WARNING filter onto each cover (7).
When checking the oil level, be sure that the
parking brake is applied and all road wheels are 4. Install new gaskets (5& 6) on respective covers and
securely blocked. align holes in gasket with holes in cover.
5. Install filter (1 & 2) and cover (7) assemblies into

WARNING filter compartment. Index each filter / cover assembly
An accurate fluid level check cannot be made to the holes in the channel of the sump. Push in by
unless the engine is idling (500 - 800 rpm) in 'N' hand to seat the seals.
(neutral), the transmission fluid is at the proper
operating temperature and the vehicle is on a 6. Install 6-off bolts into each cover (7) and tighten to a
level surface. torque of 51 - 61 Nm ( 38 - 45 Ibf ft).
SM 2416 Rev1 03-07 21

Section 120-0010
7. Refill transmission oil.
Transmission breather should be checked on a regular

basis, and as frequently as necessary, depending on
operating conditions. Although checking should be
carried out at 250Hr intervals and replaced where
necessary. A badly corroded or plugged breather
restricts proper breathing and causes a buildup of
condensation and subsequent oil deterioration.
SERVICE TOOLS
number of service tools which should be used in
conjunction with procedures outlined in the
transmission manufacturers service manual, and,
available from your dealer. Any fabricated tools are
shown on page 23.
22 SM 2416 Rev1 03-07

Section 120-0010
140 SM - 3529
ENGINE SUPPORT BRACKET (LHS)
85 43 90
25
" "
50 10 100 Ø 20 4 POS'N
332 245
210 12
75
¾"unc
10 100 50
190
(mm)
Fig. 17 - Engine Support Bracket
SM - 3530
140 ENGINE SUPPORT BRACKET (RHS)
10
25
"
43 90
"
5
" "
100 Ø 20
4 POS'N VIEW ON 'A'
"
377 280
50 "
155 70
10 80
'A'
12
5
5 ¾"unc
60
12
225 (mm)
Fig. 18 - Engine Support Bracket
SM 2416 Rev1 03-07 23

Section 120-0010

TORQUE
1 7 Nut 921 680
1 8 Bolt 228 - 266 168 - 196
1 10 Bolt 40 30
1 13 Bolt 921 680
* * * *
24 SM 2416 Rev1 03-07

TRANSMISSION - Power Takeoff
Section 120-0090
SM - 3402
7 8
10
28
26
27
5 6
11
12
1,2,3
13
4
14
25 26 27
15
24
23 16
22
17
21
20
19
18
1 - Stud 8 - Name Plate 15 - Circlip 22 - Idler Shaft

2 - Washer 9 - Key 16 - O-ring (4-Off) 23 - PTO Case
3 - Nut 10 - Bearing Housing 17 - Grubscrew 24 - O-ring (2-Off)
4 - Circlip 11 - Circlip 18 - Key 25 - Ball Bearing
5 - Pump Adaptor Plate 12 - Drive Shaft 19 - Idler Gear 26 - Bolt
6 - Idler Gear 13 - Ball Bearing 20 - Taper Bearing (2-Off) 27 - Bolt
7 - Drive Screw (2-Off) 14 - Idler Gear 21 - Shim 28 - O-ring
Fig. 1 - Sectional View of Transmission Power Take Off
DESCRIPTION Mounted off power takeoff housing is the main

hydraulic pump which is driven by drive shaft (12).
Refer to Section 230-0050, MAIN HYDRAULIC PUMP.
The power takeoff (PTO) is mounted off a machined
face on the front left hand side of the transmission. REMOVAL
Numbers in parentheses refer to Fig. 1. Unless
OPERATION otherwise stated.
otherwise stated.
WARNING
Idler gear (14) meshes with the transmission and
damage, be sure wheel chocks and lifting
rotates at transmission speed. Rotational movement is
transferred to drive shaft (12) through a series of gears
(19 & 6) which are keyed.
SM 2371 01-06 1
Transmission - Power Takeoff
Section 120-0090
1. Position the vehicle in a level work area, apply the 7 SM -3483
6 8
parking brake and switch off the engine.
14
2. Turn steering wheel in both directions several times 13
to relieve pressure in the steering circuit. Block all road

3,4,5
wheels. 2 9
1
3. Match mark the main hydraulic pump housing and
pump adaptor plate (5, Fig.1) to facilitate assembly.
Remove main hydraulic pump following procedures
outlined in Section 230-0050, MAIN HYDRAULIC
PUMP. 11
11
4. Attach suitable lifting equipment to the power takeoff 10
9
assembly and remove 10-off bolts (10, Fig .2) . Lift the 12
power takeoff assembly and shim (12, Fig.2 ) from the

transmission housing. Discard shim (12, Fig.2 ) as a 1 - O-ring 8 - Bearing Housing
2 - Pump Adaptor Plate 9 - O-ring
new shim must be fitted at assembly stage. Cover 3 - Stud
transmission housing with mating plate to prevent entry 10 - Bolt
4 - Nut 11 - Grubscrew
of dirt. 5 - Circlip 12 - Shim
6 - 'O' Ring 13 - Bolt
7 - PTO Case 14 - Bolt
Note: Identify or mark the number and thickness of
shim (12, Fig. 2) removed. This procedure is necessary
so as not to alter the backlash of the gears during Fig. 2 - Exploded View of Power Takeoff Assembly
assembly.
7. Remove bearing (13) from housing using a suitable
Note: The gasket used at the steering pump mounting
driver, plastic mallet or device which will not damage the
face should be discarded and replaced at installation.
bearing.
DISASSEMBLY 8. Remove circlips (4 & 11) from drive shaft (12).

9. Carefully chap drive shaft (12) from idler gear (6).
otherwise stated.
Remove key (9).
1. Remove main hydraulic pump to allow removal of
10. Remove grubscrew (17), chap idler shaft (22) from
the transmission pto. Refer to Section 230-0050, MAIN
bore of PTO case (23).
HYDRAULIC PUMP for detail.
11. Discard o-rings (16). Remove idler gears (14 &19),
2. Remove the bolts (13, Fig. 2) securing pump adaptor
bearings (20), key (18) and shim (21) from assembly.
plate (5) to PTO case (23). Remove adaptor plate.
12. Separate individual components as required.
3. Remove and discard o-ring (24) from adaptor plate
(5).
INSPECTION
Note: Careful removal of pump adaptor plate is required
so that bearing (25) is not damaged.
1. Clean all parts, except bearings (13, 20 & 25), in a
4. Remove bearing (25) from adaptor plate (5).
suitable solvent and dry with compressed air.
5. Remove bolts (27) securing bearing housing (10) to
2. Clean bearings (13, 20 & 25) in volatile mineral
PTO case (23). Carefully remove bearing housing (10).
spirits, and wipe dry with clean, lint-free cloth.
Note bearing (13) should be removed at this stage.
Lubricate with light oil, and spin by hand to check for
wear and roughness. Replace with new bearings if
6. Remove and discard 'O' ring (28) from bearing housing
excessively worn, or if operation is rough or noisy.
(10).
2 SM 2371 01-06
Section 120-0090
against circlip.
3. Check the condition of splines and teeth on all gears
and shafts for burrs or signs of excessive wear. 11. Fit bearing (13) inner race to spigot end of driveshaft
(12), ensuring fully home.
4. Idler shaft (22) and drive shaft (12) should not be 12. Using a suitable device, orientate driveshaft (12)
rough, worn, cracked or damaged. If either shaft is sub-assembly and chap home till contact is obtained
distorted, it should be replaced. with bearing (13) inner race.
5. Check all threaded parts and tapped holes for Installation

stripped or battered condition. Numbers in parentheses refer to Fig. 1.
6. Inspect PTO case, bearing housing and pump Note: Tighten all fasteners to standard torques listed in
adaptor plate (23, 10 & 5) for cracks or bearing bores Section 300-0080, STANDARD BOLT AND NUT
out-of-roundness. TORQUE SPECIFICATIONS.
7. Gear teeth should not be worn, cracked or broken. Note: Tighten all hydraulic lines fitted with ORFS
8. Any small nicks, scratches or burrs should be BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
smoothed up with a fine stone or crocus cloth, and part where used.
cleaned in solvent and dried with lint-free cloth.
WARNING
ASSEMBLY
Numbers in parentheses refer to Fig. 1. unless damage, be sure wheel chocks and lifting
otherwise stated. equipment are properly secured and of adequate
capacity to do the job safely.
1. Sub assemble bearing (20), gear (19) and key (18),
secure using circlip (15). 1. Remove 10-off setscrews from the transmission PTO
cover plate located on the front left hand side of the
2. Locate in mating slot of PTO case (23). transmission.
3. Fit new o-rings (16) to idler shaft (22). Offer shaft to 2. Remove cover plate and existing gasket from the
bore of PTO casing (refer to Fig. 1). Chapping lightly, transmission. Clean the face to ensure no foreign
ensure bearings locate onto outer diameter of the idler particles are present on the face.
shaft.
3. Taking stud mounting kit 15502084, screw 2-off studs
Note: Orientate idler shaft ensuring threaded bore into top and bottom of PTO opening on the
mates with hole on base of to casing. transmission, ensure long thread portion is used for this
operation.
4. Once in place, secure using grubscrews (17) locking
idler shaft (22) in place. 4. Place new gasket (12) onto mating face of
transmission and offer assembled PTO onto studs.
5. Locate bearing (13) outer race in place on bearing
housing (10), using a suitable device, seat fully home. 5. Place nuts and washers provided onto the studs and
tighten.
6. Fit o-ring (28) to groove on bearing housing (10).
6. Take bolts (10, Fig. 2) and screw into remaining 8-off
7. Secure idler gear (6) in place to drive shaft (12) positions.
using key (9), secure using circlip (11).
7. Main hydraulic pump must be fitted to PTO assembly
8. Fit bearing housing (10) to mating surface on PTO using the o-ring supplied in the stud mounting kit
case (23). Fit bolts (27), securing housing to the case. 15502084. O-ring should be placed on the pump spigot
before assembly. For detail of pump, refer to procedures
9. Fit circlip (4) to drive shaft (12), now locate bearing outlined in Section 230-0050, MAIN HYDRAULIC PUMP
(25) inner race onto drive shaft (12), seating fully home for detail.
SM 2371 01-06 3
Section 120-0090
SERVICE TOOLS
Note: Stud mounting kit 15502084 is required for
installation of the PTO to the transmission.

numbers of other tools referenced in this section and
* * * *
4 SM 2371 01-06
Dropbox - Dropbox and Mounting
Section 125-0010
SM - 3840
30
7
29
5 25
15 1 7
6 25 27
16
2
11 7
17 6
12
14 4
9 12 11
(IF REQUIRED)
10
18 1
1
(WELDNUTS)
14 4
5
8 13 1
8
3 18
(IF REQUIRED)
23
6 5
13
8 8 22 8
34 31
32
19 28
26
20 33 24
21
1 - Isolation Mount 10 - Screw 19 - Drain Plug (non drip) 28 - Washer

2 - Front Mounting Bracket 11 - Bolt 20 - Hose Adaptor 29 - Bracket
3 - Cross-member 12 - Spring Washer 21 - Elbow 30 - Breather
4 - Rear Mounting Bracket 13 - Hardened Washer 22 - Dipstick Tube 31 - Security Kit
5 - Snub Washer 14 - Bolt 23 - Dipstick 32 - Lock
6 - Hardened Washer 15 - Antiflail Guard Assy. 24 - Bolt 33 - Key
7 - Bolt 16 - Bolt 25 - Elbow 34 - Washer
8 - Locknut 17 - Washer 26 - Lockwasher
9 - Spring Washer 18 - Spacer 27 - Tube
Fig. 1 - Exploded View of Dropbox and Mounting
DESCRIPTION gearbox taking drive from the engine and transmission

and feeding it to the front and centre axles via a
lockable differential.
For Dropbox make, model and specification, refer to
Section 000-0000, GENERAL INFORMATION. For OPERATION
dropbox servicing and repair data refer to dropbox
manufacturers service manual. The Dropbox has self-contained hydraulic gear
selection and differential locking mechanisms. The
The dropbox is supported by the front mounting bracket hydraulic supply circuits for gear activation and
(2), which is bolted to the dropbox. This in turn is differential lock are separate.
secured to the frame mounted cross-member (3).Two
rear mounting brackets (4) which are bolted to the Gear activation is from a supply via the main hydraulic
dropbox and attached to front frame mounting brackets valve assembly at port 'DL', refer to Section 215-0050
through isolation mounts (1) secure the rear. Isolation MAIN HYDRAULIC VALVE ASSEMBLY.
mounts (1) provide sufficient flexibility to absorb
varying dropbox vibration and torsional loads. Differential lock supply is via a single stage gear pump
which is driven off the main hydraulic pump. This
The dropbox is a remote mounted two-speed transfer draws the sump oil from within the dropbox to satisfy
locking and lubrication requirements of the system.
SM 2367 Rev4 07-07 1

Section 125-0010
SM - 3392
1B 6
1A
10
4
2
1 - High Range Solenoid (A) 3 - Diff. Lock Relief Valve (CT5) 6 - Check Valve (CT6)
1 - Low Range Solenoid (B) 4 - Pressure Control Valve (CT1) 9 - Pressure Switch (SW5)
2 - Differential Lock Solenoid (CT4) 5 - Check Valve (CT3) 10 - Temperature Switch (SW6)
Fig. 2 - Valve Block Detail
Gear selection and differential lock are operated via 5. Desired gear ratio will be activated.
switches in the vehicle by continuously rated 24V dc 6. Release the service brake pedal.
solenoids. These solenoids (1 & 2 Fig. 2) are located
on the externally mounted valve block (Fig. 2). 7. The park emergency brake will now automatically
disengage.
SWITCHES AND PRESSURE POINTS When either high or low ratio is selected, the
Numbers in parentheses refer to Fig. 2 & 3. corresponding solenoid (1A or 1B) will be energised.
On start up, the gear range the vehicle will be in is
Gear Selection dependant on the position that the gear selection switch
was left in, prior to leaving the vehicle.
High and low range gear selection is by face driven dog
engagement. To engage high or low gear ratio, the Numbers in parentheses refer to Fig. 2 unless otherwise
following steps must be adhered to: stated
1. Bring vehicle to a stop with the service brakes. Diff. lock solenoid (2) is energised to select the
Maintain pressure on service brakes. differential lock. The inter-axle differential lock is a
multi-plate clutch device that locks the front and rear
2. Engine RPM must be less than 750 and
drives together (50/50 torque split) to provide more
transmission must be shifted to neutral.
traction in arduous conditions. It is selectable on the
3. Press the high / low ratio request switch into the move, provided the vehicle speed is not greater than 5
desired gear range. km/hr. With the differential lock disengaged there is
4. The park/emergency brake will now automatically normal torque biasing of 2/3 to the rear and 1/3 to the
apply. (High to low shift only) front axle.
2 SM 2367 Rev4 07-07

Section 125-0010
SM - 3393
TP2
(12)
B
(13) 1 - Range Selector Solenoid (CT2)

P1 GS1 2 - Differential Lock Solenoid (CT4)
(17) (4) GS2 3 - Differential Lock Relief Valve (CT5)
(14) 4 - Pressure Control Valve (CT1)
(1) 5 - Check Valve (CT3)
T1
(18) 6 - Check Valve (CT6)
A 7 - Oil Cooler Feed Port- OC1
8 - Oil Cooler Return Port- OC2
(15) 9 - Pressure Switch- SW5
TP1 DL
(11) 10 - Temperature Switch- SW6
(5) 11 - Differential Lock Test Point- TP1
(7)
OC1 12 - Pressure Test Point- TP2
(2) 13 - High Gear Range Port- GS1
14 - Low Gear Range Port- GS2
15 - Differential Lock Port- DL
16 - Supply Port - P2
17 - Supply Port - P1
18 - Return Port - T1
(9)
SW5
(6) (8)
SW6 OC2
(10) (3)
(16) Fig. 3 - DropBox Schematic Detail

P2
Diagnostic Points SM - 3615
Numbers in parentheses refer to Fig. 2 & 3. unless 1

2
otherwise stated. 3
4
5
Differential lock actuation pressure can be checked at 6
9 7
the diagnostic test point (7, Fig. 4). This is set at 27.5 10 8
11
±2.5 bar (399 (399 ± 36 Ibf/in²). Differential lock relief 12
13
valve (3) is adjustable and may be set too low if the 14
differential lock pressure is not reaching the correct 15
value. This valve is set to 33 bar (478 Ibf/in²).
There may be high internal leakage, either in the clutch

device or externally mounted gear pump unit; in these
cases adjustment of relief valve (3) will not restore or 1 - Front Brake Accumulator 9 - Steering Pressure
2 - Rear Brake Accumulator 10 - Transmission Pressure
improve pressure. 3 - Primary Accumulator 11 - DropBox Lube Pressure
4 - Front Brake Pressure 'TP3'
Gear selection actuation pressure can be checked at 5 - Rear Brake Pressure 12 - Main Pump (Front)
pressure test point 'TP2' (8, Fig. 4). This is set by 6 - Parking Brake Pressure 13 - Main Pump (Rear)
pressure control valve 'CT1' (4) to 15 bar (217 Ibf/in²). 7 - Diff-lock Pressure 'TP1' 14 - Pump LS Pressure
8 - High / Low Select 'TP2' 15 - Body System Pressure
Pressure will dip momentarily when the high or low
Fig. 4 - Diagnostic Pressure Check Points Left Hand
solenoids are energised as the cylinder moves. Fender
Continued low pressure would indicate high internal
leakage in the section that is energised. Low pressure
indication when no solenoids are energised would
suggest the supply to the valve from port 'DL' on the
main hydraulic valve is not sufficient, or pressure
control valve 'CT1' (4) is set too low.
SM 2367 Rev4 07-07 3

Section 125-0010
SM - 3842
123,109,
104
1
63 51
106
113 96
4 122 99 57 110
92
121 43 49
47
117 116 86
63 32
14 86 11 9
59 74 51 2
18 96 95
47 82 87
102 39 80 48 40 81 41,42
73 88 49 45 112
20 6 5 121
10 94 122
21 51 113
58 64 19
73
114 100 85 70 22 TO REAR AXLES
RHS 79 8
105 67
FROM TRANS. 7 68 114
95 87 52
23,119 78
3 46 72
51
17 65 35
65
115
54 53
30,16 61
106
44,89 84
90 28 27
34,77 26 69 101
66 93 45 119
25 108 29 68 76 108
71
61 114 23 36 15
TO FRONT AXLE 78 62
22 38
13 125
90 120
72 60
98 37 24 73 46 12
97 50 31 103 118
55
75 91 56 107
TEMP. SW.
126 124
SEC. 190-0270
34 - Oil Distribution Ring 67 - Needle Roller 108 - Capscrew

2 - Input Gear 109 - Stud
35 - Output Shaft 68 - Needle Roller
3 - Gear 110 - Washer
36 - Front Gear 69 - Washer
4 - Gear 111 - Capscrew
37 - Pressure Plate 70 - Washer
5 - Gear 112 - Circlip
39 - Rod Selector 71 - Needle Roller
6 - Gear 113 - Plunger Switch
40 - Switch Housing 72 - Taper Roller
7 - Gear Differential 114 - Bolt - flanged
41 - Primary Piston 73 - Oil Seal
8 - Gear (Drop) 115 - Screw - flanged
42 - Piston (secondary) 74 - Oil Seal
9 - Input Shaft 116 - Ball - detent
43 - Hydraulic Cylinder 77 - 'O'-ring
10 - Countershaft 117 - Spring detent
44 - Diff. Case 80 - Bush
11 - Sleeve selector 118 - Nameplate
45 - Washer 82 - Piston Seal
12 - Rear Case 119 - Setscrew
46 - Oil Seal 84 - Piston Ring
13 - Front Case 120 - Washer
47 - Needle Roller 85 - Washer
14 - Lifting Bracket 121 - Ball
48 - 'O'-ring 86 - Washer
15 - Bearing Housing 122 - Spacer
49 - 'O'-ring 87 - Locknut
16 - Diff. Support Ring 123 - Nut
50 - Taper Roller 88 - Key
17 - Cover Plate 124 - Washer
51 - Taper Roller 89 - Shim
18 - Oilseal housing 125 - Magnetic Plug
52 - Needle Roller 91 - Bolt - flanged
19 - Rear Yoke 126 - Adaptor
53 - Friction Plate 93 - Pin
20 - Input Yoke
54 - Plain Plate 94 - Wiper Seal
21 - Retainer Plate
55 - Quad Ring 95 - Grubscrew
22 - Retainer Plate
56 - Quad Ring 96 - Stud
23 - Baffle
57 - Cylinder Cap 97 - Locknut
24 - Shaft (rear)
58 - O Ring 98 - Lockwasher
25 - Sun Gearshaft
59 - Shim 99 - Stud
26 - Planet Carrier
60 - Washer 100 - Set screw
27 - Planet Gear
61 - Washer 101 - Key
28 - Planet Spindle
62 - Shim 102 - Capscrew
29 - Annulus Gear
63 - Washer 103 - Drive Screw
30 - Clutch Basket
64 - Taper Roller 104 - Washer
31 - Piston (difflock)
65 - Needle Roller 105 - Dowel
32 - Fork Selector
66 - Washer 106 - Dowel
33 - Pump Drive Adaptor
107 - Suction Tube
Fig. 5 - Sectional View Of Dropbox assembly
4 SM 2367 Rev4 07-07

Section 125-0010
REMOVAL from dropbox, by removing bolts (10) and spring

washers (9).
13. If necessary remove rear mounting brackets (3)
from dropbox by removing bolts (11) and spring
washers (12).
body is fully lowered, apply the parking brake and
switch off the engine. Operate steering right and left
Note: Do not mix up bolts (10) with bolts (11), as bolts
several times to relieve any pressure in the steering
(11) are a larger diameter and are not interchangeable
system.
with the front mounting bracket (2) bolts (10).
2. Operate the treadle valve continuously to discharge
the accumulators, block all road wheels, place the DISASSEMBLY
steering lock bar in the 'Locked' position and the
3. Disconnect the following cables and connectors in
1. The major components of the dropbox assembly are
order to prevent damage to vehicle electrical
shown in the section view Fig. 4. This should be used
components. All wiring and harness connections to the
for guidance only.
dropbox valve block and associated switches and
sensors located on the dropbox.
2. Refer to manufacturers guidelines for specific
instructions and any special tools / requirements.
4. Place a suitable container under the dropbox drain
port. Remove drain plug (19) and drain oil through hose
adaptor (20) into a suitable container . After draining, INSPECTION
reinstall drain plug and tighten securely.
5. Remove cab from the machine. Refer to Section
260-0010, CAB AND MOUNTING. Ensure all
1. Inspect rubber isolation mounts (1) for damage and
connections and lines connect to the cab are
replace if required.
disconnected.
2. Check front and rear mounting brackets (2 & 3) and
6. Disconnect all drivelines connected to the dropbox
mounting brackets of frame assembly for cracks and/
and secure clear of the dropbox. Refer to Section 130-
or damage. Repair or replace as necessary.
0010, DRIVELINES.
7. Attach suitable lifting equipment to the lifting ASSEMBLY
brackets on the dropbox and raise the lifting equipment
to take up the slack.
8. Remove 3-Off bolts (7), locknuts (8), snubbing
1. The major components of the dropbox assembly are
washers (5) and hardened washers (6) which secure
shown in the section view Fig. 4. This should be used
the front bracket (2) and rear bracket (3) assemblies to
for guidance only.
their respective frame mounting positions.
2. Refer to manufacturers guidelines for specific
9. Check to make certain that all necessary lines and
instructions and any special tools / requirements.
electrical disconnections have been made before lifting
the dropbox.
specified to standard torques listed in Section 300-
10. If necessary remove isolation mounts (1) to aid
0080, STANDARD BOLT AND NUT TORQUE
removal. Carefully lift the dropbox clear of the frame,
SPECIFICATIONS.
remove to a suitable work area and mount securely on
a work stand. INSTALLATION
11. Remove anti-flail guard assembly (15) as
necessary, by removing 2-off bolts (16), washers (17).
12. If necessary remove front mounting bracket (2)
SM 2367 Rev4 07-07 5

Section 125-0010
MAINTENANCE
WARNING
To prevent personal injury and property Periodic Inspections
damage, be sure lifting device is properly
secured and of adequate capacity to do the job For easier inspection, the dropbox should be kept
safely. clean. Make periodic checks for loose mounting bolts
and leaking oil lines. Check the condition of electrical
Note: Tighten all fasteners without special torques harnesses and connections regularly. Because the
specified to standard torques listed in Section 300- dropbox oil cools, lubricates and transmits hydraulic
0080, STANDARD BOLT AND NUT TORQUE power it is important that the proper oil level be
SPECIFICATIONS. maintained at all times. It is absolutely necessary that
Note: Tighten all hydraulic lines fitted with ORFS the oil put into the dropbox is clean.
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings SM - 3638
where used.
COLD COLD
1. Attach suitable lifting equipment to dropbox lifting
FULL ADD
brackets and carefully position dropbox assembly in
the tractor frame.
Fig. 6 - Dropbox Oil Dipstick
2. If previously removed, orientate cross-member (3)
and secure in place using bolts (17), washers (13) and
locknuts (8). Torque bolts (17) to a value of 921Nm Topping Up Oil
(680 Ibf ft).
Oil Level Check- Engine Off
3.Lightly coat bolts (11) with retaining compound
(9371048). Secure rear mounting brackets (4) to either This check should be made to determine if the dropbox
side of the dropbox using bolts (11) and washers (12). contains sufficient oil for safe starting. Oil should be
Torque bolts (11) to a value of 410Nm (303 Ibf ft). well above the 'cold full' mark (Fig. 5) on the dipstick. If
there is a deficit of oil, this must be replenished till it is
4. Lightly coat bolts (10) with retaining compound up to the correct level
(9371048). Secure front mounting bracket (2) to
dropbox using bolts (10) and washers (9). Torque bolts Oil Level Check- Engine Running
(10) to a value of 185Nm (136 Ibf ft).
1. Position the vehicle on a level work area, apply the
5. Fit isolation mounts (1) in the correct orientation to parking brake and block all road wheels securely.
the front and rear mounting brackets (2 & 4).
2. With the transmission in neutral and the engine
Note: Orientation of snubbing washers (5) and running, allow the vehicle to run for 1 minute (vehicle
hardened washers (6) is different for front and rear stationary). This allows for oil to distribute itself round
brackets. Ensure correct orientation during fit up. the circuits.
6. Secure brackets in place using snubbing washers 3. Check the oil levels in the dropbox. Oil should be
(5), bolts (7), hardened washers (6) and locknuts (8). within the 'cold full' and 'cold add' level mark (Fig. 5) on
Torque locknuts (8) to a value of 921Nm (680Ibf ft). the dipstick. If there is a deficit of oil or indeed an
excess of oil this must be rectified till it is within the
7. Remove blanking caps and connect all solenoids, correct band.
switches and sensor connections associated with the
dropbox, which were removed at the dissassembly Oil and Filter Change
stage.
The dropbox oil and oil filter cartridge should be
8. Remove blanking caps and connect associated changed every 500 hours. Clean oil filter head when
hydraulic line to the main hydraulic valve block. replacing the filter cartridge. Replace the oil filter.
Oil must be changed whenever there are traces of dirt

or evidence of high temperature indicated by
6 SM 2367 Rev4 07-07

Section 125-0010
discolouring or strong residue; in certain operating
conditions filter and oil change periods may need to be WARNING
more frequent. Consult the relevant manufacturer with When checking the oil level, be sure that the
any queries regarding change intervals. parking brake is applied and all road wheels are
securely blocked.
Every 500 Hours
Oil and filter must be changed; the system should be SERVICE TOOLS
refilled with 8 approximately 8 litres of oil as specified Refer to Section 300-0070, SERVICE TOOLS, for
in Section 300-0020, LUBRICATION SYSTEM. service tools which should be used in conjuction with
procedures outlined in dropbox manufacturers service
manual and general service tools required. These tools
Troubleshooting: are available from your dealer.
Problem Possible Cause Corrective Action
Low Pressure Indication • Wiring or Pressure Switch • Check pressure at diagnostic test point - Pressure
(Engine Running). failure. at TP2 should be 15 bar (217 Ibf/in²). If OK check
wiring and switch.
• Partial/ Full blockage of • Check and replace filter element.
valve block filter.
• Failure of main hydraulic
• Check flow and pressure to dropbox from main
system.
hydraulic valve port 'DL'.
• Failure/ wear in dropbox • Replace pump unit- checks must be made to
pump unit. establish primary cause i.e. contaminated oil.
• Low oil level • Check oil level and unit for leaks.
High Temperature Warning.
• Vehicle cooler circuit • Check oil cooler circuit for failure, damage or
failure. radiator blockage.
Differential lock Inoperative • Wiring or solenoid failure. • Check for power to solenoid and that solenoid
energises when differential lock switch activated-
replace or repair as necessary.
• Low pressure • Check oil pressure at pressure point TP1 on
dropbox valve block - should be 27.5 ±2.5 bar (399
(399 ± 36 Ibf/in²) on activation of diff. lock switch -
Low pressure indicates either worn pump unit,
leaking valve (CT3) in the valve block or worn
differential piston and/ or shaft seals. Check and
replace as necessary. Verify and rectify primary
cause i.e. contaminated oil.
• Clutch plate wear • If pressure is within specification check oil line for
blockage. If oil flow is present examine and replace
clutch plates in the differential.
• Differential lock partially • Check oil pressure at pressure point TP1 on
Squeal from differential engaged. dropbox valve block- should be 0Bar with Diff. lock
with dif. lock not engaged.
off. If pressure is indicated, ensure solenoid (CT4) is
not being energised, check solenoid valve for
leakage. Replace as necessary.
• Clutch plates warped or • Examine and replace clutch plates in differential.
damaged
• Check pressure on dropbox valve block- Pressure

Cannot change gear range
at TP2 should be 15 ±2.5 bar (217 ± 36 Ib/in²). If OK
• Wiring or solenoid failure check wiring and switch.
SM 2367 Rev4 07-07 7

Section 125-0010
Problem Possible Cause Corrective Action

• Low pressure • Check pressure on dropbox valve block- pressure at
Fail To Engage Range - No TP2 should be 15 ±2.5 bar (217 ± 36 Ib/in²).
Drive
• Check that pressure control valve (4) is not faulty.
• Ensure supply from main hydraulic valve is correct.
• Gear selector mechanism • Test selector mechanism manually by removing

damage/ wear hydraulic selector cylinder and push and pull on the
selector rod. Note: Full gear selection will require some
rotation of the input shaft to align dog selector. Check
for bent or broken shaft or selector fork. Strip dropbox
and replace where necessary.

TORQUE
1 7 Bolt 921 680
1 8 Locknut 921 680
1 10 Bolt 185 156
1 11 Bolt 410 303
1 17 Bolt 921 680
VALVE BLOCK TORQUE SPECIFICATIONS

TORQUE
2 1 CT2 20 14.75
2 2 CT4 30 22
2 3 CT5 45 33
2 4 CT1 60 44.25
2 5 CT3 45 33
2 6 CT6 45 33
8 SM 2367 Rev4 07-07

DRIVELINES - Front Drivelines
Section 130-0010
SM - 3414
10
12,13,14 15
9 17
11
8
7
6 9
1 16 8
7
4,5
4,5
TRAILER
2
TRANSMISSION
FRONT AXLE
3 4,5
4,5
4,5 4,5
1 - Driveline Assembly 5 - Capscrew 9 - Bolt 13 - Washer

2 - Driveline Assembly 6 - X-member 10 - Anti-Flail Guard 14 - Bolt
3 - Driveline Assembly 7 - Locknut 11 - Support Plate 15 - Bolt
4 - Bolt 8 - Washer 12 - Locknut 16 - Locknut
17 - Washer
Fig. 1 - Front Drivelines and Mounting
DESCRIPTION
Numbers in parentheses refer to Fig. 1. compression loads from causing serious damage to the
components.
The function of the driveline is to transmit rotating
power from one point to another in a smooth and Note: Extra care should be taken when handling the
continuous action while allowing a degree of movement drivelines since chips, dents, burrs or deformity on any
or misalignment of the components it connects. rotating mass creates vibration and excessive wear
during any operation.
The drivelines must operate through constantly
changing relative angles between the components they There are three driveline assemblies installed between
are mounted to and must also be capable of changing various components in the tractor frame as follows:
length while transmitting torque.
Driveline assembly (1) is connected between the
A typical driveline consists of universal joints which transmission final drive and dropbox input drive.
allow some misalignment and permit the driveline to
pivot in any direction, and, a light rigid hollow slip yoke Driveline assembly (2) is connected between the front
and splined shaft assembly forming a slip joint. axle drive flange and dropbox final drive.
The slip joint accommodates length variations Driveline assembly (3) connects the rear final drive of
generated during operation, preventing tension or the dropbox to the articulation and oscillation pivot.
SM 2385 01-06 1
Drivelines - Front Drivelines
Section 130-0010
REMOVAL assembly (1). If necessary tap driveline assembly (1)

from its mating components with a soft faced hammer.
Note: Access to driveline assemblies (2 & 3) can be
Note: Extra care should be taken when handling
obtained from underneath the vehicle.
drivelines since carelessness can result in premature
failure of the components. Chips, dents, burrs, or any
8. Match mark universal joints and their mating
other deformity of universal joints will prevent accurate
surfaces to ensure correct mating alignment when
mating. This will cause misalignment which is
installing driveline assemblies (2 & 3).
accompanied by vibration and excessive wear.
9. Support driveline (2) with suitable lifting equipment
WARNINGS and remove capscrews (5) securing universal joints
To prevent personal injury and property to their mating components and remove driveline
damage, be sure wheel chocks, blocking assembly (2). If necessary tap driveline assembly (2)
materials and lifting equipment are properly from its mating components with a soft faced hammer.
safely. 10. Support driveline (3) with suitable lifting equipment
and remove bolts (4) securing universal joints
To prevent serious injury or death, DO to their mating components and remove driveline
NOT go under the vehicle when the engine is assembly (3). If necessary tap driveline assembly (3)
running. Rotating shafts can be dangerous. You from its mating components with a soft faced hammer.
can snag clothes, skin, hair, hands, etc..
DISASSEMBLY
parking brake and switch off the engine. Depress the Universal Joint
brake pedal continuously to relieve any pressure in the
braking circuit. Turn the steering wheel several times to Numbers in parentheses refer to Fig. 1.
relieve any pressure in the steering circuit.
1. Place the yoke end of driveline assembly (1) in a
2. Block all road wheels and place the battery master soft jawed vice, clamping on the tube of shaft.
switch in the off position.
Note: Do not distort the tube with excessive grip.
3. Remove mounting hardware securing insulation
quilts under the fenders to allow access to driveline 2. Remove screws (5) and universal joint from driveline
assembly (1). Remove insulation quilts. assembly (1).
Note: Access to driveline assembly (1) can be 3. Place the shaft end of driveline assembly (1) in a
obtained from underneath the vehicle. soft jawed vice.
4. Remove Locknuts (12), washers (13 & 18) and bolts 4. Remove screws (5) and universal joint from driveline
(18), securing Support plate (11) to anti-flail guard (10). assembly (1).
Remove support plate (11).
5. Repeat steps 1 to 4 for drivelines (2 & 3).
5. Remove bolt (15), locknut (16) and washer (17)
securing anti-flail guard (10) to cross-member (6).
Remove anti flail guard (10) clear of driveline assembly INSPECTION
(1).
1. Clean all metal parts in a suitable solvent, and dry
6. Match mark universal joints and their mating all parts with compressed air.
surfaces to ensure correct mating alignment when
installing driveline assembly (1). 2. Inspect splines of shaft and yoke for nicks, burrs
and excessive wear. Replace if wear is excessive or
7. Support driveline (1) with suitable lifting equipment splines are nicked. Burrs may be removed with a fine
and remove bolts (4) securing universal joints file or medium India stone.
to their mating components and remove driveline
2 SM 2385 01-06
Section 130-0010
SM - 088 INSTALLATION
APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
specified to standard torques listed in Section
STRAIGHT EDGE
SPECIFICATIONS.

REMOVE ALL other deformity of universal joints will prevent accurate
BURRS AND mating. This will cause misalignment which is
PAINT FROM accompanied by vibration and excessive wear.
THESE SURFACES
WARNINGS
Fig. 2 - Checking Parallelism damage, be sure wheel chocks, blocking
3. Check the surfaces of the components that universal safely.
joints mate against for parallelism. Refer to Fig. 2.
4. Check condition of mounting capscrews and replace To prevent serious injury or death, DO
if required. NOT go under the vehicle when the engine is
running. Rotating shafts can be dangerous. You
5. Check that anti-flail guard (10), support plate (11) can snag clothes, skin, hair, hands, etc..
and cross-member (6) are not damaged prior to
assembly.
1. If removed at disassembly stage. Secure cross-
ASSEMBLY member (6) to chassis frame, using bolts, locknuts and
washers (9,8 & 7). Tighten bolts to a torque of 921 Nm
Universal Joint (680 Ibf ft).
Numbers in parentheses refer to Fig. 1. 2. Position driveline assembly (3) on the vehicle as
shown in Fig. 1 and align match marks on universal
1. Place the yoke end of driveline assembly (1) in a joints with those on their mating surfaces.
soft jawed vice, clamping on the tube of shaft.
3. Apply Loctite 638 to the threads of bolts (4). Secure
Note: Do not distort the tube with excessive grip. universal joints to their mating surfaces with bolts (4).
2. Install universal joint to yoke end of driveline
assembly (1) and secure with screws (5). 4. Position driveline assembly (2) on the vehicle as
3. Place the shaft end of driveline assembly (1) in a joints with those on their mating surfaces.
soft jawed vice.
5. Apply Loctite 638 to the threads of bolts (4). Secure
4. Install universal joint to shaft end of driveline universal joints to their mating surfaces with bolts (4).
assembly (1) and secure with screws (5). Tighten bolts (4) to a torque of 153 Nm (113 lbf ft).
5. Repeat steps 1 to 4 for drivelines (2 & 3). 6. Position driveline assembly (1) on the vehicle as
joints with those on their mating surfaces.
SM 2385 01-06 3
Section 130-0010
7. Apply Loctite 638 to the threads of bolts (4). Secure Every 2 000 Hours: Check drivelines for leaks and
universal joints to their mating surfaces with bolts (4). damage, and replace if required.
7. Locate anti-flail guard (10) over cross-member (6) Periodic Inspection

mating holes. Secure guard in place using bolts (15), Use a small pry bar to check the companion flange
washers (17) and locknuts (16). Tighten bolts (15) to a yokes for looseness. If loose, drop one end of the
torque of 185 Nm (136 Ibf ft). driveline and twist the yoke to check the backlash
between the splines and yokes. Replace any yoke that
8. Secure support plate (11) to anti-flail guard (10) does not fit snugly.
using bolts (14), washers (13), locknuts (12) and
washers (18). With the pry bar, check the universal joints for play. If
loose, replace the universal joints. Check the splines
8. Secure insulation quilts under fenders and on to at the slip joint and replace the yoke if excessively
mounting brackets with hardware removed during worn.
removal.
9. Ensure the parking brake is applied and remove SPECIAL TOOLS

wheel chocks from all road wheels. There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
MAINTENANCE tools and adhesives required. These tools and
adhesives are available from your dealer.
Universal Joints
Every 500 Hours: Check the universal joints for wear
and replace if required.
DRIVELINE DIAGNOSIS CHART

CONDITION REASON REMEDY
Vibration or noise Driveline bent or out of balance Clean driveline in a suitable solvent. Inspect for
contact with adjacent parts. If driveline is
distorted or sprung, replace. If driveline does not
run smoothly, and vibration is felt, remove
driveline and dynamically balance the assembly.
Driveline loose at yoke/flange Check driveline mounting capscrews for
tightness. If loose, replace capscrews and
torque tighten to the proper specification.
Excessive wear of Poor yoke/flange alignment Check yoke/flange for alignment, run-out and
universal joints and/or run-out balance. Repair or replace as required.
Driveline imbalance Check to see if balance weights are missing or if
driveline is distorted. If driveline is distorted,
replace; if weights are missing, check balance of
driveline dynamically and rebalance.

TORQUE
1 4 Bolt 153 113
1 9 Bolt 921 680
1 15 Bolt 185 136
* * * *
4 SM 2385 01-06
DRIVELINES - Rear Drivelines
Section 130-0020
SM - 2944
2,3
2,3 5,6 4 5,6
CENTRE AXLE REAR AXLE
1 - Driveline Assembly 3 - Screw 5 - Capscrew

2 - Capscrew 4 - Driveline Assembly 6 - Screw
Fig. 1 - Rear Drivelines and Mounting
DESCRIPTION centre and rear axles to the drive supplied from the
transmission, through the pivot drive arrangement, as
follows:
The function of the driveline is to transmit rotating
Driveline assembly (1) is connected between the
power from one point to another in a smooth and
articulation and oscillation pivot and the centre axle.
continuous action while allowing a degree of
movement or misalignment of the components it
Driveline assembly (4) is connected between the centre
connects.
axle and the rear axle.
The drivelines must operate through constantly
changing relative angles between the components REMOVAL
they are mounted to and must also be capable of
changing length while transmitting torque.
A typical driveline consists of universal joints which
allow some misalignment and permit the driveline to
pivot in any direction, and, a light rigid hollow slip yoke
and splined shaft assembly forming a slip joint.
other deformity of universal joints will prevent accurate
mating. This will cause misalignment which is
The slip joint accommodates length variations
accompanied by vibration and excessive wear.
generated during operation, preventing tension or
compression loads from causing serious damage to
the components.
WARNINGS
Note: Extra care should be taken when handling the
drivelines since chips, dents, burrs or deformity on any
rotating mass creates vibration and excessive wear
during any operation.
safely.
There are two driveline assemblies connecting the
SM 2386 03-06 1
Drivelines - Rear Drivelines
Section 130-0020
4. Remove screws (3) and universal joint from driveline
To prevent serious injury or death, DO assembly (1).
NOT go under the vehicle when the engine is
running. Rotating shafts can be dangerous. You 5. Repeat steps 1 to 4 for driveline (4).
can snag clothes, skin, hair, hands, etc..
INSPECTION
Disconnecting or removing any of the
rear drivelines will make the parking brake 1. Clean all metal parts in a suitable solvent, and dry
ineffective. all parts with compressed air.
1. Position the vehicle in a level work area, apply the 2. Inspect splines of shaft and yoke for nicks, burrs
parking brake and switch off the engine. Depress the and excessive wear. Replace if wear is excessive or
brake pedal continuously to relieve any pressure in the splines are nicked. Burrs may be removed with a fine
braking circuit. Turn the steering wheel several times to file or medium India stone.
relieve any pressure in the steering circuit.
3. Check the surfaces of the components that universal
2. Block all road wheels and place the battery master joints mate against for parallelism. Refer to Fig. 2.
switch in the off position.
4. Check condition of mounting capscrews and replace
Note: Access to driveline assemblies (1 & 4) can be if required.
obtained from underneath the vehicle.
ASSEMBLY
surfaces to ensure correct mating alignment when Universal Joint
installing driveline assembly (1).
4. Remove capscrews (2) securing universal joints to
their mating components and remove driveline 1. Place the yoke end of driveline assembly (1) in a
assembly (1). If necessary tap driveline assembly (1) soft jawed vice, clamping on the tube of shaft.
from its mating components with a soft faced hammer.
Note: Do not distort the tube with excessive grip.
surfaces to ensure correct mating alignment when 2. Install universal joint to yoke end of driveline
installing driveline assembly (4). assembly (1) and secure with screws (3).
6. Remove capscrews (5) securing universal joints to 3. Place the shaft end of driveline assembly (1) in a
their mating components and remove driveline soft jawed vice.
assembly (4). If necessary tap driveline assembly (4)
from its mating components with a soft faced hammer. 4. Install universal joint to shaft end of driveline
assembly (1) and secure with screws (3).
DISASSEMBLY 5. Repeat steps 1 to 4 for driveline (4).
Universal Joint
INSTALLATION
1. Place the yoke end of driveline assembly (1) in a otherwise specified.
soft jawed vice, clamping on the tube of shaft.
Note: Do not distort the tube with excessive grip. specified to standard torques listed in Section
2. Remove screws (3) and universal joint from driveline SPECIFICATIONS.
assembly (1).
3. Place the shaft end of driveline assembly (1) in a drivelines since carelessness can result in premature
soft jawed vice. failure of the components. Chips, dents, burrs, or any
2 SM 2386 03-06
Section 130-0020
SM - 088 4. Apply Loctite 648 to the threads of capscrews (5).

Secure universal joints to their mating surfaces with
APPLY PRESSURE MAXIMUM PERMISSIBLE capscrews (5). Tighten capscrews (5) to a torque of
HERE BY HAND GAP IS 0.2 mm (0.008 in)
153 Nm (112 lbf ft).
5. Ensure the parking brake is applied and remove

STRAIGHT EDGE wheel blocks from all road wheels.
MAINTENANCE
Universal Joints
REMOVE ALL Every 500 Hours: Check the universal joints for wear
BURRS AND
PAINT FROM and replace if required.
THESE SURFACES
Every 2 000 Hours: Check drivelines for leaks and
damage, and replace if required.
Fig. 2 - Checking Parallelism Periodic Inspection

Use a small pry bar to check the companion flange
other deformity of universal joints will prevent accurate yokes for looseness. If loose, drop one end of the
mating. This will cause misalignment which is driveline and twist the yoke to check the backlash
accompanied by vibration and excessive wear. between the splines and yokes. Replace any yoke that
does not fit snugly.
WARNINGS With the pry bar, check the universal joints for play. If
To prevent personal injury and property loose, replace the universal joints. Check the splines at
damage, be sure wheel blocks, blocking the slip joint and replace the yoke if excessively worn.
safely. SPECIAL TOOLS
There are no special tools required for procedures
To prevent serious injury or death, DO outlined in this section. Refer to Section 300-0070,
NOT go under the vehicle when the engine is SERVICE TOOLS, for part numbers of general service
running. Rotating shafts can be dangerous. tools and adhesives required. These tools and
You can snag clothes, skin, hair, hands, etc.. adhesives are available from your dealer.
Disconnecting or removing any of the

rear drivelines will make the parking brake
ineffective.
1. Position driveline assembly (1) on the vehicle as

2. Apply Loctite 648 to the threads of capscrews (2).

Secure universal joints to their mating surfaces with
capscrews (2). Tighten capscrews (2) to a torque of
153 Nm (112 lbf ft).
3. Position driveline assembly (4) on the vehicle as

SM 2386 03-06 3
Section 130-0020
DRIVELINE DIAGNOSIS CHART

Vibration or noise Driveline bent or out of balance Clean driveline in a suitable solvent. Inspect for
contact with adjacent parts. If driveline is
distorted or sprung, replace. If driveline does not
run smoothly, and vibration is felt, remove
driveline and dynamically balance the assembly.
Driveline loose at yoke/flange Check driveline mounting capscrews for
tightness. If loose, replace capscrews and
torque tighten to the proper specification.
Excessive wear of Poor yoke/flange alignment Check yoke/flange for alignment, run-out and
universal joints and/or run-out balance. Repair or replace as required.
Driveline imbalance Check to see if balance weights are missing or if
driveline is distorted. If driveline is distorted,
replace; if weights are missing, check balance of
driveline dynamically and rebalance.

TORQUE
1 2 Capscrew 153 113
* * * *
4 SM 2386 03-06
CENTRE AXLE - Differential Drive Head
Section 150-0020
DESCRIPTION and short axle shafts are removed. Refer to

The differential assembly is mounted to the axle Section 160-0030, AXLE GROUP (HUB).
housing. It comprises of two differentials; one for the
normal cross-axle drive function; the other for the thru- 6. Identify the relationship of the front and rear
drive. driveline flanges and differential flanges with punch
marks.
The differential is a spiral bevel ring gear type with an
automatically limited slip element (See Fig. 2). 7. Disconnect the drivelines from the differential
flanges. The drivelines can be removed if it is
The thru-drive differential is lockable by the operator. convenient to do so.
Note: Never engage or disengage the Differential 8. Support the weight of differential housings (2 & 31)
Lock when moving or when the wheels are spinning. and layshaft housing (3) with suitable lifting equipment.
Remove bolts securing differential housing (2) to axle
casing and carefully remove differential assembly clear
REMOVAL AND INSTALLATION of axle casing.
INSTALLATION
Installation is the reversal of the 'Removal' procedure.
WARNING
To prevent personal injury and property Note: Use sealing compound (Loctite 574) between the
damage, be sure wheel blocks, blocking axle housing and differential housing mounting faces.
secured and of adequate capacity to do the job Tighten bolts securing differential assembly to axle
safely. casing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure the Note: Tighten all fasteners to standard torques listed in
body in the partially raised position. Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
2. Apply the parking brake and switch off the engine.
Fill the layshaft housing (3) and the differential housing
3. Block all road wheels, place the steering lock bar in (31) with 1.5 litres (0.4 US gallon) of gear oil of the type
the 'Locked' position and the battery master switch in specified in Section 300-0020, LUBRICATION
the 'Off' position. SYSTEM, through the differential filler/level hole. Fill
the axle casing with gear oil of the type specified in
4. Drain the gear oil out of the axle housing and both Section 300-0020, LUBRICATION SYSTEM, through
planetaries into a suitable container. the differential filler/level hole until the oil is level with
the bottom of the filler/level hole. Fill the planetary
5. Remove the planetary assemblies and axle shafts assemblies up to the 'Oil Level Check Line'. Check oil
from the axle housing. Note from which side the long levels after a few minutes to ensure level remains
constant.
SM 2249 9-03 1
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3022
Fig. 1 - Exploded View Of Centre Differential
2 SM 2249 9-03
Section 150-0020
SM - 3023
Fig. 2 - Exploded View of Limited Slip Cross-axle Differential
LEGEND FOR FIGS. 1 & 2.

1 - Adjusting Nut 26 - Spacer Ring 51 - Side Gear 76 - Spring
2 - Differential Housing 27 - Slotted Nut 52 - Thrust Washer 77 - Centering Ring
3 - Layshaft Housing 28 - Bolt 53 - Pinion Gear 78 - Cylinder
4 - Plug 29 - Bolt 54 - Thrust Washer 79 - Bolt
5 - 'O' Ring 30 - Slotted Pin 55 - Differential Axle 80 - Filter Element
6 - Plug 31 - Differential Housing 56 - Bolt 81 - Adjusting Bolt
7 - 'O' Ring 32 - Slotted Pin 57 - Housing Cover 82 - Nut
8 - Plate 33 - Plug 58 - Capscrew 83 - Disc
9 - Pin 34 - 'O' Ring 59 - Bearing 84 - Contact Pin
10 - Bushing 35 - Plug 60 - Shim 85 - Seal Ring
11 - Capscrew 36 - 'O' Ring 61 - Shaft Seal 86 - Contact Switch
12 - Bearing 37 - Differential Case Half 62 - Flange 87 - Drive Shaft Flange
13 - Bush Spacer 38 - Thrust Washer 63 - Bolt 88 - Flange
14 - Adjusting Ring 39 - Pin 64 - Bolt 89 - Shaft Seal
15 - Bearing 40 - Quill Shaft 65 - Bolt 90 - Bearing
16 - Shim 41 - Side Gear 66 - Washer 91 - Shim
17 - Bearing 42 - Pinion Gear 67 - Slotted Nut 92 - Retaining Ring
18 - Bearing 43 - Thrust Washer 68 - Sliding Dog 93 - Bolt
19 - Adjusting Nut 44 - Spider 69 - Shifter Fork Assembly 94 - Drive Flange
20 - Slotted Pin 45 - Flange 70 - Thrust Block 95 - Dust Cap
21 - Washer 46 - Ring Gear 71 - Shifter Fork Lock Pin 96 - Pinion Gear
22 - Slotted Nut 47 - Differential Housing 72 - Bolt 97 - Spur Gear
23 - Bearing 48 - Externally Splined Disc 73 - Seal 98 - Spur Gear
24 - Bearing 49 - Internally Splined Disc 74 - Piston 99 - Shim
25 - Adjusting Ring 50 - Thrust Ring 75 - 'U' Ring
SM 2249 9-03 3
Section 150-0020
DISASSEMBLY SM - 3024
Numbers in parentheses refer to Figs. 1 & 2.
WARNING
safely.
Note: The following removal procedure assumes the

Fig. 3 - Removing Drive Shaft Flange
complete axle assembly was removed from the
vehicle.
SM - 3025
1. Ensure oil is drained from planetaries, axle casing,

differential housings (2 & 31) and layshaft housing (3).
2. Remove bolts (93) securing flange (88) to axle

casing. Using special tools (15271101 Back-up Tool
and 15500905 Extractor) remove drive shaft flange (87)
as shown in Fig. 3.
3. Remove retaining ring (92) and shim (91) from drive

shaft flange (87). Press off flange (88) and bearing (90)
from drive shaft flange (87).
Fig. 4 - Removing Differential Assembly
4. Press shaft seal (89) out of flange (88).
SM - 2951
5. Remove both planetary assemblies and axle shafts
by following the procedure in Section 160-0030, AXLE
GROUP (HUB). Using suitable lifting equipment,
support differential assembly. If not done already,
remove nuts and bolts and remove the differential
assembly from the axle casing as shown in Fig. 4.
6. Loosen ring gear bolts (56) as shown in Fig. 5.
Fig. 5 - Removing Ring Gear Bolts
7. Remove slotted pins (20) before loosening adjusting SM - 2952

nuts (1 & 19) as shown in Fig. 6.
Fig. 6 - Removing Adjusting Nuts
4 SM 2249 9-03
Section 150-0020
SM - 2953 8. Using special tool (15269899 220V Hot Air Blower or

15269900 110V Hot Air Blower) heat the area around
the threaded holes and loosen bolts securing bearing
caps. Remove bearing caps.
Fig. 7 - Removing Bearing Caps
SM - 858 9. Lift the differential assembly out of differential

housing (2) with the special tool (15269929 Lifting
Pliers) as shown in Fig. 8.
Fig. 8 - Removing Differential
SM - 2954 10. Remove both bearings (17 & 18) inner rings using
special tools (15272560 Puller, 15500887 Gripping
Insert, 15500888 Gripping Insert and 15500889
Reducer) as shown in Fig. 9.
Fig. 9 - Removing Bearing Inner Rings
SM - 2955 11. Remove capscrews (58) and separate housing (47)

from cover (57). Remove single components as shown
in Fig. 10.
Fig. 10 - Differential Components
SM 2249 9-03 5
Section 150-0020
12. Using suitable lifting equipment, remove bolts (28 & SM - 3026
29) and separate layshaft housing (3) and differential
housing (31) from differential housing (2) as shown in
Fig. 11.
Fig. 11 - Separating Differential
13. Using special tool (15269899 220V Hot Air Blower SM - 3027
or 15269900 110V Hot Air Blower) heat the slotted nut
(67) to around 120 oC before loosening using special
tools (15500890 Socket and 15270120 Clamping Yoke)
as shown in Fig. 12. Do not remove nut (67) at this
point.
Fig. 12 - Loosening Nut
14. Remove bolts (65) and using suitable lifting SM - 3028

equipment, separate the inter-axle differential with
flanges (45 & 62) from housing (31) as shown in Fig.
13.
Fig. 13 - Separating Housing
15. Remove slotted nut (67), washer (66) and drive SM - 3029
flange (94). Press the inter-axle differential out of

flanges (45 & 62) as shown in Fig. 14.
Fig. 14 - Pressing Differential
6 SM 2249 9-03
Section 150-0020
SM - 3030 16. Separate flanges (45 & 62) and press out bearing (59).
Shims (60 & 99) should also be removed at this stage.
17. Pull off bearing inner race from differential case (37)
using special tool (15500906 Puller) as shown in Fig. 15.
Fig. 15 - Removing Bearing
SM - 3031 18. Remove capscrews (11) and separate inter-axle

differential as shown in Fig. 16.
Fig. 16 - Inter-axle Differential
SM - 3032 19. Loosen bolts (79) evenly and separate cylinder (78)
from the housing (31) as shown in Fig. 17.
Fig. 17 - Removing Cylinder
SM - 1111 20. Remove switch (86), seal ring (85) and contact pin
(84) from housing (31) as shown in Fig. 18. Remove
both shifter fork lock pins (71).
Fig. 18 - Removing Contact Switch
SM 2249 9-03 7
Section 150-0020
21. Remove shifter fork assembly (69) and piston (74) SM - 1116
assembly as shown in Fig. 19.
22. Remove adjusting bolt (81) and nut (82) from

housing (31).
Fig. 19 - Removing Shifter Fork And Piston
23. Using special tool (15500907 Fixture) lock quill SM - 3033

shaft (40) as shown in Fig. 20.
24. Using special tool (15269899 220V Hot Air Blower

or 15269900 110V Hot Air Blower) heat slotted nut (27)
to around 120 oC before removing using special tool
(15500908 Socket). Remove fixture installed in Step
23.
Fig. 20 - Locking Shaft
25. Press out quill shaft (40) using special tool SM - 3034
(15269946 Puller Set) as shown in Fig. 21.
Fig. 21 - Pressing Shaft
26. Remove adjusting ring (25) from shaft (40). Support SM - 3035
shaft (40) on sliding dog (68) and press off bearing (24)
inner race as shown in Fig. 22.
Fig. 22 - Pressing Bearing Inner Race
8 SM 2249 9-03
Section 150-0020
SM - 2962 27. Remove bearing (23) inner race and spacer ring
(26) from housing (3) as shown in Fig 23.
Fig. 23 - Removing Bearing Inner Race
SM - 3036 28. Remove bolts (64) securing differential housing (31)

to layshaft housing (3) and separate housings using
suitable lifting equipment as shown in Fig. 24. Remove
spur gear (97).
Fig. 24 - Separating Housings
SM - 3037 29. Using special tool (15269899 220V Hot Air Blower
to around 120 oC before removing using special tool
(15500891 Socket). Block spur gear (98) with wooden
block, as shown in Fig. 25.
Fig. 25 - Removing Slotted Nut
SM - 2965 30. Press pinion gear (96) out of bearing (12) using
special tool (15269946 Puller Set) as shown in Fig. 26.
Remove bearing (12) inner race from housing (3).
Fig. 26 - Pressing Out Pinion Gear
SM 2249 9-03 9
Section 150-0020
31. Pull off the bearing (15) inner race from the pinion SM - 2966
gear (96) using special tools (15500892 Gripping Insert
and 15272560 Bearing Puller).
Fig. 27 - Removing Bearing From Pinion Gear
32. Remove bush spacer (13) and adjusting ring (14) SM - 2967
from layshaft housing (3). Using special tool (15269946
Puller Set) press out bushing (10) as shown in Fig. 28.
33. Press out the bearing (15) outer ring from the
bushing (10) and remove the shim (16).
Fig. 28 - Pressing Out Bushing
INSPECTION SM - 2968
The importance of careful and thorough inspection

cannot be overstressed. Thorough inspection and
necessary replacement of parts now may eliminate
costly and avoidable trouble later.
1. Clean all parts in petroleum base solvent.
2. Immediately after cleaning, dry all parts, except

bearings, with compressed air, or with a soft, clean lint
free wiping cloth. Compressed air has a corrosive
effect on bearings, therefore, they must be wiped dry
with a cloth. Fig. 29 - Pressing Bearing Outer Race in Housing
3. Coat cleaned, dried parts immediately with light oil to SM - 2969
prevent corrosion. If parts are not to be assembled

immediately, treat them with a good rust preventive
and wrap them with treated paper or other suitable
material designed to prevent corrosion.
4. Before installing the differential assembly to the

machine, clean the inside and outside of the axle
housing to remove any foreign material.
5. Inspect all gears, pinions, and splines for cracked or

broken teeth, excessive wear, and pitted or scored
surfaces. Repair or replace as necessary. Fig. 30 - Pressing Bearing Outer Race in Housing
10 SM 2249 9-03
Section 150-0020
SM - 2970 Note: If either ring gear or pinion gear is defective, both
gears must be replaced, because they are serviced
only as a matched set. Make sure the ring gear and
pinion gear have the same mating numbers.
6. Check for pitted, scored or worn thrust surfaces of

differential case halves.
Fig. 31 - Installing Spur Gear
SM - 2971 ASSEMBLY
Numbers in parentheses refer to Figs. 1 & 2 unless
specified otherwise.

specified to torques listed in Section 300-0080, AXLE
BOLT AND NUT TORQUE SPECIFICATIONS.
Note: During assembly and installation, make sure that

mated, punch marked, or otherwise identified parts are
returned to their original positions, if still serviceable.
Fig. 32 - Installing Bushing
WARNING
SM - 2972 To prevent personal injury and property
safely.
1. Press bearing (12) outer race into housing (3) bore

as shown in Fig. 29.

Fig. 33 - Measuring Dimension 'A' 3. Insert spur gear (98) into housing (3) bore, ensuring
that inner diameter (85 mm) is facing down, as shown
SM - 2973 in Fig. 31.
4. Press the bushing (10) into housing (3) bore and

ensure it is firmly home, as shown in Fig. 32.
5. At this stage in the assembly procedure the

thickness of shim (16) must be determined to ensure
correct contact pattern between pinion gear (96) and
ring gear (46). As shown in Fig. 33, measure
Dimension 'A' from the mounting face of housing (3) to
the locating face of the bearing (15) outer ring, using
special tools (15270113 Gauge Blocks, 15269948
Fig. 34 - Assembling The Measuring Shaft Straight Edge and 15270114 Digital Depth Gauge).
SM 2249 9-03 11
Section 150-0020
Eg. Dimension 'A' = 29.70 mm SM - 2974
6. As shown in Fig. 34, use special tools (15500893

Shims, 15500894 Shims and 15269934 Measuring
Shaft) and place shims into the bores of differential
housing (2) and assemble the measuring shaft.
7. Measure Dimension 'B' from mounting face of

housing (2) to Measuring Shaft (see Fig. 35).
Eg. Dimension 'B' = 196.75 mm
Example: Fig. 35 - Measuring Dimension 'B'

Dimension 'A' 29.70 mm
+ Dimension 'B' 196.75 mm
SM - 868
- Dimension 'C' (1/2 diameter of Measuring
Shaft) 15.00 mm
= Dimension 'X' 241.45 mm
8. Measure thickness of bearing (15) as shown in Fig.

36 using special tools (15270113 Gauge Blocks and
15270114 Digital Depth Gauge). Record as Dimension
'D'.
Eg. Dimension 'D' = 42.70 mm

Fig. 36 - Measuring Bearing Thickness
9. The arrow in Fig. 37 is pointing to a dimension SM - 2975

stamped on the face of pinion gear (96). Record as
Dimension 'E'.
Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm
Example:
Dimension 'D' 42.70 mm
+ Dimension 'E' 197.90 mm
= Dimension 'Y' 240.60 mm
Fig. 37 - Dimension On Pinion Face
10. Calculate shim (16) thickness by subtracting SM - 2976

Dimension 'Y' from Dimension 'X'.
Example:
Dimension 'X' 241.45 mm
- Dimension 'Y' 240.60 mm
= Required thickness 0.85 mm
Install shim (16) of required thickness into the bushing

(10) as shown in Fig. 38.
Fig. 38 - Installing Spacing Washer
12 SM 2249 9-03
Section 150-0020
SM - 2977 11. Freeze bearing (15) outer race and install in
bushing (10), ensuring it is firmly home.
WARNING
To prevent personal injury, wear protective
gloves when handling bearing.
Fig. 39 - Installing Bearing Outer Race
SM - 873 12. Heat inner race of bearing (15) to approximately 90°

C (190° F) and press it on to the shaft of pinion gear
(96). Be sure it is firmly seated against the shaft
shoulder as shown in Fig. 40.
WARNING
Fig. 40 - Installing Bearing Inner Race
SM - 2978 13. Install assembled pinion gear (96) in layshaft

housing (3) using special tool (15269946 Puller Set) as
shown in Fig. 41. Do not remove special tool at this
point.
Fig. 41 - Installing Pinion Gear
SM - 2979 14. The adjusting ring (14) is used to obtain the rolling
resistance of the pinion bearing. Rolling resistance
should be 3.5 - 4.0 Nm (2.6 - 2.9 lbf ft). This rolling
resistance is checked once pinion gear (96) is secured
in housing (3) (Step 17).
As shown in Fig. 42, install bush spacer (13) with the
small collar showing up (ref. arrow) into the bore of the
spur gear (98) and install adjusting ring (14).
Fig. 42 - Installing Spacer Bush and Adjusting Ring
SM 2249 9-03 13
Section 150-0020
15. Heat inner race of bearing (12) to approximately 90° SM - 2980
(96) until it is firmly home as shown in Fig. 43.
WARNING
After bearing (12) inner race has cooled, remove special

tool installed in Step 13.
Fig. 43 - Installing Bearing
16. Coat threads of slotted nut (22) with Loctite 649. SM - 2981
Locate washer (21) and install slotted nut (22). Using
special tool (15500891 Socket) tighten slotted nut (22)
Note: When tightening nut (22), rotate the pinion gear (96)
in both directions several times.
Fig. 44 - Tightening Slotted Nut
17. Check the rolling resistance of the pinion bearing SM - 2982

as shown in Fig. 45 by using special tool (15500895
Torque Spanner). If the rolling resistance is outwith
range (3.5 - 4.0 Nm), adjusting ring (14) thickness must
be changed.
Record this torque as Tpinion e.g. 3.5 Nm.
Fig. 45 - Checking Rolling Resistance
18. Install spur gear (97) in housing (3) as shown in SM - 2983

Fig. 46.
14 SM 2249 9-03
Section 150-0020
SM - 3038 19. Install bearing (24) outer race into bore of

differential housing (31) as shown in Fig. 47.
SM - 3039 20. Apply Loctite 574 to mounting face of layshaft

housing (3). Using suitable lifting equipment, install the
differential housing (31) to layshaft housing (3) as
shown in Fig. 48.
Fig. 48 - Installing Differential Housing
SM - 3040 21. Insert the slotted pin (32) (ref. arrow) and new bolts
(64) as shown in Fig. 49. Torque bolts (64) to 155 Nm
(114 lbf ft).
Fig. 49 - Tightening Bolts
SM - 3041 22. Install sliding dog (68) on quill shaft (40) with the
gearing showing downwards as shown in Fig. 50.
Fig. 50 - Installing Sliding Dog
SM 2249 9-03 15
Section 150-0020
23. Press bearing (24) inner race onto quill shaft (40) SM - 3042
until it is firmly home as shown in Fig. 51.
24. Install adjusting ring (25) in housing (31) before SM - 3043

installing sub assembled quill shaft (40) as shown in
Fig. 52.
Fig. 52 - Installing Shaft
25. Using special tool (15500907 Fixture) lock quill SM - 3033

shaft (40) as shown in Fig. 53.
Fig. 53 - Locking Shaft
26. The spacer ring (26) is used to obtain the rolling SM - 2985
resistance of the shaft (40) bearing. Rolling resistance
resistance (THo) is calculated once shaft (40) is
secured in housing (Step 29). As shown in Fig. 54,
install spacer ring (26) on shaft (40) with the collar
facing down.
Fig. 54 - Installing Spacer
16 SM 2249 9-03
Section 150-0020

C (190° F) and press it on to the shaft (40) until it is
firmly home as shown in Fig. 55.
WARNING
SM - 3044 28. Allow bearing (23) to cool, then coat threads of

slotted nut (27) with Loctite 649. Assemble slotted nut
(27) on shaft (40) and tighten using special tool
(15500908 Socket). Torque slotted nut (27) to 1200 Nm
(885 lbf ft) as shown in Fig. 56.
Note: When tightening nut (27), rotate the shaft (40) in

both directions several times.
SM - 2997 29. Remove special tool (15500908 Fixture) installed at

Step 25. As shown in Fig. 57, check total rolling
resistance of pinion gear (96) and shaft (40) by using
special tool (15500895 Torque Spanner). Record this
torque as Ttot e.g. 4.5 Nm.
Example:
Ttot e.g. 4.5 Nm
Tpinion e.g. - 3.5 Nm
Results in THo = 1.0 Nm
As specified in Step 26, rolling resistance (THo) of shaft

Fig. 57 - Checking Rolling Resistance (40) should be 0.5 - 2.0 Nm. If outwith this range,
spacer ring (26) thickness must be changed.
SM - 3045
X 30. Attach thrust blocks (70) to shifter fork assembly
(69) and install in differential housing (31) as shown in
Fig. 58. Thrust blocks (70) fit into sliding dog (68)
groove.
Note: Shifter fork assembly is not symmetrical, 'X'

denotes short side.
Fig. 58 - Installing Fork Assembly
SM 2249 9-03 17
Section 150-0020
31. Place 'U' section ring (75) on piston (74) with SM - 3046
sealing lip towards outside. Slide spring (76) on the
piston stem. Locate the centering ring (77) in the
recess as denoted by arrow in Fig. 59. Insert the
assembled piston into its bore in differential housing
(31). Be sure the piston stem makes contact with
shifter fork (69).
Fig. 59 - Installing Piston
32. Place new seals (73) on shifter fork lock pins (71). SM - 3047
Position the shifter fork assembly (69) and fix in place
with shifter fork lock pins (71) as shown in Fig. 60.
Secure lock pins (71) with bolts (72) and torque to 45
Nm (33 lbf ft).
Fig. 60 - Installing Lock Pins
33. Apply Loctite 574 to mounting face of cylinder (78) SM - 3048

and secure to differential housing (31) using bolts (79).
Ensure port is at top, as shown in Fig. 61. Tighten
bolts to 23 Nm (17 lbf ft).
Fig. 61 - Installing Cylinder
34. Sub-assemble inter-axle differential by installing SM - 3049

thrust washer (38) in differential case half (37), with
lubrication groove facing up. Secure thrust washer with
pins (39).
Note: Ensure pins do not protrude above contact face

of thrust washer.
Fig. 62 - Installing Thrust Washer
18 SM 2249 9-03
Section 150-0020
SM - 3050 35. Install side gear (41) in differential case half (37).
36. Sub-assemble differential spider (44), pinion gears

(42) and thrust washers (43), ensuring thrust washers
are correctly fitted. Install sub-assembly as shown in
Fig. 63.
Fig. 63 - Installing Spider Assembly
SM - 3051 37. Install differential case half (37) and fasten with
capscrews (11). Tighten capscrews to 115 Nm (85 lbf
ft).
Note: Use part number stamped on differential cage

halves (37) to ensure correct alignment, as shown in
Fig. 64.
ZF-No.:
Fig. 64 - Assembling Differential
SM - 3052 38. Install the pre-assembled inter-axle differential in

differential housing (31).
To meet required differential end float (0.18 - 0.23 mm)

shim (99) dimension should be calculated. Initially
measure Dimension 'A' from the housing (31) mounting
face to inter-axle differential locating face as shown in
Fig. 65.
Eg. Dimension 'A' = 5.00 mm
Measure at several points and determine average

Fig. 65 - Measuring Dimension 'A' dimension.
SM - 3053
39. On flange (45) measure Dimension 'B' from the
mounting face to the locating face as shown in Fig. 66.
Example:
Dimension 'B' 6.70 mm
Dimension 'A' - 5.00 mm
= 1.70 mm
Required End Float + 0.20 mm
Shim (99) Dimension = 1.90 mm
Fig. 66 - Measuring Dimension 'B' Place calculated shim (99) into the flange (45).
SM 2249 9-03 19
Section 150-0020
40. Press bearing (59) into flange (45) until firmly SM - 3054
home.
41. Install both bearing (59) inner rings. Place pre- SM - 3055
assembled flange (45) on inter-axle differential and
press until firmly home as shown in Fig. 68.
Fig. 68 - Installing Flange to Differential
42. Using special tool (15269899 220V Hot Air Blower SM - 3056
or 15269900 110V Hot Air Blower) heat housing (31)
bore and coat mounting face with sealing compound
Loctite 574.
Note: Carry out following steps (43 - 46) promptly

before sealing compound hardens.
43. Install flange (62) on housing (31) as shown in Fig.

69. Use guide screws if necessary.
Fig. 69 - Installing Flange
44. To remove bearing (59) backlash, initially measure SM - 3057

Dimension 'X' from the bearing (59) face to the flange
(62) mounting face as shown in Fig. 70.
Eg. Dimension 'X' = 10.40 mm
Fig. 70 - Measuring Dimension 'X'
20 SM 2249 9-03
Section 150-0020
SM - 3058 45. Remove flange (62) and measure Dimension 'Y'

from mounting face to bearing contact face as shown
in Fig. 71.
Eg. Dimension 'Y' = 11.10 mm
Example:
Dimension 'Y' 11.10 mm
Dimension 'X' - 10.40 mm
Shim (60) Dimension = 0.70 mm
Place calculated shim (60) into the flange (62).

Fig. 71 - Measuring Dimension 'Y'
46. Again coat mounting face with sealing compound

SM - 3059
Loctite 574. Assemble flange (62) complete with shim
(60) on housing (31) and secure with bolts (65). Tighten
47. Using special tool (15500896 Driver) install shaft

seal (61) as shown in Fig. 72.
Note: If seal outer diameter is rubber coated, coat with

spirit. If seal outer diameter is metallic, coat with
Loctite 574.
Fig. 72 - Installing Shaft Seal
SM - 3060 48. Press dust cap (95) onto drive flange (94) using
special tools (15500909 Driver and 15270121 Handle).
49. Install drive flange (94) and secure with washer (66)
and slotted nut (67). Using special tools (15500890
Socket and 15270120 Clamping Yoke) tighten nut to
1 000 Nm (738 lbf ft).
Note: Coat threads of slotted nut (67) with Loctite 649.
Fig. 73 - Installing Drive Flange
SM - 3061 50. Set inter-axle differential lock by installing special

tool (15500910 Compressed Air Connection) and
pressurising piston with compressed air (maximum 10
bar (145 lbf/in2)) as shown in Fig. 74. Ensure differential
lock is engaged by turning the drive flange (94).
51. Coat threads of adjusting bolt (81) with sealing

compound Loctite 574 and hand tighten until bolt
contacts piston (74). Tighten adjusting bolt (81) a
further 1/3 of a turn, and lock with nut (82).
Fig. 74 - Compressing Diff-lock Cylinder
SM 2249 9-03 21
Section 150-0020
52. Install contact pin (84), seal ring (85) and contact SM - 3062
switch (86). Connect special tool (15500911 Indicator)
Fig. 75 - Installing Indicator
53. Pressurise piston with compressed air (maximum SM - 3063

10 bar (145 lbf/in2)) as shown in Fig. 76. Ensure
differential lock is engaged by turning the drive flange
(94). The warning lamp on the Indicator should
illuminate when the sliding dog (68) is fully engaged.
Fig. 76 - Checking Contact Switch
54. Install disc (83) and filter element (80) in bore SM - 3064
arrowed in Fig. 77. Cover port until final installation of
hose.
Fig. 77 - Installing Filter
55. Coat mounting face of differential housing (2) with SM - 3065

sealing compound Loctite 574. Using suitable lifting
equipment, install pre-assembled layshaft housing on
the differential housing (2). Install new bolts (28 & 29)
and slotted pins (30) in correct locations (arrowed in
Fig. 78). Tighten bolts to 155 Nm (114 lbf ft).
Fig. 78 - Installing Pre-assembled Layshaft Housing
22 SM 2249 9-03
Section 150-0020
SM - 3074 56. Heat ring gear (46) and install it on the differential
housing (47) until it is firmly home as shown in Fig. 79.
WARNING
gloves when handling ring gear.
Fig. 79 - Installing Ring Gear
SM - 2999 57. Prior to assembly, coat components with gear oil

as specified in Section 300-0020, LUBRICATION
SYSTEM. Place both thrust washers (52 & 54) in the
housing (47), installing steel thrust washer (52) first as
shown in Fig. 80.
Fig. 80 - Installing Thrust Washers
SM - 3000 58. Install disc set A (Fig. 2) in housing (47), beginning

with externally splined disc (48) as shown in Fig. 81.
Fig. 81 - Installing Disc Set A
SM - 3001 59. Install thrust ring (50) as shown in Fig. 82.
Fig. 82 - Installing Thrust Ring
SM 2249 9-03 23
Section 150-0020
60. Install side gear (51) as shown in Fig. 83. Ensure SM - 3002
both internally splined discs (49) of set A are located

on side gear (51).
Fig. 83 - Installing Side Gear
61. Sub-assemble pinion gears (53) and differential SM - 3003
axles (55). Install sub-assembly as shown in Fig. 84.
Fig. 84 - Installing Differential Pinion Gears
62. Install second side gear (51) as shown in Fig. 85. SM - 3004
63. Install second thrust ring (50) as shown in Fig. 86. SM - 3005
24 SM 2249 9-03
Section 150-0020
SM - 3006 64. Install disc set B (Fig. 2) beginning with internally
splined disc (49) as shown in Fig. 87.
Fig. 87 - Installing Disc Set B
SM - 3007 65. The clearance between the assembled differential

housing and the cover (57) should be 0.2 - 0.6 mm.
Press outer externally splined disc (48) evenly on and
measure Dimension 'A' from the mounting face of
housing (47) to the outer disc (48) as shown on Fig. 88,
using special tool (15270114 Digital Depth Gauge).
Fig. 88 - Measuring Differential Housing Clearance
SM - 3008 66. Measure Dimension 'B' from the contact face to the
mounting face of housing cover (57) using special tool
(15270114 Digital Depth Gauge) as shown in Fig. 89.
Fig. 89 - Measuring Housing Cover
SM - 3009 67. With reference to Steps 65 - 66, calculate

clearance as shown in the example below.
Example:
Results in clearance 0.30 mm
If clearance falls outwith specification (0.2 - 0.6 mm),

then thicker or thinner outer externally splined discs
(48) should be installed.
Fig. 90 - Installing Thrust Washers Note: If necessary to change the outer externally
SM 2249 9-03 25
Section 150-0020
splined discs (48) to obtain correct clearance, these SM - 3010
should be changed so that the overall thickness of disc

sets A and B (Fig. 2) are identical.
Note: If installing new discs, the lower clearance

should be aimed for.
68. Place both thrust washers (52 & 54) in the cover
(57), installing steel thrust washer (52) first as shown in
Fig. 90.
69. Secure cover (57) to housing (47) with two

capscrews (58). Torque capscrews to 46 Nm (34 lbf ft). Fig. 91 - Installing Bearing Inner Race
70. Heat bearings (17 & 18) inner races and install on SM - 3011
assembled differential, as shown in Fig. 91.
WARNING
71. Using suitable lifting equipment, position the

assembled differential in the differential housing (2) and 55˚
install bearings (17 & 18) outer rings, as shown in Fig.

92.
Fig. 92 - Installing Differential
72. Install adjusting nuts (1 & 19) and locate bearing SM - 3012
caps using bolts and washers as shown in Fig. 93.
Coat thread of bearing cap bolts with Loctite 649.
Torque bolts to 390 Nm (288 lbf ft).
Note: Bearing adjusting nuts (1 & 19) have two basic

functions: preloading the bearings and positioning ring
gear (46) to obtain the correct backlash between it and
pinion gear (96).
Fig. 93 - Installing Bearing Caps
73. Install new bolts (56) in differential assembly and SM - 3013
torque bolts to 390 Nm (288 lbf ft) as shown in Fig. 94.
Fig. 94 - Tightening Differential Bolts
26 SM 2249 9-03
Section 150-0020
SM - 3014 74. Check the backlash between ring gear (46) and
pinion gear (96). Mount special tools (15500897
Magnetic Stands and 15500898 Dial Indicator) at right
angles to the outer diameter of the ring gear tooth flank
as shown in Fig. 95. Establish the backlash by
alternately setting both adjusting nuts (1 & 19). Rock
the ring gear back and forth being careful not to move
the pinion gear. Backlash should be 0.27 - 0.33 mm.
Fig. 95 - Measuring Backlash
SM - 3015 75. Determine the bearing (17 & 18) rolling resistance
and bracket dimension by further tightening of both
adjusting nuts (1 & 19). The bearing rolling resistance
should be 3 - 4 Nm (2.2 - 2.9 lbf ft). Measure bracket
dimension as shown in Fig. 96 using 15500899
Micrometer. Dimension should be 358-0.1 mm.
Fig. 96 - Measuring Bracket Dimension
SM - 891 76. To check the tooth pattern of ring gear (46), coat
about twelve ring gear teeth with prussian blue, oiled
red lead or some other easily removed print or dye.
When the pinion is rotated, the paint is squeezed away
by the contact of the teeth, leaving bare areas the
exact size, shape and location of the contacts as
shown in Fig. 97.
Compare the contact pattern obtained with the Gear

tooth patterns for the Gleason Gear Tooth system
shown on the following pages.
Fig. 97 - Checking Contact Pattern
SM - 3016 77. Fasten adjusting nuts (1 & 19) with slotted pins (20)
Fig. 98 - Installing Slotted Pin
SM 2249 9-03 27
Section 150-0020
78. Install studs in positions shown by arrows in Fig. SM - 3017
99. Apply Loctite 262 to studs and torque to 55 Nm (40
lbf ft).
Fig. 99 - Installing Studs
79. Apply Loctite 574 to axle casing mounting face. SM - 3018

Using suitable lifting equipment, install differential
assembly in axle casing and secure using new bolts
and nuts. Torque bolts to 375 Nm (277 lbf ft) and nuts
to 280 Nm (206 lbf ft).
80. Install shaft seal (89) into flange (88) using special SM - 3066
tool (15500912 Driver) as shown in Fig. 101.
Note: If seal outer diameter is rubber coated, coat with

spirit. If seal outer diameter is metallic, coat with
Loctite 574.
81. Install flange (88) on drive flange shaft (87). Heat SM - 3067
bearing (90) to approximately 90° C (190° F) and press
it on to the drive flange shaft (87) and locate it on the
collar as shown in Fig. 102.
WARNING
Install shim (91) and retaining ring (92) to secure

bearing on shaft.
28 SM 2249 9-03
Section 150-0020
or 15269900 110V Hot Air Blower) heat axle housing
bore and coat mounting face with sealing compound
Loctite 574.
83. Install pre-assembled flange shaft (87) and secure

with bolts (93). Tighten bolts to 23 Nm (17 lbf ft) as
shown in Fig. 103.
Install axle shafts as noted on removal. Refer to

Section 160-0030, AXLE GROUP (HUB).
Fig. 103 - Tightening Bolts
SM 2249 9-03 29
Section 150-0020
GLEASON GEAR TOOTH SYSTEM SM - 893
Ideal tooth-contact patterns are shown in Figs. 104 & 105

indicating the pinion distance is correct.
If the patterns obtained are the same as that shown in

Figs. 106 & 107 then decrease the pinion distance.
Refer to Fig. 108.

Figs. 109 & 110 then increase the pinion distance.
Refer to Fig. 111.
MAINTENANCE
Proper lubrication of the differential assembly is
essential if the differentials are to deliver the service
intended. Section 300-0020, LUBRICATION SYSTEM Fig. 104 - Coast Side (Concave)
gives full information on the proper lubrication intervals
and the lubricant which should be used.
SM - 894
SPECIAL TOOLS
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
tools and sealants required.
Fig. 105 - Drive Side (Convex)
SM - 895
Fig. 106 - Coast Side (Concave)
30 SM 2249 9-03
Section 150-0020
SM - 896 SM - 899
Fig. 107 - Drive Side (Convex) Fig. 110 - Drive Side (Convex)
SM - 897 SM - 900
Fig. 108 - Pinion Distance Must Be Decreased Fig. 111 - Pinion Distance Must Be Increased
SM - 898
SM 2249 9-03 31
Section 150-0020

TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
1 22 Slotted Nut 1 200 885
1 64 Bolt 155 114
1 27 Slotted Nut 1 200 885
1 72 Bolt 45 33
1 79 Bolt 23 17
1 65 Bolt 155 114
1 67 Slotted Nut 1 000 738
1 28/29 Bolt 155 114
1 58 Capscrew 46 34
- - Bearing Cap Bolt 390 288
1 56 Bolt 390 288
- - Stud 55 40
- - Axle Casing Bolts 375 277
- - Axle Casing Nuts 280 206
1 93 Bolts 23 17
DIFFERENTIAL DIAGNOSIS
Noises and vibrations originating in the tyres, WARNING
transmission, planetaries and drivelines are easily To prevent personal injury and property
transmitted and may be erroneously attributed to the damage, be sure wheel blocks, blocking
differential. Therefore, all possible sources of noise materials and lifting equipment are properly
should be investigated before the differential is taken secured and of adequate capacity to do the job
apart. safely.
Whenever noises such as a grating or rattle are heard WARNING

coming from the differential, stop the unit immediately. Removing the axle shafts or drivelines will
One tooth from a gear can cause damage to all gears make the parking brake ineffective.
and bearings. When the differential is definitely at fault,
remove the axle shafts and disconnect the driveline
before moving the vehicle.
DIAGNOSIS CHART
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust
32 SM 2249 9-03
Section 150-0020
DIAGNOSIS CHART (CONTINUED)

Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case
* * * *
SM 2249 9-03 33
REAR AXLE GROUP - Differential Drive Head
Section 160-0020
SM - 849
1 - Bearing Adjuster 4 - Drive Flange 7 - Side Gear

2 - Housing 5 - Ring Gear 8 - Differential Case Assembly
3 - Pinion Gear (Drive) 6 - Spider (Pinion) Gear
Fig. 1 - Sectional View of Typical Differential
DESCRIPTION driveline yoke attaches directly to differential

Numbers and letters in parentheses refer to Fig. 1. flange (4) which is splined to the shaft of pinion gear (3).
Fig. 1 illustrates both a standard pinion gear and

spider differential (A) and a limited slip type (B). Limited Slip Assembly
Basically the differential consists of pinion gear (3) and Numbers in parentheses refer to Fig. 2.
ring gear (5). The differential is a spiral bevel ring gear
type with an automatically operating limited slip The limited slip assembly consists of housing (1), thrust
element (B). washers (2 & 11), externally splined discs (3), internally
splined discs (4), thrust ring (5), side gears (6), pinion
The differential is mounted to the axle housing. The gears (7), differential axle (8) and cover (9).
SM 2248 8-03 1
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 2949
6
5
10 A
7 4
3
4
3
11 12
2
1 2
11
3
4
3
4 9
B
5
1 - Cover 5 - Thrust Ring 9 - Housing

2 - Thrust Washers (Steel) 6 - Side Gears 10 - Bolts
3 - Externally Splined Discs 7 - Pinion Gears 11 - Thrust Washers (Brass)
4 - Internally Splined Discs 8 - Differential Axle 12 - Capscrews
Fig. 2 - Exploded View of Limited Slip Assembly
OPERATION turn creating the same effect, one gear continues to

Numbers in parentheses refer to Fig. 2, unless revolve but pinion gears (7) cease to act rigidly with it.
otherwise specified. Pinion gears (7) now rotate on their own axis,
permitting one drive wheel to rotate at a different
Pinion gear (3, Fig. 1) is mated with ring gear (5, Fig. 1) speed from the other. Since the ratio of the pinion and
which is bolted to differential case assembly (8, Fig. 1). side gear assembly is approximately 2 to 1, the result
is that as one drive wheel slows down, the speed of
When both drive wheels are free to turn under equal the other proportionately increases. This prohibits the
resistance loads, ring gear (5, Fig. 1) and four small application of a torsional load to either axle, which is
pinion (spider) gears (6, Fig. 1) act as one rigid unit, greater than that existing during normal operation.
transmitting torque to both splined side gears (6). Side
gears (6), being splined to the axle shafts, then drive Thus pinion gears (7) serve a dual purpose:
each rear wheel with the same amount of torque at
identical rates of speed. In this instance, pinion gears (7) 1. They allow a differential in speed between the two
do not rotate on their axis, therefore, side gears (6) drive wheels, permitting maximum manoeuvrability.
rotate at the same rev/min as ring gear (5, Fig. 1).
2. They prohibit the application of all torque to one axle
When resistance on one drive wheel exceeds the shaft.
resistance on the other, or when the vehicle makes a
2 SM 2248 8-03
Section 160-0020
REMOVAL 9. Loosen and remove nuts and bolts from the

Numbers in parentheses refer to Fig. 3. differential and axle housings. Thread in three puller
bolts to break the seal between the differential and axle
housings and to partially pull the differential assembly
WARNING out of the axle housing.
damage, be sure wheel blocks, blocking 10. Using suitable lifting equipment, support the weight
materials and lifting equipment are properly of the differential assembly.
safely. Note: When removing the rear differential, weld a loop
to the bottom side of the body above the differential
1. Before attempting to remove the road wheels, drive and attach the lifting device.
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil. 11. Pull out the differential assembly until it clears the
axle housing, then carefully lower it to the floor. Slide
Note: If the rear differential is being removed, raise the the differential assembly out from beneath the vehicle.
body and prop it up with the body prop.
INSTALLATION
Installation is the reversal of the 'Removal' procedure.
3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in Note: Use sealing compound (Loctite 574) between the
the 'Off' position. axle housing and differential housing mounting faces.
4. Drain the gear oil out of the axle housing and both Tighten bolts securing differential assembly to axle
planetaries into a suitable container. housing to 375 Nm (277 lbf ft). Tighten nuts to 280 Nm
(207 lbf ft).
5. Remove the planetary assemblies and axle shafts
from the axle housing. Note from which side the long Note: Tighten all fasteners without specified torques to
and short axle shafts are removed. Refer to Section standard torques listed in Section 300-0080,
160-0030, AXLE GROUP (HUB). STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
6. Identify the relationship of the driveline flange and
differential pinion flange with punch marks. Fill the layshaft housing (3) with 1.5 litres (0.4 US
gallon) of gear oil of the type specified in Section 300-
7. Disconnect the driveline from the differential drive 0020, LUBRICATION SYSTEM, through the differential
flange. The driveline can be removed if it is convenient filler/level hole. Fill the axle casing with gear oil of the
to do so. type specified in Section 300-0020, LUBRICATION
SYSTEM, through the differential filler/level hole until
8. Index mark differential housing (1) and the axle the oil is level with the bottom of the filler/level hole. Fill
housing to ensure that differential housing (1) is the planetary assemblies up to the 'Oil Level Check
installed in the same position. Line'. Check oil levels after a few minutes to ensure
level remains constant.
SM 2248 8-03 3
Section 160-0020
SM - 2950
42
1 43
39 40,41
5
12 10
44
11
10
38
8
9 14
13
18
23 26
19 21
24
22 25
32
33
20
34
2
3 35
27
4 28
29,30 15
6 36
7 16
31 37
17
1 - Differential Housing 16 - Bearing 31 - Pin

2 - Slotted Nut 17 - Pinion Gear 32 - Spacer
3 - Washer 18 - Ring Gear 33 - Bearing
4 - Drive Flange 19 - Bolt 34 - Shim Support
5 - Seal Holder 20 - Pin 35 - Retainer
6 - Dust Shield 21 - Slotted Nut 36 - Spur Gear
7 - Shaft Seal 22 - Washer 37 - Bushing
8 - Bearing 23 - Bearing 38 - Slotted Pin
9 - Spacer 24 - Adjusting Ring 39 - Bolt
10 - Adjusting Nut 25 - Spacer Bush 40 - Bolt
11 - Quill Shaft 26 - Layshaft Housing 41 - Bolt
12 - Bearing 27 - Plug 42 - Plate
13 - Spur Gear 28 - 'O' Ring 43 - Pin
14 - Cover 29 - Plug 44 - Bearing
15 - Spacing Washer 30 - 'O' Ring
Fig. 3 - Exploded View of Rear Differential
4 SM 2248 8-03
Section 160-0020
SM - 3020 DISASSEMBLY
WARNING
safely.
Note: The following removal procedure assumes the

Fig. 4 - Removing Drain Plugs
complete axle assembly was removed from the
vehicle.
SM - 3021
1. Ensure oil is drained from both axle casing and
layshaft housing as shown in Fig. 4.
2. Remove both planetary assemblies and axle shafts

by following the procedure in Section 160-0030, AXLE
GROUP (HUB). Using suitable lifting equipment,
support differential assembly. Remove nuts and bolts
and remove the differential assembly from the axle
casing as shown in Fig. 5.
Fig. 5 - Removing Differential Assembly
SM - 2951 3. Loosen ring gear (18) bolts as shown in Fig. 6.
Fig. 6 - Removing Ring Gear Bolts
SM - 2952 4. Remove slotted pins (38) before loosening adjusting

nuts (10) as shown in Fig. 7.
Fig. 7 - Removing Adjusting Nuts
SM 2248 8-03 5
Section 160-0020
5. Using special tool (15269899 220V Hot Air Blower or SM - 2953
15269900 110V Hot Air Blower) heat the area around
the threaded holes and loosen bolts securing bearing
caps. Remove bearing caps.
Fig. 8 - Removing Bearing Caps
6. Lift the differential assembly out of differential SM - 858

housing (1) with the special tool (15269929 Lifting
Pliers) as shown in Fig. 9.
Fig. 9 - Removing Differential
7. Remove both bearings (12 & 44) inner rings using SM - 2954
special tools (15272560 Puller, 15500887 Gripping
Insert, 15500888 Gripping Insert and 15500889
Reducer) as shown in Fig. 10.
Fig. 10 - Removing Bearing Inner Rings
8. Remove capscrews (12, Fig. 2) and separate SM - 2955

housing (9, Fig. 2) from cover (1, Fig. 2). Remove
single components as shown in Fig. 11.
Fig. 11 - Differential Components
6 SM 2248 8-03
Section 160-0020
SM - 2956 9. Remove bolts (40 & 41) securing layshaft housing

(26) to differential housing (1). Separate the housings
using suitable lifting equipment, and secure layshaft
housing to a suitable fixture.
Fig. 12 - Separating Layshaft Housing
or 15269900 110V Hot Air Blower) heat the slotted nut
(2) to around 120 oC before loosening using special tool
(15500890 Socket) as shown in Fig. 13. Remove
slotted nut (2), washer (3) and drive flange (4).
SM - 2958 11. Remove bolts (39) and seal holder (5) from cover
Fig. 14 - Removing Seal Holder
SM - 2959 12. Remove retainer (35) and shim support (34) from
layshaft housing (26) as shown in Fig. 15.
Fig. 15 - Removing Retainer
SM 2248 8-03 7
Section 160-0020
13. As shown in Fig. 16 use special tool (15269946 SM - 2960
Puller Set) to press quill shaft (11) out of the bearing.
Fig. 16 - Pressing Out Shaft
14. Remove spacer (9) and press the bearing (8) inner SM - 2961
race from the shaft (11).
Fig. 17 - Pressing Inner Race of Bearing
15. Remove bearing (33) inner race and spacer (32) SM - 2962
from housing (26).
Fig. 18 - Removing Inner Race of Bearing
16. Remove bolts (19) and separate cover (14) from SM - 2963
layshaft housing (26) as shown in Fig. 19. Remove
spur gear (13) at this time.
Fig. 19 - Separating Cover From Housing
8 SM 2248 8-03
Section 160-0020
SM - 2964
17. Using special tool (15269899 220V Hot Air Blower
before removing using special tool (15500891 Socket)
SM - 2965 18. With the special tool (15269946 Puller Set) shown
in Fig. 21, press the pinion gear (17) out of the bearing
(23).
Fig. 21 - Pressing Out Pinion Gear
SM - 2966 19. Pull off the bearing (16) inner race from the pinion
gear (17) using special tools (15500892 Gripping Insert
and 15272560 Bearing Puller).
Fig. 22 - Removing Bearing From Pinion Gear
SM - 2967 20. Remove adjusting ring (24) and spacer bush (25)
from housing (26). Using special tool (15269946 Puller
Set) press out bushing (37) and spacing washer (15).
Fig. 23 - Pressing Out Components
SM 2248 8-03 9
Section 160-0020
INSPECTION SM - 2968
1. Clean all parts with a suitable solvent. Dry all parts,

except bearings, with compressed air or with soft,
clean lint free cloths. DO NOT spin bearings with
compressed air. Place bearings on a clean surface,
cover with lint free cloths and allow to dry.
2. Coat cleaned, dried parts immediately with light oil to

prevent corrosion. If parts are not to be assembled
immediately, treat them with a good quality rust
preventive and wrap them with treated paper or suitable
material designed to prevent corrosion.
Fig. 24 - Pressing Bearing Outer Race in Housing
3. Before installing the differential assembly into the
axle housing, clean the inside and outside of the axle SM - 2969
housing to remove any debris or dirt.
4. Inspect all gears, pinions and splines for cracked or

broken teeth, excessive wear, and pitted or scored
surfaces. Repair or replace as necessary.
Note: If either ring gear or pinion gear is defective, both

gears must be replaced, because they are serviced
only as a matched set.
5. Check for pitted, scored or worn thrust surfaces of

differential case halves. Fig. 25 - Pressing Bearing Outer Race in Housing
6. During assembly and installation, make sure that SM - 2970

mated, punch marked or otherwise identified parts are
returned to their original positions, if still serviceable.
ASSEMBLY

specified to standard torques listed in
Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNING
SM - 2971
safely.


Fig. 27 - Installing Bushing
10 SM 2248 8-03
Section 160-0020
SM - 2972 3. Insert spur gear (36) into housing (26) bore, ensuring
that inner diameter (85 mm) is facing down, as shown
in Fig. 26.
4. Press the bushing (37) into housing (26) bore and

ensure it is firmly home, as shown in Fig. 27.
5. At this stage in the assembly procedure the

thickness of spacing washer (15) must be determined
to ensure correct contact pattern between pinion gear
(17) and ring gear (18). As shown in Fig. 28, measure
Dimension 'A' from the mounting face of housing (26) to
Fig. 28 - Measuring Dimension 'A' the locating face of the bearing (16) outer ring, using
special tools (15270113 Gauge Blocks, 15269948
Straight Edge and 15270114 Digital Depth Gauge).
SM - 2973
6. As shown in Fig. 29, use special tools (15500893

Shims, 15500894 Shims and 15269934 Measuring
Shaft) and place shims into the bores of differential
housing (1) and assemble the measuring shaft.
Fig. 29 - Assembling The Measuring Shaft
SM - 2974 7. Measure Dimension 'B' from mounting face of

housing (1) to Measuring Shaft (see Fig. 30).
Example:
+ Dimension 'B' 196.75 mm
- Dimension 'C' (1/2 diameter of Measuring
Shaft) 15.00 mm
= Dimension 'X' 241.45 mm

Fig. 30 - Measuring Dimension 'B'
SM - 868 8. Measure thickness of bearing (16) as shown in Fig.

31 using special tools (15270113 Gauge Blocks and
15270114 Digital Depth Gauge). Record as Dimension
'D'.
Eg. Dimension 'D' = 42.70 mm
Fig. 31 - Measuring Bearing Thickness
SM 2248 8-03 11
Section 160-0020
9. The arrow in Fig. 32 is pointing to a dimension SM - 2975
stamped on the face of pinion gear (17). Record as
Dimension 'E'.
Eg. Dimension 'E' = 198 - 0.1 = 197.90 mm
Example:
Dimension 'D' 42.70 mm
+ Dimension 'E' 197.90 mm
= Dimension 'Y' 240.60 mm
Fig. 32 - Dimension On Pinion Face
10. Calculate spacing washer (15) thickness by SM - 2976

subtracting Dimension 'Y' from Dimension 'X'.
Example:
Dimension 'X' 241.45 mm
- Dimension 'Y' 240.60 mm
= Required thickness 0.85 mm
Install spacing washer (15) of required thickness into

the bushing (37) as shown in Fig. 33.
Fig. 33 - Installing Spacing Washer
11. Freeze bearing (16) outer race and install in SM - 2977

bushing (37), ensuring it is firmly home.
WARNING

(17). Be sure it is firmly seated against the shaft
shoulder as shown in Fig. 35.
WARNING
12 SM 2248 8-03
Section 160-0020
SM - 2978 13. Install assembled pinion gear (17) in layshaft

housing (26) using special tool (15269946 Puller Set)
as shown in Fig. 36. Do not remove special tool at this
point.
Fig. 36 - Installing Pinion Gear
SM - 2979 14. The adjusting ring (24) is used to obtain the rolling
resistance of the pinion bearing. Rolling resistance
resistance is checked once pinion gear (17) is secured
in housing (26) (Step 17).
As shown in Fig. 37, install spacer bush (25) with the
small collar showing up (ref. arrow) into the bore of the
spur gear (36) and install adjusting ring (24).
Fig. 37 - Installing Spacer Bush and Adjusting Ring

(17) until it is firmly home as shown in Fig. 38.
WARNING
After bearing (23) inner race has cooled, remove special

tool installed in Step 13.
SM - 2981 16. Coat threads of slotted nut (21) with Loctite 649.
Locate washer (22) and install slotted nut (21). Using
special tool (15500891 Socket) tighten slotted nut (21)
Note: When tightening nut (21), rotate the pinion gear (17)
in both directions several times.
SM 2248 8-03 13
Section 160-0020
17. Check the rolling resistance of the pinion bearing SM - 2982
as shown in Fig. 40 by using special tool (15500895
Torque Spanner). If the rolling resistance is outwith
range (3.5 - 4.0 Nm), adjusting ring (24) thickness must
be changed.
Record this torque as Tpinion e.g. 3.5 Nm.
Fig. 40 - Checking Rolling Resistance
18. Install spur gear (13) in housing (26) as shown in SM - 2983

Fig. 41.
19. Install quill shaft (11) into housing (26) using SM - 2984
special tool (15269946 Puller Set) as shown in Fig. 42.
Do not remove special tool at this point.
Fig. 42 - Installing Quill Shaft
20. On the other side of shaft (11), install spacer (32) SM - 2985
with the collar facing down as shown in Fig. 43.
14 SM 2248 8-03
Section 160-0020

WARNING
SM - 2987 22. Install shim support (34) and snap in the retainer
Fig. 45 - Installing Shim Support and Retainer
SM - 2988 23. Remove special tool (15269946 Puller Set) installed

in Step 19, and install it to the retainer (35) end of shaft
(11). Press the shaft (11) until the shim support (34) is
located on retainer (35).
Do not remove special tool at this point.
Fig. 46 - Pressing Shaft
SM - 2989 24. Press bearing (8) outer race into cover (14) until firmly
home, as shown in Fig. 47.
Fig. 47 - Pressing Bearing Outer Race
SM 2248 8-03 15
Section 160-0020
25. Apply Loctite 574 to mounting face of housing (26) SM - 2990
as shown in Fig. 48. Place the housing cover (14) on
housing (26) and secure using pin (20) and new bolts
(19). Torque bolts (19) to 155 Nm (114 lbf ft).
E
CTIT
LO
Fig. 48 - Applying Loctite 574
26. The spacer (9) is used to obtain the rolling SM - 2991

resistance of the shaft (11) bearing. Rolling resistance
resistance (TAn) is calculated once shaft (11) is
secured in housing (26) (Step 32). As shown in Fig. 49,
install spacer (9) on shaft (11).

WARNING
Once the bearing (8) has cooled, remove special tool

(15269946 Puller Set) installed in Step 23.
28. Apply Loctite 574 to mounting face of cover (14). SM - 2993

Place the seal holder (5) on cover (14) and secure
using new bolts (39). Torque bolts (39) to 155 Nm (114
lbf ft) as shown on Fig. 51.
Fig. 51 - Tightening Seal Holder Bolts
16 SM 2248 8-03
Section 160-0020
SM - 2994 29. Coat outer diameter of shaft seal (7) with Loctite
574 and install in seal holder (5) using special tool
(15500896 Driver). Ensure sealing lip faces inboard.
SM - 2995 30. Press dust shield (6) over drive flange (4) as shown
in Fig. 53.
Fig. 53 - Installing Dust Shield
SM - 2996 31. Coat threads of slotted nut (2) with Loctite 649.
Coat faces of washer (3) with Loctite 574. Assemble
drive flange (4), washer (3) and slotted nut (2) on shaft
(11). Using special tools (15500890 Socket and
15270120 Clamping Yoke) torque slotted nut (2) to 750
Nm (553 lbf ft) as shown in Fig. 54.
Note: When tightening nut (2), rotate the shaft (11) in

both directions several times.
SM - 2997 32. As shown in Fig. 55, check total rolling resistance

of pinion gear (17) and shaft (11) using by using special
tool (15500895 Torque Spanner). Record this torque as
Ttot e.g. 5.5 Nm.
Example:
Ttot e.g. 5.5 Nm
Tpinion e.g. - 3.5 Nm
Results in TAn = 2.0 Nm
As specified in Step 26, rolling resistance (TAn) of shaft

(11) should be 1.5 - 3.0 Nm. If outwith this range,
Fig. 55 - Checking Rolling Resistance spacer (9) thickness must be changed.
SM 2248 8-03 17
Section 160-0020
33. Coat mounting face of differential housing (1) with SM - 2998
Loctite 574. Using suitable lifting equipment, install the

pre-assembled layshaft housing to the differential
housing (1).
34. As shown in Fig. 56, secure the pre-assembled

layshaft housing to the differential housing (1) with pins
(refer to arrows) and new bolts (40 & 41). Torque bolts
(40 & 41) to 155 Nm (114 lbf ft).
Fig. 56 - Installing Pre-assembled Layshaft Housing
35. Heat ring gear (18) and install it on the differential SM - 3074
housing (9, Fig. 2) until it is firmly home as shown in

Fig. 57.
WARNING
gloves when handling ring gear.
Fig. 57 - Installing Ring Gear
36. Prior to assembly, coat components with gear oil SM - 2999
as specified in Section 300-0020, LUBRICATION

SYSTEM. Place both thrust washers (2 & 11, Fig. 2) in
the housing (9, Fig. 2), installing steel thrust washer (2,
Fig. 2) first as shown in Fig. 58.
Fig. 58 - Installing Thrust Washers
37. Install disc set A (Fig. 2) in housing (9, Fig. 2), SM - 3000
beginning with externally splined disc (3, Fig. 2) as
shown in Fig. 59.
Fig. 59 - Installing Disc Set A
18 SM 2248 8-03
Section 160-0020
SM - 3001 38. Install thrust ring (5, Fig. 2) as shown in Fig. 60.
SM - 3002 39. Install side gear (6, Fig. 2) as shown in Fig. 61.
Ensure both internally splined discs (4, Fig. 2) of set A
are located on side gear (6, Fig. 2).
SM - 3003 40. Sub-assemble pinion gears (7, Fig. 2) and

differential axles (8, Fig. 2). Install sub-assembly as
shown in Fig. 62.
Fig. 62 - Installing Differential Pinion Gears
SM - 3004 41. Install second side gear (6, Fig. 2) as shown in Fig.
63.
SM 2248 8-03 19
Section 160-0020
42. Install second thrust ring (5, Fig. 2) as shown in SM - 3005
Fig. 64.
43. Install disc set B (Fig. 2) beginning with internally SM - 3006

splined disc (4, Fig. 2) as shown in Fig. 65.
Fig. 65 - Installing Disc Set B
44. The clearance between the assembled differential SM - 3007
housing and the cover (1, Fig. 2) should be 0.2 - 0.6

mm. Press outer externally splined disc (3, Fig. 2)
evenly on and measure Dimension 'A' from the
mounting face of housing (9, Fig. 2) to the outer disc
(3, Fig. 2) as shown on Fig. 66, using special tool
(15270114 Digital Depth Gauge).
Fig. 66 - Measuring Differential Housing Clearance
45. Measure Dimension 'B' from the contact face to the SM - 3008
mounting face of housing cover (1, Fig. 2) using
special tool (15270114 Digital Depth Gauge) as shown
in Fig. 67.
Fig. 67 - Measuring Housing Cover
20 SM 2248 8-03
Section 160-0020
SM - 3009 46. With reference to Steps 44 - 45, calculate
clearance as shown in the example below.
Example:
Results in clearance 0.30 mm
If clearance falls outwith specification (0.2 - 0.6 mm),

then thicker or thinner outer externally splined discs (3,
Fig. 2) should be installed.
Fig. 68 - Installing Thrust Washers Note: If necessary to change the outer externally
splined discs (3, Fig. 2) to obtain correct clearance,
SM - 3010
these should be changed so that the overall thickness
of disc sets A and B (Fig. 2) are identical.
Note: If installing new discs, the lower clearance

should be aimed for.
47. Place both thrust washers (2 & 11, Fig. 2) in the

cover (1, Fig. 2), installing steel thrust washer (2, Fig.
2) first as shown in Fig. 68.
48. Secure cover (1, Fig. 2) to housing (9, Fig. 2) with

two capscrews (12, Fig. 2). Torque capscrews to 46
Nm (34 lbf ft).
49. Heat bearings (12 & 44) inner races and install on
SM - 3011
assembled differential, as shown in Fig. 69.
WARNING
50. Using suitable lifting equipment, position the

55˚
assembled differential in the differential housing (1) and
install bearings (12 & 44) outer rings, as shown in Fig.
70.
SM - 3012 51. Install adjusting nuts (10) and locate bearing caps
using bolts and washers as shown in Fig. 71. Coat
thread of bearing cap bolts with Loctite 649. Torque
Note: Bearing adjusting nuts (10) have two basic

functions: preloading the bearings and positioning ring
gear (18) to obtain the correct backlash between it and
pinion gear (17).
Fig. 71 - Installing Bearing Caps
SM 2248 8-03 21
Section 160-0020
52. Install new bolts (10, Fig. 2) in differential assembly SM - 3013
and torque bolts to 390 Nm (288 lbf ft) as shown in Fig.

72.
Fig. 72 - Tightening Differential Bolts
53. Check the backlash between ring gear (18) and SM - 3014
pinion gear (17). Mount special tools (15500897
Magnetic Stands and 15500898 Dial Indicator) at right
angles to the outer diameter of the ring gear tooth flank
as shown in Fig. 73. Establish the backlash by
alternately setting both adjusting nuts (10). Rock the
ring gear back and forth being careful not to move the
pinion gear. Backlash should be 0.27 - 0.33 mm.
Fig. 73 - Measuring Backlash
54. Determine the bearing (12 & 44) rolling resistance SM - 3015
and bracket dimension by further tightening of both

adjusting nuts (10). The bearing rolling resistance
should be 3 - 4 Nm (2.2 - 2.9 lbf ft). Measure bracket
dimension as shown in Fig. 74 using 15500899
Micrometer. Dimension should be 358-0.1 mm.
Fig. 74 - Measuring Bracket Dimension
55. To check the tooth pattern of ring gear (18), coat SM - 891
about twelve ring gear teeth with prussian blue, oiled
red lead or some other easily removed print or dye.
When the pinion is rotated, the paint is squeezed away
by the contact of the teeth, leaving bare areas the
exact size, shape and location of the contacts as
shown in Fig. 75.
Compare the contact pattern obtained with the Gear

tooth patterns for the Gleason Gear Tooth system
shown on the following pages.
Fig. 75 - Checking Contact Pattern
22 SM 2248 8-03
Section 160-0020
SM - 3016 56. Fasten adjusting nuts (10) with slotted pins (38) as
shown in Fig. 76.
Fig. 76 - Installing Slotted Pin
SM - 3017 57. Install studs in positions shown by arrows in Fig.

77. Apply Loctite 262 to studs.
Fig. 77 - Installing Studs
SM - 3018 58. Apply Loctite 574 to axle casing mounting face.

Using suitable lifting equipment, install differential
assembly in axle casing and secure using new bolts
and nuts. Torque bolts to 375 Nm (277 lbf ft) and nuts
to 280 Nm (206 lbf ft).
Install axle shafts as noted on removal. Refer to

Section 160-0030, AXLE GROUP (HUB).
SM 2248 8-03 23
Section 160-0020
GLEASON GEAR TOOTH SYSTEM SM - 895
Ideal tooth-contact pattern shown in Figs. 79 and 80

indicating the pinion distance is correct.

Figs. 81 and 82 then decrease the pinion distance (Fig.
83). Refer to Steps 5 - 10.

Figs. 84 and 85 then increase the pinion distance
(Fig. 86). Refer to Steps 5 - 10.
SM - 893 SM - 896
Fig. 79 - Coast Side (Concave) Fig. 82 - Drive Side (Convex)
SM - 894 SM - 897
Fig. 80 - Drive Side (Convex) Fig. 83 - Pinion Distance must be Decreased
24 SM 2248 8-03
Section 160-0020
SM - 898
SM - 899
Fig. 85 - Drive Side (Convex)
SM - 900
Fig. 86 - Pinion Distance must be Increased
SM 2248 8-03 25
Section 160-0020
MAINTENANCE should be investigated before the differential is taken

apart.
Proper lubrication of the differential assembly is
essential if the differentials are to deliver the service
Whenever noises such as a grating or rattle are heard
intended. Section 300-0020, LUBRICATION SYSTEM
coming from the differential, stop the unit immediately.
gives full information on the proper lubrication intervals
One tooth from a gear can cause damage to all gears
and the lubricant which should be used.
and bearings. When the differential is definitely at fault,
remove the axle shafts and disconnect the driveline
SPECIAL TOOLS before moving the vehicle.
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
WARNINGS
tools and sealants required.
DIFFERENTIAL DIAGNOSIS secured and of adequate capacity to do the job
Noises and vibrations originating in the tyres, safely.
transmission, planetaries and drivelines are easily
Removing the axle shafts or drivelines
transmitted and may be erroneously attributed to the
differential. Therefore, all possible sources of noise will make the parking brake ineffective.
DIAGNOSIS CHART
Vibration Broken gear teeth Replace damaged gear
Excessive run-out of pinion or flanged case Disassemble, correct or replace faulty
part
Continual noise Bearing worn Replace worn parts
Gears damaged or worn Replace gears
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Loose ring and pinion gear adjustment Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case
26 SM 2248 8-03
Section 160-0020

TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
2 12 Capscrew 46 34
2 10 Bolt 390 288
3 2 Slotted Nut 750 553
3 19 Bolt 155 114
3 21 Slotted Nut 1 200 885
3 39 Bolt 155 114
3 40, 41 Bolt 155 114
- - Bearing Cap Bolts 390 288
- - Axle Casing Bolts 375 277
- - Axle Casing Nuts 280 206
* * * *
SM 2248 8-03 27
REAR AXLE GROUP - Axle Group (Hub)
Section 160-0030
SM - 3449
27 25
6 5
7
4
8 23
30
17 18
3
1 19
12
13 26
22
14
16 24
15
28
21 20,29
10
9
11
1- Hub Carrier 11 - Snap Ring 20 - Planet Gear

2- Shim 12 - Locking Plate 21 - Retainer Ring
3- Shaft Seal 13 - Lock Screw 22 - Thrust Washer
4- U-Ring 14 - Sun Gear Shaft 23 - Bolt
5- Roller Bearing 15 - Driver 24 - Capscrew
6- Bolt 16 - Planet Carrier 25 - Wheel Nut
7- Roller Bearing 17 - 'O' Ring 26 - Plug
8- Hub 18 - Plug Screw 27 - Lockwasher
9- Ring Gear Carrier 19 - 'O' Ring 28 - Slotted Nut
10 - Ring Gear 29 - Roller Bearing
30 - Drive shaft
Fig. 1 - Exploded View of Planetary and Wheel
OPERATION
Numbers and letters in parentheses refer to Fig. 1. with sun gear shaft (14) rotate anticlockwise. Ring gear
(9) is splined to hub carrier (1) and does not rotate but
Power from the differential is transmitted through a causes planet gears (20), which are meshed with ring
fully floating axle shaft connected to sun gear shaft (14) gear (10), to move around it in a clockwise direction.
by driver (15). As sun gear shaft (14) rotates in a As planet carrier (16) is bolted to wheel hub (8) the
clockwise direction, the three planet gears (20) meshed wheel then rotates in a clockwise direction.
SM 2408 Rev1 10-06 1

Rear Axle Group - Axle Group (Hub)
Section 160-0030
REMOVAL AND DISASSEMBLY SM - 3450
Note: On dismantling, clean all parts in paraffin or other

suitable cleaning agent and place on a clean work
surface.
WARNINGS
materials and lifting equipment are properly Fig. 2 - Install adjusting screws.
safely.
9. Remove drain plugs and drain cooling oil from brake
packs into a clean container. Refit drain plugs.
damage, the procedure for removing tyre and
10. Index mark planet carrier (16) and hub (8) to aid in
rim assembly described in Section 160-0050,
installation as shown in Fig. 2.
WHEEL, RIM AND TYRE, must be strictly
followed.
11. Loosen bolts (23) and install adjusting screws
When necessary to drive out components (15502331) to aid in removal of planet carrier (16) sub
assembly as shown in Fig. 2. Remove bolts (23) then
during disassembly, be sure to use a soft drift
prise planet carrier (16) from hub (8) and remove with
to prevent property damage and personal
suitable lifting equipment (15501178) as shown in
injury.
Fig. 3.
1. Before attempting to remove the road wheels, drive SM - 3451
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil.
3. Block the appropriate road wheels, place the

4. Whilst road wheels are still on the ground, loosen

wheel nuts (25).
Fig. 3 - Removing Planet Carrier Assembly
5. Jack up the axle and support with suitably placed
12. Place on the floor with planet gears (20) facing
stands or timbers.
upwards. Remove O-ring (19) as shown in Fig. 4.
6. Support tyre and rim assembly with a suitable sling
and lifting device. Remove wheel nuts (25) and remove SM - 3452
tyre and rim assembly from the machine. Remove

opposite road wheel in the same way. Refer to Section
160-0050, WHEEL, RIM AND TYRE.
7. Place suitable containers under the differential and

both hubs (8). Remove differential drain plug and drain
oil from the differential.
8. Rotate hubs (8) until plug screws (26) are at their

lowest points. Remove plug screws (26) and 'O' rings
and drain oil from hubs. Remove capscrew (24). Fig. 4 - Removing O-ring.
2 Sm 2408 Rev1 10-06

Section 160-0030
SM - 3453 16. Remove two lock screws (13) and remove locking
plate (12) from the ring gear (10) as shown in Fig. 8.
17. Remove slotted nut (28) from hub carrier (1) with
the special tools (15500882, Socket and 15500883
Centering Bracket) as shown in Fig. 9.
18. By means of lifting tackle 15501170 and suitable

pry bar 15270131, separate hub (8) assembly from the
hub carrier (1) as shown in Fig. 10.
SM - 3456
Fig. 5 - Extracting Planet Gears.
13. Unsnap retaining rings (21) from planet gears (20)

using suitable pliers 15270145. Extract planet gears
(20) from the planet carrier (16) using extractor tool
15271107 as shown in Fig. 5. Remove thrust washer
(22).
Note: Roller bearings (29) within the planetary gear (20)
are fixed with a circlip and these components are
destroyed at separation. Planetary gear and roller
bearing must be replaced together at reassembly.
Fig. 8 - Remove lock screws / Plate.
14. Remove driver (15) as shown in Fig. 6.
SM - 3454 SM - 3126
Fig. 6 - Removing Driver Fig. 9 - Removing Slotted Nut.
15. Remove drive shaft (30) as shown in Fig. 7. Note

that left and right driveshafts are of a different length. 19. Remove the hub Fig. 11. Note: Pay attention to
released bearing inner ring and the ring gear.
SM - 3455 SM - 3457
Fig. 7 - Remove Driveshaft Fig. 10 - Removing Hub from Carrier
SM 2408 Rev1 10-06 3

Section 160-0030
SM - 3458 INSPECTION
Thoroughly clean all parts with a suitable solvent and

dry with compressed air. Inspect all parts for damage
or excessive wear and replace where necessary.
Inspect thrust washer (22) to make sure it is free of
burrs and is absolutely flat. Replace all 'O' rings.
ASSEMBLY AND INSTALLATION

Fig. 11 - Removing Hub.
20. Remove ring gear (10) from hub (8) as shown in specified to standard torques listed in Section
Fig. 12. 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
SM - 3459
WARNING
damage, be sure lifting equipment is properly
safely.
1. Install brake pack on axle as described in Section

165-0015, OIL COOLED DISC BRAKES.
2. Grease sealing lips and wet outer diameter of shaft

Fig. 12 - Removing Hub from Carrier seal (3) to aid in installation of components.
21. Unsnap snap ring (11) and separate the ring gear SM - 3122
carrier (9) from the ring gear (10) as shown in Fig. 13.
SM - 3460
Fig. 13 - Removing Ring Fig. 14 - Inserting Shaft Seal
3. Insert roller bearing (7), U-ring (4) and shaft seal (3)
22. Using a suitable pry bar 15270131, lever and press into hub (8). Shaft seal (3) should be inserted with
shaft seal (3) out of the hub carrier (1) bore and remove care, using special tools; mounting tool 15501177 and
U-ring (4). If required remove both bearing (5 & 7) outer handle 15269898. Refer to Fig. 14.
races from the bore of the hub (8).
23. For further disassembly of brake packs refer to

Section 165-0015, OIL COOLED DISC BRAKES.
4 Sm 2408 Rev1 10-06

Section 160-0030
4. Mount inner installer 15502336 on hub carrier (1) as 7. Push hub (8) until contact is obtained, now remove
shown in Fig. 15. centering bracket and inner installer tools. Refer to
Fig 18.
SM - 3462 SM - 3465
Fig. 15 - Mounting Installer Fig. 18 - Remove Installer / Bracket
5. Using suitable lifting tackle 15501170 and chain 8. Heat inner race of roller bearing (5) using a suitable
15501178, mount hub (8) over the inner installer. hot air blower 15269899 or 15269900. Refer to Fig. 19.
Ensure care is taken not to damage shaft seal (3)
SM - 3466
during this process. Before fully seating sealing
elements in place, apply a thin film of oil onto sliding
surfaces. Refer to Fig. 16.
SM - 3463
Fig. 19 - Heating Bearing
9. Mount shim (2) and roller bearing (5) inner race onto
hub carrier (1) until contact is obtained. Refer to Fig.
20. Note: Shim (2) will be used to adjust the rolling
Fig. 16 - Mounting Hub moment to the desired value.
6. Use centering bracket 15500883 to centre hub (8) on SM - 3467
the inner installer. Mount hub (8) in the brake pack.

Ensure hub is free to rotate. Refer to Fig. 17.
SM - 3464
Fig. 20 - Shim Detail
10. Pre-assemble ring gear (10), ring gear carrier (9)

Fig. 17 - Centering Hub
and snap ring (11). Insert ring gear sub assembly and
screw on slotted nut (28). Ensure chamfer on nut is
showing to outside. Refer to Fig. 21.
SM 2408 Rev1 10-06 5

Section 160-0030
SM - 3468 SM - 3471
28
30
Fig. 21 - Insert Slotted Nut Fig. 24 - Insert drive shaft
11. Using centering bracket 15500883 and slotted nut SM - 3472

wrench 15500882, torque slotted nut (28) to a value of
2000 - 2200Nm (1475 - 1622Ibf ft). Refer to Fig. 22.
SM - 3469
15
Fig. 25 - Mounting Driver
15. Press roller bearing (29) into bore of planet gear

Fig. 22 - Torque Slotted Nut (20) until the circlip has snapped into place in planet
gear (20). Refer to Fig. 26.
12. Install lock plate (12), securing in place with 2-off
SM - 3473
new lock screws (13). Torque lock screws (13) to a
value of 86Nm (63.5 Ibf ft). Refer to Fig. 23. 1
SM - 3470
12
Fig. 26 - Planetary Gear Detail

13
16. Heat inner diameter of roller bearing (29), mount
planetary gears (20) onto planet carrier (16) and secure
Fig. 23 - Secure Lock Plate
in place by means of retaining ring (21). Refer to Fig.
26.
13. Insert driveshaft (30) into the unit until contact is
obtained. Ensure correct shaft is fitted, as left and right Note: Ensure correct orientation of planet gears in
shafts are of differing length. Refer to Fig. 24. planet carrier.
14. Mount driver (15) until contact is obtained as shown

in Fig. 25.
6 Sm 2408 Rev1 10-06

Section 160-0030
17. Mount Planet gears (20) until fully home and secure SM - 3477
in place using retaining rings (21). Refer to Fig. 27.
22
SM -3464
Fig. 30 - Fit Thrust Washer
Fig. 27 - Mount Planet Gears 21. Example: Dim 'A'..................9.4 mm

Dim 'B'..................4.0 mm
18. Adjust the axial float of the sun gear shaft (14); this Difference 5.4 mm
should be within the range of 0.3mm to 0.8mm, as Required axial end play e.g 0.4 mm, hence thrust
follows: washer (22) should be 5.4 - 0.4 = 4.0 mm thick.
SM - 3475
22. Once correct thrust washer (22) has been
14
determined, grease washer and locate in place in
planet carrier (16). Refer to Fig. 30.
23. Insert sun gear shaft (14) into position over thrust
washer (22) as shown in Fig. 31. Note: Ensure o-ring
(19) is grease and fitted at this time as well.
SM - 3478
14
Fig. 28 - Measurement
19. Insert sun gear shaft (14) until seated. Determine

the depth from the mounting face of the hub (8) to the
top face of the sun gear (14) using a straight edge
15269948 and digital depth gauge 15270114. Call this
dimension 'A'. Refer to Fig. 28. 19
20. Measure dimension from mounting face of planet Fig. 31 - Fit Sun Gear
gear (20) to contact surface of thrust washer (22) using
measuring equipment used in previous step, including 24. Using suitable lifting tackle 15502405 and adjusting
block gauges 15502404. Call this dimension 'B'. Refer screws 15502331 to aid in location, insert planet carrier
to Fig. 29. (16) sub-assembly into ring gear (10) bore and locate it
SM - 3476
in the hub (8) till fully home. Refer to Fig. 32.
SM - 3479
Fig. 29 - Measurement Fig. 32 - Locate Planet assembly
SM 2408 Rev1 10-06 7

Section 160-0030
Note: Ensure that planet carrier (16) is aligned to in 27. Install differential drain plug. Add gear oil of the
correct orientation with hub so that drain and fill holes type specified in Section 300-0020, LUBRICATION
are in the correct position as shown if Fig. 33. SYSTEM, through the differential filler/level hole until
the oil is level with the bottom of the filler/level hole.
SM - 3480
28. Fill the planetary assemblies up to the 'Oil Level

Check Line' with gear oil of the type specified in
Section 300-0020, LUBRICATION SYSTEM.
29. Fill the brake coolant tank with oil as specified in

Section 300-0020, LUBRICATION SYSTEM. Fill until
oil is halfway up sight glass. Install filler cap on brake
coolant tank filler neck. Once engine has been started,
oil level will drop as brake packs are filled. Top up oil
as necessary.
Fig. 33 - Alignment
30. Refit road wheels, securing with wheel nuts (25).
Remove stands or timber supports and lower the
25. Apply loctite 574 to threads of cap screw (24) and machine to the ground. Fully tighten wheel nuts to a
secure planet carrier (16) in place to hub (8); tightening torque of 600 Nm (442 lbf ft). Remove blocks from the
screw as shown if Fig. 34. Taking bolts (23), secure wheels.
carrier in place, torque bolts (23) to a value of 280 Nm
(207 Ibf ft). Note: Wheel nuts should be checked and tightened if
necessary, after the first 10 hours of operation. Check
SM - 3481
torque every 50 hours (weekly) thereafter.
23
MAINTENANCE
Proper lubrication of the axle group is essential if axles
are to deliver the service intended. Section
300-0020, LUBRICATION SYSTEM gives full
information on the proper lubrication intervals and the
lubricant which should be used.
24 SPECIAL TOOLS
Fig. 34 - Torque Bolts
The special tools referenced throughout this section
are available from your dealer. Refer to Section
26. Secure plug screw (18), o-ring (17) and plug (26) in 300-0070, SERVICE TOOLS, for part numbers of
place on planet carrier (16) face as shown in Fig. 35. general service tools and sealants required.
Torque plug (18) to a value of 40 Nm (29.5 Ibf ft) and
torque plug (26) to a value of 150 Nm (111 Ibf ft).
SM - 3482
18
26
Fig. 35 - Torque Plugs
8 Sm 2408 Rev1 10-06

Section 160-0030
AXLE DIAGNOSIS True axle noises may be located by lifting or jacking

the machine up until all tyres are clear of the floor or
Noises originating in the tyres, transmission, brakes or
ground. Securely block the machine in this position.
drivelines might be attributed by mistake to the axle
Run power train at moderate speed. Be certain all tyres
components, therefore, all possible sources of noise
are off the ground to prevent damage to the differential
should be investigated before deciding the axle is at
and make sure that there is no brake drag.
fault.
WARNING
safely.
AXLE DIAGNOSIS CHART

Noises Insufficient or incorrect lubricant Check level. Fill with proper type and grade of
lubricant.
Wheel bearings scored or rough Replace wheel bearings
Gear teeth in planetary chipped Replace gear
Loss of lubricant Lubricant foams excessively Drain and fill with proper type and grade of
lubricant
Worn or broken oil seal Replace oil seal
Loose nuts or bolts Tighten nuts or bolts
Gain of lubricant Incorrect lubricant Drain and fill with proper type and grade of
lubricant
Planetaries running hot Bearings seized Replace bearings

TORQUE
1 25 Wheel Nut 600 442
1 13 Lock Screw 86 63
1 23 Bolt 280 206
1 18 Plug Screw 40 30
1 28 Slotted Nut 2 000 1 475
* * * *
SM 2408 Rev1 10-06 9

REAR AXLE GROUP - Wheel Rim and Tyre
Section 160-0050
SM - 1176
1 - Flanges 4 - Lock Ring 7 - Cap

2 - 'O' Ring 5 - Wheel Rim 8 - Driver
3 - Bead Seat Band 6 - Valve Assembly 9 - Wheel Nut
Fig. 1 - Cutaway View of Wheel Rim
DESCRIPTION AND OPERATION One of the following pieces of hoisting equipment

The wheel assembly is designed to allow the tyre and should be used to lift the tyre and rim: chain block and
rim assembly to be replaced with a pre-assembled tyre tackle, overhead crane, fork lift truck, boom truck, or
and rim. The tyre and rim may be removed from the tripod tyre changing tool.
machine as an assembly and transported to a more
suitable location for removing the tyre from the rim.
PREPARATION FOR SERVICING
Procedures for removing tyre and rim assembly from
machine, dismounting tyre from rim and the use of
hand and special tools, are described in this section. WARNING
Before performing any service on the tyres or
The rim assembly consists of the following rim components, to prevent personal injury
components which are illustrated in Fig. 1: wheel rim, and property damage, completely deflate the
inner and outer flange, 'O' ring, bead seat band, driver tyre by removing the valve cap and core. Insert
and lock ring. a thin wire through valve to be sure valve is
not plugged. Even a flat tyre, in some cases,
When dismounting a tyre and rim assembly from the will retain sufficient air pressure to blow off a
machine, special equipment and careful handling are rim component with enough force to cause
required because of the size and weight of the tyres. bodily injury or death.
SM 2389 Rev1 06-06 1

Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
REMOVING TYRE AND RIM ASSEMBLY SM - 1039
FROM MACHINE
Note: If tyre and rim assembly is to be replaced pre-

assembled, it is not necessary to remove the tyre from
the rim. It may be removed as an assembly.
WARNING
safely.

parking brake and shutdown the engine. Turn the
steering wheel in both directions several times to
relieve pressure in the steering system.
2. Block all road wheels, except the one to be raised,

and place the battery master switch in the 'Off' 1 - Outer Flange 4 - Lock Ring
position. 2 - Driver 5 - Wheel Rim
3 - Bead Seat Band 6 - Inner Flange
3. Break wheel nuts (9) loose with tyre still on the Fig. 2 - Typical Rim Assembly
ground, but do not remove from wheel studs.
4. Jack up the axle to the height required to allow SM - 205
removal of the tyre and rim assembly.
5. Place safety blocks under the axle.
6. Support tyre and rim assembly with a suitable sling

and attach a suitable lifting device.
Fig. 3 - Pry Bar
7. Remove wheel nuts (9) securing wheel rim (5).
SM - 206
8. With lifting device, remove tyre and rim assembly
from wheel and lift clear of machine.
DISMOUNTING TYRE FROM RIM

Note: The following instructions apply to use of hand

tools. For procedures and tooling required to dismount
the tyre from the rim using hydraulic tools, contact the
relevant tyre manufacturer.
Fig. 4 - Breaking Typical Tyre Bead
2 SM 2389 Rev1 06-06

Section 160-0050
14. Using suitable lifting equipment, remove tyre from

WARNING rim. This completes the removal of the tubeless tyre.
When lifting tyre from rim, be sure the
equipment is of sufficient capacity and 15. If necessary, remove inner flange (6).
properly secured to do the job safely.
Note: If tyre rim is on machine, and no tyre lifting
1. Remove valve cap and valve core and leave valve equipment is available, 'walk' tyre off rim as follows:
open to prevent trapping of air in tyre. Tape valve Force bottom of tyre outward as far as possible; lower
threads for protection. jack enough to allow weight of tyre to rest on ground;
force top of tyre out as far as possible; raise jack to
2. Remove driver (2) from bead seat band (3) and original height and repeat the above until tyre is off rim.
wheel rim (5).
3. Break outer tyre bead loose with pry bar shown in INSPECTION
Fig. 3.
Tyre
4. Insert flat hooked end of pry bar into breaking slots Check the interior surface of the tyre to determine its
between bead seat band (3) and outer flange (1) (See condition. Inspect for cuts or fabric breaks that have
Fig. 4). A pipe over the straight end of the pry bar will penetrated the tyre body. The casing should be
increase leverage. inspected closely for any sharp , pointed object that
may have penetrated the tyre body but is invisible from
5. Twist bar toward tyre to break bead. the outside. All dust, dirt, water or other foreign matter
should be cleaned from the inside of tyre.
6. A second bar may be inserted in space between
bead seat band (3) and outer flange (1). Twist second Rim Assembly
bar to maintain space gained by the first bar.
Overloading, improper tyre inflation, rough terrain, high
7. Move the first bar around the rim, twisting and speed, accidents, dirt accumulation, and corrosion all
following with the second bar, until the outer tyre bead tend to reduce the service life of rims and rim
is loose. components. It is recommended that rims be
inspected, as below, not less often than at every tyre
8. Pry bead seat band (3) away from lock ring (4) by change and that, as the warranty limit approaches,
placing hooked end of pry bar in groove of wheel rim consideration be given to periodic replacement.
(5), between ends of lock ring (4), and prying up with
bar. Using two bars, as in Step 7, work completely The rim and its components are designed with built-in
around wheel rim (5). safety factors, to prevent the components from flying
off with killing force during inflation. Check components
9. Pry lock ring (4) out in same manner by starting at for cracks, bends, distortion, or other damage. If
prying notch in rim assembly and work all the way damage is found, the component must be replaced.
around rim with two pry bars.
10. Remove and discard 'O' ring (2, Fig. 1). WARNING
Never mix components of one manufacturer's
11. Remove lock ring (4), pry out and remove bead rims with those of another. Using the rim base
seat band (3). of one manufacturer with the lock ring of
another or vice versa is dangerous. The lock
12. Breaking slots are provided inside the rims. The ring of one may not fully engage with the lock
inner bead may be broken as described in Steps 4 ring groove of the other. Always consult the
through 8. If tyre and rim assembly are on the rim manufacturer for proper matching and
machine, the following procedure may be used for assembly instructions. Also, use and servicing
breaking the inner bead. of damaged, worn out, or improperly
assembled rim assemblies is a very dangerous
13. Place jack between inner flange (6) and machine practice. Failure to comply with the above
frame. Extend jack until tyre bead is broken. Continue warnings could result in explosions from tyre
around rim until tyre bead is broken at all points. pressure causing serious personal injury and
property damage.
SM 2389 Rev1 06-06 3

Section 160-0050
Clean all rust and dirt from the rim parts and wheel SM - 207
and apply a coat of good grade primer paint. Allow the

paint to dry thoroughly before remounting tyre.
The rim parts used with tubeless tyres form an

important part of the air chamber. Therefore, they
should be carefully checked for distortion or mutilation
that would prevent an effective air seal when the tyre
and rim are reassembled.
Rubber 'O' rings are air seals for tubeless tyre and rim
assemblies and therefore should be carefully handled
to provide an airtight seal when the tyre is remounted
on the rim. Always use new 'O' rings when mounting a
tubeless tyre. 1 - Lock Ring 2 - Drive Lug
Fig. 5 - Installing Typical Lock Ring
Note: Handle 'O' rings carefully, as damage will
prevent an airtight seal for tyre inflation. soft hammer to rotate lug. Use bar for installing lock
ring, as illustrated in Fig. 5.
MOUNTING TYRE ON RIM 8. Force bead seat band (3) past 'O' ring groove in
Numbers in parentheses refer to Fig. 2, unless wheel rim (5) by prying, or with lift truck forks. Use
otherwise specified. blocking between the forks and tyre to prevent
damage. Insert a new 'O' ring (2, Fig. 1) in groove of
For mounting a tyre with rim on or off machine, the the rim behind lock ring (4). Lubricate area of front
procedure is basically the same. taper of bead seat band adjacent to 'O' ring, with a thin
solution of soap and water or another approved
lubricant which is not harmful to rubber. Avoid using an
WARNING excessive amount of lubricant.
When lifting tyre onto rim, be sure the
equipment is of sufficient capacity and 9. Install driver (2). Make sure all rim components are
properly secured to do the job safely. correctly assembled.
1. For off-machine installation, lay rim on blocks or 10. Lift the tyre upwards to effect a seal between bead
mounting stand with 'O' ring groove up. Rim should be seat band (3) and 'O' ring (2, Fig. 1). In some cases
off floor enough to allow tyre to rest on rim and not on the tyre will automatically spring out, making this step
floor. Blocks are not to extend more than 13 mm unnecessary.
(0.50 in) beyond rim base.
11. Refer to 'Tyre Inflation' in this section for the proper
2. If removed, install inner flange (6) over wheel rim (5). procedure for inflating the tyre.
3. Lubricate tyre beads and 'O' ring, with a thin solution

MOUNTING TYRE AND RIM ASSEMBLY
of vegetable base soap and water.
ON MACHINE
4. Using suitable lifting equipment, lower tyre onto rim. Numbers in parentheses refer to Fig. 1.
Seat tyre firmly against inner flange (6).
5. Install outer flange (1) on rim (5). WARNING

When jacking, lifting, or blocking the machine,
6. Align lock ring driver notch in bead seat band (3) be sure the equipment is of sufficient capacity
with notch in wheel rim (5) and install bead seat band to do the job safely.
on rim.
1. Support tyre and rim assembly with a chain, or rope
7. Install lock ring (4) in groove of wheel rim (5) so that sling. Attach sling to overhead lifting device. Slide
lock ring lug engages both notches. Notches and lock assembly on to wheel of machine, with lock ring (4)
ring lug must line up correctly. If necessary, use only a and bead seat band (3) facing outward.
4 SM 2389 Rev1 06-06

Section 160-0050
2. Install wheel nuts (9) on wheel studs. Gradually C.

tighten nuts opposite each other until all nuts are snug. Be sure to thoroughly flush and blow off all
Torque tighten wheel nuts (9) to 730 Nm flammable solvents used for cleaning the air
(540 lbf ft). Torque tighten wheel nuts (9) again, after compressor inlet screen before using the
10 hours of machine operation. compressor for tyre inflation, or any other
purpose.
TYRE INFLATION D.
Do not charge batteries, either in or out of a
machine, near the air inlet of a compressor
WARNING used for inflating tyres. Charging batteries
To prevent personal injury and property produces highly explosive hydrogen gas
damage, the tyre and rim assembly should be which can be readily drawn into a nearby
placed in a safety cage before inflating. If no compressor inlet and pumped into the tyre.
safety cage is available or tyre is on the
machine, the tyre and rim assembly should be E.
wrapped with safety chains or with lash cables Never exceed the specified concentration of
before inflating. alcohol when adjusting the alcohol vaporizer,
or adding alcohol to the auxiliary air tank, used
Even with these precautions remember that on machine air systems to prevent freezing or
air-blast is a potential hazard. Tyre inflation moisture condensate in below-freezing
should be carried out away from busy working temperatures. Excessive alcohol, added to the
areas. machines air tanks in this manner can produce
flammable vapours that will be pumped into a
WARNING tyre when this air supply is used for tyre
To avoid personal injury and property damage, inflation if the tyre inflation kit is not equipped
never stand or sit in front of a mounted tyre with a moisture filter. Alcohol added to
during tyre inflation. Use a clip-on air chuck machine air systems in recommended
with a long hose and stand to one side while concentration to prevent condensate freezing
the tyre is being inflated. are below hazardous levels for tyre inflation.
WARNING F.
To prevent personal injury and property Another source of hazardous flammable
damage, always prevent flammable vapours vapours in tyres is the tyre bead lubricant.
that could produce tyre explosions, from being Always use bead lubricants that do not
pumped into tyres during inflation, by introduce flammable vapours into the tyre.
observing the following precautions:
A. Inflation
Use an air compressor and reservoir located Note: Always use tyre inflation equipment with an air
inside a heated building, when available, so filter that removes moisture from the air supply, when
that alcohol, methanol, or other flammable available, to prevent moisture corrosion of internal rim
antifreeze liquids are not needed in the air parts.
tanks to prevent moisture freezing in the tank
and lines in subfreezing outside temperatures. 1. Inflate tyre to 1 bar (15 lbf/in²) initially to seat
components and tap lock ring lightly to ensure correct
B. seating. Visually check that all components are in
Make sure that paints, lacquers, paint thinners, place, then continue inflation observing all safety
or similar materials that produce volatile, precautions. (See Step 2).
flammable vapours are not used or stored near
the air intake of the compressor that supplies 2. If the tyre is off the machine, place it in a safety
the air for inflating tyres. The compressor cage after initially inflating to 1 bar (15 lbf/in²) to seat
should be isolated from all such sources of components. See Fig. 6.
flammable vapours.
SM 2389 Rev1 06-06 5

Section 160-0050
3. Inflate tyres to 5.2 bar (75 lbf/in²) to seat beads and SM - 208
seal the 'O' ring, then adjust to the recommended
inflation pressure.
4. For recommended operating air pressure, refer to

the 'Tyre Inflation Pressures Table'.
NITROGEN TYRE INFLATION

Note: All Warnings and procedures under 'Tyre
Inflation' will apply, except for differences covered by
this passage.
In certain environments it is recommended that tyres

be inflated with dry nitrogen gas, and that the resulting
oxygen content of the inflation does not exceed 5%.
All machines whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on the body
or frame.
Nitrogen gas improves tyre pressure retention, Fig. 6 - Typical Safety Cage
increases tyre life by reducing carcass oxidation from
within, minimizes rim rust and has no detrimental
effects on the tyre. It also reduces the potential of a SM - 1040
tyre explosion because it is an inert gas and will not

support combustion inside the tyre.
The same tyre inflation pressure used for air inflation

should be used for nitrogen inflation. Tyre valves
formerly used with air inflation are entirely satisfactory
for use with nitrogen gas.
Nitrogen Tyre Inflation Kit
WARNINGS
DO NOT USE charging assembly, Part No.
9359489, for tyre inflation because this
assembly does not include a pressure
regulator, safety relief valve, and adequate
pressure gauging which is mandatory for tyre
inflation purposes. Tyre volume is as much as
90 times greater than the average accumulator
volume and hence it takes very much longer to
inflate a tyre - up to 40 minutes or more for
very large tyres.
Nitrogen gas cylinders used to inflate

tyres are generally charged to approximately Fig. 7 - Nitrogen Tyre Inflation Kit
152 bar (2 200 lbf/in2). A tyre blowout and/or
rim failure could occur if inflation equipment is 1. A nitrogen tyre inflation kit is available from your
not properly used. Proper nitrogen charging dealer and consists of the following. Refer to Fig. 7.
equipment and personnel training for its use is
a must to avoid over inflation. a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with
two dual pressure gauges.
6 SM 2389 Rev1 06-06

Section 160-0050
b. Safety relief valve, 8.6 bar (125 lbf/in²), that will b. If the required service inflation pressure is greater
assure an upper limit to the pressure available for tyre than 4.1 bar (60 lbf/in²), further inflate, with dry
inflation. nitrogen gas only, to the pressure level required. Then
remove the clip-on chuck and adjust the pressure with
c. A 15.2 m (50 ft) length of flexible hose with the tyre gauge in the usual manner.
interconnecting fittings. On the tyre end of the hose is
a large bore quick connect/disconnect clip-on chuck.
New Tyre Mounts and Remounts
2. The pressure regulator is connected to a nitrogen To newly mount or remount a tyre to its rim, use only
compressed gas cylinder available from local suppliers. dry nitrogen gas; this includes the pressure required to
seat the beads. After seating the tyre beads, remove
3. The usual procedure for using this type of the clip-on chuck and adjust the pressure with the tyre
equipment is as follows: gauge in the usual manner.
a. Connect nitrogen tyre inflation kit to nitrogen Note: Although a little more nitrogen gas is used to seat
compressed gas supply. DO NOT connect clip-on beads than that used for re-inflation of a mounted tyre,
chuck to the tyre valve at this time. refer to 'Re-inflation of a Mounted Tyre', its cost is
generally negligible in comparison to the time and labour
b. Open valve on nitrogen supply. saving and, longer tyre life achievable with the reduced
oxygen content which results.
c. With flexible hose and clip-on chuck connected to
nitrogen tyre inflation kit assembly but not connected
to the tyre, adjust pressure regulator so that its output TYRE EXPLOSION HAZARD
pressure is not more than 1.4 bar (20 lbf/in²) higher
than the desired tyre inflation pressure.
WARNINGS
d. Connect clip-on chuck to the tyre valve. The tyre will Whenever a machines tyre(s) is (are) exposed
now inflate. Tyre pressure can be monitored by to excessive heat such as a machine fire or
observing the gauge at the pressure regulator. STAY extremely hot brakes the hazard of a
AWAY FROM THE TYRE. subsequent violent tyre explosion must be
recognized. All persons must avoid
e. When desired inflation pressure has been achieved, approaching the machine so as not to be
back off the regulator or close the valve on the physically endangered in the event of an
compressed gas cylinder. explosion of the tyre and rim parts. The
machine should be moved to a remote area,
f. Remove the clip-on chuck and adjust the tyre but only when this can be done with complete
pressure with the tyre gauge in the usual manner. safety to the operator operating or towing the
machine. All other persons should stay clear of
the machine. The fire or overheated brakes,
Re-inflation of a Mounted Tyre wheel, etc. should be extinguished or cooled
To re-inflate a tyre with dry nitrogen gas which is now from a safe distance. Do not attempt to
inflated with air, proceed as follows: extinguish the fire or cool the machine by use
of hand-held fire extinguishers.
1. Exhaust the tyre until only air at atmospheric
pressure remains in the tyre. If it is absolutely necessary to approach a
machine with a suspect tyre, approach only
2. Re-inflate the tyre using only dry nitrogen gas to from the front or the back. Stay at least 15 m
4.15 bar (60 lbf/in²) gauge as a minimum, or to bead- (50 ft) from the tread area. Keep observers out
seating pressure as a maximum. of the area and at least 460 m (1 500 ft) from
the tyre sidewall. Refer to Fig. 8. The tyre(s)
3. Adjust to the service inflation pressure required: should be allowed at least eight (8) hours
cooling time after the machine is shut down or
a. If the required service inflation pressure is LESS the fire extinguished before approaching
than 4.1 bar (60 lbf/in²), remove the clip-on chuck and closer.
adjust the pressure with the tyre gauge in the usual
manner.
SM 2389 Rev1 06-06 7

Section 160-0050
SM - 1041
WARNINGS AT LEAST AT LEAST

There is always a possibility of a tyre explosion 15 m (50 ft) 460 m (1 500 lbf
whenever the smell of burning rubber or ft)
excessively hot brakes is detected. The danger
is also present when a fire on the machine
reaches the tyre and wheel area. Under such
conditions, all personnel must avoid
approaching the machine in a manner that
could result in injury should an explosion
actually occur. Move the machine to a remote
area only if it can be done without endangering
the operator or other personnel in the area.
DO NOT WELD ON OR HEAT RIM

COMPONENTS. For several years the company
and tyre and rim manufacturers have warned
users never to weld rim components with the
tyre mounted on the rim. The gases that build
up inside the tyre during arc welding or
heating on rim components can ignite,
resulting in one of these explosive-like failures
of the tyre and rim. This warning also applies Fig. 8 - APPROACH AREA.
to nitrogen inflated tyres. Ignition will not Do Not Approach Tyre in Shaded Area
occur in the nitrogen atmosphere, but the
pressure buildup from the heat of welding may less than 13 mm (0.50 in) in size can be repaired with a
be sufficient to cause a blowout severe enough plug and hot patch. Insert a repair plug into the hole to
to injure or kill. It is recommended to scrap the keep out moisture and to back up the hot patch. Trim the
part if heat is necessary to repair any rim plug off flush with the inside of the casing, buff, and apply
component. the hot patch according to the instructions supplied with
the hot patch equipment.
TYRE AND WHEEL RIM MAINTENANCE Punctures 13 mm (0.50 in) or larger, large cuts, or
bruise breaks require sectional or reinforced
Tyre Repairs vulcanized repair. Cover the repair patch with a layer
Prompt repair of tyre injuries will prevent small injuries of cushion gum after application to the tubeless tyre to
from enlarging and causing tyre failure. Use the best ensure an airtight repair. Any cords of the inside ply
tyre facilities available. If good repair facilities are not that are exposed in buffing and are not covered with
available, have the nearest dealer make the necessary repair patch must be coated with cushion gum to
repairs. prevent air leakage into the carcass plies on tubeless
tyres.
Minor cuts, snags, or punctures should be repaired
upon discovery. Skive with a sharp pointed knife
around any cut in the tyre tread area that is of Recapping and Retreading
sufficient depth or shape to hold pebbles or dirt. The There are two general methods employed in restoring
angle of the skive should be no more than sufficient to the tread surface of off-the-highway tyres: recapping
expel all foreign material and should extend no deeper and retreading.
than the breaker. The skive should go to the bottom of
the hole. Tyres with shallow cuts, if treated promptly, A recapped tyre has a new tread cured right over the
may be allowed to continue in service. If the cut old tread surface.
extends deeper into the tyre carcass, the tyre should
be removed for repair. A retreaded tyre has the old tread removed entirely
and a new tread cured directly onto the body of the
The tyre must be removed from the rim to repair larger tyre. A tyre can be recapped or retreaded if the cord
punctures or cuts. Irregular shaped punctures or cuts body is free of cuts, bruises and separation, and is
thoroughly sound, including previous repairs.
8 SM 2389 Rev1 06-06

Section 160-0050
TYRE CARE Prevent Contact with Oil

To obtain maximum service from off-highway tyres, the Prevent tyre contact with petroleum products. Rubber
following common-sense precautions should be that is exposed to oil, gasoline, or grease becomes
followed. soft and spongy and deteriorates rapidly. Always avoid
driving machine through a puddle of gasoline, fuel oil,
lubricating oil, or grease. Never let a tyre stand in an
Maintain Correct Inflation oil or grease spot overnight.
The most common cause of tyre damage is improper
inflation. Both over-inflation and under-inflation are
detrimental to tyre life. Tyre pressure should be Store Tyres Properly
checked daily, preferably before the machine is placed The best of care given to tyres in service by operators
in operation. Refer to 'Tyre Inflation Table'. and maintenance personnel can be completely
nullified by careless storage. Time is not the only
The valve cores should be checked for leaks. Keep in contributing factor to the deterioration of rubber
mind that valve cores are delicate mechanisms that products. Therefore, tyres that are to be stored must
wear out in service; therefore, they should be replaced be protected from light, heat, oils, dirt, moisture, and
with new ones when they become worn. Each tyre ozone. Stored tyres should be carefully covered with a
should be equipped with a valve cap to prevent dirt tarpaulin or some other suitable material, such as
from damaging the valve core and causing air leakage. opaque plastic sheets, to prevent contact with the
contaminants listed above.
Maintain Good Haul Roads

Because haul roads are considered temporary roads
Proper Handling of Tyres and Wheel Rim
they are frequently neglected. The better the haul Parts
road, the longer the tyre and machine life of off- Tyres should be stored vertically. Horizontal stacking
highway machines. may compress the tyre walls, making inflation difficult. If
tyres are stored in racks, the lower supporting members
Although it takes time and effort to maintain good haul should provide as broad a surface as possible to the tyre
roads, the delay and cost of tyres and machine tread to avoid a concentration of load.
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 when
Inspect Tyres Regularly lifting these tyres. If forklift trucks are used for handling,
A systematic plan for tyre inspection will more than they should be equipped with broad, well-rounded arms
pay for itself in lowered tyre costs per hour of to distribute the load and prevent damage to the tyre
operation. All tyres should be checked regularly for bead. When handling tyres with the fork truck do not
cuts, bruises, ply material breaks, excessive or scrape the fork across the bead.
uneven wear, embedded foreign matter, and any other
damage which can be repaired. A considerable Tubeless tyre rims perform an important function as part
increase in tyre service can be realized if tyre injuries of the assembly air seal. Proper care, therefore, must be
are repaired before they have progressed to the taken not to distort or mutilate the rim parts because they
irreparable stage. must mate properly to form part of the basic air chamber.
Since the rim base and bead seat band are mating
The rim mounting nuts should also be checked surfaces, distortion may prevent easy assembly as well
periodically and tightened to the torque specified. as possibly resulting in no seal.
Never drop, tumble, or roll rim parts.

Prevent Overloading
Off-highway machines are designed to carry a If rim parts are stored outdoors, they should be given a
maximum allowable payload. Excessive loading will protective coat of a good commercial primer.
overstress both the machine and tyres and shorten the
life of both. Similar parts should be stacked neatly to prevent distortion.
SM 2389 Rev1 06-06 9

Section 160-0050
Babbit or lead hammers, not sledge hammers, should machine is placed in operation. Refer to 'Tyre Inflation
be used in assembling rim parts. Pressures Table'.
'O' rings are seals and should be carefully stored in a Every 50 hours of operation (weekly), torque tighten
cool, dry place where they will not be injured or wheel rim nuts to 730 Nm (540 lbf ft).
damaged.
Check tyres regularly and replace or repair if required.
Valve cores should also be stored in a cool, dry and
clean place.
SERVICE TOOLS
MAINTENANCE numbers of the nitrogen tyre inflation kit shown in
Check tyre pressures daily, preferably before the Fig. 7 and general service tools required.
TYRE INFLATION PRESSURES (BRIDGESTONE)

FRONT CENTRE AND REAR
2
MODEL TYRE SIZE bar lbf/in bar lbf/in2
TA40 29.5 R 25** 3.31 48 4.41 64
TYRE INFLATION PRESSURES (MICHELIN)

2
TA40 29.5 R 25** 2.90 42 3.86 56
TYRE INFLATION PRESSURES (GOODYEAR)

2
TA40 29.5 R 25** 3.24 47 4.6 66
TYRE INFLATION PRESSURES (CONTINENTAL)

2
TA40 29.5 R 25** 3.0 44 4.5 65

TORQUE
1 9 Wheel Nut 730 540
10 SM 2389 Rev1 06-06

Section 160-0050
TUBELESS TYRE LEAK DIAGNOSIS TABLE499
Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of leakage,
the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be checked using a
soap solution.
This table lists various causes of air loss and possible remedy.
CAUSE REMEDY
Defective valve Tighten parts. Replace defective parts. Use valve caps.
Cracked rim or weld Replace defective part
WARNING
Do not attempt repair of wheel components.
Twisted or damaged 'O' ring Replace 'O' ring (lubricate)
Tyre cuts and snags Repair tyre damage
Bead area awl holes Repair inner liner (preferred)
Leakage between tyre bead trim With tyre removed from rim:
Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5 degree tapered bead seat band and the rim base
in the bead seating area to determine if the transverse weld
trims are flat or concave. Replace defective part(s). Note:
Weld trim should follow rim contour.
Mount tyre using a lubricant such as Murphy's Tyre and Tube

Mounting Compound, or equivalent, on tyre beads and rim bead
seat area.
* * * *
SM 2389 Rev1 06-06 11

BRAKE ASSEMBLY - Oil Cooled Disc Brakes
Section 165-0015
DESCRIPTION AND OPERATION

Numbers in parentheses refer to Fig. 1. Hydraulic fluid will remain within the
braking system after engine shutdown. Operate
The service brakes are of the enclosed, forced oil- the treadle valve continuously until the
cooled multiple disc type. The service brakes are pressure has dissipated before carrying out any
actuated by hydraulic oil as specified in Section 300- work on the braking system or serious injury
0020, LUBRICATION SYSTEM. DO NOT use BRAKE could result.
FLUID (J 1703). Multiple discs within the brake
assemblies are cooled by brake cooling oil as specified Use extreme caution to prevent personal
in Section 300-0020, LUBRICATION SYSTEM. injury when removing wheels. The exact
procedure must be followed as described in
The brake assembly is bolted to the stub axle and Section 160-0050, WHEEL, RIM AND TYRE.
houses a sandwich of friction discs splined to a hub
rotor. There are four friction discs (20) in each brake 1. Position the vehicle in a level work area, apply the
assembly. parking brake and switch off the engine.
When the treadle valve is actuated, hydraulic oil enters 2. Turn the steering wheel in both directions several
the brake assembly and forces the brake piston (14) times to relieve any pressure in the steering circuit.
against the rotating friction discs (20) which react with Operate the treadle valve continuously to relieve any
stationary reaction discs (21). The reaction discs (21) pressure in the braking system. Block all road wheels.
are retained by scalloped tangs at the outside
diameter, which in turn transfers the reaction torque to 3. Remove drain plug and drain cooling oil from brake
the rigid outside housing (1), slowing or stopping wheel packs into a clean container. Reinstall plugs.
rotation.
4. Drain oil from hubs and differentials. Refer to
In an emergency situation, application of the park/ Section 160-0030, AXLE GROUP (HUB) and Section
emergency valve will actuate the service brakes and 160-0020, DIFFERENTIAL DRIVE HEAD.
the parking brake to bring the machine to a halt. In this
condition, a restriction in the 'Px' line from the brake 5. Refer to Section 160-0030, AXLE GROUP (HUB) for
manifold valve will slow oil flow from the parking brake disassembly instructions.
allowing the service brakes to actuate momentarily
ahead of the parking brake. 6. Attach suitable lifting equipment to brake assembly
and support weight. Loosen and remove bolts securing
When the treadle valve or park/emergency brake is brake assembly and hub carrier to axle stub.
released, hydraulic pressure against piston (14) is
relieved and cup springs (24) force the piston (14) to 7. With brake assembly supported, remove brake
return to its original position, thus, relieving the assembly from axle stub.
pressure against the brake disc pack.
8. Place brake assembly on a clean work surface for
disassembly.
REMOVAL
9. Remove and discard all 'O' rings and oil seals from
brake assembly.
WARNINGS
secured and of sufficient capacity to do the job
safely.
SM 2390 01-06 1
Brake Assembly - Oil Cooled Disc Brakes
Section 165-0015
SM - 3099
1 - Brake Housing 11 - Anchor Plate 20 - Friction Disc

2 - 'O' Ring 12 - 'O' Ring 21 - Reaction Disc
3 - Sealing Holder 13 - Screw 22 - Pin
4 - 'O' Ring 14 - Brake Piston 23 - Gripping Ring
5 - Seal Slide Ring 15 - 'U' Ring 24 - Cup Spring
6 - Screw Neck 16 - Support Ring 25 - Shim Support
7 - 'O' Ring 17 - 'U' Ring 26 - Snap Ring
8 - Vent Valve 18 - Support Ring 27 - Snap Ring
9 - Plug 19 - Guide Ring 28 - Slot Pin
10 - 'O' Ring
Fig. 1 - Brake Pack Explosion
INSTALLATION
1. Refer to Fig 33. Using suitable lifting equipment, 4. Refill brake coolant tank with oil as described in
offer Anchor plate (3), brake assembly (5) and hub Section 250-0025, BRAKE COOLANT TANK.
carrier (1) up to axle stub (8) and secure with washers
(7) and bolts (6); applying adhesive 15500690 to bolts
WARNINGS
(6) and torquing to a value of 460 Nm (339 Ibf ft).
2. Refer to Section 160-0030, AXLE GROUP (HUB) for
assembly instructions.
secured and of sufficient capacity to do the job
safely.
3. Fill hubs and differentials with oil. Refer to Section
160-0030, AXLE GROUP (HUB) and Section 160-0020,
DIFFERENTIAL DRIVE HEAD.
2 SM 2390 01-06
Section 165-0015
DISASSEMBLY 3 13
Numbers in Parentheses refer to Fig. 1 , unless

otherwise stated. For removal of AXLE HUB refer to
section 160-0030.
1. Loosen the hex headed screws (13) and separate 1
the sealing holder (3) from the brake housing (1). As

shown in Fig 2. Install adjusting screws 15501167, to
maintain remaining assembly together.
SM - 3145 Fig. 2 -Sealing Holder removal
3
STEP 1 5
2. Lever the slide ring seal (5) out of the sealing holder
(3) using pry bar 15270132 and then remove the 'O'-ring
(4) from the holder (3). Shown in Fig 3.
4
STEP 2
3
SM -3112 Fig. 3 - 'O'-ring removal
3.Remove the 'disc set' (20 & 21) from the brake
housing (1).Now carefully remove the brake housing (1) 20,21
from the Anchor plate (11) by means of a lifting tackle 1
15501170 and Eyebolts 15270115 . Shown in Fig 4.
11
SM - 3113 Fig. 4 - 'Disc set / Brake Housing removal'
14
28
4. Drive back the slotted pins (28) to be flush and

unsnap the snap ring (27) from the Brake piston (14).
shown Fig 5.
27
SM - 3114 Fig. 5 Snap Ring removal
SM 2390 01-06 3
Section 165-0015
5. Press out the support shims (25) by means of screws to aid in removal. Remove bolts (6, Fig 36)
automatic adjusting from the Brake piston (14). Shown and washers (7, fig 36) as shown in fig. 8.
Fig 6. using tool 15270132.
SM - 3510 fig. 8 - Loosening Hub carrier
12. Remove hub carrier (1, fig 36) from axle housing
(8, fig 36) using suitable lifting straps 15501168 as
shown in Fig. 9.
SM - 3115 fig. 6 - Support Shim Removal
6.Tap out the slotted pins (28) from the Shim support
(25) shown in Fig 7.
SM - 3511 fig. 9 - Separate Hub carrier
13. Separate anchor plate (11, fig. 1) from axle

housing (8, fig. 36) using suitable eyebolts 15270115
and lifting chain 15501178 as shown in fig. 10.
SM - 3116 fig. 7 - Support Shim breakdown
7. Using the tools - Clamping pliers 15501175 and

Assembly fixture 15502408. Remove the snap rings
(26). Preload the cup springs (24) to ease removal.
8. Pull the pin (22) out of the Shim support (25) and
remove released cup springs (24), then remove the
Gripping ring (23) from the pin (22).
9. By means of compressed air, press the piston out of

the brake housing (1).
10. Remove the guide ring (19), U-rings (15 & 17) and SM - 3512 fig. 10 - Separate Hub carrier
support rings (16 & 18) from the annular grooves of the
brake housing (1).
11. Loosen bolts (6, Fig 36) connecting hub carrier (1,
Fig 36) to axle housing (8), Fig 36). Install adjusting
4 SM 2390 01-06
Section 165-0015
ASSEMBLY 4. Refer to Fig. 14, FLUSH MOUNT SLOTTED PINS
(28)- install slots of pins in direction of force and by
Numbers in parentheses refer to Fig. 1, unless 180 Deg turned to each other.
otherwise stated.
1. Apply sealing compound to the mounting face of the

axle stub and install adjusting screws 15501167.
Shown in Fig. 11
SM - 3120 Fig. 14 Slotted Pins
5. Ensure adhesive 15500690 has been applied to bolts

(6, Fig. 33) prior to tightening. Now tighten bolt (6, Fig.
36 ) connections to 460 Nm (339 lb ft ).
SM - 3118 Fig. 11 Sealing / adjusting screws
Note : It is now necessary to adjust the rolling moment

2. Refer to Fig 12. Taking Eyebolts 15270115, mount of the wheel bearing, prior to final fit of the brake pack
the Anchor plate (11) to the axle. Now apply sealing assembly.
compound to the face of the plate.
6. Press the wheel bolts into the output shaft until
contact, using wheel bolt puller 15500884 and inserts
15269895.
7. Refer Fig.15, Press both bearing outer rings into the

hub until contact is made using a suitable Driver and
Handle 15269898.
SM - 3119 Fig. 12 Fitting Anchor Plate
3. Refer to Fig. 13. Locate the screw connection hub

carrier/ brake anchor & anchor plate (1,3,8 , fig 36) by
means of hex screws with washers provisionally until
contact is obtained ( do not tighten).
SM - 3120 Fig. 15 Wheel bolts & Bearing Mounting
8. Fig.16, Using a suitable lifting aid, mount the bearing

inner ring (1) onto the hub carrier (2).
9. Fig. 16, Heat the inner diameter of the bearing inner

ring to approximately 120Deg Celsius using Hot air
SM - 3120 Fig. 13 Screw Connection blower 15269899. At which point mount the ring (1) and
SM 2390 01-06 5
Section 165-0015
bearing (2) onto the hub carrier (3) until seated home. Rotate Hub in a clockwise directions several times to
ensure free rotation.
SM - 31203 Fig. 16 Mounting to Hub. SM - 3127 Fig. 19 - Checking Rolling Moment
10. Refer to Fig 17. Insert the ring gear carrier (1) into
the ring gear (2) and fasten it by means of the retaining 12. Refer to fig. 19, Check the rolling moment by
ring (3). means of a spring balance 15501169. As follows:
3
Rolling moment 'Torque' must be within range :-
T= 20 Nm (max) - 14.5 Nm (min)
(Hub dia. 444 mm therefore r = 0.222m.)
Tensile force Fmax = T / r = 20 / 0.222 = 90N

1 Tensile force Fmin = T / r = 14.5 / 0.222 = 65N
Note: If the rolling moment is not achieved, it has to

2 be corrected by means of the Shim (35, fig. 36). i.e.
Moment to low, then a thinner ring must be installed.
Conversely if the moment is too high, then a thicker
ring must be installed.
If bearings are being used which have already been
SM - 3123 Fig. 17 - Ring Gear Sub-assembly. run, it is acceptable to reduce the max and min rolling
moment range by 50%. i.e. within the range of :-
11. Refer to Fig. 18, Insert the ring gear sub assembly
(fig 14) . Now screw on the slotted nut (34, fig. 33) and 32N - 45 N
tighten nut to 2000 Nm Max, using Socket 15500882
and Centering bracket 15500883. 13. Now loosen the nut (34, fig. 36) and remove the
hub (16, fig. 36) from the hub carrier (1, fig. 36) using
STEP 2
Socket- 15500882 & Centering bracket- 15500883.
STEP 1
THE BRAKE DISC ASSEMBLY CAN NOW BE

INSTALLED.
Numbers in parentheses refer to Fig 1. unless stated

otherwise.
1. Clean the annular grooves of the brake housing (1)

with spirit.
SM - 3125, 3126 Fig. 18 - Securing Nut.
2. Refer to Fig 20. Install the support rings (16) , U-
rings (15 & 17) and guide rings (19) as shown.
6 SM 2390 01-06
Section 165-0015
Secure the guide ring with Loctite (type No 415) at its 5. Refer to fig. 22, Insert the pins (28) into the
extremities. assembly fixture 15501174, until contact.
14
SM - 3130 Fig. 22 - Pin fitment
6. Refer to fig. 23, Press gripping rings (23) onto the

19 pins until contact on the Assembly fixture 15501174.
16
15
23
17
18
9 1
SM - 3128 Fig. 20 - Brake Housing Assembly.
3. Refer to fig. 20, Insert the piston (14) into the Brake
housing, ensuring adequate levels of oil have been
applied to sliding /contact surfaces of the constituent
parts.
4. Refer to fig. 21, Mount the piston by means of SM - 3132 Fig. 23 - Gripping ring fitment
tooling fixture, comprising of Sliding Pads 15501171,

Two armed puller 15501172 and Support shim 7. Refer to fig. 24 & 25 , Exact installation dimension
15501173. 'X' is obtained when using the specified assembly
fixture, the value of which should be in the range 8.2 -
8.5mm. Observe the installation position , install
gripping rings with the orifice offset by 180Deg to each
other.
26
25
24
23
22
SM - 3130 Fig. 21 - Piston Mounting / tooling SM - 3133 Fig. 24 - Pin installation setup
SM 2390 01-06 7
Section 165-0015
27
26
25
24
X
23
22
SM - 3136 Fig. 27 - Retaining Support Shim in Piston
SM - 3134 Fig. 25 - Pin installation Detail 10. Insert the pre-assembled support shim into position
and fasten by means of Snap ring (27) as shown
8. Refer to fig. 25, Mount cup spring (24) onto the pin. in Fig. 27
11. Drive 6 off , slot pins (28) into bore holes of

support shim (25) - thus locking snap ring (27) as
shown in fig. 28.
Note: Apply grease to pins on extremities.

Snap ring opening must be located between 2
Slotted pins.
Always use new pins.
12. Refer to fig. 29, Grease 'O' -ring (4) and insert into
pressure oil supply bore.
13. Grease the 'O' -ring (12) and insert into the annular
groove. Install plug (9) with a new 'O'- ring (10) as
SM - 3135 Fig. 26 - Locking pins to support shim
shown in fig. 29
9. Take the pre-assembled pins and insert into the

support shim (25) and secure in place by means of Note: Plug tightening Torque 60Nm max
snap rings (26), using Clamping pliers 15501175,
shown in fig. 26.
INSTALLTION DIMENSION 'X' OF SLOTTED PINS SHOULD BE

IN THE RANGE OF 4mm - 4.5mm max. LOCATED AS SHOWN :-
14 27 X
1 22 25 28
SM - 3137 Fig. 28 - Brake Housing sub assembly
8 SM 2390 01-06
Section 165-0015
Y
21 1
14
3
11
20
SM - 3138 Fig. 29 - 'O'-Ring fitting X
14. Using Eye bolts 15270115, locate the brake carrier SM - 3141 Fig. 32 - Lined Disc Clearance details.
onto the Anchor plate (11) and fasten 3 Hex screws at

equal intervals to the brake housing. As shown in fig. Max clearance for new lines discs: 1.3 +0.3 / -0 mm
30.
Max. Clearance (Worn ) : 4.1 mm
To determine the clearance, proceed as follows;
Refer to Fig. 29,
Determination of clearance for lined disc:
X......................................= 28.00mm
Y...................................= 26.60mm
Clearance -1.40mm.
SM - 3139 Fig. 30 - Fit Brake Housing to Axle hub If required , correct the clearance with an adequate
outer disc.
15. Take Adjusting screws 15501167 and locate on
Hub carrier (1, fig. 36). Using Spline mandrel 15501176, 17. Grease 'O'-ring (4) and insert into the annular
install Reaction & Friction Discs (20,21) alternately , groove of the sealing holder (3).
starting with a Reaction disc, as shown in fig. 31.
Note: Oil Disc to ZF list of Lubricants TE-ML 05 18. Wet the 'O'-ring of seal slide ring (5) and insert into
the seal slide ring.
19. Press the seal slide sing (5) into sealing holder (3)
ensuring the surface of the seal slide ring does not
show any profiled grooves, scratches or other damage,
which could affect the performance / integrity of the
sealing elements.
WARNINGS
Seal slide ring has a sharp edge so safety gloves

must be worn to prevent injury to user.
SM - 3139 Fig. 31 - Install Frction / Reaction discs.
16. There may be the requirement for a new lined

(inner ) disc to keep the clearance within the specified
tolerance range: -
SM 2390 01-06 9
Section 165-0015
20. Mount sealing holder (3) on to the brake housing (1) 22. Remove the Mandrel 15501176 for aligning the Disc
until contact is obtained and fasten with hex screws set (20 & 21). As shown in Fig. 35.
(13) to 390Nm max, as shown in Fig. 33,
13
SM - 3169 Fig. 33 - Mounting Sealing Holder / Mandrel SM - 3171 Fig. 35 - Removing Mandrel
21. Install valve vent plug (8), new 'O'-ring (7) and
screw neck (6). Now install a suitable adaptor and MAINTENANCE
pressurize the piston with air to approximately 4 bar to
fasten the disc set. As shown in Fig. 34
WARNING
safely.
Oil Change Period

Note: For recommended oils, refer to Section
Drain (preferably after a short run to warm the oil) oil

from brake coolant tank every 1 000 hours. Refer to
Section 250-0025, BRAKE COOLANT TANK. Remove
drain plugs and drain brake cooling oil from each brake
SM - 3170 Fig. 34 - Pressurizing Disc Set assembly every 1 500 hours of operating. Change oil
filter every 1 500 hours. Refill brake coolant tank as
described in Section 250-0025, BRAKE COOLANT
TANK.
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for
details of service tools and adhesives required. These
tools and adhesives are available from your dealer.
10 SM 2390 01-06
Section 165-0015
SM - 3172
4 5
13
2 14
12 15
11
10
16 24
25 26
9
20 22
6
7 21 27
31
32
33 23 28
35 34
30 29
19
18
17
1 - Hub Carrier 9 - Shaft Seal 18 - Ring Gear Carrier 27 - Plug

2 - Drive shaft 10 - Ring 19 - Ring Gear 28 - Capscrew
3 - Anchor Plate 11 - Roller Bearing 20 - Locking Plate 29 - Planet Gear Assy
4 - 'O'-Ring 12 - Bolt 21 - lock Screw 30 - Retainer Ring
5 - Brake Assembly 13 - Lockwasher 22 - 'O'-Ring 31 - Thrust Washer
6 - Bolt 14 - Wheel nut 23 - Planet Carrier 32 - Sun Gear Shaft
7 - Washer 15 - Roller Bearing 24 - Bolt 33 - Drive
8 - Axle Housing 16 - Hub 25 - 'O'-Ring 34 - Slotted Nut
17 - Snap ring 26 - Plug Screw 35 - Shim
Fig. 36- Brake Assembly / Axle Stub installation
* * * *
SM 2390 01-06 11
PARKING BRAKE - Parking Brake and Mounting
Section 170-0010
SM - 3519
7,8
13 10
2
12 15 11
9
4,5
1
6
14
3
1 - Mounting Plates 6 - Nut 11 - Washer

2 - Calliper Head Assembly 7 - Clevis Pin 12 - Control strap
3 - Slack Adjuster 8 - Cotter Pin 13 - Cap assembly
4 - Bolt 9 - Actuator 14 - Slack adjuster screw
5 - Washer 10 - Nut 15 - Bolt
16 - Bolt
Fig. 1 - Parking Brake Mounting
Operation is by a spring applied/hydraulically released

actuator (9). Actuator (9) is connected through slack
WARNINGS adjuster (3) to the power screw shaft (19, Fig. 2) that is
Use only hydraulic oils meeting specifications screwed into piston (6, Fig. 2) in calliper head
outlined in Section 300-0020, LUBRICATION assembly (2). Calliper head assembly (2) slides on
SYSTEM. Do Not use Brake Fluid (J1703). Use mounting plates (1) bolted to the frame. Slack adjuster
of improper fluids is destructive to rubber (3) automatically maintains brake clearance after each
components of brakes resulting in loss of application through the control strap (12). Control strap
braking and possible catastrophic failure. (12) connects the slack adjuster (3) to the cap
assembly (13).
Exercise extreme caution while working
on the braking system. A push control on the dash panel activates the park
brake solenoid in the main hydraulic valve, controlling
oil pressure from the accumulators to actuator (9).
DESCRIPTION AND OPERATION Application of the push control releases oil from
Numbers in parentheses refer to Fig. 1, unless actuator (9) allowing internal springs in the actuator to
otherwise specified. apply the parking brake. Pulling out the push control
directs oil pressure from the accumulators to actuator
The parking brake consists of a sliding calliper acting (9), compressing internal springs, to release the parking
on a brake disc on a rear drive line. The parking brake brake.
is of 'Inverted Design' i.e. requiring pressure to hold the
parking brake off. Note: The parking brake is automatically applied when
the ignition is switched off.
SM 2428 01-06 1
Parking Brake - Parking Brake and Mounting
Section 170-0010
REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 2.
1. Remove calliper head assembly as described under
removal.
WARNINGS
To prevent personal injury and property 2. Remove snap ring (13) from power screw shaft (18),
damage, be sure wheel blocks, blocking and remove fasteners securing control strap (27) to
materials and lifting equipment are properly slack adjuster (14).
safely. 3. Slide slack adjuster (14) from power screw shaft (18).
Hydraulic fluid pressure will remain 4. Remove and discard washer (16), wave spring
within the braking system after engine shut washer (15) and packing (17) from power screw
down. Operate the treadle pedal continuously shaft (18).
carrying out any work on the braking system or 5. Remove bolts (2) and washers (3) securing cap
serious injury could result. assembly (21) to calliper (6).
1. Position the vehicle on a level surface, apply the 6. Remove as a unit, power screw shaft (18),
parking brake, block all road wheels and place the piston (5) and cap assembly (19 through 22) from
steering lock bar in the 'Locked' position. calliper (6).
2. Raise the body and install body safety prop to 7. Slide power screw shaft (18) and piston (5) from cap
secure in partially raised position. assembly (21).
3. Pull out push control to release the parking brake. 8. Unscrew piston (5) from power screw shaft (18).
4. Release spring tension on slack adjuster clevis pin 9. Remove and discard thrust bearing (19) from power
(7) by unscrewing tensioning bolt on slack adjuster (3) screw shaft (18) and gasket (20) from cap
until clevis pin (7) feels loose. Remove cotter pin (8) assembly (21).
and clevis pin (7) from actuator (9).
10. Remove and discard piston seal (4) from calliper (6).
Note: On engine shutdown the parking brake will
automatically apply. Ensure there is sufficient
clearance for actuator rod travel. INSPECTION
5. Switch off the engine and place the battery master
switch in the 'Off' position. 1. Thoroughly clean all parts. Inspect journal bearing
(22) in cap assembly (21) for wear. Journal bearing (22)
6. Disconnect and plug hydraulic line from actuator (9). ID should not exceed 38.35 mm (1.51 in). Replace if
Cap actuator (9) to prevent ingress of dirt. necessary.
7. Remove nuts (10) and washers (11) securing 2. Replace cap assembly (21) if excessively worn.
actuator (9) to cap assembly (13). Remove actuator (9)
from cap assembly (13). 3. Inspect all brake parts for cracks, excessive wear or
scoring. Replace brake parts as required.
8. Support calliper head assembly (2) and remove bolts
(4 & 16), washers (5) and nuts (6) securing mounting
plates (1) to mounting bracket on the frame. ASSEMBLY
9. Remove mounting plates (1) and calliper head
assembly (2) from the vehicle. 1. Install new piston seal (4) into seal groove in calliper
(6).
2. Apply grease (Lubriplate Aero or equivalent) to flat
2 SM 2428 01-06
Section 170-0010
SM - 2802
18
19 20
21
6 3
2
12
'A'
11
22 26
24 25
17
10 15
14
16 7
1
'A'
27
4
8
23 5
9 13
AT POSITION 'A'
1 - Brake Pad 8 - Clevis Pin 15 - Wave Spring Washer 22 - Journal Bearing

2 - Bolt 9 - Cotter Pin 16 - Washer 23 - Plug
3 - Washer 10 - Nut 17 - Packing 24 - Pressure Relief Fitting
4 - Piston Seal 11 - Washer 18 - Power Screw Shaft 25 - Lockwasher
5 - Piston 12 - Actuator 19 - Thrust Bearing 26 - Nut
6 - Calliper 13 - Snap Ring 20 - Gasket 27 - Control Strap
7 - Clevis 14 - Slack Adjuster 21 - Cap Assembly
Fig. 2 - Exploded View of Parking Brake Assembly
face of new thrust bearing (19). 6. Line up gasket (20) and bolt cap assembly (21), with
assembled power screw shaft (18) and piston (5), to
3. Install and seat new thrust bearing (19) over splined calliper (6) using bolts (2) and washers (3). Tighten bolts
end of power screw shaft (18) with greased side of (2).
thrust bearing (19) against thrust collar of power screw
shaft (18). Note: Care should be taken not to push piston seal (4)
out of seal groove in calliper (6) when assembling cap
Note: Ensure correct installation of thrust bearing (19) assembly (21), with piston (5) and power screw shaft
by verifying that installation was made over the larger (18), to calliper (6).
diameter end of power screw shaft (18), and, that thrust
bearing (19) ID lip is towards splined end of power 7. Install new packing (17), wave spring washer (15)
screw shaft (18). and washer (16) over power screw shaft (18), in the
order shown in Fig. 2.
4. Lubricate threads of power screw shaft (18) with
grease (Lubriplate Aero or equivalent) and screw power 8. Mount actuator (12) on cap assembly (21) with nuts
screw shaft (18) into piston (5). (10), lockwashers (25) and washers (11). Tighten nuts
(10) finger tight only at this stage.
5. Coat outside of piston (5) with grease (Lubriplate
Aero or equivalent) then slide assembled power screw 9. Apply coat of grease (Lubriplate Aero or equivalent)
shaft (18) and piston (5) into cap assembly (21), shaft to mounting spline of slack adjuster (14).
end first.
SM 2428 01-06 3
Section 170-0010
10. With adjusting screw facing towards actuator (12) 6. Align actuator (9) to slack adjuster (3) and tighten
slide slack adjuster (14) on power screw shaft (18) nuts (10).
aligning slack adjuster (14) arm with clevis (7).
7. Loosen bolt (15) at the control arm of slack adjuster
11. Install snap ring (13) on power screw shaft (18). (3) and control strap (12).
12. Remove nuts (10), lockwashers (25) and washers 8. Position control arm of slack adjuster (3) in fully
(11) securing actuator (12) to cap assembly (21). released position (forcing it in a direction away from
Remove actuator (12) from cap assembly (21) to aid in actuator (9)) by turning adjustment screw (14) on the
installation. slack adjuster (3), until it comes to a positive stop
inside the control strap (12).
INSTALLATION 9. Tighten bolt (15) at the control arm of slack adjuster

Numbers in parentheses refer to Fig. 1, unless (3) and control strap (12).
Note: Failure to position the slack adjuster against the
internal stop may result in brake drag.
WARNING
To prevent personal injury and property 10. Use feeler gauges between brake pads in calliper
damage, be sure wheel blocks, blocking head assembly (2) and brake disc. Turn the adjustment
materials and lifting equipment are properly screw (14) on the slack adjuster (3) until the total pad-
secured and of adequate capacity to do the job to-disc clearance is between 0.04 - 0.06" (1.0 - 1.5
safely. mm), which is 0.02 - 0.03" (0.5 - 0.75 mm) per side.
1. Attach suitable lifting device and position mounting 11. Remove feeler gauge and apply brake several
plates (1) in mounting bracket and calliper head times. The automatic slack adjuster will adjust the
assembly (2) over brake disc. Secure mounting plates brake pad clearance with each application, which can
(1) to mounting bracket on the frame with bolts (4 & be seen by the rotation of the adjustment screw (14).
16), washers (5) and nuts (6). Tighten nuts (6) to a
torque of 75 Nm (55 lb ft). 12. When the adjustment screw (14) stops rotating, the
specified clearance has been obtained and the brake is
2. Remount actuator (9) on cap assembly (21, Fig. 2) ready for normal operation.
and install washers (11), lockwashers (25, Fig. 2) and
nuts (10). Tighten nuts (10) finger tight only at this 13. Remove wheel blocks and place the steering lock
stage. bar in the 'Stowed' position.
WARNING MAINTENANCE
Do not pressurize actuator until the following
instruction has been carried out. Pressurizing Every 250 hours
the actuator beforehand can result in serious Test park brake for proper operation. Check brake pads
brake damage. and disc for wear. Replace brake pads when lining
thickness is 3.0 mm (0.125 in) or less. Replace disc
3. Turn adjustment screw (14) on the slack adjuster (3) when worn by 3.0 mm (0.125 in) or more.
in a clockwise direction until the brake pads in calliper
head assembly (2) are tight against the brake disc.
Brake Pad Replacement
4. Connect hydraulic line to actuator (9). Place the 1. Remove calliper head assembly as described under
battery master switch in the 'On' position, start the 'Removal'.
engine and pull out parking brake control knob to
extend the actuator. 2. Replace worn brake pad and carrier assemblies.
5. Connect slack adjuster (3) to actuator (9) by 3. Install calliper head assembly and adjust slack
inserting clevis pin (7) through clevis (7, Fig. 2) on adjuster as described in 'Installation'.
actuator (9). Secure clevis pin (7) with cotter pin (8).
4 SM 2428 01-06
Section 170-0010
SPECIAL TOOLS
dealer.

TORQUE
1 4 Bolt 680 501.5
1 6 Nut 680 501.5
1 16 Bolt 680 501.5
1 17 Bolt 70 52
* * * *
SM 2428 01-06 5
SUSPENSION SYSTEM - Front Suspension
Section 180-0020
SM - 3484
16
17
15
9
11
7 8 8,9,10,11
7
14 12,13,14,15
19 16,17,28
26 13
10
3 18
25 12 19
24 28 26
1
21,22
2 18
25
23
24
5,6 24
30
25 27
5,6 24
23 29
4
30
5,6 20
30
25 20
23
5,6
1 - Bracket LHS 9 - Rebound Mount (Rubber) 17 - Washer 25 - Hardened Washer

2 - Bracket RHS 10 - Chain 18 - Bolt 26 - Washer
3 - Plate 11 - Adjusting Screw 19 - Bolt 27 - Bolt
4 - Bolt 12 - Pin 20 - Nut 28 - Spacer
5 - Control Link 13 - Pin 21 - Panhard Rod 29 - Bolt
6 - Bushing 14 - Suspension Bush 22 - Bush 30 - Hardened Washer
7 - Shock Absorber 15 - Washer 23 - Bolt
8 - Front Suspension Mount 16 - Nut 24 - Locknut
Fig. 1 - Exploded View of Front Suspension
DESCRIPTION plate of brackets (1 & 2) which have internal chain (13)

Numbers in parentheses refer to Fig. 1. assemblies to provide extra retention on rebound.
Additional damping is provided by four heavy duty
The front axle assembly is mounted off the suspension double acting shock absorbers (7) (two off each side)
bracket (1 & 2) assemblies, which in turn are linked to to smooth out the ride.
the chassis frame through a system of shock Panhard rod (21), provides the traverse link between
absorbing / rubber mount assemblies through the the left and right had sides of the suspension
vertical axis. assembly, whilst control links (5) provide the means of
Suspension is provided by two heavy duty rubber retaining longitudinal control over the length of the
suspension mounts (8 & 9) mounted on the central tractor frame, between suspension and front frame
pivot.
SM 2391 05-06 1
Suspension System - Front Suspension
Section 180-0020
REMOVAL 13. Remove bolts (23), washer (25) and nuts (24) securing
control links (5) to chassis frame brackets. Both LHS and
RHS of frame.
WARNING 14. Using suitable lifting equipment and jacks, lower axle
To prevent personal injury and property / suspension assembly sufficiently to allow disassembly
damage, be sure wheel blocks, blocking of the remaining components.
secured and of adequate capacity to do the job 15. Ensure jacks are central under the suspension
safely. frame brackets (1 & 2). Lower jacks until rubber
mounts are free of compression.
body is fully lowered, apply the parking brake and 16. Position a suitable trolley under suspension frame,
switch off the engine. Turn steering wheel several carefully lower suspension and axle onto the trolley
times to relieve any pressure in the steering system. and remove from under the vehicle.
2. Block rear road wheels, place the steering lock bar

in the 'Locked' position and place the battery master Disassembly
switch in the 'Off' position. Numbers in parentheses refer to Fig. 1.
3. Whilst the front road wheels are still on the ground,

loosen the wheel nuts. WARNING
4. Using suitable lifting equipment, raise the machine damage, be sure lifting equipment is properly
until both front tyres are off the ground. Support the secured and of adequate capacity to do the job
vehicle with suitable stands and blocking at the tractor safely.
frame and articulation pivot area.
5. Support one tyre and rim assembly with suitable 1. Support panhard rod (21) prior to removal.
lifting equipment and remove wheel nuts securing the
rim to the axle. Remove tyre and rim assembly. 2. Remove bolts (4), washers (25) and nuts (24)
securing panhard rod (21) between LHS and RHS
6. Repeat step 5 for the opposite tyre and rim brackets (1 & 2).
assembly.
3. Remove Panhard rod (21) from assembly.
7. Remove sump guards from chassis frame if
necessary. Refer to Section 100-0010 CHASSIS. 4. Remove front suspension mounts (8) from brackets
(1 & 2).
8. Prior to axle removal, support axle using suitable
fixture. 5. Remove pin (13) securing Chains (10) to adjusting
screws (11).
9. Disconnect hydraulic brake line at tee on front axle
assembly. Disconnect differential breather line. Cap 6. Remove pin (12) securing chains (10) to brackets (1
lines and fittings to prevent ingress of dirt. & 2).
10. Support driveline and remove bolts securing 7. Remove adjusting screws (11), chains (10) and
driveline to front axle. Refer to Section 130-0010, bushes (14)
FRONT DRIVELINES.
8. Remove remaining bolts (18), washers (25) and nuts
11. Remove bolts (19) and washers (26) securing (24) securing control links (5) to LHS and RHS
shock absorbers (7) to front frame mounting point. brackets.
12. Remove nut (16) and washer (17), securing rebound 9. Remove control links
mounts (9) to the chassis frame. remove rebound mounts
(9) and washers (15).
2 SM 2391 05-06
Section 180-0020
ASSEMBLY 3. Using two jacks centrally positioned under the axle,

draw axle up to chassis frame to set initial ride height.
4. Nuts (16) should be torqued to pre-compress mounts (8
& 9).
Note: Do not torque against chain (10).
SPECIFICATIONS.
5. Lock off nuts (16) on the end of adjusting screw (11) and
set pre-compressed length of rebound mount (9) to the
WARNING
value shown in Fig. 2.
Note: Pre-compressed length shown in Fig 2. is for the
axle with no tyre supported. Should the tyres be fitted, the
safely.
pre-compressed length should be set at 203mm.
1. Ensure axle is positioned on suitable trolley / jig to allow SM - 3593
sub-assembly of the suspension, prior to installation to
the unit.
155 mm
2. Fit LH and RH bracket (1 & 2) in position to axle at

respective points. Secure in place using bolts (27),
washers (30) and nuts (20).
3. Install spacer (28) and bush (14) to each bracket fitted

to the axle.
4. Secure chains (10) to boss on axle through spacer,

using 2-off pins (12) with loctite 638. Install adjusting
screws (11) to chains (10) using pins (13) with loctite 638.
Install front suspension mounts (8) over chains (10) and
adjusting screw (11) onto axle.
Fig. 2 - Rubber Length
INSTALLATION
Numbers in parentheses refer to Fig. 1. 6. Torque nut (16) to a value of 250 Nm (183 Ibf ft).
7. Install panhard rod (21) between axle brackets on

WARNING LHS and frame bracket on RHS.
damage, be sure lifting equipment is properly 8. Secure at axle bracket using 2-off bolts (4), washers
secured and of adequate capacity to do the job (25) and nuts (24). Torque bolts to a value of 570 Nm
safely. (420 Ibf ft).
9. Secure at rear frame bracket using 2-off bolts (23),

Note: LH and RH assembly of suspension are largely the washers (25) and nuts (24). Torque bolts to a value of
same, where applicable, carry out same procedure steps 570 Nm (420 Ibf ft).
for both sides of suspension.
10. Install bottom control links (5) to frame bracket and
1. Using suitable lifting equipment, lower chassis frame axle bracket using 4-off bolts (23), washers (25) and
over axle and onto suitable stands. nuts (24)on both sides. Torque bolts to 570 Nm (420
Ibf ft).
2. Pull adjusting screw (11) through front frame bracket
and fit rebound mount (9). Fit washers (15 & 17) over 11. Install top control links (25) and connect to upper
adjusting screw (11) and on to top of rebound mount (9) frame brackets using 2-off bolts (23), washers (25) and
and fit 2-off nut (16) to adjusting screw (11) threaded end. nuts (24) on both sides. Torque bolts to 570 Nm (420
Ibf ft).
SM 2391 05-06 3
Section 180-0020
23. Remove wheel blocks from rear road wheels and

12. Connect to top of axle brackets using 2-off bolts place the steering lock bar in the 'Stowed' position.
(18), washers (25) and nuts (24) on both sides. Torque
bolts to 570 Nm (420 Ibf ft). 24. Bleed all air from hydraulic brake lines. Refer to
Section 165-0010, BRAKE PARTS.
13. Release jack pressure to allow axle to drop to set
height.
ADJUSTMENTS
14. Place 2-off shock absorbers (7) upside down in a Numbers in parentheses refer to Fig. 1.
suitable jig or fixture.
15. Remove nut, washer and 1-off rubber bush from the WARNING
bottom of each shock absorber. To prevent personal injury and property
16. Fit mounting plate (3) over shock absorber. Re-fit secured and of adequate capacity to do the job
nut, washer and rubber bush to each shock absorber. safely.
17. Secure plate (3) (and shock absorbers) to axle 1. Position the vehicle in a level work area, ensure the
bracket using 4-off bolts (19) and washers (26). Torque body is fully lowered, apply the parking brake and
bolts (19) to a value of 169 Nm (125 Ibf ft). switch off the engine. Turn steering wheel several
times to relieve any pressure in the steering system.
18. Remove nut, washer and 1-off rubber bush from top
end of each shock absorber. 2. Following instructions at 'Removal' adjust inner nuts
(16) to give desired compression of rubber mounts (9).
19. Attach shock absorber to front frame mounting
point. Re-fit nut, washer and rubber bush to each shock 3. Apply Loctite Activator 'T' and Loctite 638 to threads
absorber. above inner nuts (16). Tighten down outer nuts (16)
against inner nuts (16), making sure that inner nuts (16)
20. Using suitable lifting equipment, position one tyre do not move.
and rim assembly on a front wheel and secure with
wheel nuts. Tighten locknuts to a torque of 730 Nm 4. Complete installation of front suspension. Refer to
(540 lbf ft). 'Installation'.
21. Using suitable lifting equipment, position opposite

tyre and rim assembly on the opposite front wheel and SPECIAL TOOLS
secure with wheel nuts. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of hydraulic jack, power press, press tool and
22. Using suitable lifting equipment, raise tractor frame general service tools and sealants required. These
sufficiently to remove stands and blocking from the tools and sealants are available from your dealer.
tractor frame and articulation pivot. Lower vehicle to the
ground and remove lifting equipment. Tighten all wheel
nuts to a torque of 730 Nm (540 lbf ft).
4 SM 2391 05-06
Section 180-0020

TORQUE
1 4 Bolt 570 420
1 18 Bolt 570 420
1 23 Bolt 570 420
1 16 Nut 250 183
1 19 Nut 169 125
- - Wheel Nut 730 540
* * * *
SM 2391 05-06 5
SUSPENSION SYSTEM - Rear Suspension
Section 180-0040
SM - 3521
12 15 12 14
11 'A' 30 DETAIL 'C'

12 5,6 19 'D'
'C'
34
'A'
24,23
'C' 4
26 17
7 5,6
13 29 30
21 20 11
22 4 19
25 30 16 8 'A' 12
30 19
27 DETAIL 'D' 19 19
7
3 'A'
8
29 'A' 9 18
33 2 16
16 32 10
18 'A'
19 7
19 33 5,6 'B'
33 'E'
31 33 8
1 5,6
32
33 31 32
9 'B' 'A'
'A' 33
10 7 'E'
29
'A' 33 9
39 5,6 32 'A'
33 10
1
5,6 16
35
29 19
37 8
51 38
39
DETAIL 'B' 36
3 FORWARD
9
'A' 10
35
37
14 39
12 40
28 36
38
DETAIL 'A' TYPICAL 39
DETAIL 'E' FRAME MTG.
1 - Bracket assembly 9 - Hardened Washer 17 - Washer 25 - Cover Plate 33 - Retainer

2 - Bracket assembly 10 - Locknut 18 - Bolt 26 - Bolt 34 - Bracket Assembly
3 - Bracket assembly 11 - Bolt 19 - Lockwasher 27 - Lube fitting 35 - Pin
4 - Equalizer Beam 12 - Hardened Washer 20 - Wear Ring 28 - Bolt 36 - Lockwasher
5 - Control Link 13 - V-Ring Seal 21 - Bushing 29 - Bolt 37 - Bolt
6 - Bushing 14 - Locknut 22 - Retaining Plate 30 - Locknut 38 - Washer
7 - Interleaf Mount 15 - Bolt 23 - Washer 31 - Panhard Rod 39 - V-Ring Seal
8 - Bolt 16 - Bolt 24 - Bolt 32 - Spherical Bearing 40 - Spacer
Fig. 1 - Exploded View of Rear Suspension
DESCRIPTION
Loads acting on the centre and rear axles are balanced by
Numbers in parentheses refer to Fig. 1 unless centrally pivoting equalizer beams (4) with rubber cushioning
otherwise stated. interleaf mounts (7) between axles and beam ends.
Interleaf mounts (7) are rubber/steel laminated
Each axle is coupled to the chassis by three rubber compression units with chain link ties.
bushed leading or trailing control links (5) which provide
longitudinal restraint. Lateral restraint is by transverse Lubrication of spherical bearings (32) in panhard rods
panhard rods (31). (31) is through remote mounted lube fittings (43, Fig. 2)
SM 2392 01-06 1
Suspension System - Rear Suspension
Section 180-0040
1 SM - 3520
47
BRACKET RH
48 41
43
41 49
42
44
41 31 42 45,46
1
47
42 50
31
51
BRACKET LH
47 TRAILER CHASSIS
LH FRAME RAIL
41 - Elbow 44 - Manifold Plate 48 - Hose Assembly

42 - Elbow 45 - Bolt 49 - Hose Assembly
43 - Nipple 46 - Washer 50 - Hose Assembly
47 - P-Clip 51 - Hose Assembly
Fig. 2 - Rear Suspension - Lubrication Lines
secured to manifold plate (43). Lubrication of bushings 4. Using suitable blocking equipment, block equalizer
(21) in equalizer beams (4) is through lube fittings (27). beams to prevent movement when raising the trailer
frame.
REMOVAL 5. Whilst the rear road wheels are still on the ground,
Numbers in parentheses refer to Fig. 1 unless loosen the wheel nuts.
otherwise stated.
6. Using suitable lifting equipment, raise the machine
until the rear wheels are off the ground. Support the
vehicle with suitable stands and blocking at the trailer
WARNING frame, articulation pivot area and centre and rear axle
To prevent personal injury and property assemblies.
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly 7. Support one tyre and rim assembly with suitable
secured and of adequate capacity to do the job lifting equipment and remove wheel nuts securing the
safely. rim to the axle. Remove tyre and rim assembly.
1. Position the vehicle in a level work area, raise the 8. Repeat step 7 for the remaining rear tyre and rim
body and install body safety prop to secure body in assemblies.
partially raised position
9. Disconnect hydraulic brake lines from tee at both the
2. Apply the parking brake and switch off the engine. centre axle and rear axle assemblies. Cap lines and
Turn steering wheel several times to relieve any fittings to prevent ingress of dirt.
pressure in the steering system.
10. Remove blocking equipment from equalizer beams
3. Block front road wheels, place the steering lock bar (4).
in the 'Locked' position and the battery master switch in
the 'Off' position. 11. Disconnect grease lines (48,49,50 & 51 Fig. 2) from
elbows (41 & 42, Fig. 2), on both panhard rods (31).
2 SM 2392 01-06
Section 180-0040
Cap lines and fittings. If necessary remove elbows (41 Remove mounting bracket (2).
& 42 , Fig. 2) from panhard rods (31).
26. Remove locknuts (10), hardened washers (9) and
12. If necessary, remove p-clips (47) and manifold bolts (8) securing mounting bracket (3) on the centre
bracket (44) from the chassis frame. Refer to Fig. 2. axle. Remove mounting bracket (3).
13. Remove locknuts (30), lockwashers (19) and 27. Remove locknuts (10), hardened washers (9) and
bolts (29) securing interleaf mounts (7) to equalizer bolts (8 & 18) securing mounting bracket (1) on the
beams (4). centre axle. Remove mounting bracket (1).
14. Remove bolts (16) and lockwashers (19) securing 28. Remove bolts (11) and hardened washers (12)
interleaf mounts (7) to brackets (1 & 3) mounted on the securing mounting bracket (34) on the centre axle.
centre and rear axles. Remove interleaf mounts (7).
INSTALLATION
15. Remove bolts (26) and washers (17) securing cover Numbers in parentheses refer to Fig. 1.
(25) to equalizer beam (4). Remove cover (25).
16. Remove bolts (24) and washers (23) securing WARNING

retaining plate (22) to shaft on frame. Remove retaining To prevent personal injury and property
plate (22). damage, be sure blocking materials and lifting
17. Using suitable lifting equipment, support equalizer adequate capacity to do the job safely.
beam (4) and withdraw from shaft on frame. If
required remove bushing (21) from equalizer beam (4). 1. Install bracket (2) on rear axle with holes on control
link (5) mounting lugs to the rear. Apply Loctite 243 to
18. Remove wear ring (20) and 'V' ring seal (13) from bolts (11) and secure bracket (2) to rear axle with bolts
shaft on frame. (11) and hardened washers (12). Tighten bolts (11) to a
19. Repeat steps 13 through 16 to remove the opposite
equalizer beam (4). 2. Install RH bracket (1) on rear axle with control link
(5) mounting brackets to underside and bracket
20. Remove locknuts (14), hardened washers (12) and extension to the front. Secure bracket (1) to rear axle
bolts (15 & 28) securing control links (5) between the with bolts (8 & 18), hardened washers (9) and locknuts
rear and centre axle brackets (1, 2 , 3 & 34) and frame (10). Install bolts from the top with hardened washers
mounting brackets. Remove control links (5). and locknuts at the bottom. Tighten bolts
(8 & 18) to a torque of 790 Nm (583 lbf ft).
21. Refer to detail 'B' & 'E'. Remove bolts (37),
lockwashers (36) and washers (38) securing pins (35) 3. Install LH bracket (3) on rear axle with control link (5)
through mounting brackets (1) on both centre axle/ LH mounting brackets to underside and pointing inwards
frame mounting bracket and the rear axle / RH frame towards the rear. Secure bracket (3) to rear axle with
mounting brackets. bolts (8), hardened washers (9) and locknuts (10).
Install bolts from the top with hardened washers and
22. Remove both panhard rods (31), v-ring seals (39) locknuts at the bottom. Tighten bolts (8) to a torque of
and spacers (51). If necessary remove retainers (33) 790 Nm (583 lbf ft).
and spherical bearings (32) from panhard rods (21).
4. Install interleaf mountings (7) on the rear axle. Apply
23. Remove locknuts (10), hardened washers (9) and Loctite 243 to bolts (16) and secure interleaf mounts (7)
bolts (8) securing mounting bracket (3) on the rear axle. on the rear axle with bolts (16) and lockwashers (19).
Remove mounting bracket (3). Tighten bolts (16) to a torque of 169 Nm (125 lbf ft).
24. Remove locknuts (10), hardened washers (9) and 5. Install bracket (2) on centre axle with holes on
bolts (8 & 18) securing mounting bracket (1) on the rear control link (5) mounting lugs to the front. Apply Loctite
axle. Remove mounting bracket (1). 243 to bolts (11) and secure bracket (2) to centre axle
with bolts (11) and hardened washers (12). Tighten
25. Remove bolts (11) and hardened washers (12) bolts (11) to a torque of 457 Nm (337 lbf ft).
securing mounting bracket (2) on the rear axle.
SM 2392 01-06 3
Section 180-0040
6. Install LH bracket (1) on centre axle with control link Locate spacers (51), v-ring seals (39) and panhard rod
(5) mounting brackets to underside and bracket (31) ends in place. Insert pins (35) into bores and
extension to the rear. Secure bracket (1) to centre axle secure pins (35) in place with washers (38),
with bolts (8 & 18), hardened washers (9) and locknuts lockwashers (36) and bolts (37).
(10). Install bolts from the top with hardened washers
and locknuts at the bottom. Tighten bolts (8 & 18) to a Note: Ensure that there is at least 2/3 mounting
torque of 790 Nm (583 lbf ft). surface area contact. Check contact area using a
0.05 mm (0.002 in) feeler gauge.
7. Install RH bracket (3) on centre axle with control link
(5) mounting brackets to underside and pointing 13. Using a suitable solvent, clean equalizer beam (4)
inwards towards the rear. Secure bracket (3) to centre shaft on the frame. Install new 'V' ring seal (13) and
axle with bolts (8), hardened washers (9) and locknuts new wear rings (20) on the shaft with flanges to the
(10). Install bolts from the top with hardened washers inside. Ensure mounting holes on the ends of the shaft
and locknuts at the bottom. Tighten bolts (8) to a are clean.
14. Using a suitable solvent, clean the bores of
8. Install interleaf mountings (7) on the centre axle. equalizer beams (4). Install new bushings (21) in
Apply Loctite 243 to bolts (16) and secure interleaf equalizer beams (4) aligning holes in bushings with
mounts (7) on the centre axle with bolts (16) and holes in equalizer beams.
lockwashers (19). Tighten bolts (16) to a torque of 169
Nm (125 lbf ft). 15. Using suitable lifting equipment, install equalizer
beam (4) on frame shaft. Apply Loctite 243 to bolts (24)
9. Install control links (5) between rear and centre axle and secure equalizer beam (4) to shaft with bolts (24),
mounting brackets (1 & 3) and frame mounting washers (23) and retaining plate (22). Tighten bolts (24)
brackets and secure with bolts (28), hardened washers to a torque of 169 Nm (125 lbf ft).
(12) and locknuts (14). Install bolts (28) with bolt heads
to the brackets. Tighten bolts (28) to a torque of 531 16. Apply Loctite 243 to bolts (26). Install cover plate
Nm (392 lbf ft). (25) to equalizer beam (4) and secure with bolts (26)
and washers (17). Tighten bolts (26) to a torque of
Note: Ensure that there is at least 2/3 mounting 73 Nm (54 lbf ft).
surface area contact. Check contact area using a
0.05 mm (0.002 in) feeler gauge. 17. Apply Loctite 243 to lube fitting (27) and install in
cover plate (25). Lubricate with grease specified in
10. Install control links (5) between rear and centre axle Section 300-0020, LUBRICATION SYSTEM, until
mounting brackets (2) and frame mounting brackets excess lube is seen.
and secure with bolts (15), hardened washers (12) and
locknuts (14). Tighten bolts (15) to a torque of 531 Nm 18. Repeat steps 15 through 17 to install opposite
(392 lbf ft). equalizer beam (4).
Note: Ensure that there is at least 2/3 mounting 19. Connect interleaf mounts (7) to equalizer beams (4)
surface area contact. Check contact area using a with bolts (29), lockwashers (19) and locknuts (30).
0.05 mm (0.002 in) feeler gauge. Tighten bolts (29) to a torque of 169 Nm (125 lbf ft).
11. Install panhard rod (31) between mounting bracket 20. Remove caps and connect hydraulic brake lines to
(1) on centre axle and LH frame mounting bracket. tees on centre axle and rear axle assemblies.
Locate spacers (51), v-ring seals (39) and panhard rod
(31) ends in place. Insert pins (35) into bores and 21. Using suitable blocking equipment, block equalizer
secure pins (35) in place with washers (38), beams (4) to prevent movement when installing rear
lockwashers (36) and bolts (37). wheels.
Note: Ensure that there is at least 2/3 mounting 22. Secure manifold bracket (43, Fig. 2) to chassis
surface area contact. Check contact area using a frame.
0.05 mm (0.002 in) feeler gauge.
23. Route grease lines (48,49,50 & 51, Fig. 2); securing
12. Install panhard rod (31) between mounting bracket to frame using p-clips (47, Fig. 2). Connect grease
(1) on rear axle and RH frame mounting bracket. lines to their respective elbows (41 & 42, Fig. 2).
4 SM 2392 01-06
Section 180-0040
24. Secure grease fittings (43, Fig. 2) to manifold 27. Remove wheel blocks from front road wheels and
bracket (44, Fig. 2). place the steering lock bar in the 'Stowed' position.
24. Using suitable lifting equipment, position one tyre 28. Bleed all air from hydraulic brake lines. Refer to
and rim assembly on one rear wheel and secure with Section 165-0010, BRAKE PARTS.
wheel nuts.
25. Repeat step 24 for remaining rear wheels. MAINTENANCE

26. Using suitable lifting equipment, raise trailer frame otherwise stated.
sufficiently to remove stands and blocking from the
axles, articulation pivot and trailer frame. Lower vehicle Every 250 Hours: Lubricate equalizer beam bushings
to the ground and remove lifting equipment. Tighten all (21) through lube fittings (43, Fig. 2) with grease
wheel nuts to torque specified in Section 160-0050, specified in Section 300-0020, LUBRICATION
WHEEL RIM AND TYRE. SYSTEM, until excess lube is seen.

TORQUE
1 8 & 18 Bolt 790 583
1 11 Bolt 457 337
1 15 & 28 Bolt 531 392
1 16, 24 & 29 Bolt 169 125
1 26 Bolt 73 54
* * * *
SM 2392 01-06 5
Electrical System - Circuit Diagrams
Section 190-0000
COMPONENT DESIGNATIONS
A4 - 12V Radio/Cassette L8 - Body Raise / Lower S57 - Steering Pressure Switch
A5 - Radio/Cassette Speaker joystick S60 - Difflock Request Switch
L9 - Transmission Shift Lever S68 - Engine Diagnostic
B7 - Coolant Level Sensor L10 - Transmission Retarder Lever request switch
B8 - Fuel Level Sender S69 - Accel idle validation Switch
B13 - Rotational Speed Sensor M1 - Starter Motor S79 - Heated Mirror Switch
B19 - Throttle Position Sensor M4 - Washer Motor, Front S80 - Engine brake 'med' &'high'
B21 - Trans Oil Temp Sender M5 - Wiper Motor, Front stages
B32 - Trans Oil Retarder Temp M6 - Wiper Motor, Back S82 - Engine brake 'low' stage
Sender M7 - Washer Motor, Back
S93 -OCDB High Press Switch
B37 - Brake Axle Oil Temp M13 - Air Seat Compressor
S100 - Dropbox low ratio select Sw
Sensor
B38 - Trans Oil Level Sender N3 - 24V/12V Voltage Converter S101 - Dropbox Primary High Temp.
N4 - Speedo Frequency Divider S102 - Dropbox High Range
E3 - Interior Light N7 - PWM/Analogue Indicator Sw
E5 - Reverse Light convertor module S103 - Dropbox Low Range
E11 - Side Marker Light, Left Indicator Sw
E12 - Taillight, Left R10 - Rkr Switch 'Locating' LED S104 - Dropbox Low Oil Press Sw
E13 - Side Marker Light, Right R11 - Rkr Switch 'Function' LED S105 - Hood raise / Lower Sw
E14 - Taillight, Right R12 - 12V Work Socket S106 - Brake pedal Position Sw
E15 - High/Low Beam H'lamp, Left S108 - Dropbox Secondary High
R13 - 24V Work Socket
E16 - High/Low Beam H'lamp, Right Temp. Switch
E19 - Rear Fog Lamp
E21 - Rotating Beacon S1 - Battery Master Switch Y4 - Emergency/ Park Brake
E23 - Work Light S2 - Starter Keyswitch Solenoid
E26 - High Beam H'lamp, Left S7 - Emerg/Park Brake Switch Y7 - Difflock Solenoid (mid axle)
E27 - High Beam H'lamp, Right S9 - Washer Switch, Front Y14 - Retarder Solenoid
E35 - Heated Mirror S10 - Wiper Switch, Front Y26 - Body Raise Solenoid
S11 - Rear Wash/Wipe Switch Y27 - Body Lower Solenoid
G1 - Generator/Alternator S13 - Horn Button Y32 - Trans Radiator Fan
G2 - Battery S14 - Hazard w/l Switch Proportional Solenoid
S15 - Direction Ind Switch Y33 - System Hydraulics Unloader
H6 - Direction Indicator; F, L S18 - Lights Switch Valve
H7 - Direction Indicator; B, L S19 - Dipswitch Y34 - System Hyd Float Valve
H8 - Direction Indicator; F, R S20 - Headlamp Flash Switch Y36 - Trans Oil Cooler Fan
H9 - Direction Indicator; B, R S22 - Body Proximity Switch Isolation Solenoid
H10 - Brake Light, Left S29 - Trans Retarder Request Sw Y37 - OCDB Triple Pump Motor
H11 - Brake Light, Right S31 - Park Brake w/l Switch Solenoid
H29 - Work Socket Illumination S37 - Axle difflock position Switch Y39 - Engine Radiator Fan
S38 - Hydraulic Filter restrict Press Isolation Solenoid
K5 - A/C Comp Clutch/Relay Sw Y40 - Engine Radiator Fan
K21 - Trans Shift / Actuator Clutch S41 - Auxilliary Lights Switch Proportional Solenoid
S48 - Accumulator Press Sw Y41 - Low Range Select Solenoid
L3 - Reverse / Back Alarm (Tractor) Y42 - High Range Select Solenoid
L4 - Warning Buzzer S49 - Accumulator Press Sw Y43 - Difflock Solenoid (Dropbox)
L5 - Electric Horn (Trailer) Y44 - Hood Raise/Lower Actuator
L7 - Reverse Camera Monitor S56 - Air Cleaner restrict Press Sw
Wire Colours
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 B - Black O - Orange
L - LEFT, R - RIGHT, F - FRONT, B - BACK N - Brown Y - Yellow
U - Blue P - Purple
DIODE RESISTOR FUSE PLUG R - Red W - White
G - Green S - Slate
TRAILER CONNECTION L - Light Green K - Pink
SM 2439 Rev1 04-07 1

Section 190-0000
A Harness interface - Dash Harness and Main Chassis Harness (48 way connector)
B Harness interface - Dash Harness and Main Chassis Harrness (102 way connector)
C Harness interface - Main Chassis Harness and Engine Harness (21 way socket housing on main chassis
section)
D Harness interface - Main Chassis Harness and Engine Harness (21 way pin housing on main chassis section)
E Harness interface - Main Chassis Harness and Transmission Interface Harness
F Harness interface - Main Chassis Harness and Dropbox Harness
G Harness interface - Main Chassis Harness and Hydraulic Valve Harness
H Harness interface - Main Chassis Harness and Rear Frame Harness
Harness Auxilliary Components Connection
All stated dash Harness splices are located in the controls area underneath the passenger seat
FUSES
Location Fuse No. Circuit Current Rating
1 Ignition Wipers 20A
2 Keyswitch 15A
3 Hazards 7.5A
4 Rear Wash/Wipe 10A
5 Horn Relay Coil, Front Wash/Wipe 10A
Main Fuse Box - 6 Air Seat Compressor 10A
Column A 7 Lights Switch 10A
8 Main Beam/Flash 10A
9 Wiper Park Front and Rear 7.5A
10 Transmission Battery Supply 15A
11 Transmission System Ignition Supply 10A
12 Reverse Alarm/Light 7.5A
13 Hydraulic Electronic Controls 30A
14 Interior Light 5A
15 Direction Indicators/Rocker Switch Search LEDs 5A
16 Emergency/Park Brake 3A
Main Fuse Box - 17 Instrument Panel Ignition Supply 7.5A
Column B 18 Heated Mirrors 15A
19 Ignition Sensed Relay Coils 3A
20 +24V Auxiliary Work Socket 15A
21 Neutral Start 3A
22 Washers, Front 3A
23 Washers, Rear 3A
24 Horn 10A
25 Ignition Auxiliary Supplies 30A
26 Air Conditioning/Heater/Ventilation System 15A
27 Reverse Camera 10A
28 Front Working Lights 15A
Main Fuse Box - 29 Rear Working Lights 15A
Column C 30 Rotating Beacon 5A
31 Engine Ignition Supply 10A
32 Engine Battery Supply 30A
33 Body Proximity Switch Supply 10A
34 Dropbox/Difflocks Control System 15A
35 Brake Pedal Switch 5A
36 24V/12V Voltage Converter Battery Supply 20A
As FL Hood Raise / Lower Actuator 10A
Lettered FM Instrument Panel / CPU Battery Supply 15A
FK Auxiliary 12V Supply (12V Work Socket & Radio) 20A
2 SM 2439 Rev1 04-07
Section 190-0000
FUSES
Location Fuse No. Circuit Current Rating
Battery Box 61 Alternator System 100A
62 Vehicle System 100A
RELAYS
Location Letter Relay Circuit
Designation
B K66 Overspeed Relay
Main Fuse Box C K48 Range Inhibit Relay
Column D D K25 Service Brake Status Relay
Main Fuse Box E K23 Ignition Air Con / Heater Relay

Column E F K23 Ignition Wipers Relay
G K34 Horn Relay
H K15 Headlamp Relay
Main Fuse Box I K17 Reverse alarm / Light Relay

Column F J K14 Neutral Start Relay
K K65 Dropbox ratio Select Relay
L K63 Retarder Warning Light
Main Fuse Box M K50 Brake Lights Relay

Column G N K23 Ignition Engine ECU Relay
O K27 Mid-Axle Diff-lock Relay
P K4 Indicator Flasher Unit Relay
Main Fuse Box Q K32 Engine Brake Relay

Column H R K52 Body Proximity Switch Relay
S K64 Dropbox Diff-lock Relay
T K23 Ignition radio/cassette Relay
SM - 3600
Column A B C D E F G H
12 24 36
FD FH FM A E I M Q
FC FG FL B F J N R
FB FF FK C G K O S
FA FE FJ D H L P T
1 13 25
Fig. 1 - Main Fuse Box - Fuse/Relay Location
SM 2439 Rev1 04-07 3

SM 2439 Rev1 04-07 4
E D C B A
R/B TACHOMETER R/B
F C
23 A
N/Y NO CHARGE
SIGNAL (NOT USED) N/Y INDICATOR R or N R or N
43 B
33 A
A D
R/B
(NOT USED)
R or N R or N
60 B
15318776
N/Y
F62
1
1
B O R F32
O F31
F61
R F10
O
S1
R F'M'
F'L'
G2
G2
B B O
N/K N/K
POST
HOOD MOTOR
BATTERY -VE
BOX
O
2
2
24VDC
R F36
JUNCTION
B 169
B 109
R F20
F28
W TO K63 U/Y U/Y

FRONT WORK
TRANS TCU
TRANS TCU
LIGHTS
W
F34
B TO DDEC ECM
B TO DDEC ECM
B TO DDEC ECM
B TO DDEC ECM
W/B DROPBOX/
R K23 RADIO/CASSETTE
B MAIN CHASSIS HARNESS SPLICE
DIFFLOCK CONTROLS
F25
B HYDRAULICS CONTROLS ECU

W
B TO INSTRUMENT CLUSTER/CPU
87
30
W TO K32 W W/G W/G

3
3
85
86
W/L F19
F13
R HYD ELEC W/L K23

B MAIN DASH HARNESS SPLICE B IGNITION WIPERS
CONTROLS
B MAIN DASH HARNESS SPLICE B
48 B 49 B
W
R/O K52
F33
AUX SUPPLIES
B TO DASH HARNESS
K23 IGN AIR/CON
R/O S22 SPLICE

B
N
P P
W
B
F27
B MAIN CHASSIS HARNESS SPLICE B HORN

N/W
C D
R REVERSE
F24
CAMERA (OPT)
4
4
R/U R/U
K1
W
F18
INTERIOR LIGHT
24 VOLT BUS BAR
G/S HEATED
F14
MIRRORS (OPT)
A
W/R W/R W/R

10 B
F D
W
F26
R/P K50
W/R
G/P AIR/CON W/G W/G

87
30
PARK FNT/WIPER
F35
F9
PARK REAR/WIPER
85
86
5
5
W/R
TRACTOR STANDARD EQUIPMENT

U/W
W/L K23 IGNITION
MAIN FLASH
AIR/CON/AUX SUPPLIES
K14
W/Y
F19
R/U R/U
W
F21
MAIN BEAM
F8
141
G/S HEATED MIRRORS
U/R U/R
MAIN LIGHTS SWT
F18
F7
6
6
S2
B DASH HARNESS SPLICE

R INSTRUMENT PANEL/CPU
R R
TO TRANS TCU
F17
AIR SEAT
W
F6
W/R
P/W S7
W/U W/U
0 R 1 2
HAZARD LIGHTS SWT
F16
F3
7
7
0,R,1,2
W/G S14
30
75
W/L K23 N/W N/W
RADIO/CASSETTE
F15
W
F2
R/B K17
87
30
15
W/G TO F4 W/G W/G
R/B K17 W
F12
W/G TO F5
F1
W
85
8
8
R 163 TRANS TCU

K23
86 WIPERS
50
IGNITION
R L9
F11
PAGE 1
E D C B A
SM - 3594A
Section 190-0000
SM - 3594B
1 2 3 4 5 6 7 8
24 VOLT BUSBAR TO K23 24 VOLT BUSBAR
F5 W F16 W F12
WIPERS
F15
P
U/R
W/U
R/U
A
A
W/G
F3 F8 F24 F7
W/G
SM 2439 Rev1 04-07

S9/S10/S13 2 1 1
S15/S19/S20 B W/G
R DASH HARNESS
R10 IGN SPLICE
F9 S18
R MAIN DASH
HARNESS SPLICE
U/R
R/N
0 P
LH
B/W
B/G
U B R 10
FL/AL (53a)
R
L R 15 H
1 2
1 R
HORN
1 1
0
W/G
3 8 6 9
G/P
G/N
10
6 5 7 U/R
2 S14 R
1 J 0
1
WIPE 0 R MAIN DASH
WASHER 8 2 1 3
HARNESS SPLICE
B
B
ON TURN
OFF TURN
ON TURN
SIGNAl LEFT
OFF TURN
49a 56a 56b 56 15/1 31b 53b 53 J 53c
SIGNAL LEFT
SIGNAL RIGHT
SIGNAL RIGHT
B DASH
HARNESS SPLICE
R L9
B/W
W
Y
W/B
R
N/B
B/S
B/P
B/R
P/Y
G
3 6 5 8 4 4 2 3 7 6 5
W/G
U/W
G
U/N P/G INSTRUMENT PANEL
CONN D CAV 23
U/W INSTRUMENT U/W
G
PANEL CONN D CAV 15 G/P
G/N
49a K4 49 K15 86 30
DIODE BLOCK
W/G
LG/G
G/U
G/B
MOUNTED TO
B DASH
HARNESS SPLICE
6 5 DASH HARNESS
C
C
85 87 87a
R/U
R AIRCON/HEATER/VENTILLATION
CONTROL PANEL
31 R/N S41
U
B
R
U/N
U/W
M5
G
K34 86 30
G
2 23 B 16 B
G/P
G/N
R/N
F22 SPLICES
B
3 85 87 LOCATED IN
W/G
P
SPLICE
W/G M6 LOCATED IN MAIN CHASSIS 25 B 24 B 22 B
HARNESS
U/N
D
D
17 B MAIN CHASSIS
G/S
HARNESS
G/P
G/N
R/N
P
13 B
R/N
G/S
L5
G/P
W/G
W/O
W/S
K/O
R/N
R/N
4 K47 3 M4 3 5 4H 4H 5 3
J 53 2H 2H
P
G/P E16 E27 E26 E15
U/N
U/W
U/W
U/N
G/N
R/N
R/N
L5
H8 E13 E11 H6
31 86 31b 15 R L
G/B
E
E
6 5 1 2 R H P H N H
B
B
B
B
B
B
B
B
B
B
B
B
B
1
1 1
B MAIN CHASSIS
HARNESS SPLICE
B MAIN DASH HARNESS SPLICE
15318776 TRACTOR STANDARD EQUIPMENT PAGE 2
1 2 3 4 5 6 7 8
Section 190-0000
5
SM 2439 Rev1 04-07 6
E D C B A
M13
B
A
14
B B R R R R
15318776
F6
1
1
13
B R/U R/U R/U

E3
P/W INSTRUMENT PANEL CONN D CAV 9

F14
P/W INSTRUMENT PANEL CONN D CAV 18

K50

2
2
85
TRAILER
86
F35
CONNECTION
R/U R/U R/U R/P

27 B
F H
87
30
R/P
K25
W F19
P/W
P/W TO HYDRAULIC
CONTROLLER ECU PIN 27
B MAIN DASH HARNESS SPLICE R/P
85
24 VOLT BUS BAR
86
W 103 TRANS TCU CAV 3 N 162 TRANS TCU CAV 62

S106
87
30
3
3
B MAIN CHASSIS G/B G/B

5
14 B
HARNESS SPLICE
7
G/B
G/U
M7
F23
4
W/G
1
G/U
S11
1
W/G
W/G
G/U G/U
3
2
M6
4
4
W/S B MAIN DASH HARNESS SPLICE

G/U
1
1
R
9
R TO MAIN DASH HARNESS SPLICE W/G
2
3
W/S
10
0
1
R
F4
F1
F5
87
30
W/G M5 W/G TO W/G W/G W/G

HORN, F/WASH/WIPE
85
86
W/L K23 IGN AIRCON/

B DASH HARNESS SPLICE AUXILLARY SUPPLIES
5
5

W/L K23 IGNITION
K23
ENGINE
WIPERS
IGNITION
R12
B MAIN CHASSIS R R R G2
9 B
HARNESS SPLICE
R DASH HARNESS SPLICE
F36
H29
6
6
R13
B MAIN CHASSIS R R R G2
20 B
HARNESS SPLICE
F20
H29
1
B/K B/K
7 B
Y44
F'L'
2
B/R B/R
7
7
8 B
N/K N/K
S105
F28
S41
15
B U/Y U/Y U/Y U/Y U/Y U/Y
U/Y
1
1
R
E23
8
8
R MAIN DASH HARNESS SPLICE

24 VOLT BUSBAR
B U/Y U/Y
0
1
R
HARNESS
U/Y SPLICE
LOCATED IN CAB
E23
PAGE 3
E D C B A
SM - 3594C
Section 190-0000
7 SM 2439 Rev1 04-07
E D C B A
15318776
1
1
S38
2
1
B MAIN CHASSIS P/K P/K INSTRUMENT PANEL CONN D CAV 26

29 B
HARNESS SPLICE
2
2
S56
2
1
B MAIN CHASSIS S/K S/K INSTRUMENT PANEL CONN D CAV 3

32 B
HARNESS SPLICE
3
3
B/S B/S INSTRUMENT PANEL CONN E CAV 24

34 B
B8
S93
2
1
4
4
B MAIN CHASSIS P/N P/N INSTRUMENT PANEL CONN D CAV 34

37 B
HARNESS SPLICE
5
5

K23
RADIO/
IGNITION
CASSETTE
B MAIN DASH HARNESS SPLICE W/L S2
A4
85
86
R G2 R W/G AIR/CON UNIT R/Y
26 B
87
30
6
6
R
B MAIN DASH
HARNESS SPLICE
4
O O
7
7
S S
S
7
Y Y
8
N N
N
A5
A5
L.H
R.H
8
8
PAGE 4
E D C B A
Section 190-0000 SM - 3594D
8
SM - 3594E
1 2 3 4 5 6 7 8
A
A
Section 190-0000
W K23 AIRCON/
AUXILLARY SUPPLIES
11 B
AIR CONDITIONING/HEATER/VENTILLATION UNIT
B
G/O (NOT USED)
F26
B
B
BLOWER BINARY SW
N/U
7 GROUND T'STAT
P/G
8 INPUT M N/S G/O
G/O
P/K 6
10 + W/G
B 4
3 G C
WATER VALVE ACTUATOR G/P G/P
1
G/O HYD CONTROLS ECU CAV '18'
G/O
U/B
O
C
C
RESISTOR
Y
1 K5
EVAPORATOR UNIT
2
10 kOHM POT
B
TEMPERATURE CONTROL
M C C
L H
B C B C
N/U
D
D
7 GROUND 3 SP A/C ON/OFF

P/G
8 INPUT BLOWER SWT SWT
P/K
B MAIN DASH
HARNESS SPLICE
W/G K23 RADIO/CASSETTE
10 + FRESH/RECIRC DEFROST MODE

SWITCH SWITCH
B MAIN CHASSIS
HARNESS SPLICE
FRESH/RECIRC ACTUATOR
B C B C
N/U
7 GROUND
P/G
8 INPUT
P/K
10 + DASH MOUNTED CONTROL PANEL
R S14
E
E
2
1
DEFROST ACTUATOR
15318776 HEATING/VENTILATION/AIR CONDITIONING SYSTEM PAGE 5

1 2 3 4 5 6 7 8
SM 2439 Rev1 04-07

SM - 3594F
1 2 3 4 5 6 7 8
W K23 IGN AIRCON/
AUXILLARY SUPPLIES
30 86 K66 U SPLICE
LOCATED
IN ENGINE
85
HARNESS R SPLICE R SPLICE
87
LOCATED LOCATED
A
A
B/R Y/B SPLICE IN ENGINE IN ENGINE

DDEC 5 HARNESS
SM 2439 Rev1 04-07

ECM B/R B/R B/R
LOCATED HARNESS
IN ENGINE
N/W N/W N/W HARNESS
T C U C
18 A 19 A
50
53
10
31
38
57
58
59
61
62
63
64
65
66
67
68
K 15
G/B 1
B/Y 2
Y/L
Y/R 11
U/Y 13
R/W 16
G/W 24
S
U/W 39
O/B 40
U/R 43
U/Y 44
U/W 51
G/S 56
G
U
U
Y/B 60
R
R
B
B
R
R
B
B
B
B
K C J C K D L C MC E C S D H C L D MD T D R C A C N D H D S C P C
R
R
B DD D E DG D
G/Y
G/B
B/Y
Y/L
Y/R
U/Y
R/W
G/W
U/W
O/B
U/R
U/Y
U/W
G/S
G
U
B C B G2 D C
B G2
B G2
B G2
U
36 A 35 A 45 A 37 A 38 A 27 A 31 A 34 A 46 A 47 A 20 A 41 A 32 A 48 A 43 A 42 A 40 A
R
R
K
B7
Y/B
A
Y/L
G/W
25 A 24 A
W K23 IGN AIRCON/

AUXILLARY SUPPLIES
30 86 K32 5
C
C
B J D N D
R
R
S68 R
K
1
87a 85 0
K23 1 U
Y/B
IGN F32
W/L K23 IGN

WIPERS
30 86 ENGINE U CAN_L DASH SPLICE
U/W
U/W
G/S
G
U
44 A 39 A
U/R CAN_H DASH SPLICE
U
Y/R
U/Y
R/W
R
87 85
P D
U/W
Y/B
O
U/Y CAN_SHIELD DASH SPLICE
26 A
TRANS TCU
U
F31
S TACHO PULSE (NOT USED)
104
D
D
O
O/B INST PANEL CONN D CAV 17
29 A
R F62
28 A
S
U/Y CAN_SHIELD DASH HARNESS SPLICE
U CAN_L DASH HARNESS SPLICE
G/B INSTRUMENT PANEL CONN D CAV 30

B/Y INSTRUMENT PANEL CONN D CAV 4
U/R CAN_H DASH HARNESS SPLICE
B DASH
HARNESS SPLICE
O F62
TRANS TCU
TRANS TCU
U/W
U/W
157
N
R D
W/B 158
K/S
10
1 1 2
8 6 2 R
10
U
D B 1
R 0
E
E
1 5 6
E 9 0 R MAIN DASH HARNESS SPLICE
A B C D E F G H J
C B19 A S69 3
30 A S80 B MAIN DASH HARNESS SPLICE ENGINE/TRANS/INSTRUMENT S82
U
PANEL DIAGNOSTIC
Y/B
PROGRAMMING CONNECTOR
G/U CPU CONN C CAV 13
U/G INST PANEL CONN F CAV 4
15318776 DETROIT DIESEL SERIES 60 ENGINE ELECTRONIC CONTROLS PAGE 6

1 2 3 4 5 6 7 8
Section 190-0000
9
SM 2439 Rev1 04-07 10
E D C B A
W
W 103 K25 W 103 3

R
S 104 K32
103
4
110
B/S 105 K64 5

PCS5
15318776
&K
SPLICE
0 115
1
1
INTEGRAL TO
IN DASH
LOCATED
HARNESS
Y 107 7
TRANSMISSION
SPLICE LOCATED
SPLICES LOCATED
IN DASH HARNESS
112
PCS1
B G2 B 109 9
90 B
F10
R F62 R R 110 10
92 B
1
0 111 0 111 0 111 11

82 B
16
K 112 K 112 K 112 K 112 12

5 E
B38
2 E 89 B
W 115
B
W 115 W 115 W 115

2
2
15
15
A Y14
U 116 U 116 U 116 16

8 E 32 E
73 B 86 B
C3PS
RESISTOR
19
TERMINATION
LOOP WIRE FOR
U 120 U 120 U 120

Y
20
K63
B MAIN DASH
36 E 1
INTEGRAL TCU 120ohm
NOT USED P/R 121 P/R 121 21

70 B 93 B
HARNESS SPLICE
131
W K23 IGN AIRCON/

2
AUXILLARY SUPPLIES W 103 NOT USED

94 B
Y/W INSTRUMENT PANEL Y/W 124 24

CONN D CAV 25
R/W 125 SPEEDOMETER OUTPUT (NOT USED) 25
W 103
3
3
RESISTOR
Y 128 28
B
A
25 OHM,3 WATT
B/N 129 INSTRUMENT PANEL CONN D CAV 31 29

W/U 130 K27
SPEED
30
B13
TURBINE
15
Y 131 Y 131 Y 131 31

10 E
74 B
B
A
TCC
Y 131
SPLICE
SPEED
ENGINE
B13
LOCATED
HARNESS
IN TRANS
INTERFACE
Y 133 Y 133 Y 133 33

3 E
76 B
B
A
W 134 34
PCS4
4
4
SPEED
B13
OUTPUT
4
O 136 O 136 O 136 36

9
W 137 W 137 W 137 37

12 E 14 E
78 B 72 B
PCS2
O 139 O 139 O 139 39

K48
G 140 G 140 G 140 40

37 E 29 E
66 B 68 B
B MAIN DASH Y K52

HARNESS SPLICE W/Y 141 K14 41
86
85
W 103 N/Y 142 42
ALLISON WTEC4 TCU
87
30
O/B 143 S60
5
43
5
SS1
U/R 148 CAN_H DASH SPLICE 48
ALLISON WTEC4 ELECTRONIC CONTROLS

U/Y 149 CAN_SHIELD DASH SPLICE 49
PCS3
10
W 151 W 151 W 151 51

5
Y 171
G 152 G 152 G 152 52
4 E 17 E
75 B 77 B
INTEGRAL TO
K 112
B21
TRANSMISSION
SPLICE LOCATED
18
N 154 N 154 N 154 54
A
2
W 155 W 155 W 155 55

B B32
26 E 20 E
85 B 81 B
6
6
56 Y 156
K/S 157 S82 57
S29
1
5
W/B G 158 W/B 158 W/B 158 58 W/S 158
19
N 159 N 159 59
B
C
Y 160 Y 160
0
1
R
60
22 E 33 E 34 E
88 B 67 B 69 B
W/B
W/S 161 61
Y
G
W
158
W/B 158 S82 N 162 K25 62
G 158
K17
R 163 F11
HARNESS
63
RETARDER
SPLICE LOCATED
R/B F12
HARNESS
7
7
O/B 164 INSTRUMENT PANEL CONN D CAV 5
IN MAIN DASH
64 RESISITOR
86
85
IN TRANS INTERFACE
SPLICE LOCATED
& B 169
MODULE
R/B E5,L3 R/B F12 U/G 163 65
87
30
U 168 CAN_L DASH SPLICE 68
R/B REVERSE
P CAV 4
R CAV 8
Y CAV 7
G CAV 6
U CAV 2
O CAV 3
W CAV 1
CAMERA OPTION B 169 G2 B 169 69
91 B
R 170 70
6
L10
Y 171 Y 171 Y 171 71
8
U 174 U 174 U 174 74
RED CAV 3 S18
R CAV 13
O 175 O 175 O 175 75
U/Y CAV 14 CAN_SHIELD SPLICE
20
U CAV 15 CAN_L DASH SPLICE Y 176 Y 176 Y 176
TRANS ID 76
8
8
U/R CAV 8 CAN_H DASH SPLICE
L9
G 177 G 177 G 177 77
B CAV 5
W 134 CAV 11 O 180 O 180 O 180 80
19 E 7 E 21 E 30 E 31 E 35 E
79 B 80 B 87 B 84 B 83 B 71 B
R CAV 12 F11
PAGE 7
E D C B A
SM - 3594G
Section 190-0000
11 SM 2439 Rev1 04-07
E D C B A
W/B
K64
87
30
R/L R/L R/L P/B

A F
F34
41 B
5
1
W K23 IGN AIR/CON

15318776
W/B
2
1
B
85
86
B/S 105 TRANS ECU PIN 5 AUX SUPPLIES

1
1
P/B
R
Y43
10
R TO MAIN DASH HARNESS SPLICE

9 1 0
1 1
R R
B DASH
HARNESS
O/B 143 TRANS ECU PIN 43 SPLICE
S60
K27
87
30
B/G B/G B/G

42 B
2
2
2
1
85
86
B G2 W/U 130 TRANS ECU PIN 30

Y7
B MAIN CHASSIS
HARNESS SPLICE
3 W/B
3
B B MAIN CHASSIS
B F
HARNESS SPLICE
K/B HYDRAULIC CONTROLS ECU PIN 20
6
2
8
K/B
9
B
2
1
B
1
1
R
10
R S14
0
1
R
B DASH HARNESS
Y42
SPLICE
4
4
S100
B SPLICE LOCATED
IN DROPBOX HARNESS
K/Y K/Y K/Y
L F
51 B
K/B K/B K/B HYDRAULIC CONTROLS ECU PIN 52

MF
52 B
2
1
5
5
DROPBOX/DIFFLOCKS CONTROLS
87
30
P/W S7 P/W Y4
Y41
85
86
B DASH HARNESS SPLICE P/W HYDRAULIC CONTROLS ECU PIN 50

K65
S102
B K/O K/O K/O INSTRUMENT PANEL CONN D CAV 16
F F
45 B
1
2
6
6
S103
B K/G K/G K/G INSTRUMENT PANEL CONN D CAV 13
H F
46 B
1
2
S101
B K/U K/U K/U INSTRUMENT PANEL CONN D CAV 6
J F
47 B
7
7
2
1
B
K/U
S108
S104
K/N K/N K/N INSTRUMENT PANEL CONN D CAV 12
K F
50 B
2
1
2
1
B
8
8
3
2
B K/L K/L K/L INSTRUMENT PANEL CONN K CAV 4
P F
56 B
B13
PAGE 8
DRIVE
SPEEDO
E D C B A
Section 190-0000 SM - 3594H
SM 2439 Rev1 04-07 12
E D C B A
B P/W P/W P/W INSTRUMENT PANEL CONN D CAV 32
30 B
M G
B G2 B 1
16 A
S31
15318776
N/Y N/Y 4
14 A
1
1
2
1
B MAIN CHASSIS
HARNESS SPLICE R F13 R 5
Y39
S48
N 6
ECU
SPLICES
IN DASH
HARNESS
LOCATED
B P/R P/R P/R INSTRUMENT

31 B
W 7
PANEL CONN D
1
CAV 33
HYDRAULIC CONTROLS
PORT
S49
B/U 8
9
5
ECU DIAGNOSTIC/
PROGRAMMING RS232
HYDRAULIC CONTROLS
2
2
B B/Y B/Y B/Y INSTRUMENT B 12

32 B
P G
PANEL CONN D
B37
CAV 22
B/U B 15
1A
Y/R Y/R K/O INSTRUMENT

33 B
R G
S57
PANEL CONN D
CAV 14
R R B/W TO Y45 16
2 A
B
G/O AIR CON/HEATING/VENTILATION SYSTEM 18
1
R
3
3
3
2
P/W K65 P/W F16 B

S7
B(U) 19
2
1
B P/W P/W P/W K65

12 B
S G
Y K48 K/B S100 20

Y4
+24VDC(R)
PWM IN (B)
GND(U)
Y INSTRUMENT
PANEL CONN D
87
30
R/O F33 CAV 21

R 23
4
4
R 24
N7
85
86
B MAIN CHASSIS P/G S22

HARNESS SPLICE
K52
U CAN_L DASH SPLICE 25

GND(U)
+5VDC(B)
U/R CAN_H DASH SPLICE 26

B B MAIN CHASSIS HARNESS SPLICE P/W K25 27
B B MAIN CHASSIS HARNESS SPLICE 29
D GB G
U/P U/P U/P 31
5 A
F G
5
5
2
1
ELECTRONIC/HYDRAULICS CONTROLS
B S 33
R 34
Y33
U/B 35
2
1
K INSTRUMENT PANEL CONN 'D' CAV '2' 42
Y/S Y/S 43
13 A
Y36
B MAIN CHASSIS
1 2
HARNESS SPLICE
6
6
B/S B/S B/S 44

3 A
A G
2
1
B U/S U/S U/S 45
6 A
H G
Y26
2
1
Y
B
N/G
R/W
B/W
B SPLICES LOCATED IN MAIN VALVE HARNESS

Y27
3 2 1 2 1
B
R
R
Y
B
G
7
7
U/G U/G U/G 46

4 A
C G
2
1
L8
B K/W K/W K/W 47

7 A
J G
2
1
Y40
2
1
B MAIN CHASSIS U/R 48
11 A
Y32
HARNESS SPLICE
B
Y37
B/O B/O B/O B/O 49
8 A
K G
50
8
8
S78
2
1
B B/W TO Y46 51
1
5
R B/O
K/B Y41 52
P/W K65
Y34
PAGE 9
K/U S101 55
0
1
R
E D C B A
SM - 3594I
Section 190-0000
SM - 3594J
1 2 3 4 5 6 7 8
G/U DIAGNOSTIC/PROGRAMMING CONNECTOR CAV H
B INSTRUMENT PANEL CONN E CAV 33 R INSTRUMENT PANEL CONN E CAV 35
B INSTRUMENT PANEL CONN E CAV 34 R INSTRUMENT PANEL CONN E CAV 36
B INSTRUMENT PANEL CONN K CAV 33 R INSTRUMENT PANEL CONN K CAV 35
B INSTRUMENT PANEL CONN K CAV 34 R INSTRUMENT PANEL CONN K CAV 36
B INSTRUMENT PANEL CONN F CAV 9 R INSTRUMENT PANEL CONN F CAV 12
A
A
G/S INSTRUMENT PANEL CONN B CAV 5
SM 2439 Rev1 04-07

G/K INSTRUMENT PANEL CONN B CAV 2
B B G2
B
28
R R F17
N R R F62
B
F'M' 62
B SPLICE
LOCATED IN R SPLICE
DASH LOCATED IN
HARNESS DASH
HARNESS
G/N INSTRUMENT PANEL CONN E CAV 8
O/N S37 (DIFFLOCK POSISTION ICON)

P/W K50 (BRAKE LIGHTS APPLY ENGINE BRAKE ACTIVE)
K/N S104 (DROPBOX OIL PRESSURE ICON)
P/N S93 (OCDB HIGH OIL PRESSURE ICON)
P/R S48 (TRACTOR BRAKE PRESSURE ICON)
B DASH HARNESS INSTRUMENT PANEL/CPU SPLICE
R DASH HARNESS INSTRUMENT PANEL/CPU SPLICE
B/S B8 (FUEL LEVEL GAUGE)
Y/R S57 (STEERING/MAIN PRESSURE ICON)
G/P INSTRUMENT PANEL CONN E CAV 15

G/N INSTRUMENT PANEL CONN K CAV 17
G/B INSTRUMENT PANEL CONN E CAV 9
G/Y INSTRUMENT PANEL CONN K CAV 15

G/P INSTRUMENT PANEL CONN B CAV 6
U CAN_L DASH SPLICE
B
B
U/R CAN_H DASH SPLICE
1 10 19 28
2 11 20 29
3 12 21 30
4 13 22 31
C
C
5 14 23 32
6 15 24 33
7 16 25 34
8 17 26 35
9 18 27 36
K/U HYDRAULIC CONTROLS ECU CAV 55

G INSTRUMENT PANEL CONN E CAV 27 1 10 19 28
G/R
2 11 20 29
S/K S56 (AIR CLEANER RESTRICTION ICON) 3 12 21 30

G/B DDEC ECM (ENGINE CHECK ICON)
Y K52 (BODY UP ICON)
B/Y DDEC ECM (ENGINE STOP ICON) B/N 129 TRANS TCU (CHECK TRANS ICON)
4 13 22 31
B/Y S49 (TAILER BRAKE PRESSURE ICON)
O/B 164 TRANS TCU (TRANS SUMP TEMPERATURE ICON) 5 14 23 32
P/W S31 (PARK BRAKE ICON)
U/W S19 (MAIN BEAM ICON)
K/U S101 (DROPBOX OIL TEMPERATURE ICON) 6 15 24 33 10 11 12
Y/W K51 (RETARDER ENABLE ICON)
7 16 25 34 7 8 9
K/O S102 (DROPBOX HIGH RATIO ICON)
8 17 26 35 4 5 6
O/B DDEC ECM (ENGINE BRAKE ACTIVE ICON)
D
D
12 9 6 3
9 18 27 36 1 2 3
36 27 18 9
11 8 5 2
35 26 17 8
10 7 4 1
34 25 16 7
G/Y INSTRUMENT PANEL CONN E CAV 7
33 24 15 6
G/R INSTRUMENT PANEL CONN E CAV 26
32 23 14 5
31 22 13 4
K/L B13 (SPEEDOMETER PULSE)
30 21 12 3
29 20 11 2
28 19 10 1
G/L
E
E
L4
B MAIN CHASSIS
HARNESS SPLICE
K/G S103 (DROPBOX LOW RATIO ICON)
P/W K50 (BRAKE LIGHTS APPLY RETARDER ACTIVE ICON)
P/K S38 (HYDRAULIC FILTER RESTRICTION ICON)
P/W DIODE BLOACK (DIRECTION INDICATORS ICON)
G/0 INSTRUMENT PANEL CONN E CAV 18

G/K CPU CONN B CAV 2
G/W INSTRUMENT PANEL CONN E CAV 17
G/B INSTRUMENT PANEL CONN K CAV 18
G/W INSTRUMENT PANEL CONN B CAV 3
G/O INSTRUMENT PANEL CONN B CAV 4
G/R INSTRUMENT PANEL CONN K CAV 6
G INSTRUMENT PANEL CONN D CAV 1
U/G DIAGNOSTIC/PROGRAMMING CONN CAV J
G/S CPU CONN B CAV 5
15318776 INSTRUMENT PANEL/CPU SYSTEM PAGE 10

1 2 3 4 5 6 7 8
Section 190-0000
13
SM - 3594K
14
1 2 3 4 5 6 7 8
A
A
Section 190-0000
B
B
RESISTOR TERMINATION
INTERNAL TO ENGINE RESISTOR TERMINATION
HARNESS INTERNAL TO
TRANSMISSION TCU
U DIAGNOSTICS/PROGRAMMING CONNECTOR CAV D
U/R HYDRAULICS ELECTRONIC CONTROLLER CAV 26

U HYDRAULICS ELECTRONIC CONTROLLER CAV 25
U/R DIAGNOSTICS/PROGRAMMING CONNECTOR CAV C
U/Y DIAGNOSTICS/PROGRAMMING CONNECTOR CAV E
U/R DDEC ECM CAV 43 U/R 148 TRANSMISSION TCU CAV 48
U/Y DDEC ECM CAV 44 U/Y 142 TRANSMISSION TCU CAV 42
C
C
U DDEC ECM CAV 58 U 168 TRANSMISSION TCU CAV 68
U/R (CAN_H)
SPLICE LOCATED
IN DASH HARNESS U/R CPU CAV 13
U CPU CAV 14
U/Y (CAN_SHIELD)
SPLICE LOCATED
IN DASH HARNESS
U (CAN_L)
SPLICE LOCATED
IN DASH HARNESS
D
D
E
E
U TRANSMISSION SHIFT LEVER CAV 15
U/R TRANSMISSION SHIFT LEVER CAV 8

U/Y TRANSMISSION SHIFT LEVER CAV 14
15318776 J1939 CONTROL NETWORK PAGE 11

1 2 3 4 5 6 7 8
SM 2439 Rev1 04-07

SM - 3594L
1 2 3 4 5 6 7 8
A
A
SM 2439 Rev1 04-07

R/O F33
P/G K52
15 B 19 B
O/N INST PANEL CONN 'D' CAV '8'

R/B K17
36 B 18 B
B
B
R/O
P/G
O/N
R/B

TRAILER CONNECTION
MH B H D H P H N H F H R H J H H H K H
O/N
R/O
P/G
G/N
R/N
R/U
G/P
R/B
B
B
S37
A
2 A C
N
U
B
C
C
S22
B
B
R/B
B SPLICE
B
LOCATED IN
REAR FRAME G/P
HARNESS R/U
R/N
R/B SPLICE
D
D
R/N & R/U SPLICE 3 2 4 LOCATED IN

LOCATED IN REAR LIGHTS
REAR FRAME ACCESSORY 2 4 3
HARNESS HARNESS
G/N
R/N
P/U
R/B
R/B
B
R/N
P/U
G/N
E12 A E14
H7 H10 E5 L3 H11 H9
B
B
B B
B
B
E
3 3
E
B
B
B E19
1 1
B
B
15318776 TRAILER STANDARD EQUIPMENT PAGE 12

1 2 3 4 5 6 7 8
Section 190-0000
15
SM 2439 Rev1 04-07 16
E D C B A
B G/R
15318776
1
1
E35
B B B G/R G/R G/R

S79
TO F27
F18
E35
G/S W
5
G/R
1
1
R
B B B G/R G/R G/R

0
1
R
2
2
E35
B TO MAIN DASH HARNESS SPLICE

B G/R
HARNESS
G/R SPLICE
LOCATED IN
HEATED MIRROR
E35
B SPLICE
HARNESS
24 VOLT BUSBAR
LOCATED IN
S41
F29
3
3
HEATED MIRROR
15
5
1
B Y/U Y/U Y/U Y/U Y/U Y/U

Y/U
1
1
R
E23

0
1
R
B Y/U Y/U B TO MAIN DASH HARNESS SPLICE

HARNESS
Y/U SPLICE
LOCATED IN CAB
E23
4
4
S41
B
A
1
5
1
B R/Y R/Y R/Y R/Y R/N

21 B
L H
R/Y
E19
B
1
1
R
K15
B SPLICE
3
HARNESS
LOCATED IN
B REAR FRAME HARNESS SPLICE R TO MAIN DASH HARNESS SPLICE
REAR LIGHT
ACCESSORY
0
1
R
5
5
S41
F30
VEHICLE OPTIONAL EQUIPMENT

15
5
1
24 VOLT BUSBAR
B U/R U/R W/U W/U W/U

1
1
R
W/U
E21
0
1
R

R
6
6
F27
K17
W TO F18
L7
85
86

TV
R/B
87
30
B/W B/W B/W HYDRAULIC CONTROLS ECU CAV 16
10 A
A H
7
7
2
1
B REAR CHASSIS
HARNESS SPLICE
Y45
B/W B/W B/W HYDRAULIC CONTROLS ECU CAV 51
12 A
C H
2
1
B REAR CHASSIS
8
8
HARNESS SPLICE
Y46
PAGE 13
E D C B A
SM - 3594M
Section 190-0000
SM - 3594N
1 2 3 4 5 6 7 8
TRAILER
HARNESS
MAIN CHASSIS HARNESS CONNECTORS
A
A
DASH HARNESS CONNECTORS
SM 2439 Rev1 04-07

CONNECTORS 1
8 20 32 51 57 62 70 102
5
48 28 24 12 40 45 82 94
102 94 82 70 62 57 51 45 40 32 20 8 36 20 12 24 28 48 2
20 36 X J
H 1 2
W K
49
55
4 G B
55
49
G/N V F A C L
3
43
60
U M HYDRAULIC TAILGATE
60
43
MAIN LIGHTS T E D N
OPEN AND CLOSE
S R P
48
54
CLUSTER CONNECTORS SOLENOIDS
54
48
MIDAXLE DIFFLOCK (OPTIONAL)
POSITION SWITCH
1 9 21 33 41 46 52 58 63 71 83 95
95 83 71 63 58 52 46 41 33 21 9 1 CONNECTION.
P/G G/P 1 2 NO CAVITY FRONT FRAME HARNESS
DIRECTION
29 13 CONNECTION
CAB BULKHEAD 37 25 21 1 INDICATORS CAB BULKHEAD 13 29 IDENTIFICATION,
21 25 3
DIODE BLOCK CONNECTION 1 37 OPERATION NOT POLARITY
CONNECTOR
CONNECTION SENSITIVE
CAB BULKHEAD OCDB/PANIC STOP
CONNECTOR CAB BULKHEAD PRESSURE SWITCH
CONNECTION 1
CONNECTION
X J 2 5
H
W K
G B
20
V F A C L C B A
1
1 8 U M
A B C T E D N 3 4
9 14
S R P 4 1 BODY POSITION
21 40 1 REAR LIGHT CLUSTER/
PROXIMITY SWITCH
TRANSMISSION SHIFT TRANSMISSION RETARDER CONNECTION REAR ACCESSERIES
B
B
41 60 RESISTANCE MODULE CONNECTOR CONNECTION

LEVER CONNECTOR 22 16 2
61 80 1 2 ENGINE HARNESS/DROPBOX HARNESS/

HYDRAULIC VALVE HARNESS/TRAILER HOOD RAISE/LOWER
PWM/ANALOGUE 37 34
TRANSMISSION TCU CONNECTOR MODULE HARNESS CONNECTION ACTUATOR CONNECTION
CONNECTOR
1 5 TRANSMISSION HARNESS
6 9 4 CONNECTION
55 3
ELECTRONIC/HYDRAULIC ECU 2
DIAGNOSTIC/PROGRAMMING 2
37
19 36 1
1 1 2
1 18
CONNECTOR 1 2 3
PWM/ANALOGUE 3
TRANSMISSION
2
BODY CONTROL LEVER BODY CONTROL LEVER MODULE
ELECTRIC/HYDRAULIC ECU CONNECTOR ENGINE COOLER FAN 2 1
CONNECTOR CONNECTOR 4 1 HARNESS
CONNECTOR ISOLATION SOLENOID/
TRANSMISSION COOLER FAN
ISOLATION SOLENOID/OCDB MOTOR
AIR FILTER RESTRICTION OCDB TEMPERATURE SENSOR
SOLENOID/HYDRAULIC FILTER RESTRICTION CONNECTION
CONNECTORS
E D PRESSURE SWITCH
C PRESSURE SWITCH CONNECTION/MIDAXLE DIFFLOCK
B
K J H G F SOLENOID CONNECTION
F A
A B C D E 28 36
A B C
G
19 27
J
H ACCELERATOR PEDAL ACCELERATOR PEDAL 10 18
CONNECTOR CONNECTOR 1 9
ENGINE/TRANSMISSION/INSTRUMENT PANEL
DIAGNOSTIC/PROGRAMMING CONNECTOR
INSTRUMENT
CLUSTER (CONNECTION D)
CONNECTOR X J
9 1
ENGINE HARNESS W
H
K
C
C
G B
18 10 V F A C L
21 22
A B 1 4
U M
27 19
T E D N
36 28
CONNECTORS S R P
TRANSMISSION
16 22
RETARDER SOLENOID
CONNECTION 34 37
12 3 FRONT FRAME HARNESS
INSTRUMENT
13 14 CONNECTION
CLUSTER (CONNECTION K)
CONNECTOR 10 1 MAIN CHASSIS
28 36
1 10 11 15 HARNESS CONNECTION
61 64 X J
19 27 H
16 25 26 30 W K
10 18 G B
INSTRUMENT 65 68 V F A C L
12 3 CLUSTER (CONNECTION F) 31 40 41 45
1 9 U M 1 2
CONNECTOR T E D N A B
46 55 56 60 S R P
1 2
10 1
1 2 INSTRUMENT SYSTEM FLOAT/PARK BRAKE/ RETARDER TEMPERATURE 1 6
CLUSTER (CONNECTION E)
INSTRUMENT PANEL CONNECTOR
ENGINE ECU COLD START UNLOADER/
INSTRUMENT PANEL 3 1 SENSOR CONNECTION
CPU (CONNECTION C) INSTRUMENT CONNECTION FRAME HARNESS TRANSMISSION COOLER PROPORTIONAL/
CPU (CONNECTION A)
CONNECTOR CONNECTOR CLUSTER (CONNECTION B) CONNECTION ENGINE COOLER PROPORTIONAL/
CONNECTOR BODY RAISE PROPORTIONAL/
15 13
BODY LOWER PROPORTIONAL
SOLENOID CONNECTION 15 20
B A 6 5 4
A B 3 2 1 CAB MANUFACTURERS HARNESS
6 5 4 CONNECTOR 1 2 TRANSMISSION
1 2 A
1 COLUMN SWITCH B A VALVE BLOCK CONNECTION
3 4 3 2 B A
C CONNECTOR
5 6 CONNECTOR 'D' AIR/CON COMPRESSOR
HEATED MIRROR BRAKE PEDAL STARTER MOTOR
7 8 CONNECTOR
D
D
CONNECTOR CONNECTOR CONNECTION COOLANT LEVEL

9 10 HARNESS CONNECTION
SENSOR CONNECTION
2 1 1 2
6 2 1
5 7 8
DASH ROCKER 4 3 4 3
1 2 3 4 3
SWITCHES CONNECTOR 6 5 4 6 5 4 6 5 6 5
3 2 1 3 2 1 8 7 8 7 PARK BRAKE/STEERING
COLUMN SWITCH A B
AIR/CON INTERFACE FRONT WIPER MOTOR CONNECTOR TRACTOR/TRAILER
CONNECTOR CONNECTOR RADIO/CASSETTE/CD RADIO/CASSETTE/CD PRESSURE SWITCH
1 UNIT POWER UNIT SPEAKERS
CONNECTOR CONNECTION OUTPUT SPEED/TURBINE SPEED/
CONNECTOR
2 X J ENGINE SENSOR SENSOR
H 1
W K CONNECTION
G B
V F A C L
HEATER/AIRCON/VENTILLATION
PANEL ILLUMINATION U M 2 1
T E D N 1 2
CONNECTOR S R P
3 2
HIGH/LOW RANGE
SOLENOID HIGH/LOW RANGE INDICATOR
SPEEDSENSOR SWITCH/DIFFLOCK SOLENOID
HYDRAULIC
FRONT FRAME HARNESS CONNECTION CONNECTION
CONNECTION CONNECTION
VALVE
1 2
3
HARNESS
LOW DROPBOX PRESSURE
SWITCH/HIGH DROPBOX CONNECTORS
TEMPERATURE SWITCH
CONNECTION
DROPBOX
E
E
HARNESS CONNECTORS
15318776 ELECTRICAL CONNECTORS DETAIL PAGE 14

1 2 3 4 5 6 7 8
Section 190-0000
17
THIS PAGE IS INTENTIONALLY BLANK
ELECTRICAL SYSTEM - Hydraulic System ECU
Section 190-0085
SM - 3565
Fig. 1 - IFM Electronic Control Unit
SM - 3566
DESCRIPTION 3
The hydraulic electronic control unit (ECU) (Fig. 1) is a
stand alone control which controls the machines
hydraulic systems, including body hoist and oil cooler
fan drives. The IFM ECU communicates with a variety
of input and output devices. It utilises analog/digital
inputs, proportional current outputs and digital outputs. 2
The ECU continuously monitors the system and warns
the operator when a fault develops, and also helps
diagnose the nature of the fault. ECU is located inside
1
the cab, on mounting plate, inside the instructor seat
(next to the transmission TCM) (see Fig. 2). 1 - Hyd ECU 2 - Trans TCM 3 - Bolt
WARNING Fig. 2 - Hydraulic ECU Location

Before any welding is done on a machine ECU Inputs
equipped with an Integrated hydraulic system,
Refer to Fig. 3 and Section 190-0000, CIRCUIT
disconnect the following in this order:
DIAGRAMS.
Battery earth cable, battery supply cable,
alternator earth cables, alternator supply
cables and electrical connections at the engine Analog Inputs
ECM, transmission TCM, body control lever,
hydraulics ECU, Instrument panel (VDU) ECU, Body Control Lever (Pin 29 - The body control lever
and cab bulkhead to avoid damage to electrical sends an analog signal (0-5V) tothe ECU dependant
components. Turn off battery master switch to upon the position the lever has been pulled or pushed
isolate the batteries before disconnecting any into, indicating a raise or lower signal to the ECU.
components. After welding connect all of the
above in the reverse order. Brake Temperature (Pin 8) - temperaturesensor at the
front axle brake manifold sends analog signal to ECU
dependent on brake cooling oil temperature
.
SM 2443 Rev1 05-07 1
Electrical System - Hydraulic System ECU
Section 190-0085
SM - 3674
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Fig. 3 - Hydraulic ECU System Pin Order
Digital Inputs
Body Up Proximity Switch (Pin 19) - When the body switch the detente solenoid is de-energised disenabling
is raised from the chassis the proximity switch is the magnet allowing the lever to return to the neutral
closed circuit energising body up relay K52. From K52 position.
a signal is ent to the ECU indicating thebody is up.
With the body up upshifts are restricted within the Cold Start Unloader Solenoid (Pin 31) -When the
transmission, the body up warning lamp is illuminated ECU receives the signal of the engine starting on the
and the body control lever detente is energised for use. communication link, the ECU sends an output signal to
When the body makes the proxy switch (switch open energise the cold start solenoid for 5 seconds. This
circuit) K52 is de-energised removing the signal from prevents the engine starting under hydraulic load.
pin 19. The upshift inhibit is disabled, the lamp is off
and the detente is de-energised. The ability to power Transmission Cooling Fan Stop Solenoid (Pin 43) -
down the body is cancelled and the float solenoid is The ECU sends a signal energising the solenoid,
energised. blocking hydraulic flow to the transmission cooling fan.
When any of the following parameters are met the stop
Air condition Signal (Pin 18)- When the air solenoid is de-energised allowing hydraulic flow to the
conditioning has been selected, a signal is sent to the fan.
ECU to request the Engine Cooling Fan. ˇ Trans Oil Temp greater than or equal to 80°C (176° F)
Dropbox Temperature Switch (Pin 55) - When the ˇ Retarder Oil Temp greater than or equal to 90° C
dropbox temperature reaches 100°C (212°F) the (194° F)
dropbox temperature switch closes sending a signal to
the ECU to activate the transmission cooling fan. ˇ Dropbox Oil Temp greater than or equal to 100° C
(212° F)
Dropbox Low Ratio Request (Pin 20) - When dropbox
low ratio switch (S100) is selected a signal is sent to ˇ Brake Cooling Oil Temp greater than or equal to 59°
the ECU. C (138° F)
ECU Outputs Engine Cooling Fan Stop Solenoid (Pin 4) - The

ECU sends a signal energising the solenoid, blocking
Digital Outputs hydraulic flow to the engine cooling fan. When any of
the following parameters are met the stop solenoid is
Body Control Lever Detente (Splice from Pin 19) - de-energised allowing hydraulic flow to the fan.
When the body is off the chassis the body control lever ˇ Inlet Manifold Temp greater than or equal to 54°C
detente solenoid is energised. The solenoid acts as a (129° F)
magnet to hold the lever in the power down position to
save operator action. When the body makes the proxy
2 SM 2443 Rev1 05-07

Section 190-0085
SM - 3567
ANALOGUE_IN
Brake Temp PIN 08 0
PIN 27 1
PIN 09 2 DIG OUT
Analog Inputs PIN 28 3
PIN 10 4 PIN 43 Transmission cooling fan stop solenoid
Body Control Lever PIN 29 5
PIN 11 6
PIN 30 7 PIN 04 Engine cooling fan stop solenoid
DIG IN
Tipper prox [n/c] PIN 19 PIN 48 Brake cooling motor solenoid Digital Outputs
Starter Motor Signal PIN 55
Aircon full speed PIN 18
Dropbox Low Ratio PIN 20 PIN 49 Float solenoid
Digital Inputs PIN 39
PIN 03
PIN 40 PIN 31 Cold start unloader solenoid
PIN 22
PIN 41
PIN 42 PIN 50 Dropbox - Park Brake Enable
PIN 51
FREQ IN
PIN 20 PIN 52 Dropbox Low Ratio Solenoid
PIN 02
PIN 21
PIN 38 PIN 16
PIN 36
PWM/I OUT
PIN 44
Power Up
VBBo
Proportional Solenoid
GNDo
PIN 45
Power Down
VBBo
GNDo Current
PIN 46
Transmission Cooling Fan Drive Outputs
VBBo
GNDo
POWER PIN 47
Engine Cooling Fan
Central Processing Unit/Sensors PIN 01 0VDC VBBo
Central Processing Unit/Sensors PIN 23 + 24VDC GNDo
Ground Outputs GNDo PIN 15 0VDC PIN 35
Power In Supply Outputs VBBo PIN 05 +24VDC VBBr PWM / Analog Module
Ground Analogues GNDa PIN 12 0VDC GNDo
Supply Outputs via relay VBBr PIN 34 +24VDC PIN 54
VBBr
RS-232 GNDo
PIN 06 RXD PIN 17
PIN 07 TXD VBBr
Communication Port
PIN 33 GND GNDo
PIN 24 TEST PIN 53
VBBr
CAN 2.0B [11] PIN 14 CAN1H GNDo
CAN 2.0B [11] PIN 32 CAN1L
'CAN' Communication Port SAEJ1939 [29] PIN 26 CAN2H
SAEJ1939 [29] PIN 25 CAN2L
Fig. 4 - IFM ECU Pin Connections
ˇ Engine Oil Temp greater than or equal to 108° C (226° the body cylinders are vented to tank, allowing body to
F) lower onto chassis under it's own weight. It prevents
pressure being trapped in the hoist side of cylinders
ˇ Engine Coolant Temp greater than or equal to 89° C when travelling, ensuring body is resting on the
(192° F) chassis. If body is not resting on the chassis when
travelling, hinge points and cylinders may be damaged,
ˇ Air Conditioning ON especially when body is laden. If the ECU receives a
raise request from the body lever the float solenoid
Float Solenoid (Pin 49) - When the body makes the signal is cancelled allowing pressure to build in the
proxy switch the ECU outputs a signal to energise the raise circuit.
body float solenoid. This ensures that the hoist side of
SM 2443 Rev1 05-07 3

Section 190-0085
LED Colour Status Description

- Off No Operating Voltage
Orange 1 X on Initialisation or reset checks
5Hz No operating system Loaded
Green 0.5Hz Run,CANopen;PREOPERATIONAL
2Hz Run,CANopen;OPERATIONAL
Constant Stop,CANopen;PREPARED
Red 0.5Hz Run with error
(CANopen;PREOPERATIONAL)
2Hz Run with error
(CANopen;OPERATIONAL)
On Fatal error or stop with error
Blue 0.5Hz Internal communication, Extended
Controller
Fig. 5 - LED Indicator Showing Different Modes
Brake Cooling Motor Solenoid (Pin 48) - Whenever Typical output from ECU is 0 - 1000 mA, providing a
the ECU receives a signal indicating a temperature of delivery pressure between 6 - 24 bar (87 - 348 lbf/in2) at
50°C (122°F) a signal will be sent energising the brake main control valve spool.
cooling motor solenoid allowing flow to the brake
cooling triple pump motor. Engine Cooling Fan Proportional Solenoid (Pin 47)
- When certain trigger temperatures are reached (see
Dropbox Park Enable (Pin 50)- When the ECU engine cooling fan stop solenoid) the engine cooling
receives a dropbox low ratio request signal the ECU fan will be commanded ON. Depending upon the
will send a signal to momentarilly energise relay K65 temperature condition seen, will dictate the percentage
applying the park brake when the transmission output of mA current (0-275mA) sent to the engine cooling fan
speed equals zero allowing the selection of low ratio in proportional solenoid. This will cause the fan to rotate
the dropbox. at the desired fan speed.
Dropbox Low Ratio Solenoid (Pin 52) - When the Transmission Cooling Fan Proportional Solenoid-
ECU receives a dropbox low ratio request signal and When certain trigger temperatures are reached (see
the dropbox park enable has been energised the ECU transmission cooling fan stop solenoid) the
will send a signal to energise the dropbox low ratio transmission cooling fan will be commanded ON.
solenoid. Depending upon the temperature condition seen, will
dictate the percentage of mA current (0-275mA) sent to
PWM Outputs the transmission cooling fan proportional solenoid. This
will cause the fan to rotate at the desired fan speed.
Body Raise Proportional Solenoid (Pin 44) - When
ECU receives a raise signal from body control lever, PWM / AnalogModule - A PWM signal is sent to the
the ECU sends an output signal to the raise solenoid to PWM / Analog module(N7) which converts the signal to
shift the main control valve spool accordingly. Typical a 5V supply for the body control lever.
output from ECU is 0 - 1000 mA, providing a delivery
pressure between 6 - 24 bar (87 - 348 lbf/in2) at main
control valve spool.
System Safety
Input/Output Protection - all inputs to the ECU are
Body Lower Proportional Solenoid (Pin 45) - When designed to withstand the maximum specified supply
ECU receives a lower signal from body control lever, voltage. The outputs are protected against short
the ECU sends an output signal to the lower solenoid circuit. Additionally, an error on one input/output will
to shift the main control valve spool accordingly. not influence other inputs/outputs.
4 SM 2443 Rev1 05-07

Section 190-0085
ECU Power and Ground

The ECU has 3, 24V supply connections at pins 23, 5 High electrical current can cause sparks
and 34 respectively. It also has 3 corresponding and personal injury from burns. Turn battery
ground connections (0V) at pins 1, 15 and 12. master switch to the 'Off' position before
removing any components. Remove battery
All power and ground connections are required for the ground cable first, and reconnect last, to avoid
ECU to be fully operational. damaging electrical components.
Communication 1. Position the vehicle in a level work area, ensure the

The ECU is connected to the SAEJ1939 datalink at pin switch off the engine. Turn steering wheel several
26 (CAN_H) and pin 25 (CAN_L). This allows the ECU times to relieve any pressure in the steering circuit.
to communicate with the engine, transmission and
VDO panel controllers to receive signals such as 2. Operate the treadle valve continuously to discharge
engine RPM or transmission output speed. the accumulators, block all road wheels, place the
System Diagnosis battery master switch in the 'Off' position.
Refer to Fig. 5.
3. Disconnect the battery ground cable first, then the
A LED on the ECU is used to diagnose basic system battery supply cable, before disconnecting harness
errors. The ECU indicates error status through the LED from IFM ECU inside cab.
as shown in Fig. 5, giving an immediate diagnosis as
to the nature of the error that has occurred. 4. Remove bolts securing ECU to support inside the
passenger seat, and remove ECU.
If there are no errors, the LED flashes green, twice

INSTALLATION
every second to indicate the system is operational.
Any other colour designation indicates that there is a 1. Secure ECU to support below the right hand console
certain error condition, which should be investigated. using bolts removed previously.
2. Firstly connect harness to ECU, then connect

WARNING battery supply cable and battery ground cable in that
Do not use the machine if an error code is order.
present. Shutdown the machine until the
problem is resolved. 3. Turn master switch on, start engine and ensure that
the top LED runs through the correct operation
sequence. Finishing with the LED flashing green at the
Diagnosis can also be carried out via a laptop desired rate.
connected to the ECU using the RS232 connection
provided. Designated laptop software can be 4. Remove wheel blocks from all road wheels.
downloaded free of charge from the IFM website
http://ifm-electronic.com/ifmuk/web/eco_down.htm SPECIAL TOOLS

The programs required are 'ecoplus V2.1' and 'ifm There are no special tools required for procedures
downloader'. outlined in this section. To obtain IFM diagnostic
software, contact your dealer.
REMOVAL
WARNINGS
safely.
* * * *
SM 2443 Rev1 05-07 5
Electrical System - Switches and Sensors
Section 190-0270
SM - 3841
29
LINES HEADER TANK
SEC 250-0020 AIR CLEANER 9 SEC 210-0040
SEC 110-0050
STARTER
14 28 SOLENOID SW.
A2
PS1 10
A1
11 1 7
TREADLE
VALVE
SEC 250-0070
NOT USED
FUEL SENDER ON TANK 6

REF SEC 200-0010
21 PS3
22 25
4 DROPBOX VALVE
SEC. 125-0025
MAIN HYDRAULIC
PS4
20 24 VALVE
PS2 SEC 215-0050
23 5
29
27 18 16 15
BRAKE
COOLANT/HYD. TANK
SEC 250-0025 3
RHS RHS
13 2
RHS
DROPBOX
FILTER
17 SEC 125-0045
19 DROPBOX
SEC 125-0010
TRANSMISSION LHS -
SENSORS SHOWN S.W.E. TRANS. MANIFOLD BLOCK-
12 (FRONT AXLE)
ENGINE LHS - SENSORS SHOWN S.W.E. SEC. 210-0052
1 - Hydraulic Filter Restriction Gauge 12 - Dropbox Temp. Switch 23 - Oil Temp Sensor
2 - Brake Cooling Oil Pressure Switch 13 - Dropbox Filter Temp Switch 24 - Oil Pressure Sensor
3 - Brake Cooling Oil Temperature Switch 14 - Pressure Switch 25 - Coolant Temp Sensor (RHS)
4 - Parking Brake Pressure Switch 15 - Output Speed sensor 26 - Barometric Pressure Sensor
5 - Rear Brake Accumulator Pressure W/L 16 - Turbine Speen Sensor 27 - Timing Reference Sensor
6 - Front Brake Accumulator Pressure W/L 17 - Input Speed Sensor 28 - Hood Switch
7 - Coolant Level Sender 18 - Fuel Temp. Sensor 29 - Master Battery Diosconnect
8 - Starter Relay 19 - Fuel Pressure Sensor Switch
9 - Air Cleaner Restriction Gauge 20 - Synchronous Ref Sensor 30- Proximity Switch
10 - Main Hydraulic Pump Pressure Switch 21 - Air Temp Sensor 31- Fuel Sender
11 - Dropbox Pressure Switch 22 - Turbo Boost Pressure Sensor
Fig. 1 - Layout View of Switches and Sensors
DESCRIPTION Engine
Numbers in parentheses refer to Fig. 1, unless The DDEC engine management system monitors the
otherwise specified. engine at all times and sends a signal to the engine
check light (8, Fig. 2) and engine stop light (7, Fig. 2)
This section describes the location and function of on the dash panel to alert the operator of a fault in the
various switches and sensors fitted to the vehicle to engine circuit. Refer to Section 110-0030, ENGINE
monitor all major components and systems. Gauges AND MOUNTING.
and warning lights located in the dash panel, relay this
information to the operator. Engine Coolant Level Sender (7) - Located in the
radiator header tank, the sensor sends a signal to
Note: Always make sure all gauges, warning lights and engine ecm, indicating engine coolant level.
controls are working properly before operating the
vehicle. Engine Coolant Temperature Gauge (1, Fig. 2) -
Indicates the engine coolant temperature. The gauge
should read in the green zone after the engine has
warmed. If the gauge reads in the red zone, stop
engine and investigate the cause.
SM 2368 Rev2 07-07 1
Section 190-0270
SM - 3394
5 6 7 8 9 10
3 4 11 12
2 13
2 STOP P
1
20 30 15
40 10 20
30 50
20 mph 60
10 40 r / min x100
km/h 5 25
10 70
80
0 0000000 50 L H 0 30
0000
˚C 100 135˚C 165
70
40 120 60 200
150 210 275 320
105 ˚F 250 ˚F 390
140
1 16 17 15 14
1 - Engine Coolant Temperature Gauge 7 - Engine Stop W/L 13 - Tachometer

2 - Speedometer 8 - Engine Check W/L 14 - Transmission Oil Temperature Gauge
3 - Front Brake Accumulator Pressure W/L 9 - Parking Brake Ind/L 15 - Dimming Button
4 - Rear Brake Accumulator Pressure W/L 10 - Transmission Check W/L 16 - Tripmeter Reset Button
5 - Headlight Main Beam Ind/L 11 - Emergency Steering W/L 17 - Not Used.
6 - Direction Indicators Ind/L 12 - Differential Lock Ind/L 18 - Visual Display Unit (VDU)
Fig. 2 - Layout View of Instruments and Indicator/Warning Lights
Engine Specific Sensors (18-27 Fig. 1) - A number of Transmission

engine mounted sensors which monitor timing, coolant,
Transmission Specific Sensors (15-17, Fig. 1) -
fuel and oil temperatures and pressures. These send
Refer to Section 120-0010, TRANSMISSION AND
signals back to the engine ecm to allow it to determine
MOUNTING, for further information on switches and
how best to maintain outputs to keep the engine
sensors fitted to the transmission.
running at its optimum level. For specific details of
individual sensors, refer to engine manufacturer for
Oil Temperature Gauge (14, Fig. 2) - Indicates
detail.
transmission oil operating temp. Gauge should read in
the green zone during normal operation and may reach
Tachometer (13, Fig. 2) - Driven from the engine ECU,
the yellow zone when using the retarder or in convertor
the tachometer indicates the number of engine
mode. If the gauge reads above this in the red zone,
crankshaft revolutions per minute. The needle shows
stop engine and investigate the cause.
the variations in engine operating speed. Never
accelerate the engine to speeds indicated by the red
zone on the dial face. Dropbox System
Dropbox Pressure Switch (11) - Located on the
Hourmeter (8, Fig. 4) - Driven from the engine ECM,
dropbox control valve the switch signals low pressure
the hourmeter records the total number of engine
in the dropbox to the engine ECM.
hours.
Dropbox Temperature Switch (12) - Mounted on the
Starter Relay (8) - Mounted on the tractor frame rail,
difflock cover the twin temperature switch sends a
the starter relay powers up the starter motor when the
signal to the Engine ECM and the Transmission Cooler
keyswitch is turned.
that the difflock is overheating. This is caused by the
hose supplying the lubrication oil
2 SM 2368 Rev2 07-07
Section 190-0270
SM - 3408B Dropbox Filter Temperature Switch (13) - This twin

1 2 3 4 5 temperature switch measures the temperature of the oil
in the dropbox. If the temperature is too high then the
switch sends a signal to the engine ECM and to the
transmission cooler.
8
6 9
Braking System
7 10 Rear Brake Pressure Switch (5) - The normally closed
L H (NC) pressure switch 'PS2', located in port ACC2S of
the main hydraulic valve, senses the pressure in the
rear brake circuit. The pressure switch sends a signal
to illuminate 'Red' rear brake accumulator pressure
14 13 12 11 warning light (4, Fig. 2) when pressure drops to 122 bar
(1769 lbf/in2). An audible buzzer also sounds.
1 - Low Fuel
2 - Alternator Charging Front Brake Pressure Switch (6) - The normally
3 - Hydraulic Oil Filter Change closed (NC) pressure switch 'PS3', located in port
4 - Engine Air Filter Change
5 - Brake Cooling Oil Pressure ACC1S of the main hydraulic valve, senses the
6 - Body Up pressure in the front brake circuit. The pressure switch
7 - Brake Cooling Oil Temp. sends a signal to illuminate 'Red' front brake
8 - Trans. Oil Temp High accumulator pressure warning light (19, Fig. 2) when
9 - Trans. Dropbox Oil Temp. High
10 - Trans. Dropbox high/low Oil Press. pressure drops to 122 bar (1769 lbf/in2). An audible
11 - Trans. Dropbox, High ratio selected buzzer also sounds.
12 - Trans. Dropbox, Low ratio selected
13 - Engine Brake
Parking Brake Pressure Switch (4) - The normally
14 - Retarder
closed (NC) pressure switch 'PS4', located in port PBS
of the main hydraulic valve, senses pressure in the
Fig. 3 - Warning Symbol Screen
parking brake circuit. The pressure switch closes when
park brake pressure drops to 5 bar (70 lbf/in2) and
sends a signal to illuminate 'Green' parking brake
Fuel Level indicator light (9, Fig. 2), indicating that the parking
1 brake is applied.
0 25 50 75 100
Voltmeter Brake Cooling Oil Pressure Switch (2) - The normally
2 open (NO) pressure switch, located in the front axle
8 12 16 20 24 28 32
manifold block, senses the pressure in the brake
Brake Cooling
3 cooling oil circuit. The pressure switch sends a signal
50 75 100 125 150 to illuminate brake cooling oil pressure warning light (5,
Fig. 3) when pressure rises to 1.5 bar (22 lbf/in2).
00000
L H
Brake Cooling Oil Temperature Switch (3) - The
4 5 6 7 8 temperature switch, located in the front axle manifold
block, senses the temperature in the brake cooling
1 - Fuel Level
circuit. The temperature switch sends a signal to the
2 - System Voltage hydraulic ECU dependent on temperature.When a
3 - Brake Cooling temperature of 50°C (122°F) is reached the brake
4 - Retarder cooling pump is switched on. If the temperature
5 - Engine Brake
6 - Engine Hours Counter
continues to rise and reaches 60°C (140°F) the
7 - Trans. Dropbox, Low ratio selected transmission cooling fan will be switched on and the
8 - Trans. Dropbox, high ratio selected brake cooling temperature warning light (7, Fig. 3) will
illuminate.
Fig. 4 - Main Screen Display
Brake Circuit Pressure Switch (14) - Stps the
machine going into a stall condition when under heavy
braking. Tw switch signals to the transmission to drop
out of retard or lock up during the braking process.
SM 2368 Rev2 07-07 3
Section 190-0270
Steering System Body

Steering System Pressure Switch (12) - The Body Up Proximity Switch (25) - Mounted off the
normally closed (NC) pressure switch is located in port inside of the trailer left hand frame rail. When the body
PS1 of the main hydraulic valve. The pressure switch is raised off the trailer frame, the switch sends a signal
closes and sends a signal to illuminate 'Red' to the hydraulic ECU. The body symbol on the VDU
emergency steering warning light (11, Fig. 2) when warning screen (6, Fig. 3) is displayed when the body
steering pressure drops to 5 bar (70 lbf/in2) or lower. An is clear of the proximity switch.
audible buzzer also sounds. Note: Never move the vehicle until body up warning
symbol on the VDU warning screen (6, Fig.32) goes
out, indicating that the body is fully lowered onto the
Hydraulic System trailer frame. When the body is up the transmission
Hydraulic Filter Restriction Gauge (1) - The hydraulic inhibits any upshifts.
filter restriction gauge is located on top of hydraulic Note: The proximity switch prevents the body being
tank. After 1 000 hours or when the needle moves into fully powered down onto the frame. When the proximity
the red zone, whichever comes first, the hydraulic filter switch meets the body, the body control lever detent is
should be changed. Although should the restriction de-energised and float solenoid at main hydraulic valve
reach a predetermined level, the hydraulic filter is energised.
restriction warning symbol (3, Fig. 3) should flash up Hood
on the VDU warning screen on the main dash panel.
Hood Switch (26) - Thehood switch is used to raise or
lower the hood and is located on the right hand rail of
Air Cleaner
the instructor seat. when the switch is actuated an
Air Cleaner Restriction Gauge (9) - Mounted on the electrical signal is ent to the hood actuator either
air cleaner, the restriction gauge indicates the degree extending or retracting the actuator rod depending on
of air cleaner element restriction as the red panel rises switch direction.
in the gauge window. The filter element(s) should be
replaced if the red band locks in place when the engine Battery Disconnect
is shut down. Reset the gauge by pressing the button
on the gauge with the engine running. Although should
Master Battery Disconnect Switch (27) - Themaster
the restriction reach a predetermined level, the air filter
battery disconnect switch is used to isolate or connect
restriction warning symbol (4, Fig. 3) should flash up
the batteries to the rest of the vehicle electrical
on the VDU warning screen on the main dash panel.
system. The switch is located on the battery box at the
Fuel Tank left hand fender.
Fuel Level Sender (31) - Located into the top face of
the fuel tank, the fuel level sender sends a signal
which is displayed in the VDU main screen (1, Fig. 4)
as a bargraph, indicating the amount of fuel left in the
tank. Should the fuel level drop below 25% a warning
symbol (1, Fig. 3) will be displayed on the VDU
warning screen.
* * * *
4 SM 2368 Rev2 07-07

FUEL SYSTEM - Fuel System
Section 200-0040
SM - 3485
29
45
TO ENGINE - REAR
30 32
27 44
26 31 36 43
25
24
22,23 39
28 21
42
38
20 40
40
34
6,7
8 19
9,10 18
2
3 11 14
41
1 12
13
38 37
5
4
40
15,16
17
5
35
4
1 - Fuel Tank 12 - Bolt 23 - Bolt 34 - Mounting Bracket

2 - Filler / Strainer 13 - Lockwasher 24 - Bracket 35 - Fuel Line to Tank
3 - Gasket 14 - Drain Valve 25 - Nipple 36 - Fuel Supply line
4 - Bolt 15 - Screw 26 - Bushing 37 - Elbow
5 - Washer 16 - Washer 27 - Breather 38 - Bushing
6 - Washer 17 - Sender 28 - Washer 39 - Clamp
7 - Bolt 18 - Bushing 29 - Reducer 40 - Elbow
8 - Fuel Cap 19 - Connector 30 - Fuel Line to Cooler 41 - Fuel Cooler
9 - Bolt 20 - Hose 31 - Clamp 42 - Primary Fuel Filter
10 - Lockwasher 21 - Connector 32 - Clamp 43 - Secondary Fuel Filter
11 - Gasket 22 - Lockwasher 33 - Double Clamp 44 - Fuel Pressure sensor
45 - Fuel Temp Sensor
Fig. 1 - Fuel Lines and Components
DESCRIPTION (42). The word 'Primary' or 'Secondary is cast into the

Numbers in parentheses refer to Fig. 1. top of the respective adaptor.
The fuel system consists of the DDEC electronic fuel A Fuel pressure sensor (44) is installed into the side of
system controls, fuel manifolds (integral with the secondary fuel filter (43) and sends an electronic signal
cylinder head), primary fuel filter (42), secondary fuel to the ECM telling it what the engine fuel pressure is at
filter (43), fuel pump, electronic control module (ECM), any given speed.
N3 electronic unit injectors, fuel cooler (41), fuel tank
(1) and the necessary connecting fuel lines. Fuel temperature sensor (45) is installed in a tee on the
top of secondary fuel filter (43) and sends an electrical
There are two spin-on type fuel filters mounted on the signal to the ECM indicating fuel inlet temperature. The
left hand side of the engine. Primary fuel filter (42) is in ECM uses this information to calculate fuel
the fuel flow and acts as a strainer. Integral to the consumption.
Primary fuel filter (42) is the facility to manually prime
the pump via removal of the red cap located centrally Note: Both fuel pressure sensor (44) and fuel
on the filter head. The secondary fuel filter (43) filters temperature sensor (45) are non-serviceable items and
the fuel after having passed through primary fuel filter should be replaced as individual units.
SM 2394 01-06 1
Fuel System - Fuel System
Section 200-0040
The fuel pump is attached to a drive assembly A remote mounted fuel tank breather/filter assembly is
mounted on the rear side of the gear case at the front incorporated into the fuel tank (1), allowing fuel tank (1)
LH side of the engine and transfers fuel from fuel to vent to atmosphere, preventing pressure from
tank (1) to the N3 electronic unit injectors. building up within fuel tank (1) assembly.
The N3 electronic unit injector is a lightweight, compact

unit that injects diesel fuel directly into the combustion OPERATION
chamber. The amount of fuel injected and the Numbers in parentheses refer to Fig. 1.
beginning of injection timing is determined by the ECM.
The ECM sends a command pulse which activates the Fuel is drawn from fuel tank (1) through primary fuel
injector solenoid. filter (42) and enters fuel pump. Leaving fuel pump
under pressure, the fuel flows through secondary fuel
The N3 EUI performs four functions: filter (43) to the engine cylinder head. The fuel flows to
N3 electronic unit injectors in the cylinder head through
a - Creates the high fuel pressure required for efficient passages integral with the cylinder head. Surplus fuel
injection. exits at the rear of the cylinder head just above the
b - Meters and injects the exact amount of fuel required inlet, via fuel line (30) and flows through fuel cooler
to handle the load. (41) and back to fuel tank (1). Restricted fitting at rear
c - Atomizes the fuel for mixing with the air in the of engine maintains fuel pressure in the system.
combustion chamber.
d - Permits continuous fuel flow for component cooling.
N3 Electronic unit injectors are self compensating and REMOVAL

virtually eliminate engine tune-ups. Numbers in parentheses refer to Fig. 1.
Note: Never apply 12 V directly to terminals on the

injector as it will burn out. Before removing injectors, WARNING
the fuel passages must be blown out to prevent fuel To prevent personal injury and property
flow from entering the cylinder head. damage, be sure wheel blocks, blocking
Fuel cooler (41) is mounted on the front of the radiator, secured and of adequate capacity to do the job
off mounting bracket (34) and cools fuel returning to safely.
fuel tank (1).
Flexible fuel lines (30,35 & 36) are used to facilitate parking brake and switch off the engine. Operate
connection of lines leading to and from fuel tank (1), steering right and left several times to relieve pressure
and to minimize the effects of any vibration in the in the steering system.
installation. A 2.03 mm (0.08 in) restricted orifice is
incorporated in the fuel return fitting (23) at rear of 2. Block all road wheels and place the battery master
engine to maintain fuel pressure in the system. The switch in the 'Off' position.
restricted orifice is designed to provide the proper fuel
system pressure under all conditions. 3. If required, remove mounting hardware securing the
front grille on the hood assembly and remove grille for
Note: Do not alter or substitute another size of orifice access to the fuel cooler (41).
since this may alter engine performance and
emissions. 4. Switch the hood raise button located inside the panel
at the front of the battery box and raise hood.
Note: Do not use restricted fittings anywhere else in
the fuel system and do not substitute a standard fitting 5. Place the battery master switch in the 'Off' position.
for the restricted fitting.
6. Remove padlock and remove fuel cap (8) from fuel
When installing fuel lines, it is recommended that tank (1).
connections be tightened only sufficiently to prevent
leakage of fuel; thus flared ends of the fuel lines will 7. With a suitable container in position, remove
not become twisted or fractured because of excessive drain valve (14) from bowl in the side of fuel tank (1)
tightening. and drain fuel from fuel tank (x). Reinstall drain
2 SM 2394 01-06
Section 200-0040
plug and tighten securely when fuel tank (1) is 7. Fill fuel tank (1) assembly with clean diesel fuel
completely drained. specified in Section 300-0020, LUBRICATION
SYSTEM.
9. Identify and tag fuel lines (30,35 & 36) and, with a
suitable container available to catch leakage, 9. Install filler cap (8) assembly on fuel tank filler neck.
disconnect fuel lines (30,35 & 36). Cap open line ends Tighten filler cap (8) securely and secure in place with
and elbows to prevent entry of dirt. padlock.
10. Remove bolts (4) and washers (5) securing fuel 10. Place the battery master switch in the 'On' position.
tank (1) assembly in the tractor frame. Using a suitable
lifting device, remove fuel tank (1) assembly from the 11. Lower hood assembly and secure front grille
vehicle. assembly to the hood with mounting hardware removed
at removal.
11. If required, remove fuel cooler (16). Refer to
Section 210-0100, HYDRAULIC OIL COOLER. 12. Start the engine and run for a few minutes to
ensure fuel is being supplied to the engine. Check for
12. If required, remove rubber pads from the tractor leaks at fuel lines (30,35 & 36) and tighten if required.
frame. Be sure to remove all rubber and adhesive from
the tractor frame. 13. Remove wheel blocks from all road wheels.
INSTALLATION MAINTENANCE
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
WARNING WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure wheel blocks and blocking
materials and lifting equipment are properly materials are properly secured and of adequate
secured and of adequate capacity to do the job capacity to do the job safely.
safely.
Note: Tighten all fasteners to standard torques General

specified in Section 300-0080, STANDARD BOLT AND Refill fuel tank (1) at the end of each day's operation to
NUT TORQUE SPECIFICATIONS. prevent condensation from contaminating the fuel.
When filling fuel tank (1), check that there is no buildup
1. If removed, apply a suitable adhesive to new rubber of dirt and sludge in the filler / strainer (2) and at the
pads and position on the tractor frame. filler cap (8). Remove and clean filler cap as required.
2. Using suitable lifting equipment, position fuel tank (1) Every 10 Hours/Daily:
assembly in the tractor frame. Make a visual check for fuel leaks at all engine mounted
fuel lines and connections, fuel cooler, and at the fuel tank
3. Secure the front of fuel tank (1) assembly to the suction and return lines. Examine lines for leaks and
tractor frame with bolt (4) and washer (5) as shown in check all fittings, clamps and ties carefully.
Fig. 1. Tighten bolt (4) to a torque of XXX
Make sure that fuel lines are not resting on or touching
4. Secure the rear of fuel tank (1) assembly to the rotating components, heated surfaces including
tractor frame with bolt (4), washer (5) as shown in Fig. 1. exhaust manifolds or sharp edges. If fittings have
Tighten bolt (4) to a torque of XXX loosened or cracked, or if lines have ruptured or worn
through, take corrective action immediately.
5. Remove blanking caps and secure fuel lines (30,35
& 36) to elbows, as identified at removal.
6. If removed, install fuel cooler (16). Refer to Section

210-0100, HYDRAULIC OIL COOLER.
SM 2394 01-06 3
Section 200-0040
Every 500 Hours: sulphur content of 0.5% is recommended for use. Refer
Replace the primary and secondary fuel filters as to Section 300-0020, LUBRICATION SYSTEM.
follows:
Note: There is a fuel system shut off cock on the TROUBLESHOOTING

discharge side of the secondary fuel filter. Closing this
valve will prevent loss of fuel prime at time of filter Locating Air Leaks in Fuel Lines
replacement. Air drawn into the fuel system may result in uneven
running of the engine, black or white smoking and
1. Close shut off valve at secondary fuel filter and, stalling when idling, or a loss of power. Poor operation
using a strap type filter wrench, remove and discard is particularly noticeable at lower engine speeds. If air
both the primary and secondary fuel filters from the is found in the fuel, the source will normally be between
engine. the fuel tank and the fuel pump.
2. Fill the replacement filters and coat the gaskets Check for loose, faulty or improper fuel line connectors.
slightly with clean fuel oil as specified in Section Presence of an air leak may be detected
300-0020, LUBRICATION SYSTEM. by following the procedures under 'Checking Fuel Flow'.
3. Start new primary fuel filter on the filter adaptor and

tighten it by hand until the gasket contacts the adaptor Checking Fuel Flow
fully with no side movement of the filter evident. 1. Disconnect the fuel return line from the fitting at the
Tighten an additional 1/2 of a turn. fuel tank and hold the open end in a suitable container.
Note: Mechanical tightening of fuel filters is not 2. Start and run the engine at maximum rev/min and
recommended, and may result in seal and/or cartridge measure the fuel flow. Nominal fuel return spill with the
damage. Tighten fuel filters by hand only. standard 2.03 mm (0.08 in) restricted fitting is
4.1 litres/min (65 US gal/min).
4. Repeat step 3 to install a new secondary fuel filter.
3. Immerse the end of the fuel return line in the fuel. Air
5. Start the engine and check for leaks. If any leaks bubbles rising to the surface of the fuel will indicate air
are noted, have them corrected. being drawn into the fuel system on the suction side of
the pump. If air is present, tighten all fuel lines
Every 250 Hours: connections between the fuel tank and fuel pump.
Open the drain at the bottom of the fuel tank to drain
off any water and/or sediment. Check the seal in fuel 4. If the fuel flow is insufficient for satisfactory engine
tank filler neck cap and clean filler neck screen and performance then proceed as follows:
cap. Check the condition of all fuel lines and replace if
required. Clean and inspect fins on fuel cooler. a. Replace the primary and secondary fuel filters, as
described under 'Maintenance'. Start the engine and run
Every 1 000 Hours: it at maximum rev/min and recheck the fuel flow. If fuel
Fuel tank breather, replace flow is still unsatisfactory, perform step 'b'.
Diesel Fuel Oil b. Check the fuel lines for restrictions due to pinching,
The sulphur content of diesel fuel oil should be as low kinking or other damage. Be sure the correct restricted
as possible to avoid premature wear of piston rings and fitting is installed at the return port of the fuel tank. If no
liner, excessive deposit formation, and minimise problem is found, substitute another fuel pump that is
sulphur dioxide exhausted into the atmosphere. Limited known to be operating correctly and recheck the fuel flow.
amounts can be tolerated, but the amount of sulphur in When changing the fuel pump, inspect the fuel pump drive
the fuel and engine operating conditions can influence assembly, hubs and coupling. Clean all fuel lines with
corrosion and deposit formation compressed air and be sure all fuel connections are tight.
tendencies. The use of diesel fuel oil with a MAXIMUM
c. Disconnect the fuel lines from the ECM cooling plate
and, using a suitable connector, connect the two fuel
4 SM 2394 01-06
Section 200-0040
lines, bypassing the cooling plate. Run the engine at
maximum rev/min and recheck the fuel flow. If the fuel
flow with the cooling plate bypassed is normal, the
cooling plate should be replaced.
SPECIAL TOOLS
dealer.
* * * *
SM 2394 01-06 5
FUEL SYSTEM - Electronic Foot Pedal
Section 200-0051
SM - 3607
3
2
1 - Pedal Assembly
2 - Bolt
3 - Washer
4 - Idle Validation Switch connection
Fig. 1 - Electronic Foot Pedal Assembly
DESCRIPTION Numbers in parentheses refer to Fig. 2. unless

otherwise stated.
otherwise stated.
The foot pedal receives a 5V supply from the engine
ECU through the vehicle interface harness connection
The electronic foot pedal assembly provides an
at wire 11. The return line is via wire 60. The signal to
electrical signal to the engine's fuel control system in
determine the level of acceleration requested by the
proportion to the degree of pedal actuation. Maximum
operator foot is received via wire 13.
and minimum stops are built into the pedal assembly
during manufacture. The pedal assembly comes preset
For safety there is an idle validation switch
and therefore no adjustment is necessary.
arrangement to determine that the pedal is at the idle
position. When at idle, the switch S69 is closed and
Note: The DDEC controlled engine will override the
the signal is sent back to the engine ECU. Should
pedal position until the engine is warmed up to the
there be a throttle signal problem, the engine ECU will
correct operating temperature. The engine MUST be
be able to determine this via the idle validation side of
started with foot 'OFF' pedal assembly (1).
the circuit.
SM 2395 05-06 1
Fuel System - Electronic Foot Pedal
Section 200-0051
SM - 3608
ECU
TPS
U/Y Signal
V-13 A
Y/R 5 Volt
V-11 B
Y/B Return
V-60 C
R/W IVS, Closed @ Idle

V-16 E
U Return
V-29 F
VHC
Fig. 2 - Electronic Foot Pedal Wiring Detail
REMOVAL
Numbers in parentheses refer to Fig. 1. 2. Connect electrical harness (5) and idle validation
switch (4) harness.
WARNING 4. Position floor mat on cab floor and ensure that pedal
To prevent personal injury and property assembly (1) is free to operate.
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job 5. Place the battery master switch in the 'On' position,
safely. remove wheel blocks and start the engine. Ensure that
pedal assembly (1) operates correctly.
body is fully lowered, apply the parking brake and Note: The engine MUST be started with the foot 'OFF'
switch off the engine. Turn steering wheel in both pedal assembly (1).
directions several times to relieve any pressure in the
steering circuit. MAINTENANCE
2. Block all road wheels and place the battery master Numbers in parentheses refer to Fig. 2.
switch in the 'Off' position.
Limited repair of the electronic foot pedal assembly is
3. Disconnect electrical harness (4). by replacement of parts only. Refer to vehicle Parts
Book for spare part numbers.
4. Move cab floor mat back and clear from pedal
assembly (1) and mounting plates. A number of checks can be made to determine correct
voltages are being seen at the pedal, which can help in
5. Remove bolt (2) and washer (3) from pedal assembly diagnosis of problems. These are follows:
(1) and remove pedal from the cab.
Voltages range which should be seen assuming proper
operation:
INSTALLATION
Numbers in parentheses refer to Fig. 1. Input:
Y/R & Y/B = 5.05V - 4.95V
Section 300-0080, STANDARD BOLT AND NUT Idle:
TORQUE SPECIFICATIONS. U/Y & Y/B = 10 - 20% of Input (i.e. 0.5V to 1V)
1. Position pedal assembly (1) in position and secure with Full Throttle:
bolt (2) and washer (3). U/Y & Y/B = 70 - 85% of Input (i.e. 3.5V to 4.25V)
* * * *
2 SM 2395 05-06
COOLING SYSTEM - Cooling System (Series 60 Engine)
Section 210-0000
SM - 3635
12
6 10
14
7
9
1 3
5
13
8 2
1 - Header Tank 5 - Engine Oil Cooler 9 - Coolant Pipe 13 - Filter Inlet Line (not used)
2 - Radiator Assembly 6 - Thermostat Housing 10 - Bypass Line 14 - Filter Outlet Line (not used)
3 - Engine Water Pump 7 - Make-up Line 11 - Radiator Inlet Pipe
4 - Coolant Filter (not used) 8 - Radiator Outlet Pipe 12 - Deaeration Lines
Fig. 1 - Cooling Lines and Flow
DESCRIPTION
Numbers in parentheses refer to Fig. 1. thermostats located in thermostat housing (7), attached
to the right hand side of the cylinder head, control the
Two combination coolers are utilised in the system. flow of coolant.
Integral to the right hand cooler is the engine radiator ,
on the right hand side and charge-air-cooler on the left The main components of the cooling system are;
hand side. The Left hand combination cooler consists header tank (1), radiator assembly (2), engine water
of a transmission oil cooler, brake coolant oil cooler, pump (3), engine oil cooler (5) and thermostat housing
engine oil cooler and dropbox oil cooler as shown from (6).
left-to-right. Twin cooling fans are installed for cooling Attached to the front of right hand combination cooler
the respective system elements. This system has a is a condenser. Attached to the left hand combination
centrifugal type water pump (3) to circulate coolant cooler are hydraulic oil cooler and fuel cooler.
throughout the system. Two full blocking type
SM 2374 04-06 1
Cooling System - Cooling System (Series 60 Engine)
Section 210-0000
OPERATION SM - 3568
Numbers in parentheses refer to Fig. 1, unless 3

1
otherwise specified. 4
2
6
Upon starting a cold engine or when the coolant is 4
below operating temperature, the coolant is restricted 5
4 4
at thermostat housing (6) and bypass line (10) provides 5
4
water circulation within the engine during the warm-up
period. 7
Note: Engine coolant thermostats start to open at

88° C (190° F) and are fully open at 96° C (205° F). 4
Engine water pump (3) draws coolant from the radiator 6

4
through radiator outlet pipe (8). Engine water pump (3)
then pumps coolant through coolant pipe (9) into engine
oil cooler (5). The coolant then flows through the engine
block and passes up through the cylinder head to
thermostat housing (7).
1 - Air-to-Air Charge Cooler 5 - Hose
2 - Radiator 6 - Hose
Aerated coolant is drawn off to header tank (1) from 3 - Outlet Pipe 7 - Inlet Pipe
thermostat housing (6) through deaeration line (12). 4 - Clamp
Excess coolant at header tank (1) is discharged
Fig. 2 - Air-to-Air Charge Cooler Lines and Flow
through an overflow line from the filler neck.
When the coolant reaches operating temperature, the

thermostats open allowing coolant to flow into the Air-To-Air Charge Cooling
radiator through radiator inlet pipe (11). The coolant Numbers in parentheses refer to Fig. 2.
passes through a series of tubes in radiator assembly
(2) core, where the coolant temperature is lowered by In the air system used on the Series 60 engines,
the air stream created by the revolving fan, and into the outside air drawn into the engine through the air
radiator outlet pipe (8) to be re-circulated back through cleaner, passes through the air filter element and is
the system. pulled into the turbocharger where it is compressed. It
then exits the turbocharger through outlet pipe (3) and
Aerated coolant is drawn off to header tank (1) from the enters air-to-air charge cooler (1), integral to the Right
radiator, radiator inlet pipe (11) and thermostat housing hand cooler assembly, through inlet pipe (6). The hot
(6) through deaeration lines (12). Excess coolant at air travels through a series of tubes in
header tank (1) is discharged through an overflow line air-to-air charge cooler (1) core, where the air
from the filler neck. temperature is lowered from approximately 149° C
(300° F) to below 38° C (100° F). From here the air
The use of antifreeze is mandatory with the cooling flows through outlet pipe (6) and into the engine intake
system. The lack of coolant flow through the radiator manifold through inlet pipe (7). From the engine intake
with the thermostats closed allows the coolant in manifold the air travels into the cylinders where it
radiator assembly (2) to freeze under low ambient mixes with atomized fuel from the injectors. This cooler
temperature conditions. air aids combustion, thereby increasing fuel economy.
2 SM 2374 04-06
Section 210-0000
PREVENTIVE MAINTENANCE Note: It may be necessary to clean radiator and

air-to-air charge cooler fins more frequently if the
To ensure the continued efficient functioning of the
vehicle is being operated in extremely dusty or dirty
cooling system, certain checks and operations should
areas.
be performed at regular intervals.
WARNING
WARNING
To prevent possible injury when using
Do not remove the pressure control cap from
compressed air, wear adequate eye protection
the radiator header tank or attempt to drain the
and do not exceed 2.75 bar (40 lbf/in²).
coolant until the engine has cooled. Once the
engine has cooled, use extreme caution when
removing the cap. Always release pressure Every 1 000 Hours
from the system by depressing the pressure
Replace coolant filter. Check and replenish coolant
relief button on the cap. Remove cap slowly as
inhibitor as required.
the sudden release of pressure from a heated
cooling system can result in a loss of coolant
Note: Failure to use and maintain coolant and coolant
and possible personal injury (scalding) from
inhibitor mixture at sufficient concentration levels can
the hot liquid.
result in damage to the cooling system and its related
components. Conversely, over-concentration of coolant
Every 10 Hours (Daily) and/ or inhibitor can result in poor heat transfer, leading
to engine dropout or both. Always maintain
Check coolant level and add if low. Fill the radiator
concentration at recommended levels.
header tank with coolant until coolant reaches the
bottom of the filler neck and holds at that level.
Inspect water pump drain hole to make sure it is open.
Note: Any time a significant amount of coolant is
Note: A small chemical build up or streaking at the
added, the coolant inhibitor MUST be checked. If the
drain hole may occur. This is not an indication of a
concentration is low, engine damage will result.
defective water pump or seal. If coolant does not leak
Conversely, over-inhibiting antifreeze solutions can
from the drain hole under normal operating conditions,
result in silicate dropout. Refer to 'Test Kit Procedures'.
do not replace the water pump.
Check cooling fan for cracks, loose rivets and bent or Every 2 000 Hours
loose blades. Check fan mounting and tighten if
Check coolant level and add if low. Fill the radiator
required. Replace cooling fan if damaged.
header tank with coolant until coolant reaches the
bottom of the filler neck and holds at that level.
Check coolant lines, pipes and components for leaks
and wear.
added, the coolant inhibitor MUST be checked. If the
Every 50 Hours concentration is low, engine damage will result.
Conversely, over-inhibiting antifreeze solutions can
Check all drive belts for wear and tension. Refer to
result in silicate dropout. Refer to 'Test Kit Procedures'.
Section 110-0030, ENGINE AND MOUNTING for belt
tension specifications.
Every 250 Hours

Inspect the radiator and air-to-air charge cooler fins
and, if necessary, clean with a quality grease solvent
such as mineral spirits and dry with compressed air.
Note: Fuel oil, kerosene or gasoline should not be used

to clean fins.
SM 2374 04-06 3
Section 210-0000
DRAINING AND FLUSHING Back-flushing Engine Jacket

Whenever the engine water jacket is rust clogged,
pressure back-flushing should be used after the
WARNING draining of the cleaning compound. Be certain to
Do not remove the pressure control cap from remove both thermostats from thermostat housing
the radiator header tank or attempt to drain the before beginning back-flushing operation.
coolant until the engine has cooled. Once the
engine has cooled, use extreme caution when 1. Remove both thermostats from thermostat housing
removing the cap. Always release pressure and clamp flushing gun to front neck of the water
from the system by depressing the pressure manifold.
relief button on the cap. Remove cap slowly as
the sudden release of pressure from a heated 2. Temporarily block engine water pump inlet opening
cooling system can result in a loss of coolant and fill engine jacket with clean, soft water.
and possible personal injury (scalding) from
the hot liquid. 3. Unblock water pump inlet opening and blow water
from the engine jacket with air from flushing gun
1. With the engine cool, drain the coolant from the clamped to neck of water manifold. Use full air
engine and radiator assembly. pressure.
2. Refill the cooling system with clean, soft water and a 4. Repeat operation by alternately filling engine with
good radiator cleaning compound. If the engine is clean, soft water and blowing out with air until flushing
warm, fill slowly to prevent the rapid cooling and water runs out clean.
distortion of the metal castings.
3. Start the engine and operate the vehicle for fifteen Back-flushing Radiator
minutes to circulate the solution completely. 1. Disconnect all coolant lines at the engine.
4. Stop the engine and allow to cool. With the engine 2. Clamp flushing gun to lower hose on the radiator and
cool, drain the cooling system completely. fill the radiator with clean, soft water from the gun.
5. Refill the cooling system with clean, soft water and 3. Apply air pressure gradually increasing to a pressure
operate it for fifteen minutes. of 0.7 bar (10 lbf/in²). DO NOT EXCEED THIS
PRESSURE.
6. Stop the engine and allow to cool. With the engine
cool, drain the cooling system completely. 4. Alternatively fill radiator with clean, soft water and
flush with air until water runs out clear.
7. Refill the cooling system with the proper mix of
coolant and water. Refer to instructions under
'Recommended Coolants'. RECOMMENDED COOLANTS
8. Entrapped air must be purged after filling the cooling Antifreeze

system. To do this, allow the engine to warm up with Use genuine Detroit Diesel Power Cool or an equivalent
the pressure cap on the remote header tank removed. ethylene glycol base coolant (low silicate formulation)
With the transmission in neutral, increase engine speed that meets or exceeds the standard of either the GM
above 1 000 rev/min and add coolant as required. Vent 6038-M formulation (GM 1899-M performance) or
the cock on the water return line at the water-jacketed ASTM D 4985 requirements.
turbocharger until a steady stream of water (no air) is
seen. Close the cock. A 50% antifreeze/water solution is normally used as a
factory fill. Concentrations over 70% are not
9. Install the pressure cap on the remote header tank recommended because of poor heat transfer capability,
after the coolant level has stabilized at the bottom of adverse freeze protection and possible silicate dropout.
the header tank filler neck. Concentrations below 30% offer little freeze, boil over
or corrosion protection. Refer to graph in Fig. 3.
Note: If the engine overheats and the coolant level is
satisfactory, the cooling system may require cleaning
with a descaling solvent and back-flushing.
4 SM 2374 04-06
Section 210-0000
SM - 1209 Methyl alcohol-based antifreeze is not recommended

for use because of its effect on the nonmetallic
components of the cooling system and its low boiling
point. Methoxy propanol-based antifreeze is also not
recommended for use because it is not compatible
with fluoroelastomer seals found in the cooling system.
Soluble oil additives are not approved for use in the

cooling system. A small amount of oil adversely
affects heat transfer; 1.25% concentration increases
the fire deck temperature 6% and 2.5% concentration
increases fire deck temperature 15%.
Supplemental Coolant Additives (SCA)

SCA's provide protection for the cooling system
components. The coolant must have the proper
concentration of SCA's. Detroit Diesel Maintenance
products are recommended for use in all Detroit Diesel
Engines.
The proper application of SCA will provide:
a - pH control to prevent corrosion.

b - Water-softening to deter formation of mineral
deposits.
c - Cavitation protection to reduce the effects of
cavitation.
Install a new precharge coolant filter at initial cooling

system fill and whenever the coolant is changed.
Replace the precharge filter with a maintenance filter
after 250 hours then every 500 hours thereafter. Refer
to the vehicle Parts Book for coolant filter part
Fig. 3 - Coolant Freezing and Boiling Temperatures versus numbers.
Inhibited Ethylene Glycol (IEG) Concentration (Sea Level)
Note: Selection of the correct coolant filter element is
Antifreeze solution should be used year-round to vital when precharging the cooling system and at
provide freeze and boil over protection as well as a maintenance intervals. A fully formulated cooling
stable environment for seals and hoses. In extremely system must not have SCA's added at initial fill.
hot environments, clean, soft, properly inhibited water
may be used if Detroit Diesel Maintenance Product SCA Concentration Limitations Table650
supplemental corrosion inhibitors are also added in the MINIMUM MAXIMUM
right concentration. If water is used, supplemental PPM PPM
coolant additive levels should be increased from 3% to
Boron (B) 1 000 1 500
6% by volume.
Nitrite (NO2) 800 2 400
Nitrates (NO3) 1 000 2 000
Only non-chromate inhibitors should be used with
Silicon (Si) 50 250
coolant solutions. Chromate coolant inhibitors are not
Phosphorous (P) 0 500
compatible with ethylene glycol antifreeze (low silicate pH 8.5 10.5
formulation) and if these compounds are combined a
green sludge will be produced. This sludge will deposit The concentration of SCA will gradually deplete during
on cooling system passages and reduce heat transfer normal engine operation and should be checked after
from the engine to coolant. every filter change. Additional SCA must be added to
the coolant when it becomes depleted below the level
specified in the table on the following page.
SM 2374 04-06 5
Section 210-0000
Maintenance dosage of SCA must only be added if For best results make the tests while the coolant is
nitrite concentration is less than 800 parts per million between 10° - 60° C (50° - 140° F). Wait at least 60, but
(PPM). If nitrite concentration is greater than 800 PPM, not longer than, 75 seconds before reading the nitrite
do not add additional SCA. Refer to 'Test Kit level. Promptly replace and tighten container cap after
Procedures'. each use. Discard unused strips if they have turned
light pink or tan.
Test Kit Procedures Note: Failure to properly maintain coolant with SCA
Coolant Test Strips should be used to measure nitrite can result in damage to the cooling system and its
and glycol concentrations (See Special Tools). related components. Conversely, over-concentration of
Cavitation/corrosion protection is indicated on the strip SCA inhibitor can result in poor heat transfer, leading to
by the level of nitrite concentration. Freeze/boil over engine damage. Always maintain concentrations at
protection is determined by glycol concentration. Use recommended levels.
the test strips as follows:
a. Dip the strip into coolant for one second. Remove SPECIAL TOOLS
and shake briskly to eliminate excess fluid. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the coolant test strips and general service
b. Immediately compare end pad (% glycol) to the tools required. These strips and tools are available
colour chart. from your dealer.
c. Sixty seconds (one minute) after dipping, compare

the nitrite pad.
COOLING SYSTEM DIAGNOSIS CHART

Engine coolant temperature too Low coolant level Fill cooling system to correct fill level
high
Check for leaks and repairs
Faulty radiator pressure cap Check pressure cap, replace if required
Air in cooling system Purge air from cooling system
Front of radiator obstructed Remove obstruction and clean radiator
preventing free flow of air fins
Fan drive belts broken or slipping Adjust or replace fan belts
Thermostats not opening Replace thermostats
Restricted cooling system passages Flush cooling system
Faulty engine water pump Repair or replace water pump
Engine coolant Thermostats remain open or open Replace thermostats
temperature too low at too low a temperature
Leakage around the thermostat seals Replace thermostat seals
Extremely cold weather Cover radiator or install radiator shutters
* * * *
6 SM 2374 04-06
COOLING SYSTEM - Brake Cooling System Schematic
Section 210-0005
DESCRIPTION Motor/Triple Pump (1)

Numbers in parentheses refer to Fig. 1. Refer to Section 250-0045, MOTOR/TRIPLE PUMP
ASSEMBLY.
The braking system on the machine uses brake cooling
oil to cool the brake packs. This cooling oil is separate Mounted off brackets on the left hand frame rail,
from the hydraulic oil used in the main hydraulic adjacent to the brake coolant tank, the motor/triple
systems. pump assembly consists of three pump elements
coupled to a single direction hydraulic motor. The
A brief description of the individual components used in hydraulic motor within the assembly is protected by a
the brake cooling system are listed below. Detailed relief valve, which is intergral to the externally mounted
service and operating instructions can be found in the OCDB relief unloader valve. Refer to Section 250-0075
relevant component sections of this manual. OCDB RELIEF UNLOADER VALVE.
A solenoid controls the motor by restricting flow

Service Brakes through the motor until the brake cooling oil reaches 50
Refer to Section 165-0015, BRAKE ASSY - OCDB. o
C (122 oF). The motor is supplied with hydraulic oil via
the main hydraulic valve. The motor and pump
The service brakes are of the enclosed, forced oil- elements are connected by a common shaft, therefore
cooled multiple disc type. The service brakes are motor rotation causes pump elements to draw brake
actuated by hydraulic oil as specified in Section 300- cooling oil from brake coolant tank (3). Brake cooling
0020, LUBRICATION SYSTEM. DO NOT use BRAKE oil is then pumped to brake packs.
FLUID (J 1703). Multiple discs within the brake packs
are cooled by brake cooling oil as specified in Section The triple pump section supplies various circuits:
a) front section (closest to driveshaft) supplies rear
The brake assembly is bolted to the stub axle and brake cooling circuit.
houses a sandwich of friction discs splined to a hub b) middle section supplies centre axle brake cooling
rotor. There are four friction discs in each brake circuit.
assembly. c) rear section supplies the front axle brake cooling
circuit.
When the treadle valve is actuated, hydraulic oil enters
the brake assembly and forces the brake piston
against the rotating friction discs which react with
stationary reaction discs. The reaction discs are
Brake Coolant Tank (3)
retained by scalloped tangs at the outside diameter, Refer to Section 250-0025, BRAKE COOLANT /
which in turn transfers the reaction torque to the rigid HYDRAULIC TANK.
outside housing, slowing or stopping wheel rotation.
The brake coolant tank is part of the integral brake
In an emergency situation, application of the park/ coolant/hydraulic tank assembly. It is the reservoir for
emergency valve will actuate the service brakes and the brake cooling oil. It is mounted off the left hand
the parking brake to bring the machine to a halt. In this frame rail in front of the fender and is secured in three
condition, a restriction in the 'Px' line from the brake places.
manifold valve will slow oil flow from the parking brake
allowing the service brakes to actuate momentarily Integral with brake coolant tank assembly are oil level
ahead of the parking brake. sight gauge, strainer (5) and access covers. Located
on top of the tank is filler cap, remote mounted
When the treadle valve or park/emergency brake is breather and anti-slip walkway plate.
released, hydraulic pressure against piston is relieved
and cup springs force the piston to return to its original
position, thus, relieving the pressure against the brake
disc pack.
SM 2397 04-06 1
Cooling System - Brake Cooling System Schematic
Section 210-0005
Disc Brake Oil Cooler (4) Brake Cooling Oil Relief valve (7)
Refer to Section 210-0050, DISC BRAKE OIL
An internal pressure relief valve is contained within the
COOLER.
manifold blocks mounted on each axle. This valve is
set at 1 bar (14.5 Ibf/ in²) to maintain the brake cooling
The disc brake oil cooler is integral to the left hand
radiator assembly. Mounted on the left hand fender. oil at this pressure.
The fan which supplies air flow to the brake oil cooler is
driven by a hydraulic motor. The fan only turns when
hydraulic motor is supplied with oil from the main 'O' RING FACE SEALS (ORFS)
hydraulic valve, Refer to Section 215-0050 MAIN Where hydraulic lines are fitted with ORFS
HYDRAULIC VALVE ASSEMBLY. Brake cooling oil connections, the following procedure should be carried
enters the top of the cooler and flows through the out during installation. Refer to Fig. 1.
cooler before exiting at the bottom.
a. Ensure 'O' ring/seal is in place and that joining
surfaces are clean. If necessary, retain 'O' ring/seal in
Brake Cooling Oil Filter (6) place with a light coating of grease or vaseline.
The filter, mounted in the brake cooling line between
the motor/triple pump assembly and the front manifold b. Initially, the nuts should be tightened by hand.
block, ensures that the brake cooling oil is filtered. The
filter is fitted with a visual indicator to show when the c. Where a hose is fitted, ensure that it is not twisted
filter is in bypass mode. or kinked when the nuts are tightened so that it is
allowed to adopt a natural position.
Brake Cooling Oil Pressure Switch (8)
A pressure switch is mounted off the front axle brake d. Where a tube is fitted, ensure that the connection is
manifold block. The normally open pressure switch aligned correctly.
closes when brake cooling oil reaches 1.5 bar (22 lbf/
in²) a signal is sent to the VDU which will display the e. Tighten the nut a further 1/4 to 1/2 a turn using the
brake cooling oil pressure warning symbol on the VDU correct size of spanner (wrench).
panel. Refer to Section 190-0270, SWITCHES AND
SENSORS. f. Check that a satisfactory hose or tube routing has
been achieved.
Brake Cooling Oil Temperature Switch/ BRAKE COOLING OIL
Sender (10) The brake cooling system should be kept filled with
The normally closed switch opens when oil temperature brake cooling oil as specified in Section 300-0020,
reaches 50 °C (122 oF) and sends a signal to de- LUBRICATION SYSTEM.
energise the solenoid on the ocdb relief unloader valve,
allowing hydraulic oil flow from the main hydraulic valve Whenever there is a system failure, the brake cooling
assembly to supply the motorside of the motr/triple oil should be drained, the entire system flushed, oil
pump unit. thus drawing cooling oil to the axles. At the filter replaced, oil strainer thoroughly cleaned and clean
same time, a signal is sent to the fan disconnect brake cooling oil added to eliminate all metal particles
solenoid valve to de-enerrgise, thus supplying oil flow or foreign matter.
to the transmission cooling fan Refer to Section 190-
0270, SWITCHES AND SENSORS.
Should brake cooling oil temperature reaches 60 °C

(140 oF). The sender sends a signal to the VDU to
display the brake cooling temp warning symbol on the
VDU display. Refer to Section 190-0270, SWITCHES
AND SENSORS.
2 SM 2397 04-06
Cooling System - Brake Cooling System Schematic
Section 210-0005
SM - 1335 Multi-gauge
FITTING NUT The multi-gauge is basically four pressure gauges in
TUBE one. Continuous system pressure readings are
indicated on one of three simultaneously reading
gauges through a pressure range of 762 mm (30 in) of
vacuum to 345 bar (5 000 lbf/in2).
Non-contact Infrared Thermometer

The infrared thermometer can be used to spot heat
SLEEVE problems early in electrical, mechanical and hydraulic
'O' RING 'O' RING
systems. Hand held and easy to use, you simply aim,
pull the trigger, and read the temperature. Since there
Fig. 1 - Assembly of Typical ORFS Connector
is no need to touch what you are measuring,
temperatures of hard-to-reach or moving components
SERVICE TOOLS can be taken without getting burned or shocked.
It is recommended that the following tools are used
when carrying out pressure or temperature checks
during maintenance procedures. These tools, along
with other general service tools, are available from your
dealer. Refer to Section 300-0070, SERVICE TOOLS,
for part numbers of these tools.
SM 2397 04-06 3
FRONT AXLE CENTRE AXLE REAR AXLE
BRAKE PACKS BRAKE PACKS BRAKE PACKS
3 3 3
7 9 7 7
10
4 1
FROM MAIN HYD.

3
HYD. VALVE TANK
COMPONENTS 5 - Strainer 9 - Temperature Switch / Sender

1 - Motor / Triple Pump 6 - Brake Cooling Filter 10 - Manifold
2 - OCDB Relief Unloader Valve 7 - Relief Valve
3 - Brake Coolant Tank 8 - Pressure Switch
4 - Disc Brake Oil Cooler
Fig. 1 - Brake Cooling System Schematic
SM - 3617
COOLING SYSTEM - Cooling Fan and Motor
Section 210-0010
DESCRIPTION AND OPERATION SM-3622
Numbers in parentheses refer to Fig. 1 & 2. 1
Note: There are two independently controlled fans

in the system. Who's functionality is identical. Only
the preset temperature conditions of the various 3
parts of the system which they serve is different. 2
The fan located on the Left hand side of the 4
vehicle is dedicated in the majority to transmission

cooling needs. The fan located on the right hand
side in the majority is dedicated to engine cooling
needs.The rate of fan speed change and
maximum fan speed for each fan is preset to the
cooling needs of the various engine, transmission 5
and brake cooling requirements of the system.

The hydraulic fan drive system uses an electrical
signal from the hydraulic system electronic control
unit (ECU) to provide the appropriate fan speed
necessary to satisfy any cooling demand. Each fan
1 - Radiator 4 - Fan Guard
(2 & 3) is driven by a single vane type hydraulic 2 - Fan 5 - Hydraulic Motor
motor (5), which is supplied by a dedicated oil 3 - Motor Carrier Frame
supply from the main hydraulic valve assembly.
Refer to Section 215-0050 MAIN HYDRAULIC
VALVE ASSEMBLY. Fig. 1 - RHS - Hydraulic Fan Drive (Engine)
There are two fan control valves, which control oil

SM-3621
flow proportionally to the fan motors. Each serves
one of the cooling fans. These are integral to the 1
main hydraulic valve assembly. Refer to Section

215-0050 MAIN HYDRAULIC VALVE ASSEMBLY.
The hydraulic ECU will send a signal to either of
the fan proportional solenoids, when it receives an
input signal that reflects any of the preset 2
temperature parameters that have been

programmed to signal flow to the fans. 4
Relative to each proportional solenoid, the

temperature conditions are as follows:
5
Proportional Solenoid 'CT22' (Engine Fan):
1. Engine coolant temperature reaches 85°C 3
(185°F).
2. Engine oil temperature reaches 108°C (226°F).

1 - Radiator 4 - Fan Guard
2 - Motor Frame 5 - Hydraulic Motor
3. Air intake temperature reaches 54°C (129°F). 3 - Fan
4. Air conditioning 'ON'

Fig. 2 - LHS - Hydraulic Fan Drive (Transmission)
If any of the above temperatures are seen, the
hydraulic system ECU will send a signal from PWM At the same time, a signal will be sent from the
output PIN47 between 0 and 264mA to solenoid hydraulic system ECU at output PIN04 to de-
'CT22' which will determine the pressure to the fan energise the engine fan disconnect solenoid. Refer
motor. to Section 210-0044 FAN DISCONNECT VALVE,
SM 2458 Rev 1 07-06 1
Section 210-0010
allowing flow to the engine hydraulic fan motor. 6. Remove bolts, nuts and washers securing fan (2)
Proportional Solenoid 'CT23' (Transmission Fan): and motor (5) assembly to the motor carrier frame
(3). Remove fan (2) and motor (5) assembly from
1. Sump oil temperature reaches 80°C (176°F). motor carrier frame (3).
2. Retarder temperature reaches 90°C (194°F). RHS Radiator:

Refer to Fig. 1.
3. Brake Cooling oil temp reaches 50°C (122°F).
If any of the above temperatures are seen, the 7. Support radiator assembly with suitable lifting
hydraulic system ECU will send a signal from PWM equipment. Remove fan guard (4) and motor
output PIN46 between 0 and 264mA to solenoid carrier frame (3) from radiator assembly.
'CT23' which will determine the pressure to the fan
motor. 8. Remove bolts, nuts and washers securing fan (2)
At the same time, a signal will be sent from the and motor (5) assembly to the motor carrier frame
hydraulic system ECU at output PIN43 to de- (3). Remove fan (2) and motor (5) assembly from
energise the transmission fan disconnect solenoid. motor carrier frame (3).
Refer to Section 210-0044 FAN DISCONNECT
VALVE, allowing flow to the transmission hydraulic MOTOR OVERHAUL
fan motor. Internal parts of the motor are lubricated by the
operating fluid itself; therefore, preventive
maintenance is limited to keeping the fluid in the
REMOVAL system clean. Dirt should not be allowed to
Numbers in parentheses refer to Fig. 1. accumulate on the motor or around the shaft seal.
Check frequently that all fittings and bolts are tight.
WARNING Service kits are available should overhaul be

To prevent personal injury and property necessary, these include- cartridge kit, shaft and
damage, make sure blocking or lifting bearing kit and seal kits. Refer to relevant parts
equipment is properly secured and of book for specific serial number ranges of units and
adequate capacity to do the job safely. parts.
1. Position the machine on a level floor. Switch off

the engine and operate the steering several times DISASSEMBLY / ASSEMBLY
to discharge the steering system. Limited disassembly of the hydraulic motors is
available. For specific details on correct overhaul
2. Block all road wheels and place the battery and replacement of parts, refer to the
master switch in the off position. manufacturers guidelines.
3. Remove mounting hardware securing hood

assembly to the machine and, using suitable lifting INSTALLATION
equipment, remove hood assembly as described in Numbers in parentheses refer to Fig. 1 & 2.
Section 100-0040, HOOD AND MOUNTING.
4. Remove both left hand and right hand radiator specified, to standard torques listed in
assemblies from machine as described in Section Section 300-0080, STANDARD BOLT AND NUT
210-0040, RADIATORS AND MOUNTING. TORQUE SPECIFICATIONS.
LHS Radiator:
WARNING
Refer to Fig. 2. To prevent personal injury and property
damage, make sure blocking or lifting
5. Support radiator assembly with suitable lifting equipment is properly secured and of
equipment. Remove fan guard (4) and motor adequate capacity to do the job safely.
carrier frame (3) from radiator assembly.
2 SM 2458 Rev 1 07-06

Section 210-0010
LHS Radiator: TESTING
1. Install fan (3) to motor frame (2). Install motor (5) Fail-safe Check
through motor frame (2) and secure.
Note: This test is carried out with the machine
static and secured at rest. Hood should be raised
2. Using suitable lifting equipment, position
and secured.
assembly on the radiator assembly and secure
motor frame (2) to the radiator.
1. Start the engine and increase engine speed to
2 200 rev/min.
Note: Ensure there is even clearance, all the way
round, between fan (3) and the fan guard (4).
2. Maintain engine speed at 2 200 rev/min and
disconnect harness from the fan disconnect valves.
5. Install fan guard (4) to the radiator assembly and
Fans should automatically engage to full flow
secure with mounting hardware, as removed at
speed.
'Removal'.
6. Using suitable lifting equipment, install radiator MAINTENANCE

assembly to the machine as described in Section Numbers in parentheses refer to Fig. 2.
210-0040, RADIATORS AND MOUNTING. high pressure jet.
RHS Radiator: 1. DO NOT restrict fan(s) rotation during engine
0 operation for ANY reason.
1. Install fan (2) to motor frame (3). Install motor (5)
through motor frame (3) and secure. 4. DO NOT operate a machine with a damaged
fan(s) assembly. Replace a damaged fan as soon
2. Using suitable lifting equipment, position as the fault is noted.
assembly on the radiator assembly and secure
motor frame (2) to the radiator. 5. DO NOT disassemble ANY fan assembly or
associated parts that are still within the warranty
Note: Ensure there is even clearance, all the way coverage period.
round, between fan (2) and the fan guard (4).
6. IMMEDIATELY investigate and correct ANY
5. Install fan guard (4) to the radiator assembly and operator complaint involving drive or cooling
secure with mounting hardware, as removed at system performance.
'Removal'.
6. Using suitable lifting equipment, install radiator SPECIAL TOOLS

assembly to the machine as described in Section There are no special tools required for procedures
210-0040, RADIATORS AND MOUNTING. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general
7. Position the hood assembly on the machine service tools required. These tools are available
using a suitable lifting device. Secure hood from your dealer.
assembly on the machine with mounting hardware,
as described in Section 100-0040, HOOD.
TROUBLESHOOTING
8. Start the engine and check for correct operation
of the fans (2 & 3). Refer to 'Testing' procedure Refer to the tables on the following pages for
contained in this section. guidelines on troubleshooting the system:
SM 2458 Rev 1 07-06 3

Section 210-0010
MOTOR TROUBLESHOOTING GUIDE:
SYMPTOM QUESTION CORRECTIVE CHECKS

No rotation Is the flow coming to the motor? Check the circuit and hydrau-
lic schematic. Are the hoses
secure / free from leaks.
Check setting on main

pressure relief valve; ensure
it is not set too low.
Ensure main pump is supply-

ing oil flow.
Check that fan disconnect

solenoids are allowing flow
to the fan motor. Refer to
Section 210-0044 FAN
DISCONNECT VALVE Both
electrically and that the
spools are not sticking in the
wrong position.
Is the torque required higher Check pressure settings.

than the system is set at? Check if load is not greater
than what the pump is
capable of.
Is the pump ok? Check that main pump is

working correctly.
Are the motors internal drain Check if a failing check valve

check valves working properly? would not allow some flow to
return to tank and therefore
limit flow to the motor.
Stalls Easily Is the load close to the limit of the Check relief valve setting
system? and compare it to the
theoretical pressure re-
quired to deliver the torque.
Are motor internal drain check Check a failing check valve

valves working properly? would not allow some flow
to go back to return to tank
and therefore limit flow to
the motor.
Is flow going to the motor Check minimum flow re-

sufficient? quired by motor.
Check pump flow.
4 SM 2458 Rev 1 07-06

Section 210-0010

Not enough Speed Is speed lower than desired? Check theoretical displace-
ment of motor versus flow of
the pump.
Check that pump flow is

getting to the motor.
Check oil temp , may be

internal leakage due to oil
viscosity.
Check air is bled from the

system.
Erratic Speed Is the motor losing speed Check flow from pump is
erratically? getting to the motor.
Check working pressure.
Check oil temperature to

ensure oil viscosity is not
having an effect on the
internal leakage.
Check no air is in the sys-

tem.
Unusual noise level Is the motor running?
Check front shaft seal is not
leaking and allowing air
into the system.
Check that cavitation has

not been induced if inertia
of load is such that it drives
the motor faster than the
flow of oil coming from the
pump this could result.
Check oil quality. Ensure

system has been bled
properly.
Unusual heat Is oil arriving to the motor already
hot? Ensure hydraulic oil cooler
is working properly.
Ensure return oil to tank is

not restricted.
Ensure filter is not blocked.

Check velocity of fluid (5 to
6m/s max).
SM 2458 Rev 1 07-06 5

Section 210-0010

Shaft seal leakage Is seal leaking when pressurised? Check that seal profile / lips
are not degraded or dam-
aged.
Ensure shaft surface is not

damaged by irregular seal
running.
Check pressure in drain line

of motor.
Check shaft alignment.

Ensure no unbalanced
loads which may create
wear on shaft or seal.
* * * *
6 SM 2458 Rev 1 07-06

COOLING SYSTEM - Radiator and Mounting
Section 210-0040
SM - 3578
25
23
21
24
5 22 5
4 4
4 4
5 5
5
4
3 1
2
3
4
16 19 5
7
15
16 6
19
7
11 9 26
20 1
8 28
7 29
15
16 19 6
7
5 9 27
4
3 8
10 2
13 3
4
5
18 17
14
18 14
17
18
17
16
19
15 16
12 19
1 - Brace Rod 8 - Bolt 15 - Nut 22 - RH Combination Cooler

2 - Flexible Mount 9 - Washer 16 - Bolt 23 - Baffle plate
3 - Washer 10 - RH Baffle Plate 17 - lockwasher 24 - Baffle plate
4 - Lockwasher 11 - LH Baffle Plate 18 - Bolt 25 - Baffle plate
5 - Nut 12 - Mounting Bracket 19 - Lockwasher 26 - Baffle plate
6 - Rubber Mount 13 - Mounting Bracket 20 - Tie Plate 27 - Baffle plate
7 - Snubbing Washer 14 - Support Bracket 21 - LH Combination Cooler 28 - Bolt
29 - Washer
Fig. 1 - Radiators and Mounting.
DESCRIPTION The combination radiator assemblies consist of the

following separate cores:
Numbers in parentheses refer to Fig.2 & 3, unless
LH Combination Radiator (Fig. 4):
Transmission oil cooler (2), Brake oil cooler (4),
There are two Combination radiator assemblies
Dropbox oil cooler (5); mounted on front of the
mounted in front of the vehicle engine and transmission
combination radiator is a hydraulic oil cooler and fuel
cooling fans at the front end of the vehicle. The radiator
cooler.
component of the RH cooler assembly is fed from
header tank located in front of the operators
RH Combination Radiator (Fig. 5):
compartment and mounted to the goalpost
arrangement.Refer to Section 210-0000, COOLING Radiator (2) & Charge-air cooler (3); mounted on front
SYSTEM. of the combination radiator is an air conditioning
condenser (5). Refer to Section 210-0000, COOLING
SYSTEM.
SM 2445 Rev 01 07-07 1

Cooling System - Radiator and Mounting
Section 210-0040
SM - 3843
14
WARNING
1 15 damage, be sure wheel blocks, blocking
5
6 materials and lifting equipment are properly
3
7 8 secured and of adequate capacity to do the job
5 9
safely.
5
5 5 1. Position the vehicle in a level work area, apply the
4 3
10
5
5 4
13 11 5
12
2. Press hood switch under passenger seat and raise
hood.
2 13

1 - Water Tube 9 - Lockwasher
2 - Water Tube 10 - Bracket 4. Remove hood assembly from the vehicle. Refer to
3 - Elbow hose 11 - Clamp Section 100-0040, HOOD AND MOUNTING.
4 - Silicon Hose 12 - Bolt
5 - Clamp 13 - Hardened Washer
5. Disconnect electrical harness from horns, and
6 - Saddle Clamp 14 - Charge Air Cooler Core
7 - Bracket 15 - Radiator Core remove horns and mounting from front of radiator.
8 - Bracket Disconnect electrical harness from engine and
Fig. 2 - Radiator Hoses transmission cooling fans.
Fan plate assemblies fitted to both LH and RH 6. Remove filler cap carefully from header tank. Refer
assemblies improves the cooling fan efficiency, to Section 210-0000, COOLING SYSTEM.
providing a more uniform distribution of air over the
cooler cores integral to each combination cooler 7. Remove plugs and open shut-off valves at the
assembly. bottom of radiator core and transmission oil cooler core
and drain coolant and oil into suitable containers. Close
Recirculation baffles incorporated in the hood assembly shut-off valves when systems are drained and refit
prevent hot air from the engine cooling fan being plugs.
reintroduced into the cooling air circuit.
8. Remove nuts (5) and lockwashers (4) securing brace
rods (1) to the tops of the combination coolers (21 &
REMOVAL 22).
otherwise specified. 9. Remove nuts (5), lockwashers (4), washers (3) and
flexible mounts (2) securing brace rods (1) to
combination cooler supports. Remove brace rods (1).
WARNING
Do not remove the pressure control cap from 10. Ensure air conditioning lines from condenser
the radiator header tank or attempt to drain the mounted on front of RH combination cooler (22), and
coolant until the engine has cooled. Once the from receiver drier are identified for ease of
engine has cooled, use extreme caution when installation. Disconnect air conditioning lines. Fit
removing the cap. Remove cap slowly as the blanking caps to open lines and ports.
sudden release of pressure from a heated
cooling system can result in a loss of coolant Note: Refer to Section 260-0130, AIR CONDITIONING
and possible personal injury (scalding) from before disturbing the air conditioning circuit.
the hot liquid.
12. Ensure hydraulic lines connected to hydraulic oil
cooler mounted on front of LH combination cooler (21)
are identified for ease of installation and with suitable
containers available to catch leakage, disconnect
2 SM 2445 Rev01 07-07

Section 210-0040
hydraulic lines. Fit blanking caps to open lines and SM - 3844
ports. 12
13. Disconnect deaeration line from the radiator (2, Fig.

5 13
5) and deaeration line in engine. Disconnect make-up 5
5 4
3
line from coolant outlet pipe. Refer to Section 210- 5
0000, COOLING SYSTEM. Identify lines for ease of 1
installation and cap open lines and ports. 7 5
6 3
5
14. Disconnect all clips and clamps securing air 10 9
8,11
conditioning lines, hydraulic lines and deaeration lines 2 5
to radiator assembly. Move all lines away from radiator
assembly to prevent fouling on removal of radiator
4
assembly.
15. Remove bolts, washers and nuts securing fan 1 - Tube 8 - Bolt
guards (7, Figs 4 & 5) to both combination cooler (21 & 2 - Tube 9 - Washer
3 - Hose Cuff 10 - Nut
22) assemblies. Remove fan guards (7 Fig. 4 & 5) from 4 - Elbow Cuff 11 - Bolt
assemblies. 5 - Clamp 12 - Charge Air Cooler Core
6 - Saddle Clamp 13 - Radiator Core
16. Slacken saddle clamps (6,11 Fig.2),(6 Fig 3) 7 - Bracket
supporting the hoses. Fig. 3 - Air-To-Air Charge Cooler Piping
17. Slacken clamps securing cooler hoses to air inlet

pipe (2, Fig. 3) and remove air inlet pipe from charge air
DISASSEMBLY
cooler (12, Fig. 3) and engine turbocharger.
RH Combination Cooler
18. Slacken clamps securing cooler hoses to air outlet
pipe (1, Fig. 3) and remove air outlet pipe (1, Fig. 3) Numbers in parentheses refer to Fig. 5, unless
from charge air cooler (12, Fig. 3) and engine intake otherwise specified.
manifold.
Note: Take care not to damage charge air cooler core
19. Slacken clamps (5, Fig. 2) and remove coolant (3) and radiator core (2) during disassembly.
outlet pipes (2, Fig. 2), hose (3, Fig. 2). Remove
clamps (5, Fi.g 2) from radiator assembly and engine 1. Remove mounting hardware securing shroud (6) to
thermostat housing. radiator core (2) and charge air cooler core (3).
20. Slacken clamps (5, Fig. 2) and remove coolant 2. Remove top plate (10), base plate (9) and gasket (1)
outlet pipe (2, Fig, 2), hose (3, Fig. 2) and clamps (5, from the assembly. Separate the charge air cooler core
Fig. 2)) from bottom of radiator assembly and engine (3) from the radiator core (2).
water pump inlet.
LH Combination Cooler
21. Using suitable lifting equipment support RH
combination cooler (22). Numbers in parentheses refer to Fig. 4, unless
22. Remove bolts (8) and washers (9) securing RH
combination cooler (22) to the frame. Note: Take care not to damage transmission oil cooler
core (2), sump oil cooler core (3), brake oil cooler core
23. Remove RH combination cooler (22) from the (4) and dropbox oil cooler core (5) during disassembly.
vehicle to a clean area for disassembly. Support cooler
standing upright to allow access to front and rear 1. Remove mounting hardware securing shroud (6) to
cooler cores (2,3,4 & 5).
24. Follow the procedure in steps 20 to 22, for removal
of the LH combination cooler (21). 2. Remove top plate (10), base plate (9) and gasket (1)
from the assembly. Separate the four individual cooler
core elements from each other.
SM 2445 Rev 01 07-07 3

Section 210-0040
SM - 3581
2
10
4
6
3
8 5
13
12
1
11
9
1 - Gasket 5 - Dropbox Oil Cooler Core 9 - Base Plate

2 - Transmission Oil Cooler Core 6 - Shroud 10 - Top Plate
3 - Transmission Sump Oil Cooler Core 7 - Guard 11 - Fan
4 - Brake Oil Cooler Core 8 - Motor Bearing 12 - Hydraulic Motor
13 - Quick Drain
Fig. 4 - Exploded View of LH Radiator Assembly
INSPECTION ASSEMBLY
Numbers in parentheses refer to Fig. 4 & 5 unless Note: Tighten all fasteners to standard torques listed in
otherwise stated. Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATION.
1. Steam clean all parts thoroughly with a suitable
solvent. RH combination Cooler
2. Examine all 7 individual cooler core elements which Numbers in parentheses refer to Fig. 5 , unless
were separated at the disassembly stage. Repair any otherwise specified.
damage discovered if equipped to do so, or, have
repairs made at a reputable radiator repair shop. 1. Fit new gasket (1) to radiator core (2) and charge air
cooler core (3).
2. Secure radiator core (2) and charge air cooler core

(3) with base plate and top plate (9 & 10). Use
fasteners removed during the disassembly stage.
3. Position shroud (6) and secure with fasteners
4 SM 2445 Rev01 07-07

Section 210-0040
SM - 3582
3
10
8
11 5
7
4
12
1
13
9
1 - Gasket 5 - Condenser 9 - Base Plate

2 - Radiator Cooler Core 6 - Shroud 10 - Top Plate
3 - Charge Air Cooler Core 7 - Guard 11 - Fan
4 - Condenser Mtg Frame 8 - Motor Bearing 12 - Hydraulic Motor
13 - Quick Drain
Fig. 5 - Exploded View of RH Radiator Assembly
removed during the disassembly stage.

1. Fit new gasket (1) to trans oil cooler core (2), sump
4. Assemble elements of the fan (11) including oil cooler (3), brake oil cooler (4) and dropbox cooler
hydraulic motor (12) and secure elements in place to (5).
the complete cooler assembly.
2. Secure combination cooler core elements (2,3,4 & 5)
Note: When installing combination cooler, ensure with base plate and top plate (9 & 10). Use fasteners
clearance around cooling fan tips to plate assembly is removed during the disassembly stage.
of equal dimension all round.
3. Position shroud (6) and secure with fasteners
6. Install air conditioning condenser (5) to combination removed during the disassembly stage.
cooler assembly picking up mounting locations and
hardware as identified at 'Disassembly'. 4. Assemble elements of the fan (11) including
hydraulic motor (12) and secure elements in place to
LH combination Cooler the complete cooler assembly.
Numbers in parentheses refer to Fig. 4 , unless

SM 2445 Rev 01 07-07 5

Section 210-0040
INSTALLATION connect electrical harness to horns.

12. Install LH and RH fan guards (7, Figs 4 & 5) to
radiator assemblies with bolts, washers and nuts
removed during 'Removal'.
13. Remove blanking caps from deaeration lines
(12) and connect deaeration line (12) to connector in
SPECIFICATIONS.
top of radiator assembly and deaeration line (12) to
connector thermostat housing in engine. Do not clip
lines at this point. Refer to Section 210-0000,
WARNING COOLING SYSTEM.
damage, be sure lifting equipment is properly 14. Remove blanking caps from hydraulic oil cooler
secured and of adequate capacity to do the job lines and fittings. Connect all hydraulic lines to
safely. hydraulic oil cooler as identified at removal.
1. Position brace rods (1) and secure in place at 15. Remove blanking caps from air conditioning lines
bottom with nuts (5), washers (3), flexible mounts (2) and fittings. Connect air conditioning lines to condenser
and lockwashers (4). Do not tighten at this stage. and receiver drier. Refer to Section 260-0130, AIR
CONDITIONING for procedure on charging the system.
2. Using suitable lifting equipment, position each cooler
assembly on the frame and secure with bolts (8), 16. Secure all lines with clips and clamps as removed
rubber mounts (6) and washers (7). during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
3. Secure brace rods (1) to tops of coolers using nuts evident.
(5) and washers (4). Adjust brace rods (1) as
necessary at both ends and fully tighten nuts (5). 17. Ensure fittings, lines and pipes are securely
tightened to prevent leaks at initial fill and start up.
4. Install coolant outlet pipe (2, Fig. 2) between
radiator outlet port and engine water pump inlet, and 18. If removed, fit header tank to goalpost and secure
secure with hoses (3, Fig. 2) and clamps (5, Fig. 2). using bolts, nuts and washers removed as
disassembly stage.
5. Install coolant inlet pipe (1, Fig. 2) between radiator
inlet port and engine thermostat housing, and secure 19. Following installation instructions in Section
with hoses (4, Fig. 2) and clamps (5, Fig. 2). 100-0040, HOOD AND MOUNTING, install header tank
and goalpost assembly on the vehicle.
6. Install air outlet pipe (1, Fig. 3) between engine
intake manifold and charge air cooler (12, Fig. 3) and 20. Remove blanking from make-up line (7) and
secure with hoses (3 &5, Fig. 3) and clamps (4, Fig. 3). connect to header tank (1) and coolant outlet pipe (8).
Secure with clamps. Refer to Section 210-0000,
7. Install air inlet pipe (2, Fig. 3) between engine COOLING SYSTEM.
turbocharger and charge air cooler (12, Fig. 3) and
secure with hoses (3 & 5, Fig. 3) and clamps (4, Fig. 21. Remove blanking caps from deaeration lines
3). (12) and connect to appropriate fittings on header tank
(1), as noted on removal. Refer to Section 210-0000,
8. Secure pipes to the cross member with saddle COOLING SYSTEM.
clamps(6,11 Fig.2) (6 Fig. 3)
22. Connect overflow line to header tank.
9. Feed electrical harness from engine cooling fan
through hole in fan plate assemblies. 23. Secure all lines with clips and tie clips as removed
during removal. Ensure no lines are chaffing on sharp
10. Connect engine cooling fan electrical harness to edges or resting against areas where heat will be
main electrical harness. evident.
11. Install horns to front of radiator assembly and 24. Connect electrical harness to coolant level sensor
6 SM 2445 Rev01 07-07

Section 210-0040
at bottom of header tank. Note: The solvent must always be added carefully to
water, not water to solvent.
25. Refer to Section 210-0000, COOLING SYSTEM for
correct selection of coolant. Fill the cooling system
through filler in header tank with coolant until coolant Transmission Cooler Core Internal
level stabilizes at the bottom of filler neck. Cleaning - Oil Tubes
In the event of a major mechanical failure, the
26. Check all line and pipe connections for leaks prior transmission oil cooler core should be cleaned
to starting the vehicle. Tighten as required. thoroughly or replaced.
27. Switch the battery master switch to the 'On' 1. Clean transmission oil cooler before sludge hardens.
position, start up the engine, check for leaks. Tighten After transmission oil cooler is completely drained,
lines and fittings and top up coolant level as required. circulate a solution of Agmasol PS40 through the
cooler core to remove sludge.
28. Install filler cap on header tank after the coolant
level has stabilized at the bottom of filler neck. 2. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through cooler. Solution should be
29. Following installation instructions in Section circulated through cooler, in the reverse direction to
100-0040, HOOD AND MOUNTING, install hood normal flow, for approximately 15 minutes, after
assembly on the vehicle. soaking for 10 minutes. The duration of circulation
depends on how badly clogged the cooler is. Flush
30. Remove wheel blocks from road wheels. thoroughly with clean hot water.
External Cleaning
CLEANING Note: If a build up of dirt is apparent during routine
inspection, the following cleaning procedure should be
Radiator Core Internal Cleaning - Water adopted.
Tubes
If scale deposits are present inside the water tubes of
the radiator core, it is necessary to use a suitable WARNING
scale remover such as 'Powdered Scale Solvent', or To prevent possible injury when using
equivalent. This material is a free-flowing powder, compressed air or steam jet, wear adequate eye
inhibited to prevent attack on the cooling system protection and do not exceed pressure values
materials. stated.
1. Direct a steam jet at 100 - 300 kN/m², or

WARNING compressed air at 500 - 700 kN/m² on to the faces of
Take care to avoid contact of skin or eyes with the cores.
the solvent. If contact is made it should be
washed off immediately with clean water and 2. Liberally brush a liquid detergent on to those
medical advice should be taken. surfaces which were not satisfactorily cleaned at
step 1. Leave to soak for at least 1 hour.
For general cleaning use it is recommended to use a
concentration of 50 - 100 kg/m³ of water at a 3. Apply a high pressure steam jet at 100 - 300 kN/m², or
temperature of up to 60° C. Rapid circulation or compressed air at 500 - 700 kN/m² on to the treated
agitation with compressed air will reduce the time for surfaces, forcing the fouling material out from the radiator
cleaning. core.
Note: If scale deposits within the radiator are 4. Leave cores to dry before reinstalling the cooling
exceptionally heavy, concentrations up to 200 kg/m³ equipment.
may be used.
The most convenient method of use is to prepare a Note: In the case of grossly fouled surfaces which are
concentrated solution by mixing the powder in hot not cleaned adequately in steps 1 through 4, the
water in a tank and then adding the concentrated following may be used.
solution to water contained in the radiator.
5. Ensure that the cores are dry.
SM 2445 Rev 01 07-07 7

Section 210-0040
6. Liberally brush on to both sides of the cores an MAINTENANCE
emulsifying cleaner such as 'Gunk', or equivalent, and
Refer to Section 210-0000, COOLING SYSTEM for
leave to soak for at least 1 hour.
recommended preventive maintenance procedures,
service intervals and coolant selection procedures.
7. Apply a high pressure steam jet at 100 -300 kN/m²,
or compressed air at 500 - 700 kN/m² on to the treated
surfaces, from several different angles, forcing the SPECIAL TOOLS
fouling material out from the cores.
8. For surfaces with stubborn deposits, it may be SERVICE TOOLS, for part numbers of general service
necessary to repeat steps 5 through 7, brushing the tools and adhesives required. These tools and
surfaces between stages using a stiff bristle brush. adhesives are available from your dealer.
9. Leave cores to dry before reinstalling the equipment.
* * * *
8 SM 2445 Rev01 07-07

COOLING SYSTEM - Fan Disconnect Valve
Section 210-0044
SM - 3618
6
3
1 - Solenoid Coil 4 - Seal

4 2 - Cartridge Valve 5 - 'O'-ring
3 - Valve Body 6 - 'O'-ring
Fig. 1 - Fan Disconnect Valve
DESCRIPTION CT23 on the main hydraulic valve assembly, Refer to

Section 215-0050 MAIN HYDRAULIC VALVE
ASSEMBLY.
There are two fan disconnect valves located on the
truck. One is located on the left hand fender, the other
The temperature conditions which will give the desired
is on the right hand fender. The fan disconnect
output are as follows-
solenoids stop or allow hydraulic oil flow to either the
engine or transmission cooling fan circuits, Refer to
Engine Cooling Fan:
section 210-0010 COOLING FAN AND MOTOR.
1. Engine coolant temperature reaches 85°C (185°F).
OPERATION
2. Engine oil temperature reaches 108°C (226°F).
Numbers in parentheses refer to Fig. 2 & 3.
The fan disconnect valves for part of the engine and
3. Air intake temperature reaches 54°C (129°F).
transmission cooling fan circuits. The integral solenoid
valve controls oil supply from the main hydraulic
4. Air conditioning 'ON'
valve, at port 'DF1' and 'DF2' respectively, Refer to
section 215-0050 MAIN HYDRAULIC VALVE
Transmission Cooling Fan:
ASSEMBLY .
1. Sump oil temperature reaches 80°C (176°F).
The fan disconnect valve will remain energised (Fig. 2)
until any of the preprogrammed temperature values
2. Retarder temperature reaches 90°C (194°F).
are seen by the IFM controller, Refer to Section 190-
0085 HYDRAULIC SYSTEM ECU.
3. Brake Cooling oil temp reaches 50°C (122°F).
When any of the following temperature conditions are FUNCTIONAL CHECK
seen, a signal to de-energise (Fig. 3) the disconnect Numbers in parentheses refer to Fig. 1.
valve solenoid will take place and oil flow will be
allowed to the fan motor.
Checking the proper operational function of the fan
disconnect valve can be simply executed by removing
The various temperatures seen will also determine the the electrical harness connection, with the engine
degree of flow seen at the fan motors, this is controlled running. An increase in either engine cooling fan or
by the internal proportional solenoid valves CT22 and transmission cooling fan speed should be observed.
SM 2457 05-06 1
Cooling System - Fan Disconnect Valve
Section 210-0044
FAULT DIAGNOSIS SM - 3620A

TO FAN TO FAN
MOTOR MOTOR
Possible points of failure:
1. The solenoid (1) coil, although continuously rated

they may fail after long periods of service. This failure
is protected by the fail-safe design of the valve. If the
solenoid fails to energise, hydraulic oil will be allowed
to flow to the fan motor. This will default the cooling
fan to run constant at the higher speed setting, thus
safeguarding the system against high operating FROM FROM
'DF1' 'DF2'
temperatures.
Solenoid Coil Rating: 29 Watt continuous.

Fig. 2 - Fan Disconnect Valve - Solenoid Energised
2. The solenoid cartridge valve (2) to which the
solenoid is attached. Failure is only likely to occur due SM - 3620B
to contamination in the system. The valve is a low
leakage device and any contamination may cause TO FAN TO FAN
MOTOR MOTOR
either damage to the components or cause
components to stick in position. Failure may be more
difficult to detect due to the different modes of failure.
Damage to the components will allow a progressively
increasing leakage, eventually resulting in some flow
not being shut off when the solenoid is selected.
Sticking components could hold the system at either a
low fan speed or a high fan speed depending on what
position the cartridge valve (2) is stuck. FROM FROM
'DF1' 'DF2'
3. Temperature switch failure. The disc brake oil
cooler temperature switch, mounted on the front axle Fig. 3 - Fan Disconnect Valve -
manifold block, should close when the disc brake Solenoid De-energised
cooling oil temperature rises above 50°C (122°F).
Failure to close will result in the solenoid cartridge switch in the 'Off' position. Place steering lock bar in
remaining energised and the hydraulic oil flow will not the 'Locked' position.
be allowed to the fan motors. Failure will result in
higher disc brake cooling oil temperatures. 3. Remove blanking cap from remote drain line at the
REMOVAL
remote drain fitting, open drain cock and drain
Numbers in parentheses refer to Fig. 1. hydraulic oil into a suitable container. Close drain
cock, remove hose and reinstall blanking cap.
WARNING 4. Clean low temperature unloader valve and

To prevent personal injury and property surrounding area with a suitable solvent. Identify and
damage, ensure wheel blocks, blocking tag all hydraulic lines connected to the low
materials and lifting equipment are properly temperature unloader valve, to aid in 'Installation'.
secured and of adequate capacity to execute
the job safely. 5. With suitable containers available to catch leakage,
disconnect hydraulic lines. Fit blanking caps to all
1. Position the vehicle in a level work area, apply the open lines.
parking brake and switch off the engine. Operate
treadle valve continuously to relieve pressure in the 6. Remove electrical harness connector from solenoid
braking system. valve (1).
2 SM 2457 05-06
Cooling System - Fan Disconnect Valve
Section 210-0044
7. Remove bolts and lockwashers securing the fan INSTALLATION
disconnect valve to the fender. Remove fan
disconnect valve from the fender.
Note: Tighten all fasteners to standard torques listed
DISASSEMBLY in Section 300-0080, STANDARD BOLT AND NUT
1. Note location and position of all hydraulic
connectors and adaptors prior to removing them from
valve body (3).
where used.
2. Unscrew solenoid cartridge valve (4) from valve
1. Secure fan disconnect valve to hydraulic front
body (3). Disassemble the solenoid as required for
frame of the truck with bolts and lockwashers.
inspection.
2. Remove blanking caps from hydraulic lines and
INSPECTION install lines to the fan disconnect valve as identified
during 'Removal'.
3. Re-connect electrical harness connector to solenoid
1. Clean all parts with a suitable solvent and dry with
valve.
compressed air.
4. Fill hydraulic oil tank with hydraulic oil as specified
2. Check port threads and make sure they are not
in Section 300-0020, LUBRICATION SYSTEM. Refer
damaged or stripped.
to Section 230-0040, HYDRAULIC TANK, for hydraulic
oil levels. Install filler cap on hydraulic tank filler neck.
3. Check cartridge valve (2), ensure it is not worn,
nicked, cracked or scored.
5. Place the battery master switch in the 'On' position,
start the engine and bring hydraulic oil to operating
4. Check valve body (3) for damage. Ensure valve
temperature.
body (3) is not worn, nicked, cracked or scored.
6. Check fan disconnect valve and hydraulic line
5. Examine solenoid coil for any defects.
connections for leaks and tighten as required.
Any parts which need to be replaced, should be done
7. Remove all blocking from road wheels and place
so prior to fitting the valve assembly.
steering lock bar in the 'Stowed' position.
ASSEMBLY SPECIAL TOOLS

1. The level of assembly is dictated by the need to
change any of the seals, 'o'-rings or constituent parts
of the fan disconnect valve.
dealer.
2. Should any parts need to be replaced, assembly
should be carried out as the reverse of disassembly.
3. Once the fan disconnect valve is ready to be fitted

to the unit, all ports should be unblanked.
5. Ensure hydraulic connectors and adaptors are

installed to correct ports and orientation.
SM 2457 05-06 3
COOLING SYSTEM - Disc Brake Oil Cooler
Section 210-0050
SM - 3623
L.H. BRAKE
COOLANT/HYDRAULIC TANK
4
10 2
6
MANIFOLD 7
TRACTOR
11
13 8
22
MOTOR / TRIPLE 5
17 PUMP
12 BRACKET LH FRAME RAIL

16
9 21
CHECK VALVE
15 10 14
18
COOLER
20
11 1
19
R.H. BRAKE
BRACKET RH FRAME RAIL
1 - Brake Oil Cooler 7 - Filter 12 - Hose 17 - Hose

2 - Coolant Tank 8 - Supply Hose 13 - Hose 18 - Hose
3 - Motor / triple pump 9 - Manifold Block 14 - Hose 19 - Hose
4 - Inlet Hose 10 - Hose 15 - Porting block 20 - Inlet Hose
5 - Return Hose 11 - Hose 16 - Hose 21 - Return Hose
6 - Supply Hose 22 - Return Hose
Fig. 1 - Disc Brake Oil Cooler lines
DESCRIPTION AND OPERATION inlet hose (4), it is returned to the hydraulic tank (2) via
return hose (5). Cooling oil is drawn from the coolant
Numbers in parentheses refer to Fig. 1. The disc brake tank (2) via the pump and is filtered (7) before being
oil cooler can be identified as item 4 in Section 210- supplied to the manifold block (9) via supply hose (8).
0005, COOLING SYSTEM SCHEMATIC. From the manifold it is distributed to the wheels via
hoses (10 & 11). Return oil is sent to the brake cooler
The disc brake oil cooler (1) is an integral part of the (1) via hoses (14,19 & 20). There is an internal check
LHS combination cooler ,refer to section 210-0040 valve within the manifold block (9) on each axle, should
RADIATOR AND MOUNTING for specific location the pressure in the block reach 1 bar, the check valve
within the radiator assembly. The disc brake oil cooler will relieve the pressure, with flow going back to tank
is a blast air type, air being supplied via the LH cooling via hose (12). The principle is the same for all three
fan. The fan itself is driven by a hydraulic motor. The axle manifold blocks.
motor is supplied by a dedicated brake cooling section
of the motor / triple gear pump, via the OCDB relief Brake cooling oil enters the bottom of the oil cooler (1)
unloader valve. The speed of the fan is dependant on and flows through the oil cooler (1) before exiting at the
the oil flow being supplied to the motor from the relief bottom via hose (21 & 22) where it returns to the
unloader valve. Refer to Section 250-0070, OCDB coolant tank (2). There is one common inlet port and
RELIEF UNLOADER VALVE. outlet port which the return lines tee into to allow the
cooling oil to enter the cooler.
Hydraulic Oil flows from the ocdb relief unloader valve
into the motor section of the triple pump assembly via
SM 2446 05-06 1
Cooling System - Disc Brake Oil Cooler
Section 210-0050
REMOVAL
WARNING
WARNING damage, make sure blocking or lifting
To prevent personal injury and property equipment is properly secured and of adequate
damage, make sure blocking or lifting capacity to do the job safely.
equipment is properly secured and of adequate
capacity to do the job safely. Generally assembly is the opposite of disassembly. Be
careful not to damage oil cooler (1) during installation.
1. Position the machine on a level floor, apply the
parking brake and switch off the engine. Operate the Note: Ensure there is even clearance, all the way
steering several times to discharge the steering round, between the fan and the radiator assembly.
system. Operate the treadle valve continuously to Refer to section 210-0010 COOLING FAN AND
discharge the braking system. MOTOR, for specific detail.

switch in the off position. Place steering lock bar in the
INSTALLATION
locked position. Numbers in parentheses refer to Fig. 1.
3. Remove drain plug from inboard face of the brake Note: Tighten all fasteners without special torques
coolant tank. Install a length of hose and drain brake specified, to standard torques listed in
cooling hydraulic oil into a suitable container. Remove Section 300-0080, STANDARD BOLT AND NUT
hose and reinstall drain plug. TORQUE SPECIFICATIONS.
DISASSEMBLY WARNING
Numbers in parentheses refer to Fig. 1. To prevent personal injury and property
damage, make sure blocking or lifting
Note: Tighten all fasteners without special torques equipment is properly secured and of adequate
specified, to standard torques listed in capacity to do the job safely.
TORQUE SPECIFICATIONS. Note: Tighten all hydraulic lines fitted with ORFS
Note: As the brake oil cooler (1) is part of the BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
combination unit, refer to section 210-0040 RADIATOR where used.
AND MOUNTING for disassembly of major elements.
Note: As the brake oil cooler (1) is an integral part of
1. Remove hoses (20 & 21) from the inlet and outlet the LHS combination unit, refer to section 210-0040
port of the brake cooler (1) section of the LHS RADIATOR AND MOUNTING for installation of the
combination cooler. Refer to section 210-0040 radiator package.
RADIATOR AND MOUNTING.
1. Once installed, blanking caps should be removed
2. Any excess fluid contained within the cooler should from hydraulic hoses (20 & 21).
be drained prior to further disassembly.
2. Blaking caps should be removed from the cooler (1)
2. Plug ports and hoses. Ensure hoses are tagged for ports.
ease of installation at the assembly stage.
3. Install hoses (20 & 21) and secure.
ASSEMBLY
Note: Prior to start-up, ensure the hydraulic motor is
Note: Tighten all fasteners without special torques primed with clean hydraulic oil as specified in Section
specified, to standard torques listed in 300-0020, LUBRICATION SYSTEM.
2 SM 2446 05-06
Cooling System - Disc Brake Oil Cooler
Section 210-0050
4. Fill coolant tank with hydraulic oil as specified in MAINTENANCE

Section 300-0020, LUBRICATION SYSTEM. Refer to
Section 250-00025, BRAKE COOLANT / HYDRAULIC Every 250 hours
TANK, for oil levels. Install filler cap on coolant tank Check radiator / Brake cooler fins for damage. Note
filler neck. fins should be checked more often when working in
extremely dusty conditions.
8. Fill hydraulic oil tank with oil as specified in Section
300-0020, LUBRICATION SYSTEM. Fill until oil fills Refer to Section 210-0040, RADIATORS AND
the glass window nut. Install filler cap on hydraulic tank MOUNTING for in depth flushing and overhaul
filler neck. Refer to Section 250-00025, BRAKE procedure of the coolers.
COOLANT / HYDRAULIC TANK.
SPECIAL TOOLS
9. Place the battery master switch in the 'On' position, There are no special tools required for procedures
and start the engine. Top up oil levels in hydraulic tank outlined in this section. Refer to Section 300-0070,
and brake coolant tank as required. Bring hydraulic oil SERVICE TOOLS, for part numbers of general service
to operating temperature. tools required. These tools are available from your
dealer.
10. Check all motor, valve and hydraulic line

steering lock bar in the stowed position.
* * * *
SM 2446 05-06 3
Cooling System - Transmission Oil Coolers
Section 210-0060
SM - 3598
2
1
SUMP TOP
3
2
SUMP BTM
12
TRANSMISSION VIEW 4 2
FROM ABOVE
11
BTM
8
5
10 9 14 9
13
15 7
19
TOP
6 5 20
16
17
18
15 14
1 - Adaptor 7 - Hose 14 - Check valve

2 - Adaptor 8 - Tee 15 - Clamp
3 - Hose 9 - Adaptor 16 - Bolt
4 - Hose 10 - Tee 17 - Lockwasher
5 - Adaptor 11 - Elbow 18 - Washer
6 - Hose 12 - Hose 19 - Bracket
13 - Hose 20 - Combination Cooler
Fig. 1 - Transmission Oil Cooling Lines
DESCRIPTION AND OPERATION Retarder Oil Cooler.

Hydraulic oil is drawn from the retarder cooler port,
Numbers and letters in parentheses refer to Fig. 1.
through hose line (12) and enters the retarder oil cooler
portion of the combination cooler (20). Oil is cooled by
The air cooled transmission oil and retarder oil coolers
air flow through the fins and exits through hose line (5)
are integral to the LHS Combination cooler. Each is a
at the top of cooler (20) and passes back into the
separate cooler and has separate cooling flow to the
return port on the back of the transmission.
respective circuit,Refer to Section 210-0040
RADIATOR AND MOUNTING for the location of each REMOVAL
within the radiator assembly.
The purpose of the coolers is to cool the transmission
sump and retarder hydraulic oil circulating through the
WARNING
transmission.
damage, be sure wheel blocks and lifting
Transmission Oil Cooler
Hydraulic oil exits the front of the transmission through
hose (4) and enters the transmission oil cooler portion
of the combination cooler (20). Oil is cooled by air flow
through the fins and exits through hose line (3) at the
parking brake and switch off the engine. Turn steering
top of the cooler (20) and passes back into the return
wheel several times to relieve any pressure in the
port on the front portion of the transmission sump.
steering circuit. Operate brake pedal continuously to
relieve pressure in the braking system.
SM 2433 03-06 1
Section 210-0060
2. Block all road wheels and place the battery master INSTALLATION
3. Remove inlet line (4) from adaptor (2) in the
transmission oil cooler. Drain oil from inlet line (4) into
a suitable container. Plug inlet line and cap port to
prevent ingress of dirt.
4. Remove outlet line (3) from adaptor (2). Drain oil
from outlet line (3) into a suitable container. Plug outlet
STEERING SYSTEM SCHEMATIC. Renew all
line and cap port to prevent ingress of dirt.
'O' rings where used.
5. Remove inlet line (7) from adaptor (5) in the retarder
oil cooler. Drain oil from inlet line (7) into a suitable
WARNING
container. Plug inlet line and cap port to prevent
ingress of dirt.
damage, be sure wheel blocks and lifting
6. Remove outlet line (6) from tee (10). Drain oil from
outlet line (6) into a suitabl e container. Plug outlet line
and cap port to prevent ingress of dirt.
1. If the transmission oil cooler or retarder oil cooler
7. If required remove hardware and associated lines
wer eremoved from the complete combination cooler
from combination cooler, Refer to section 210-0040
assembly. They must be reassembled to the cooler
RADIATOR AND MOUNTING, to allow for removal of
prior to connecting cooling lines. Refer to Section 210-
both transmission and retrder cooler portions of the
0040, RADIATOR AND MOUNTING.
combination cooler (20).
2.Install inlet line ( 4) into adaptor (2) on the
CLEANING AND INSPECTION transmission oil cooler.
3. Install outlet line (3) into adaptor (2) on the

Note: Contaminated fins cause reduced cooling
transmission oil cooler.
performance. The condition of cooling air fins must be
checked by conducting a daily visual inspection.
4. Install inlet line (7) to adaptor (5) in the retarder oil
cooler.
1. Inspect fins on both transmission oil and retarder oil
coolers carefully, for trapped debris and damage. If any
5. Install outlet line (6) to tee (10), however if any other
of the oil cooler fins show signs of leakage or are
lines and fittings were removed at the disassembly
excessively damaged, the respective cooler portion of
stage, fit these prior to filling the unit with oil.
the combination cooler must be replaced.
6. Ensure any oil that may have been lost during the
2. Check connectors in all oil cooler ports for damaged
removal stage is replenished, so that the correct oil
threads. Replace if required.
level is in transmission. Refer to section 120-0010,
TRANSMISSION AND MOUNTING, for correct fill level
3. After both oil coolers are completely drained,
and Section 300-0020, LUBRICATION SYSTEM for
circulate a solution of Agmasol PS40 through the
specifications of oil to be used.
cooler tubes.
4. If cooler tubes are badly clogged, circulate an oakite
start engine and operate the body hydraulics several
or alkaline solution through the hydraulic oil cooler, in
times to circulate the oil. Check hydraulic oil cooler (1)
the reverse direction to normal flow, for approximately
and lines for leaks. Tighten fittings as required.
15 minutes. The duration of circulation depends on how
badly clogged the cooler tubes are. Flush thoroughly
8. Install front grille assembly to the hood with
with clean hot water and then finally flush compressed
mounting hardware, as removed at 'Removal'.
air to ensure all cleaning agent is removed. .
9. Remove wheel blocks from all road wheels.
2 SM 2433 03-06
Section 210-0060
MAINTENANCE SERVICE TOOLS

Check and clean transmission and retarder oil coolers There are no special tools required for procedures
every 250 hours, or more frequently, if required. Debris outlined in this section. Refer to Section 300-0070,
in the cooling fins can restrict the flow of air through SERVICE TOOLS, for part numbers of general service
the cooler which significantly reduces the cooling tools and adhesives required. These tools are available
effect. from your dealer.
Should fins need to be cleaned. apply compressed air

or water to the fins. Ensure the cleaning jet is applied
parrallel to the fins so that they do not get damaged.
The cleaning effect can be increased by adding
cleaning agents. Ensure that cleaning agent does not
attack or degrade the cooler material.
* * * *
SM 2433 03-06 3
COOLING SYSTEM - DropBox Oil Cooler
Section 210-0065
SM - 3525
15
3
8 14
9
TOP
7
5
13
6 2
12
1
OC1
OC2
10 11 8
4
6
7
BTM
1 - DropBox Oil Cooler 6 - Adaptor 11 - Tee

2 - Dropbox Valve 7 - Hose 12 - Adaptor
3 - Adaptor 8 - Clamp 13 - Clamp
4 - Hose 9 - Clamp 14 - Check Valve
5 - Hose 10 - Elbow 15 - Tee
Fig. 1 - Dropbox Oil Cooling Lines
DESCRIPTION AND OPERATION REMOVAL

Numbers and letters in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
The air cooled dropbox oil cooler is integral to the LHS

Combination cooler assembly. Refer to Section 210- WARNING
0040 RADIATOR AND MOUNTING. The purpose of To prevent personal injury and property
this cooler is to cool the dropbox hydraulic oil damage, be sure wheel blocks and lifting
circulating through the dropbox. equipment are properly secured and of
Hydraulic oil is drawn from the dropbox oil sump,
through the dropbox valve (2) and is then passed out 1. Position the vehicle in a level work area, apply the
of port 'OC1' through hose line (5) on the front of the parking brake and switch off the engine. Turn steering
valve . wheel several times to relieve any pressure in the
steering circuit. Operate brake pedal continuously to
From here it flows to the bottom port of the dropbox oil relieve pressure in the braking system.
cooler (1), where it is cooled by air flow through the fins
and exists through hose line (7) and passes back into 2. Block all road wheels and place the battery master
port 'OC2' on the dropbox valve (2). Where it returns to switch in the 'Off' position.
the oil sump on the bottom of the unit.
3. Remove inlet line (4) from adaptor (3) and connector
in the dropbox oil cooler (1). Drain oil from inlet line (4)
SM 2432 03-06 1
Cooling System - DropBox Oil Cooler
Section 210-0065
into a suitable container. Plug inlet line and cap port to
prevent ingress of dirt. WARNING
4. Remove outlet line (7) from adaptor (3) and damage, be sure wheel blocks and lifting
connector in dropbox oil cooler (1). Drain oil from outlet equipment are properly secured and of
line (7) into a suitable container. Plug outlet line and adequate capacity to do the job safely.
cap port to prevent ingress of dirt.
1. If removed, reinstall combination cooler and
7. If required remove hardware and associated lines associated lines prior to connecting dropbox (1) cooler
from combination cooler, Refer to section 210-0040 lines. Refer to Section 210-0040, RADIATOR AND
RADIATOR AND MOUNTING, to allow for removal of MOUNTING
the dropbox cooler (1) and its constituent parts.
2. Install inlet line (4) and outlet line (7) in their
CLEANING AND INSPECTION respective ports, as removed at 'Removal'.
1. Inspect fins on dropbox oil cooler carefully, for 3. Place the battery master switch in the 'On' position,
trapped debris and damage. If dropbox oil cooler fins start engine and bring transmission up to operating
show signs of leakage or are excessively damaged, it temperature. Check dropbox oil cooler (1) and lines for
must be replaced as an assembly. leaks. Tighten fittings as required.
2. Check connectors in dropbox oil cooler ports for 4. Remove wheel blocks from all road wheels.
damaged threads. Replace if required.
3. After dropbox oil cooler is completely drained, MAINTENANCE

circulate a solution of Agmasol PS40 through the Debris in the cooling fins can restrict the flow of air
cooler tubes. through the cooler which significantly reduces the
cooling effect. Check fins daily.
or alkaline solution through the hydraulic oil cooler, in Note: In the event of a hydraulic failure, hydraulic oil
the reverse direction to normal flow, for approximately cooler should be removed and cleaned to prevent
15 minutes. The duration of circulation depends on how clogging.
with clean hot water. For specific oil drain and refill intervals Refer to Section
INSTALLATION
Numbers in parentheses refer to Fig. 1. SERVICE TOOLS
Note: Tighten all fasteners to standard torques listed in outlined in this section. Refer to Section 300-0070,
Section 300-0080, STANDARD BOLT AND NUT SERVICE TOOLS, for part numbers of general service
TORQUE SPECIFICATIONS. tools and adhesives required. These tools are available
from your dealer.
* * * *
2 SM 2432 03-06
COOLING SYSTEM - Hydraulic Oil Cooler
Section 210-0100
SM - 3634
8
9
7
10
11
12 6
H
S
F1
F2
TANK RETURN
5 4 MANIFOLD
2 3
1 - hydraulic Oil Cooler 4 - Lockwasher 7 - Oil Inlet line 10 - Bracket

2 - Adaptor 5 - Washer 8 - Tube 11 - Elbow
3 - Bolt 6 - Oil Outlet Line 9 - Clamp
Fig. 1 - Exploded View of Hydraulic Oil Cooler, Lines and Mounting
DESCRIPTION AND OPERATION (1) from the bottom port of the cooler located on the LHS
of the cooler. Oil returns to tank through the hydraulic oil
filter.
The air cooled hydraulic oil cooler (1) is mounted to the REMOVAL
bracket (11) on the front face of the left hand radiator
assembly, directly below the fuel cooler, Refer to
Section 200-0040 , FUEL LINES for detail.
WARNING
The purpose of the cooler is cooling hydraulic oil
circulating through the hydraulic system.
Hydraulic oil cooler (1) is connected at tube (8)
between the return ports from the two hydraulic fan
safely.
motorsand the inlet to the hydraulic tank filter
assembly.
Hydraulic oil enters the hydraulic oil cooler from oil inlet
switch off the engine. Turn steering wheel several
line (7) on the RHS of the cooler at the port located on the
times to relieve any pressure in the steering circuit.
bottom. Oil passes through a series of tubes in the cooler
core, where the oil temperature is reduced by air flow
through the cooler fins, before exiting hydraulic oil cooler
SM 2459 04-06 1
Cooling System - Hydraulic Oil Cooler
Section 210-0100
3. Remove blanking cap from remote drain line at the INSTALLATION
remote drain fitting, open drain cock and drain hydraulic
Note: Tighten all fasteners to standard torques
specified in Section 300-0080, STANDARD BOLT
AND NUT TORQUE SPECIFICATIONS.
4. Remove mounting hardware securing the front grille
on the hood assembly and remove grille for access to
1. Remove blanking cap from hydraulic oil cooler (1),
hydraulic oil cooler (1).
oil inlet line (7) and oil outlet line (6). Prior to
installation.
5. Press the hood raise switch (located in the cab,
under the passenger seat). Raise the hood to allow for 2. Secure cooler (1) to the bracket (12) using washers
access to the cooler. (5), lockwashers (4) and bolts (3) at both mounting
locations.
6. Remove oil outlet line (6) from hydraulic oil cooler (1)
and drain oil into a suitable container.
3. If removed, fit adaptors (2) to both inlet and outlet
ports of the cooler (1).hte
7. Remove oil inlet line (2) from hydraulic oil cooler (1)
and drain any remaining oil into a suitable container.
5. Position oil inlet (7) and outlet (6) lines lines on the
vehicle following the route taken before removal. Do
8. Remove bolts (3), lockwasher (4) and washers (5)
not clip line in position at this stage.
securing oil cooler (1) to bracket (12).
6. Secrue oil lines to the cooler and the tube (8).
9. Remove oil cooler (1) from the vehicle.
7. Clip oil inlet line (7) and oil outlet line (6) with clips
10. Fit blanking caps to all ports and hose lines which
as noted at removal. Use tie clips where required to
will be fitted at installation.
maintain tidy line routing.
CLEANING AND INSPECTION 8. Fill hydraulic oil tank with hydraulic fluid specified in
1. Inspect fins on hydraulic oil cooler carefully, for
Section 230-0040, HYDRAULIC TANK, for correct fill
trapped debris and damage. If hydraulic oil cooler fins
level. Install filler cap on hydraulic tank.
show signs of leakage or are excessively damaged, it
must be replaced as an assembly.
9. Check all line and pipe connections prior to starting
the vehicle.
2. Check connectors in hydraulic oil cooler ports for
damaged threads. Replace if required.
start the engine and check for leaks. Tighten lines and
3. After hydraulic oil cooler is completely drained,
fittings as required.
circulate a solution of Agmasol PS40 through the
cooler tubes.
11. Lower hood assembly using the hood switch
located beneath the passenger seat.
or alkaline solution through the hydraulic oil cooler, in
12. secure front grille assembly to the hood with
the reverse direction to normal flow, for approximately
mounting hardware removed at removal. Remove all
15 minutes. The duration of circulation depends on how
wheel blocks.
with clean hot water.
SPECIAL TOOLS
dealer.
* * * *
2 SM 2459 04-06
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
SM - 2828 When the pump is not running, the priority valve (7) is
closed. As the main pump starts rotating it builds up
residual pressure and the priority valve opens, feeding
the main pump pressure through to the fan drive (22 &
23) & body tipping (27 & 28) valves.
During the body tipping operations and whilst the fan is

running, if the demand pressure at the brake charging
or the steering circuit is less than these functions, the
priority valve (7) remains open, but the oil takes the
path of the least resistance and the requirements of the
charging or steering circuits are met.
If the demand pressure for charging or steering is

higher than that demanded by the fan drive or body
tipping function, this higher pressure will be fed to the
main pump load sense line via the shuttle valves (16 &
Fig. 1 - Main Hydraulic Valve Assembly 17) and therefore enable the main pump to meet the
charging or steering pressure requirements. At the
DESCRIPTION same time the higher load sense pressure assists the
Numbers in parentheses refer to Fig. 2 spring in the priority valve (7), the priority valve will
then close to reduce the flow to the fan or body tipping
The Main Hydraulic Valve Assembly is mounted on the circuit and therefore making sure the brake charging &
left hand side of the tractor frame next to the steering always has priority over the other functions.
transmission.
The Main Hydraulic Valve Assembly controls the Steering Function

following functions; Refer to Section 220-0000, STEERING SYSTEM
(a) System relief protection for main pump. Steering actuation pressure is controlled by steering
(b) Priority function load sense orifice (15).The steering load sense orifice
(c) Steering function. (15) controls main pump pressure in the steering load
(d) Brake charging function. sense line. As pressure increases through steering
(e) Park/emergency function. load sense orifice (15), main pump pressure increases
(f) Body control function. lifting steering check valve (5) allowing steering
(g) Transmission cooler fan drive. actuation pressure to access the steering orbitrol
(h) Engine cooler fan drive control valve.
(i) Cold start function.
Valves that control all the above functions are Emergency Steering Unload Valve
integrated into the Main Hydraulic Valve Assembly and Refer to Section 220-0000, STEERING SYSTEM.
are identified in Figs. 2 through 4.
The emergency valve (3) forms part of the emergency
steering system. It is connected to the main output line
System Relief of the wheel driven Emergency Steering Pump
The system relief valve (1) protects the main hydraulic mounted on the transmission.
valve assembly components against pressure spikes.
This system relief valve is pre-set at 260 bar (3770 lbf/
in2 )and is non-adjustable. Brake Charging Function
Refer to Section 250-0000, BRAKE SYSTEM.
Priority Function Brake charge valve (12) and brake pressure reducer
This function automatically ensures that the steering valve (9) are integral valves that form part of the brake
and brake charging circuits are given preference over charging function. Brake charge valve (12) ensures that
the fan and body tipping functions. there is sufficient load sense pressure to the main
pump to allow the charge pressure to be generated.
SM 2442 Rev2 05-07 1

2
PBP TS PB PS4 ACC1 B1 PS3 ACC2 B2 PS2 ACC3 PS5 DF1 DF2 DL
CT24 CT37
CT33
CT10 CT11 TPA
CT27
PPA
Section 215-0050
CT22 CT23
CT32 CT12
CT9
CT21
T2
CT31
CT41 CT42
CT8 CT13 CT25
CT1 LOWER
CT28 B
PS1
CT35 CT7 CT39
CT14
P1
A
LSM CT43 HOIST
CT15 CT29
CT44
CT3 CT16 CT26
P2G CT5
CT17 CT36
CT20
CT30
P2
CT4 CT34
CT6 CT38
CT2
CT18 CT19
T3 TPO ORB LSO LSP P3 T1 DB WB LSA TPB

PPB
1 - Relief Valve 'CT1' 12 - Brake Charging Valve 'CT12' 22 - Proportional Pressure Control Valve 'CT22' 32 - Directional Control Valve 'CT32'
2 - Relief Valve 'CT2' 13 - Orifice 'CT13' 23 - Proportional Pressure Control Valve 'CT23' 33 - Orifice 'CT33'
3 - Bypass sequence Valve'CT3' 14 - Cold start solenoid Valve 'CT14' 24 - Shuttle Valve 'CT24' 34 - Hoist LS Shuttle Valve 'CT34'
4 - Check Valve 'CT4' 15 - Orifice 'CT15' 25 - Shuttle Valve 'CT25' 35 - Orifice 'CT35'
5 - Check Valve 'CT5' 16 - Shuttle Valve 'CT16' 26 - Shuttle Valve 'CT26' 36 - Hoist LS Valve 'CT36'
6 - Check Valve 'CT6' 17 - Shuttle Valve 'CT17' 27 - Proportional Pressure Control Valve 'CT27' 37 - Relief Valve (Diff Lock) 'CT37'
7 - Priority Valve 'CT7' 18 - Shuttle Valve 'CT18' 28 - Proportional Pressure Control Valve 'CT28' 38 - Auxilliary Check Valve
8 - Check Valve 'CT8' 19 - Shuttle Valve 'CT19' 29 - Float Solenoid 'CT29' 39 - Shuttle Valve 'CT39'
9 - Pressure Reducing Valve 20 - Body Raise LS Relief Valve 'CT20' 30 - Orifice 'CT30' 41 - Body Control spool 'CT41'
10 - Check Valve 'CT10' 21 - Pressure Reducing Valve 'CT21' 31 - Park Brake Solenoid 'CT31' 42 - Check Valve 'CT42'
11 - Check Valve 'CT11' 43 - Relief Valve 'CT43'
44 - Check Valve 'CT44'
SM3538
Fig. 2 Main Hydraulic Valve Assembly Schematic - Based on Engine Shutdown
SM 2442 Rev2 05-07

Section 215-0050
Brake pressure reducer valve (9) maintains a safe Engine & Transmission Cooler Fan Drives
operating pressure within the front and rear brake
The engine and transmission cooler fan speeds are
accumulators.
modulated by proportionally controlling the pressure at
Park/Emergency Brake Function the fan motors. Fan speed is a function of the pressure
at the fan motors. Proportional valve CT22 controls the
Refer to Section 250-0000, BRAKE SYSTEM.
flow to the engine fan and proportional valve CT23
controls the flow to the transmission fan.
Park/Emergency brake solenoid (31) is the integral
valve that controls hydraulic pressure to the park and
On a cold start, the cooler fans will not rotate. Fan
emergency brake function of the truck.
drive disconnect solenoid valves, mounted on the left
hand engine baffle plate, will remain closed, blocking
Body Control Function actuating pressure to either the engine cooling fan or
transmission cooling fan until any of the following
Refer to Section 230-0000, BODY SYSTEM
temperature conditions are met for each system:
Proportional pressure control valve (27) is the integral
Transmission Conditions
valve that controls the body tipping function. This valve
is operated via the body control lever located in the
ˇ Transmission oil temp 80°C (176°F).
operators cab. The body control lever sends an
ˇ Retarder oil temp 90°C (194°F).
electrical signal to the hydraulic ECU. (Refer to Section
ˇ Dropbox oil temp 100°C (212°F).
190-0085). The hydraulic ECU processes this signal
ˇ Brake cooling oil 60°C (140°F).
and delivers an actuating electrical signal to the
proportional pressure control valve (27). The
Engine Conditions
proportional pressure control valve (27) converts this
electrical signal into a pilot pressure, that then is
ˇ Inlet manifold temp 54°C (129°F).
allowed to stroke the body control spool to the lift
ˇ Engine Coolant temp 89°C (192°F).
position.
ˇ Engine Oil temp 108°C (226°F).
ˇ Air conditioner 'ON'.
Proportional pressure control valve (28) is the integral
valve that controls the body lower function. This valve
When any of the above conditions are seen, an
is operated via the body control lever located in the
electrical signal will be sent either directly or via the
operators cab. The body control lever sends an
J1939 datalink to the hydraulic ECU. Once a signal
electrical signal to the hydraulic ECU (Refer to Section
reflecting any of the preprogrammed temperature
190-0085). The hydraulic ECU processes this signal
parameters is met. The hydraulic ECU wil send a
and delivers an actuating electrical signal to the
signal to de-energise the appropriate fan drive solenoid
proportional pressure control valve (28). The
valve at the baffle, allowing actuation pressure to
proportional pressure control valve (28) converts this
access the fan drive circuit. The fan drive disconnect
electrical signal into a pilot pressure, that then is
solenoid valves are failsafe. If power or electrical
allowed to stroke the body control spool to the lower
connection is lost, the fan drive disconnect solenoid
position. Subsequent Load sense pressure for raise
valves will de-fault to the open (de-energised)
and lower functions is directed back to the pump via
condition.
hoist 'LS' shuttle valve (34), orifice (30) dampens the
laod sense signal.
Transmission signal
During the lower condition, when the body reaches the
The hydraulic ECU (Refer to Section 190-0085) cancels
proximity switch on the chassis frame, opening the
the electrical signal from 'Digital Out' Pin '43' to the fan
body up signal to the ECU. The ECU will energise the
drive disconnect solenoid valve. Cancelling this signal
float solenoid (29), opening the raise line to tank. This
de-energises the fan drive disconnect solenoid,
ensures hoist cylinders are vented to tank, allowing
opening the transmission cooler fan drive circuit.
body to lower onto chassis under it’s own weight.
The transmission cooler fan speed pressure is
Body relief valve (43) is located on the raise side of the
controlled by the Electro-Hydraulic Proportional Control
circuit and prevents pressure spikes at maximum
Valve (CT23). A varying current input into this valve of
extension of the cylinders when the body is raised at
between 0 to 264 mA controls the pressure between 39
maximum engine speed. Relief valve (43) is set at 250
bar (490 psi) and 138 bar (1260 psi). This pressure then
bar (3 625 lbf/in2 ).
SM 2442 Rev2 05-07 3

Section 215-0050
acts upon the Shuttle Valve (24) and onto the main The engine cooler fan speed pressure is controlled by
pump load sense connection via Shuttle Valve (17). the Electro-Hydraulic Proportional Control Valve
This pressure acts upon the spring chamber of the (CT22). A varying current input into this valve of
Logic Valve (23) that controls the pressure at the fan. between 0 to 264 mA controls the pressure between 39
bar (490 psi) and 138 bar (1260 psi). This pressure then
The hydraulic ECU reads data on the J1939 datalink acts upon the Shuttle Valve (24) and onto the main
for transmission temperatures and directly from brake pump load sense connection via Shuttle Valve (17).
cooling oil and dropbox temperature sensors. The This pressure acts upon the spring chamber of the
temperature sensor output is calibrated against actual Logic Valve (22) that controls the pressure at the fan.
temperature within the hydraulic ECU. The hydraulic The hydraulic ECU reads data on the J1939 datalink.
ECU converts the temp signal into a varying current The temperature sensor output is calibrated against
output. This varying current output, from 'PWM Out' Pin actual temperature within the hydraulic ECU. The
'46', controls Electro-Hydraulic Proportional Control hydraulic ECU converts the temp signal into a varying
Valve (23) increasing and decreasing pressure at the current output. This varying current output, from 'PWM
fan motor. The fan speed increases and decreases Out' Pin '47', controls Electro-Hydraulic Proportional
proportionally between transmission sump and retarder Control Valve (22) increasing and decreasing pressure
oil temperatures of 80 to 130°C (176 to 266°F). at the fan motor. The fan speed increases and de-
The Fan Drive Disconnect Solenoid will remain decreases proportionally between Engin oil temperatures
energised until the transmission oil temperature falls of 108 to 114°C (226 to 237°F).
below 80°C . At this point the oil flow to the
transmission cooling fan will stop. The Fan Drive Solenoid will remain de-energised until
the engine oil temperature falls below 108°C . At this
Engine signal point the oil flow to the engine cooling fan will stop.
The hydraulic ECU (Refer to Section 190-0085) cancels Note: the temperatures listed for the engine are
the electrical signal from 'Digital Out' Pin '04' to the fan specific to engine oil temp. being monitored. THe other
drive solenoid valve. This signal de-energises the fan paramaters i.e. intake manifold temp and coolant temp.
drive solenoid, opening the engine cooler fan drive will also cause the engine cooling fan to run at their
circuit. preset temp. conditions.
Refer to troubleshooting charts.

SM3539
7 - Priority Valve 'CT7'

14 - Cold Start Solenoid 'CT14'
16 - Shuttle Valve 'CT16'
22 - Hydraulic Proportional Control Valve 'CT22'
23 - Hydraulic Proportional Control Valve 'CT23'
26 - Shuttle Valve
26
7
Valve (14) Coil Rating

Ohms Amps Watts
41 0.6 14
Voltage: 24V
Valve (22 & 23) Coil Rating
Ohms Amps Watts
25 0.9 21
Voltage: 24V
22
14 23
16
Fig. 4 - Main Hydraulic Valve Assembly - Engine & Transmission Cooler Fan Valves/Cold Start Solenoid
4 SM 2442 Rev2 05-07

Section 215-0050
SM3540
17
Fig. 5 - Main Hydraulic Valve Assembly - Transmission Cooler Fan Valves Continued
Transmission Cooler Fan Drive Trouble Shooting

Symptom Possible Cause Remedy
Fan idle speed to high Fan disconnect solenoid de-energised Check wiring to solenoid / replace
when transmission oil greater than solenoid.
Note fan will not rotate on truck start 90°C.
up. Residual current still on fan solenoid Check for voltage on connector of
valve (22) or (23). valve. Refer to Section 190-0085,
HYDRAULIC ECU.
Fan control valve (22) or (23) sticking Replace Valve.
open.
Leaking shuttle valve (24). Replace Valve.
Fan unstable over the speed range Fan proportional pressure valves (22 Replace Valve.
when another function is selected. & 23) faulty.
Faulty pump. Refer to Section 230-0050, MAIN

PUMP.
Cold Start Function up, which is particularly important in cold climates.

Cold Start Solenoid (14) is the integral valve that
controls the cold start function of the Main hydraulic A starter motor high signal is received by the hydraulic
valve assembly. Cold start solenoid (14) energises ECU at Digital in 'Pin 55'. The hydraulic ECU converts
when starter motor signal is high, this dumps all load this high signal into digital output signal at 'Pin 31',
sense pressure from the main hydraulic pump, energising the cold start solenoid (14). The signal to
rendering the pump off-load. This reduces parasitic energise the cold start solenoid (14) will remain on until
losses during engine cranking procedure. a starter motor low signal is received by the hydraulic
There is about a 2 second delay before de-energising E.C.U. at 'Pin 55', this will negate the digital output
cold start solenoid (14) (starter motor signal low). This signal from 'Pin 31'. (Refer to section 190-0085 for full
function prevents brake charging during engine start Hydraulic E.C.U. detail.)
SM 2442 Rev2 05-07 5

Section 215-0050
REMOVAL 7. Disconnect mounting hardware securing main

hydraulic valve assembly to vehicle.
WARNING
To prevent personal injury and property DISASSEMBLY
All integral valves on the main hydraulic valve
assembly can easily be removed. On removal of all
integral valve assemblies, clean and examine for wear
safely.
or damage.
If integral valve is badly damaged, inpect bore of main
parking brake and switch off the engine. Turn battery
hydraulic valve housing. If the main hydraulic valve
master switch to the 'off' position. Relieve stored
housing is damaged, the main hydraulic valve
pressure in accumulators (x3). This is achieved by
assembly will have to be completely replaced.
pressing and releasing foot brake pedal continuously
until all accumulator pressure is relieved.
Always replace all o-rings and seals after inspection.
WARNINGS ASSEMBLY
Accumulators are charged with Nitrogen.
All integral valves must be re-installed into correct
The service pressure in the primary
locations on the main hydraulic valve assembly. All
accumulator is 103 bar (1494 lbf/in²) and in the
integral valves must be torqued to correct value.
Front and Rear Brake accumulators is 55 bar
(798 lbf/in²) at 20° C (68o F). To prevent personal
injury and property damage do not attempt to 1. Re-install O.R.F.S. connectors into correct ports.
remove any valves or fittings until all nitrogen Replace o-rings and seals. Ref. Fig. 6
pressure is completely relieved. SM - 1335
2. Block all road wheels and place battery master FITTING NUT
switch in the 'Off' position. TUBE
3. Remove blanking cap from remote drain line at the

SLEEVE
'O' RING 'O' RING
4. Main hydraulic valve assembly is accessed by
raising the operator cab. (Refer to Section 260-0010,
CAB AND MOUNTING.)
WARNING 2. Support main hydraulic valve assembly with suitable

Never work under or near an unsupported lifting equipment, using eye bolt located on top face of
raised operator cab assembly. Always ensure the valve assembly.
cab safety prop is in correct position.
3. Manoeuvre main hydraulic valve assembly into
position and secure to vehicle with mounting hardware.
5. Clean outer area of the main hydraulic valve
assembly with a suitable cleaning solvent. Ensure all 4. Remove blanking caps from all hydraulic lines and
hydraulic lines connected to the main hydraulic valve fittings. Re-connect hydraulic lines to correct fittings
assembly are identified for ease of installation. With astagged at removal.
suitable containers catch any oil leakage when
disconnecting hydraulic lines. Install blanking caps to
5. Lower operator cab and secure. Ref. Section 260-
all open lines and fittings.
0010, CAB AND MOUNTING.
6. Support main hydraulic valve assembly with suitable
lifting equipment, using eye bolt.
6 SM 2442 Rev2 05-07

Section 215-0050
6. Fill hydraulic tank with hydraulic oil as described in 8. Check hydraulic tank oil level and replenish if
Section 300-0020, LUBRICATION SYSTEM. Ensure required.
arear around fill area is clean. Install filler cap on
hydraulic tank. 9. Bleed brake system after main hydraulic valve
removal. Ref. Section 165-0010 BRAKE PARTS.
7. Turn battery master switch to 'on' position, remove
any wheel blocks, start engine. Operate body and
steering systems. Check hydraulic lines and fittings for
leaks. Tighten where required.
Main Hydraulic Valve Assembly - Integral Valve Tightening Torques
Valve No. Description Qty. Tighten Torque Nm
CT1 Main Relief Valve 1 150
CT2 Ground Pump Relief Valve 1 60
CT3 Ground Pump unload Cartridge 1 100
CT3A Ground Pump Unload Orifice 1 5
CT4 Ground Pump Check cartridge 1 80
CT5 Steering Pump Check cartridge 1 80
CT6 Ground pump reverse flow Check 1 80
CT7 Priority Valve 1 150
CT8 Brake Check Valve 1 60
CT9 Bake Pressure Reducer 1 60
CT10 Accumulator Check Cartridge 1 60
CT11 Accumulator Check Cartridge 1 60
CT12 Unloader Pilot Cartridge 1 45
CT13 Unloader Orifice Plug 1 5
CT14 Cold Start Solenoid Valve 1 22
Coil Nut 1 3.5
CT15 Load Sense Orifice Plug 1 5
CT16 Steering Unload Shuttle 1 9
CT17 Load Sense Shuttle 1 9
CT18 Steering Orifice Plug 1 9
CT19 Pump Load Sense Orifice Plug 1 9
SM 2442 Rev2 05-07 7

Section 215-0050
Main Hydraulic Valve Assembly - Integral Valve Tightening Torques
Valve No. Description Qty. Tighten Torque Nm
CT20 Hoist LS Relief Valve 1 45
CT21 DC Pilot Control Reducer 1 60
CT22 Fan Speed Solenoid Cartridge 1 60
Coil Nut 1 3.5
CT23 Fan Speed Solenoid Cartridge 1 60
Coil Nut 1 3.5
CT24 Dual Check 1 9
CT25 Hoist Pilot Shuttle 1 9
CT26 Hoist / Fan Shuttle 1 9
CT27 DC Pilot Control Reducer (Raise) 1 30
Coil Nut 1 3.5
CT28 DC Pilot Control Reducer (Lower) 1 30
Coil Nut 1 3.5
CT29 Body Float Solenoid Cartridge 1 22
Coil Nut 1 3.5
CT30 Hoist LS Orifice Plug 1 5
CT31 Park Brake Solenoid Valve 1 20
Coil Nut 1 3.5
CT32 Main Brake Pilot Valve 1 20
CT33 Pilot Valve Orifice Plug 1 5
CT34 Hoist Shuttle 1 9
CT35 Accumulator Orifice Plug 1 20
CT36 Hoist LS Pilot Cartridge 1 20
CT37 Diff Lock Relief 1 45
CT38 Check Cartridge 1 45
CT39 Fan Orifice Plug 1 5
CT41 Hoist DC Valve 1
CT42 Anti Cavitation Check 1 42
CT43 Hoist Relief Valve 1 42
8 SM 2442 Rev2 05-07

Section 215-0050
SM2919
43
1 - Relief Valve 'CT1'
3 - Bypass sequence Valve'CT3'
6 - Check Valve 'CT6' 34
7 - Priority Valve 'CT7'
26 7
9 - Pressure Reducing Valve
10 - Check Valve 'CT10' 5
11 - Check Valve 'CT11' 8,35
12 - Brake Charging Valve 'CT12'
40
13 - Orifice 'CT13'
14 - Cold start solenoid Valve 'CT14' 21
15 - Orifice 'CT15' 4
16 - Shuttle Valve 'CT16' 9 22
18 - Shuttle Valve 'CT18' 15,18 14 23
33
19 - Shuttle Valve 'CT19' 16
32 29
20 - Body Raise LS Relief Valve 'CT20'
21 - Pressure Reducing Valve 'CT21' 31
22 - Proportional Pressure Control Valve (Fan Drive)'CT22'
23 - Proportional Pressure Control Valve (Fan Drive) 'CT23'
27 - Proportional Pressure Control Valve (Body Raise) 'CT27'
28 - Proportional Pressure Control Valve (Body Lower) 'CT28' 38 17 20
29 - FLoat Solenoid 'CT29'
30 - Orifice 'CT30'
31 - Park Brake Solenoid 'CT31'
32 - Directional Control Valve 'CT32' 25
33 - Orifice 'CT33' 2
34 - Hoist 'LS' Shuttle Valve 'CT34'
35 - Orifice 'CT35'
36 - Hoist LS Valve 'CT36' 36
37 - Relief Valve (Diff Lock / Centre Axle) 'CT37'
38 - Auxiliary Solenoid 'CT38' 30
41 - Body Control spool 'CT41' 27
44 - Check Valve 'CT44' (Integral to Body control spool) 1 28
10
3
41
6 19
42
12
13
37
11
39 24
Fig. 7 - Main Hydraulic Valve Assembly - Integral Valve Positions
SM 2442 Rev2 05-07 9

STEERING SYSTEM - Steering System Schematic
Section 220-0000
SM - 3507
A - Steering Orbitrol Valve

B - Steering Cylinders
B B C - Emergency Steering Pump
D - Main Hydraulic Pump
L R Integral Valves to Main Hydraulic Valve Assembly

A 1 - (CT1) Relief Valve
2 - (CT2) Emergency Steering Relief Valve
3 - (CT3) Emergency Steering Unload Valve
4 - (CT4) Check Valve
7 - (CT7) Priority Valve
15 - (CT15) Steering Load Sense Orifice
16 - (CT16) Shuttle Valve
19 - (CT19) Pump Load Sense Orifice
T LS P
3 16
15
17
5
4
6
2 18 19
Fig. 1 - Steering System Schematic
DESCRIPTION valve is connected to the steering column and controls

hydraulic oil flow to the steering cylinders.
Numbers in parentheses refer to Fig. 1
Steering Orbitrol Valve (A) The steering valve is of a closed centre design,
Refer to Section 220-0090, STEERING VALVE indicating oil is dead headed at the valve until it is
operated.
Mounted off the underside of the cab floor, the steering
SM 2423 Rev1 05-07 1

Section 220-0000
Steering Cylinders (B) OPERATION

Refer to Section 220-0120, STEERING CYLINDER.
PRIORITY FUNCTION
There are two single stage, double acting cushioned Numbers in parentheses refer to Fig. 1
steering cylinders on the machine. The cylinder base
end is connected to the front frame, and, the piston rod The priority function automatically ensures that the
end is connected to the articulation and oscillation steering and brake charging circuits are given
pivot. Single stage double acting means that the piston preference over the cooler fans and tipping functions.
rod can have oil applied to either side, extending or
retracting the piston rod. When the main pump (D) is not running, the priority
valve (7) is closed. As the main pump (D) starts
Cylinder mounting is by pins, spacers, seals and, rotating it builds up residual pressure entering the main
spherical bearings secured with circlips. Spherical hydraulic valve assembly at port P1. The pressure
bearings permit a limited amount of cylinder opens priority valve (7), feeding the main pump
misalignment when travelling over rough terrain. pressure through to the cooler fan drive & lift valve.
During the tipping operations and whilst the

Emergency Steering Pump (C) transmission cooler fan is running, if the demand
The emergency steering ground driven pump, mounted pressure at the brake charging or the steering circuit is
on the dropbox, provides flow to the steering circuit in less than these functions, the priority valve (7) remains
the event that the Main Pump (D) can no longer open, but the oil takes the path of the least resistance
function effectively. and the requirements of the brake charging or steering
circuits are met.
Main Hydraulic Pump (4) If the demand pressure for brake charging or steering
Refer to Section 230-0050, MAIN HYDRAULIC PUMP. circuit is higher than that demanded by the
transmission cooler fan drive or tipping function, this
Mounted off the transmission power takeoff, the main higher pressure will be fed to the main pump load
hydraulic pump supplies hydraulic oil for operating the sense line via the shuttle valves (16 & 17) and
steering, body, brakes and cooler fan drive circuits. therefore enable the main pump (D) to meet the brake
charging or steering circuit pressure requirements. At
The main hydraulic pump is an axial piston, variable the same time the higher load sense pressure assists
displacement type, with load sense and pressure the spring in the priority valve (7). The priority valve (7)
regulator. will then close to reduce the flow to the transmission
cooler fan or tipping circuit and therefore making sure
the brake charging & steering circuit always has
Valves 1, 2, 3, 4, 5, 6, 7,15,16,17,18 & 19 priority over the other vehicle functions.
These valves for part of the steering and emergency
steering circuit and are an integral part of the main
hydraulic valve assembly, mounted on the left hand PRIORITY FLOW CONTROL TO
side of the tractor frame. Refer to Section 215-0050, STEERING
MAIN HYDRAULIC VALVE ASSEMBLY.
This function ensures that the flow from the steering
valve (A) is maintained at all times regardless of the
Diagnostic Test Point
other pressure demand within the system.
Steering, main pump and load sense pressures can be
checked at the diagnostic check points located on the To achieve this function the pressure at the steering
left hand fender at the cab door. Refer to Fig. 2. valve (A) has to be at a level equal to that demanded
by the steering plus the differential control pressure set
Maximum steering system pressure is set at 240 bar by the steering valve.
(3500 lbf/in2). This is set by the main cut off
compensator on the pump. The pressure demanded by the steering is fed back to
the main pump (D) & the priority valve (7) via shuttle
valve (16). The priority valve (7) will close & the main
pump will increase its displacement to make sure there
2 SM 2423 Rev1 05-07

Section 220-0000
is enough flow & pressure available to meet that going towards the main pump (D), which may already
demanded by the steering. have failed.
The steering load sense orifice (15) feeds oil from the
main pump supply, to boost the load sense pressure STEERING PRESSURE SETTING
back to the main pump during the steering operation.
This is to make sure an adequate flow is always WARNING
available from the main pump (D) to meet that Machine has to fully articulate to set steering
demanded by the steering. This is commonly known as pressure, therefore steering lock bar cannot be
a dynamic load sense system. 'Locked'. To prevent personal injury and
property damage, exercise extreme caution
Note: The maximum steer pressure is set by the while working around articulation and
pressure cut off (compensator) on the main hydraulic oscillation pivot area.
pump (240 bar (3480 lbf/in2)). Refer to Section 230-
0050 MAIN HYDRAULIC PUMP. The maximum steer pressure is set by the pressure
cut off (compensator) on the main pump (240 bar (3480
lbf/in2)). Refer to Section 230-0050, MAIN HYDRAULIC
EMERGENCY STEERING PUMP.
The emergency steering ground driven pump (C)
provides flow to the steering circuit in the event that Steering pressure can be checked at the diagnostic
the main pump (D) can no longer function effectively. check point located on the diagnostic plate, located
direclty outside the cab door on the base of the LH
Engine failure, transmission failure or internal failure of fender stand point. (refer to Fig. 2). Install pressure
the main pump (D) could cause ineffective gauge capable of reading at least 240 bar (3480 lbf/in2)
performance. to correct diagnostic check point (9, fig,2).
The emergency steering pump (C) will also assist with Steer truck over relief (against steering stops) to
flow from the main pump to articulate the vehicle if the observe maximum cut-off pressure of 240 bar (3480
main pump cannot deliver the flow required by the lbf/in2). Adjustment of the main pump should not be
steering circuit. This can happen at low engine speed necessary as the units are set by the manufacturer.
when the vehicle is moving and the operator attempts Should the pressure cut-off be incorrect, follow the
to articulate the vehicle rapidly. procedure given. Refer to Section 230-0050, MAIN
HYDRAULIC PUMP.
To protect the ground driven emergency steering pump
(3) the maximum pressure at the pump is set by the SM - 2849
relief valve (2) to 240 bar (3480 lbf/in2).
The emergency steering unload valve (3) is sensing the 1

2
main pump (D) pressure and the load sense pressure 3
at the spring end of the valve (3). During normal 4
5
operation the differential pressure between the main 6
9 7
pump (D) outlet and the load sense line will be 10 8
approximately 35 bar (507 lbf/in2) and the emergency 11
12
steering unload valve (3) will stroke against its spring 13
14
dumping the emergency steer pump (C) flow to tank. 15
In the event of the main pump (D) not been able to

supply sufficient flow for the steering, the differential
1 - Front Brake Accumulator 9 - Steering Pressure
pressure between the main pump (D) outlet and the
load sense line will be reduced. As soon as the 3 - Primary Accumulator 11 - DropBox Lube Pressure
differential pressure drops below 6 bar (87 lbf/in2) the 4 - Front Brake Pressure 'TP3'
emergency steering valve (19) will close and the 5 - Rear Brake Pressure 12 - Main Pump (Front)
6 - Parking Brake Pressure 13 - Main Pump (Rear)
ground driven pump (3) flow will be diverted across
7 - Diff-lock Pressure 'TP1' 14 - Pump LS Pressure
check valve (4) and supply the steering system. 8 - High / Low Select 'TP2' 15 - Body Hoist Pressure
Check valve (5) prevents the emergency steer flow Fender
SM 2423 Rev1 05-07 3

Section 220-0000
SM - 3508a-b
(1)
(7)
(5)
(4)
(15 & 18)

(16)
(17)
(2)
1 - (CT1) Relief Valve

2 - (CT2) Emergency Steering Relief Valve
3 - (CT3) Emergency Steering Unload Valve
4 - (CT4) Check Valve (3)
(6) (19)
7 - (CT7) Priority Valve
17 - (CT17) Shuttle Valve (under CT20)
19 - (CT19) Pump Load Sense Orifice
Fig. 3 - Steering System Valves Integral to Main Hydraulic Valve Assembly
4 SM 2423 Rev1 05-07

Section 220-0000
'O' RING FACE SEALS (ORFS)

Where hydraulic lines are fitted with ORFS WARNING
connections, the following procedure should be carried Do not operate the machine until all air is bled
out during 'Installation'. Refer to Fig. 4. from the oil.
a. Ensure 'O' ring/seal is in place and that the joining b. When the oil in the tank is clear (not cloudy or
surfaces are clean. If necessary, retain 'O' ring/seal in creamy), the system is free of air.
place with a light coating of grease or vaseline.
Note: Slight creep or drift of the steering wheel is
b. Initially, the nuts should be tightened by hand. normal.
c. Where a hose is fitted, ensure that it is not twisted c. Fill hydraulic tank to the recommended level and
or kinked when the nuts are tightened so that it is install the filler cap.
Hydraulic Oil
d. Where a tube is fitted, ensure that the connection is
aligned correctly. The steering system should be kept filled with
hydraulic oil as listed in Section 300-0020,
e. Tighten the nut a further 1/4 to 1/2 a turn using the LUBRICATION SYSTEM.
correct size spanner (wrench).
MAINTENANCE
f. Check that a satisfactory hose or tube routing has
been achieved. Maintenance instructions, intervals and warnings, in
the individual steering and body hydraulic component
SM - 1335 sections of this manual, should be adhered to at all
times.
FITTING NUT
TUBE
SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, SERVICE
SLEEVE TOOLS, for part numbers of these tools.
'O' RING 'O' RING
Fig. 4 - Assembly of Typical ORFS Connector Multi-Gauge

FILLING AND BLEEDING THE STEERING The multi-gauge, 15269784, is basically four pressure
gauges in one. Continuous system pressure readings
SYSTEM
are indicated on one of three simultaneously reading
1. Fill hydraulic tank to maximum level. Be ready to gauges through a pressure range of 30 in of vacuum to
add oil when the engine is started. Do not let oil drop 5 000 lbf/in².
below the pump suction line to prevent air entering the
system. The following items should be added to the multi-gauge
to enable the gauge to be used on the diagnostic
2. Start engine and let it idle. Immediately add oil to the pressure check points;
tank as required. When no more oil can be added and 15018226 Diagnostic Coupling
oil is clear, proceed as follows: 00118748 Connector (2 off)
15004085 Hose Assembly (-04 HP, 2130 mm long)
a. Turn the steering wheel from lock to lock to bleed
the air in the steering cylinders and lines.
Note: Immediately upon valve spool actuation oil must The infrared thermometer, 15269785, can be used to
be added to the hydraulic tank to replenish the oil spot heat problems early in electrical, mechanical and
moving into the circuit. hydraulic systems. Hand held and easy to use, you
SM 2423 Rev1 05-07 5

Section 220-0000
simply aim, pull the trigger, and read the temperature. O' Ring Face Seals (ORFS) - Seal Kit
Since there is no need to touch what you are
The steering system utilizes 'O' Ring Face Seal
measuring, temperatures of hard-to-reach or moving
(ORFS) connectors. An ORFS kit, 15271082, is
components can be taken without getting burned or
available. This kit contains a minimum stock
shocked.
requirement of all sizes of ORFS type seal.
Steering System Troubleshooting
SYMPTOM POSSIBLE CAUSE REMEDY

System does not reach maximum Fault with main pump or pressure Reference main hydraulic
operating pressure cut off incorrectly set. pump.
Faulty relief valve (CT1) Replace valve
Faulty priority valve (CT7) Replace valve
Contamination in LS orifice (CT15) Replace / Clean.
or (CT18)
Heavy steering due to not enough Fault with main pump or standby Reference main hydraulic
pressure being available at the pressure incorrectly set. pump.
steering valve but differential Faulty Orbitrol steer valve Check Orbitrol steer valve
pressure between the main pump output
outlet and load sense port is 35 bar Faulty priority valve (CT7) - Stick- Replace valve
(507lbf/in2) ing open. Replace / Clean
Fault in LS orifice (CT15) or (CT18). Replace Valve
Leaking shuttle valve (CT16) Replace Valve
Emergency steer unload valve Replace Valve

No steering flow available when the (CT3) spool sticking open.
vehicle is still travelling and engine Emergency steer relief valve (CT2)
is switched off - pressure set too low. Check output from ground
Faulty ground driven pump. driven pump - replace if neces-
sary.
Emergency steer valve (CT3) spool Replace Valve.

With no function operated pressure sticking closed.
at ground driven pump too high
6 SM 2423 Rev1 05-07

STEERING SYSTEM - Steering Valve
Section 220-0090
SM - 3381
28
29
27
28
29
27
9
10
26
25
24 4 3 2 1
5
9
8 7 6
10
'T'
'P'
'L'
'R'
11
12
19
15
9
10
13
17 16
18
20 14
22 21
23 'X' - Designates Port Detail
1 - Cap Screw 8 - Valve Housing 15 - Spool 22 - Dust Seal

2 - End Cap 9 - 'O'-Ring 16 - Brg Race (Outer) 23 - Retaining Ring
3 - 'O'-Ring 10 - Plug 17 - Neddle Brg (Cage) 24 - Centering Spring
4 - Gerotor 11 - Driveshaft 18 - Brg Race 25 - Ball
5 - 'O' Ring 12 - Sleeve 19 - Seal 26 - Key
6 - Wear Plate 13 - Centering Pin 20 - 'O'-Ring 27 - Relief Valve Spool
7 - 'O'-Ring 14 - Ball Valve 21 - Front Retainer 28 - Plug
29 - 'O'-Ring
Fig. 3 - Exploded View of Steering Valve Assembly
DESCRIPTION (15), sleeve (12), driveshaft (11) and gerotor gear (4)
There are five ports on valve housing (8) as follows:
The Steering Valve can be identified as item 'A' in
Section 220-0000, STEERING SYSTEM SCHEMATIC. Port 'P' - Supply from main hydraulic valve
Port 'T' - Return to tank
The steering valve is connected to the steering column Port 'R' - Cylinder supply for right hand turn
and controls hydraulic flow in the steering system. A Port 'L' - Cylinder supply for left hand turn
pressure relief line in the neutral position, between Port 'LS' - Load Sensing to main hydraulic valve
steering cylinder ports 'L' & 'R' and tank return port 'T',
means that the steering valve must only be used with Turning action of the steering wheel is transmitted
a flow amplifier valve. Refer to Section 220-0100, through the steering column to sleeve (8) and
FLOW AMPLIFIER VALVE. driveshaft (11), which is fastened to the sleeve with
centring pin (13). Rotation of driveshaft (11) causes
The steering valve consists of valve housing (8), spool gerotor gear to rotate in gerotor housing (4). When
SM 264 04-06 1
Steering System - Steering Valve
Section 220-0090
gerotor gear rotates, oil in gerotor housing (4) pockets SM - 282
(see Fig. 2) is forced out and flows through spool (15)
POCKETS
and sleeve (12) to the steering cylinder port.
Spool (15) contains porting matched to sleeve (12)

and rotates within sleeve (12) to provide directional
control of the oil. See Fig. 3.
OPERATION
When the operator turns the steering wheel a certain GEROTOR HOUSING GEROTOR GEAR
number of degrees for either a left or right hand turn,
Fig. 2 - Gerotor Gear Set
the movement is transmitted through the steering
column to spool (15). After a minimum rotation of 2.5
degrees, the ports in spool (15) start to align with ports SM - 283
in sleeve (12). When the steering wheel is rotated to a RIGHT LEFT

maximum of 10 degrees the ports are fully aligned SYSTEM TURN TURN
allowing full oil flow. After 10 degrees of travel in either PRESSURE FEED FEED
direction the spool and sleeve rotate as an assembly METER TO
PORTS TANK
through centring pin (13).
Oil from the priority valve flows into valve housing (8)
at port 'P' and is channelled through sleeve (12) and
spool (15) to gerotor housing (4). Porting in gerotor
housing (4) permits oil to flow into pockets formed by
gerotor housing (4) and gerotor gear. As spool (15)
rotates, driveshaft (11) also rotates which, in turn,
rotates gerotor gear to which it is splined. When
gerotor gear rotates it progressively forces oil out of
the pockets (see Fig. 2) of gerotor housing (4). The oil Fig. 3 - Porting of Spool and Sleeve
is channelled through sleeve (12) and spool (15) and
exits valve housing (8) through port 'R' for a right hand REMOVAL
turn, or port 'L' for a left hand turn. Oil then travels
through steering lines to the steering cylinders. Numbers in parentheses refer to Fig. 4.
As the steering cylinder pistons move, oil forced out of

the steering cylinders returns to valve housing (8). The WARNING
return oil passes through valve sleeve (12) and spool To prevent personal injury and property
(15) and exits through port 'T' to tank. damage, be sure wheel blocks, blocking
When the steering effort is released, centring spring secured and of adequate capacity to do the job
(13) which was put under tension by the rotation of safely.
spool (15), forces sleeve (12) to rotate back to its
original position. This puts the ports out of alignment 1. Position the vehicle in a level work area, apply the
and stops pump oil flow to the steering cylinders. The parking brake and switch off the engine. Turn steering
vehicle stops turning further but will hold the present wheel several times to relieve any pressure in the
turning radius until spool (12) is rotated past the 2.5 steering circuit. Operate brake pedal continuously to
degree minimum. relieve pressure in the braking system.

3. Remove hydraulic tank remote drain plug and drain
2 SM 2364 04-06
Section 220-0090
SM - 2827
12 22
20 21
13
14
18
19
12
7
6 9 16
5
10
4 11 17
2 8
1 15
1 - Steering Valve 9 - Nitrile Seal 16 - Beading

2 - Locknut 10 - Bolt 17 - Steering Column Assy
3 - Washer 11 - Lockwasher 18 - Bracket
4 - Rubber Mount 12 - Joint 19 - Column Cover
5 - Mounting Plate 13 - Bellows 20 - Steering Wheel
6 - Washer 14 - Steering Shaft 21 - Nut
7 - Bolt 15 - Lever 22 - Cap
8 - Stub Shaft
Fig. 4 - Exploded View of Steering Valve Installation
hydraulic oil into a suitable container. Reinstall drain tightens joint (12) onto stub shaft (8).
plug in hydraulic tank remote drain fitting.
7. Support steering valve (1) and remove bolts (7),
4. Pull floor mat back to allow access to bolts (7). locknuts (2) and washers (3 & 6) securing mounting
Raise cab and secure with prop. Refer to Section 260- plate (5) to cab floor. Remove steering valve (1) and
0010, CAB AND MOUNTING. mounting plate (5) to a clean area for disassembly.
Remove nitrile seal (9) and discard rubber mounts (4),
5. Clean outer area of steering valve (1) with a suitable if damaged.
solvent. Ensure all hydraulic lines connected to
steering valve (1) are identified for ease of installation
and with suitable containers available to catch
leakage, disconnect hydraulic lines. Cap all lines and
plug all ports to prevent entry of dirt.
6. Slide bellows (13) over steering shaft (14) to gain

access to bottom joint (12) and loosen bolt which
SM 264 04-06 3
Section 220-0090
DISASSEMBLY (19) over end of drive shaft (6) and engage special tool
with splined end of spool (16). Refer to Fig. 6.
8. Hold gerotor gear (19) and prevent drive shaft (6)
from turning. Twist special tool to compress centering
Note: Steering valves fitted with anti-cavitation valves
spring (11) radially CW or CCW, decreasing the coil
must be disassembled and assembled in the vertical
diameter of the centering spring (11) allowing spool
postion to prevent ball valves (24) becoming trapped in
and sleeve assembly to be removed. Refer to Fig. 7.
the wrong cavities within the valve housing (7).
SM - 2019
1. Remove bolts (10, Fig. 4) and washers (11, Fig. 4)
securing mounting plate (5, Fig. 4) to steering valve (1, 11
19
Fig. 4).
2. Clamp steering valve assembly horizontally in a soft

jawed vice and break loose the seven capscrews (1).
With capscrews (1) loosened, place steering valve
vertically in vice, end cap (2), up.
SM - 2018
10
19
10 - Pin 19 - Gerotor Gear
11 - Centring Springs
Fig. 7 - Compressing Centering Spring
9. With drive held stationary and centering spring (11)

compressed, carefully push spool (16), sleeve (8), ball
checks (9), drive shaft (6), pin (10), bearing races (13),
retainer (20) and needle thrust bearing (12), as a complete
assembly, from valve housing (7). Refer to Fig. 8.
19 - Gerotor Gear
SM - 2020
Fig. 6 - Gerotor Gear and Splined Drive Engaged
19
Note: Hidden pin. If tension on this pin is released

before these parts are fully disengaged and the pin is
not horizontal, the pin can drop and lockup can occur.
3. Remove cap screws (1) securing end cap (2),

gerotor housing (4) and spacer plate (5) to valve
housing (7). Remove end cap (2) from valve
housing (7) and discard 'O' ring (3).
4. Remove gerotor housing (4) and gerotor gear (19)

19 - Gerotor Gear
from valve housing (7). Remove and discard 'O' ring
(21) from gerotor housing (4).
Fig. 8 - Removing Spool and Sleeve Assembly
5. Remove spacer plate (5) from valve housing (7).
10. Remove bearing race (13) and needle thrust
6. Remove and discard 'O' ring (22) from valve bearing (12) from spool and sleeve assembly.
housing (7).
7.Using a cloth to protect the hand, place gerotor gear
4 SM 2364 04-06
Section 220-0090
11. Using suitable pliers, remove retainer (20) and INSPECTION

bearing race (13) from spool (16) and sleeve (8)
1. Clean all metal parts in a suitable solvent and blow
assembly. Refer to Fig. 9.
dry with compressed air. Do not wipe dry with cloth or
paper towel as lint or other matter may get into the
12. Remove centering spring (11) from spool (16) and
hydraulic system and cause damage.
sleeve (8) assembly. Refer to Fig. 9.
2. Check all mating surfaces and replace any parts
SM - 2021 that have scratches or burrs that could cause leakage.
6 8 11 13 3. Do not use course grit or try to file any metal parts.

20
Note: Replace all 'O' rings and seals with new 'O' rings
and seals at 'Assembly'. Lubricate all 'O' rings and
seals with a petroleum jelly.
ASSEMBLY

9 9 10 16
6 - Driveshaft 11 - Centring Springs
8 - Sleeve 13 - Bearing Race SPECIFICATIONS.
9 - Ball - Check 16 - Spool
10 - Pin 20 - Retainer Note: Steering valves fitted with anti-cavitation valves
must be disassembled and assembled in the vertical
Fig. 9 - Sectional View of Spool and Sleeve Assembly
postion to prevent ball valves (24) becoming trapped in
the wrong cavities within the valve housing (7).
13. Remove pin (10) and slide drive shaft (6) from 1. Use a soda straw as a guide tool to insert the roll
spool (16) and sleeve (8) assembly. Refer to Fig. 9. pin (23) and ball valve (24) into the anti-cavitation
valve ports. Insert soda straw into anti-cavitation valve
14. Carefully remove spool (16) and ball checks (9) bore. Drop ball valve (24) through straw into bore.
from sleeve (8). Refer to Fig. 9. Remove straw and drop roll pin (23) into bore. Repeat
for second anti-cavitation valve bore. Refer to Fig. 11.
15. Use a soda straw as a guide tool to remove the roll
pin (23) and ball valve (24) from the anti-cavitation 2. Apply a light coating of clean hydraulic fluid to spool
valve ports. Insert two soda straws, one in each anti- (16). Slide spool (16) and ball checks (9) into sleeve
cavitation valve bore. Remove valve housing (7) from (8). Refer to Fig. 12.
vice and tilt until roll pins (23) and ball valves (24) slide
through the straws and out of the valve housing (7). 3. Insert drive shaft (6) into spool (16) in sleeve (8)
Refer to Fig. 10. carefully so that holes line up. Install pin (10) through
sleeve (8), spool (16) and drive shaft (6) assembly
16. Remove and discard 'O' ring (14), seal (17) and until pin (10) becomes flush at both sides of sleeve (8).
backup ring (18) from valve housing (7). See Figs. 12 & 13.
17. Using a thin blade screwdriver, pry dust seal (15) 4. Position one end of centring spring (11) into slotted
from valve housing (7). Take care not to damage dust end of spool (16). Compress centring spring (11)
seal seat. radially (CCW) and engage free end of spring into slot
in spool (16). See Fig. 14.
5. Install bearing race (13) onto spool (16). Using

suitable pliers install retainer (20) onto spool (16). See
Fig. 14.
SM 264 04-06 5
Section 220-0090
SM - 2022 6. Apply a light coating of petroleum jelly to the inside

PORT FACE diameter of dust seal (15) and install in valve housing (7).
7. Apply a light coating of petroleum jelly to needle

thrust bearing (12), bearing race (13), 'O' ring (14), seal
ring (17) and backup ring (18). Install each item onto
spool (16), as shown in Fig. 15.
PORT
FACE
Note: Needle thrust bearing is positioned between the
two bearing races (13) and must be centered around
TOP retainer (20).
VIEW
24 Note: Clamp steering valve housing (7) vertically in a

Anti-Cavitation Valves -
Insert Soda Straws (2), soft jawed vice.
one into each of these
two threaded holes. 23 8. Using a cloth to protect the hand, place gerotor gear
(19) over end of drive shaft (6). Insert special tool
through valve housing (7) and engage with splined end
TILT of spool (16) and sleeve (8) assembly. Twist tool to
HOUSING compress centering spring (11) radially CW or CCW.
Refer to Fig. 16.
SODA STRAW
9. Keep centering spring (11) compressed and
carefully insert assembled parts into valve housing (7),
23 - Roll Pin
24 - Ball Valve
Fig. 10 - Removing Ball Valves 10. Release tension on centering spring (11) and
remove special tool and gerotor gear (19).
SM - 2023
PORT FACE 11. Lubricate and install new 'O' ring (22) in groove in
valve housing (7). Refer to Fig. 18.
23
12. Install spacer plate (5) with the 'O' ring groove up, on
valve housing (7). Align bolt holes in spacer plate (5) with
24
tapped holes in valve housing (7). Refer to Fig. 18.
13. Lubricate and install new 'O' ring (21) in groove in

GUIDE TOOL spacer plate (5). Refer to Fig. 18.
(Soda Straw)
14. Install gerotor housing (4) on valve housing (7).

Align bolt holes in gerotor housing (4) with tapped holes
Anti-Cavitation Valves in valve housing (7). Refer to Fig. 18.
15. Align gerotor gear (19) on driveshaft (6) and gerotor

housing (4), as shown in Fig. 18.
16. Lubricate and install new 'O' ring (3) in groove in

gerotor housing (4).
17. Install end cap (2) on gerotor housing (4), as shown

in Fig. 18.
23 - Roll Pin
24 - Ball Valve 18. Align cap screw (1) holes and install seven dry cap
Fig. 11 - Installing Ball Valves
6 SM 2364 04-06
Section 220-0090
SM - 2024 SM - 2027
6 8 11 13
6 8
16
10
6 - Drive Shaft
8 - Sleeve
9 - Ball Check
10 - Pin 9 9 10 16
16 - Spool
9
Fig. 12 - Installing Spool and Ball Checks
SM - 2025
17
6 16
18
6 - Drive Shaft
20
8 - Sleeve
9 - Ball Check 12 14
8 10 10 - Pin
11 - Centring Springs 16 - Spool
12 - Needle Bearing 17 - Seal
6 - Drive Shaft 10 - Pin 13 - Bearing Race 18 - Backup Ring
8 - Sleeve 16 - Spool 14 - 'O' Ring 20 - Retainer
Fig. 13 - Installing Centring Pin and Drive Shaft Fig. 15 - Sectional View of Seals and Bearings
SM - 2026
INSTALLATION

in Section 300-0080, STANDARD BOLT AND NUT
11 16 13 20 Note: Tighten all hydraulic lines fitted with ORFS

11 - Centring Springs 16 - Spool 'O' rings where used.
13 - Bearing Race 20 - Retainer
Fig. 14 - Installing Bearing Race and Retainer

WARNING
screws (1) in end cap (2). Pre-tighten cap screws (1) to damage, be sure wheel blocks, blocking
17 Nm (12.5 lbf ft) then tighten to a torque of 34 Nm materials and lifting equipment are properly
(25 lbf ft), in the sequence shown in Fig. 19. secured and of adequate capacity to do the job
safely.
19. Using bolts (10, Fig. 4) and washers (11, Fig. 4)
secure mounting plate (5, Fig. 4) to steering valve (1,
Fig. 4).
SM 264 04-06 7
Section 220-0090
SM - 2028 SM - 2029
Fig. 16 - Compressing Centering Spring Fig. 17 - Installing Spool and Sleeve Assembly
SM - 2030
7
3 4 19 21 5
1
22
1 - Capscrew 4 - Gerotor Housing 19 - Gerotor Gear

2 - End Cap 5 - Spacer Plate 21 - 'O' Ring
3 - 'O' Ring 7 - Valve Housing 22 - 'O' Ring
Fig. 18 - Installing Seals and Gerotor Assembly
1. Make certain area of installation is clean. 260-0010, CAB AND MOUNTING.
2. Install rubber mounts (4) if removed, and secure 7. Fill hydraulic tank with hydraulic oil, as specified in
steering valve (1) and mounting plate (5) to cab floor Section 300-0020, LUBRICATION SYSTEM. Refer to
with bolts (7), washers (3 & 6) and locknuts (2). 'Filling and Bleeding The Steering System'.
3. Install nitrile seal (9) to steering shaft (14). 8. Remove wheel blocks from all road wheels, place
the battery master switch in the 'On' position and start
4. Slide bottom joint (12) of steering shaft (14) over the engine. Operate the steering and check hydraulic
stub shaft (8) and secure by tightening bolt. Slide lines for leaks. Tighten lines and fittings as required.
bellows (13) down over bottom joint (12) and stub
shaft (8).
5. Remove plugs from steering valve ports and caps

from steering lines and install steering lines to steering
valve (1), as identified at removal.
6. Lower cab and secure with pins. Refer to Section
8 SM 2364 04-06
Section 220-0090
SM - 313
WARNING
Do not operate the vehicle until all air is bled
from the oil.
b. When the oil in the tank is clear (not cloudy or

creamy), the system is free of air.
Note: Slight creep or drift of the steering wheel is normal.

Fig. 19 - Cap Screw Tightening Sequence
c. Fill hydraulic tank with hydraulic oil specified in
FILLING AND BLEEDING THE STEERING Section 300-0020, LUBRICATION SYSTEM. Refer to
SYSTEM Section 230-0040, HYDRAULIC TANK, for correct fill
level. Install filler cap on tank.
1. Fill hydraulic tank to Maximum level. Be ready to
add oil when the engine is started. Do not let oil drop
below the pump suction line to prevent air entering the SPECIAL TOOLS
system.
Refer to Section 300-0070, SERVICE TOOLS, for
details of the centring spring installation tool
2. Start engine and let it idle. Immediately add oil to the
referenced in this section. This tool is available from
hydraulic tank as required. When no more oil can be
your dealer.
added and oil is clear, proceed as follows:
a. Turn the steering wheel from lock to lock to bleed

the air in the steering cylinders and lines.
Note: Immediately upon valve spool actuation oil must

be added to the hydraulic tank to replenish the oil
moving into the circuit.
SM 264 04-06 9
Section 220-0090

TORQUE
5 1 Capscrew 34 25
STEERING CONTROL DIAGNOSIS

Steering wheel does not centre Binding in steering linkage to valve Align as required
Worn gerotor Replace parts
Broken centring springs Replace centring springs, drain
and flush system
Burrs on sleeve or spool Disassemble and repair or replace
parts
Apparent inability to steer when Dirt in system Drain and flush system. Refill with
wheel is turned slowly clean oil
Slow steering Excessive wear in sleeve and spool Replace sleeve and spool
Excessive wear in gerotor Replace gerotor
Hard steering See 'Slow Steering'
Opposite steering Lines hooked up incorrectly Reconnect correctly
Wrong orientation between gerotor Realign per instructions
and gerotor drive
Steering wheel rocking back See 'Opposite Steering'
and forth
Steering wheel continues to turn Input linkage binding Align as required
Burr on sleeve or spool Disassemble and repair or replace
Dirt in system Drain and flush system. Refill with
clean oil
Broken centring springs Replace centring springs, drain and
flush system
No steering action Sleeve and spool locked together Disassemble and repair or replace
* * * *
10 SM 2364 04-06
STEERING SYSTEM - Steering Cylinder
Section 220-0120
SM - 3412
9,10
7 2 8 12
22 6 4 5
22
16 15 15 16
3
23 13 14
11
18 18
21 21
20 20
17 17
19 19
1 - Cylinder Assembly 9 - 'O'-ring 16 - Bearing (Spher.)

2 - Piston Rod 10 - Guide Ring 17 - Pin
3 - Rod Seal 11 - Piston 18 - Bolt
4 - 'O'-ring 12 - Wear Ring 19 - Spacer
5 - Backup Ring 13 - Circlip 20 - Hardened Washer
6 - End Cap 14 - Seal Bushing 21 - Lockwasher
7 - Cylinder Body 15 - Retaining Ring 22 - Grease Nipple
8 - 'O'-ring 23 - Wiper Seal
Fig. 1 - Sectional View of Steering Cylinder and Mounting
DESCRIPTION spherical bearings (16) secured with bolts, hardened

washers and lockwashers (18, 20 & 21). Spherical
bearings (16) permit a limited amount of cylinder
misalignment when travelling over rough terrain.
The steering cylinders can be identified as item 2 in
Section 220-0000, STEERING SYSTEM SCHEMATIC.
OPERATION
There are two single stage, double acting cushioned
When the operator turns the steering wheel for a
steering cylinders on the machine. The piston rod (2)
steering operation, movement of the piston rod
end is connected to the articulation and oscillation
generates force required to pivot the tractor frame.
pivot, and, the cylinder base end is connected to the
front frame. Single stage double acting means that
In the neutral position, with the steering valve
piston rod (2) can have oil applied to either side,
centralized, oil movement between the steering
extending or retracting the piston rod.
cylinders and the steering valve is stopped. Trapped oil
in the system locks both steering cylinders and the
Rod end cylinder mounting is by pins (17), spacers
angle of steering set by the operator is maintained.
(19) and spherical bearings (16) secured with bolts,
Refer to Section 220-0090, STEERING VALVE, for
hardened washers and lockwashers (18,20 & 21). Base
operation of the steering valve.
end cylinder mounting is by pins (17), spacers (19) and
SM 2399 01-06 1
Steering System - Steering Cylinder
Section 220-0120
REMOVAL DISASSEMBLY
WARNINGS WARNING
damage, be sure wheel blocks, blocking damage, be sure lifting equipment is properly
materials and lifting equipment are properly secured and of adequate capacity to do the job
secured and of adequate capacity to do the job safely.
safely.
1. Ensure clean working conditions, remove any port
Hydraulic fluid pressure will remain plugs thus allowing easy entry of air into the cylinder,
within the system after engine shutdown. preventing a vacuum when parts are withdrawn from
Operate the treadle pedal continuously until the cylinder body (7).
pressure has dissipated before carrying out any
work on the hydraulic system or serious injury 2. Remove retaining rings (15) from base end of
could result. cylinder body (7) and piston rod (2) end. Press out
spherical bearings (16).
parking brake and switch off the engine. Turn steering 3. Using special tool which can be fabricated as shown
wheel several times to relieve any pressure in the in Fig. 2, unscrew end cap (6) until thread is
steering circuit. Operate brake pedal continuously to disengaged from cylinder body (7).
relieve pressure in the braking system.
4. Pull end cap (6) and piston rod (2) out of cylinder
2. Place steering lock bar in the 'Locked' position. body (7) as an assembly.
Block all road wheels and place the battery master
switch in the 'Off' position. 5. Place piston rod (2) on supports which will not
damage the chrome piston rod diameter.
3. Identify, tag and with a suitable container in position
to catch the spillage, disconnect all hydraulic lines on 6. Remove and discard guide ring (10), 'O'-ring (9) and
one steering cylinder. Cap all lines and fittings to wear ring (10) from piston (11).
prevent ingress of dirt.
7. Provide an anti-torsion device through piston rod (2)
4. Support steering cylinder with a suitable lifting eye to allow unscrewing of piston (11). Unscrew piston
device. (11) from piston rod (2).
5. Remove bolt (18), lockwasher (21) and hardened 8. Remove and discard 'O' ring (8) from piston (11).
washer (20) securing pin (17) at base end of the
cylinder. Remove pin (17) securing base end to the 9. Pull end cap (6) assembly off piston rod (2). Remove
front frame. and discard back up ring (5) and 'O' ring (4) from end
cap (6) outer grooves. Remove and discard wiper (23)
6. Remove bolt (18), lockwasher (21) and hardened and rod seal (3) from end cap (6) inner grooves.
washer (20) securing pin (17) at piston rod (2) end of
the cylinder. Remove pin (17) securing piston rod (2) 11. If damaged, remove grease fittings (22) from
end to the articulation and oscillation pivot. cylinder body (7) and piston rod (2).
7. Remove cylinder assembly (1) from the machine.

Spacers (19) will come free at this time.
8. Remove cylinder assembly (1) to a clean area for

disassembly. Drain oil from cylinder assembly into a
suitable container.
9. Repeat steps 3 through 8 for opposite steering

cylinder assembly.
2 SM 2399 01-06
Section 220-0120
INSPECTION 8. Fully grease piston (11) OD and 'O' ring (4) in end
cap (6).
9. Ensure bore of cylinder body (7) is well lubricated
1. Clean all parts of the cylinder with a suitable solvent
with hydraulic oil. Carefully insert piston rod (2) and end
and dry with clean, lint-free cloths. Clean all grooves
cap (6) assembly into cylinder body (7).
carefully to remove any foreign material.
10. Engage end cap (6) and cylinder body (7), thread
2. Check cylinder body (7), end cap (5) grooves and
screw up fully. Tighten end cap (3) to a torque of 542 -
outer diameter of piston (11) for scratches, cracks or
610 Nm (400 - 450 lbf ft).
other signs of damage. Remove ridges, nicks and
scratches with a fine stone and re-clean. Replace any
11. Replace lube fittings (4) if required.
components which cannot be repaired.
3. Inspect piston rod (2) for distortion, cracks or other INSTALLATION

defects. Replace piston rod (2) if defective area is
irreparable.
4. Check spherical bearings (16) for wear and replace if
necessary.
ASSEMBLY Note: Tighten all hydraulic lines fitted with ORFS

WARNING
WARNING
safely.
safely.
1. Press spherical bearings (16) in base end of cylinder
body (7) and piston rod (2) end. Secure spherical
1. Install a suitable strap, or other lifting device, around
bearings (16) with retaining rings (15).
one cylinder assembly and position cylinder assembly
(1) on the vehicle, with piston rod (2) end of cylinder
2. Install new rod seal (3) into bore of end cap (6) with
ready for mounting.
the lip pointing towards the internal face of end cap (6).
Install new wiper (23) into bore of end cap (6).
2. Install spacers (19) either side of piston rod (2) end
of cylinder. Insert pin (17). Secure pin (17) to
3. Install new back up ring (5) and 'O' ring (4) in
articulation and oscillation pivot with bolt (18),
external groove of end cap (6).
lockwasher (21) and hardened washer (20).
4. Guide end cap (6) assembly onto piston rod (2),
3. Install spacers (19) either side of base end of
taking care not to damage rod seal (3) on the thread.
cylinder and insert pin (17). Secure pin (17) to front
frame with bolt (18), lockwasher (21) and hardened
5. Install new 'O' ring (8) into internal groove of piston
washer (20).
(11).
4. Connect hydraulic lines to steering cylinder ports, as
6. Using a suitable C-spanner or fabricated tool, screw
tagged during removal.
piston (11) on piston rod (2). Tighten piston (11) to a
torque of 746 - 813 Nm (550 - 600 lbf ft).
5. Repeat steps 1 through 4 for installation of opposite
steering cylinder.
7. Insert new 'O'-ring (9), guide ring (10) and new wear
ring (12) in piston (11) external grooves.
SM 2399 01-06 3
Section 220-0120
6. Lubricate pins (17) through grease nipples (22 ) with MAINTENANCE
lubricant, as specified in Section 300-0020,
Inspect steering cylinders regularly for leaks or
LUBRICATION SYSTEM.
damage, repair as required. Lubricate cylinder pins
every 250 hours, as specified in Section 300-0020,
7. Check oil level in hydraulic tank and add oil if low.
LUBRICATION SYSTEM.
Refer to Section 230-0040, HYDRAULIC TANK, for
correct fill level. Refer to Section 300-0020,
LUBRICATION SYSTEM, for the type of oil used. SPECIAL TOOLS
8. Place the steering lock bar in the 'Stowed' position
and remove wheel blocks.
numbers of general service tools required. These tools are
start the engine and operate the steering, from lock to
lock several times, to purge air out of the hydraulic
lines. Check hydraulic lines and fittings for leaks.
Tighten lines and fittings as required.

TORQUE
1 9 Piston 746 - 813 550 - 600
1 3 End Cap 542 - 610 400 - 450
1 10 Grub Screw 13 - 20 10 - 15
* * * *
4 SM 2399 01-06
BODY SYSTEM - Body System Schematic
Section 230-0000
SM - 3534
ACC3
PS5 DL
1 1
TPA
27
PPA
21
T2
28
8 41 42 LOWER
25
B
43
PS1
35
7
HOIST
P1 29 A
LSM
44
26
17
20 36
30
34
19
LSP T1 TPB
PPB
1 - Body Cylinders 26 - Shuttle Valve 34 - Shuttle

17 - Shuttle Valve 27 - Proportional Control Valve (Raise) 36 - Hoist Load Sense Valve
20 - Load Sense Relief Valve 28 - Proportional Control Valve (Lower) 41 - Control Spool
21 - Pressure Reducing Valve 29 - Float Solenoid 42 - Anti Cavitation Valve
25 - Shuttle Valve 30 - Orifice 43 - Relief Valve
44 - Check Valve
Fig. 1 - Body System Schematic
DESCRIPTION service and operating instructions can be found in the

Numbers in parentheses refer to Figs. 1 through 9. relevant component sections of this manual.
Other useful reference reading; Sections 190-0000
CIRCUIT DIAGRAMS, 215-0050 MAIN HYDRAULIC Body Control Lever
VALVE ASSEMBLY and 230-0081 BODY CONTROL
LEVER. Refer to Section 230-0081, BODY CONTROL LEVER.
The body hydraulic system enables the operator to lift The body control lever is mounted on the right hand
and lower the body in a safe manner with an electric side dash panel inside the operators cab. The body
output from the body control lever. control lever is manually operated to control the lift and
lower function of the body assembly.
A brief description of the individual components used in
the body hydraulic system are listed below. Detailed
SM 2441 Rev1 05-06 1
Section 230-0000
Body Cylinders (1) Valves

Refer to Section 230-0130, BODY CYLINDER. 17,20,21,25,26,27,28,29,30,24,36,41,42 & 43
These valves form part of the body cuircuit and are an
There are two single stage, double acting body hoist intregal part of the main hydraulic valve assembly,
cylinders, cushioned at both ends of the stroke, on the mounted on the left hand side of the tractor frame.
vehicle. The cylinder base end is connected to the Refer to Section 215-0050, MAIN HYDRAULIC VALVE
trailer frame and piston rod eye end is connected at the ASSEMBLY.
body. Single stage double acting means that the piston
rod can have oil applied to either end, extending or
retracting the piston rod. OPERATION
The cushioning effect when the cylinder is being
extended is obtained by a tapered spear on the piston LIFTING THE BODY
rod passing through a cushioned sleeve. This gradually Refer also to Sections 190-0000 CIRCUIT DIAGRAMS
slows the piston which in turn helps to control and 215-0050 MAIN HYDRAULIC VALVE ASSEMBLY.
destructive shock effects when the piston reaches the
full extent of its travel. When the operator pulls back on the body control lever
a voltage between 0 and 5 volts is sent to the hydraulic
The cushioning effect when the cylinder is being ECU, Analog input, 'Pin 29'. The hydraulic ECU
retracted is obtained by a tapered spear at the base converts this signal to an output current at PWM
end of the cylinder body entering a cavity in the piston Output 'Pin 44' to between 0 & 1000 mA dependent
rod through a cushioning ring. This gradually slows the upon how far the lever is selected. This current is
piston which in turn helps to control destructive shock delivered to the Electro-Hydraulic Proportional Pressure
effects when the piston bottoms. Control Valve (CT27) which converts this current into a
pilot pressure.
Cylinder mounting is by pins, spacers and spherical
bearings secured in place by circlips. Spherical The primary accumulator (ACC3) pressure is reduced
bearings permit a limited amount of cylinder to a 25 bar (362 lbf/in2) pilot control pressure by
misalignment. pressure reducing valve (CT21). This pilot control
pressure acts upon the proportional pressure control
valve (CT27) which reduces the pilot pressure to
Accumulator (9) between 6 bar (87 lbf/in2) and 24 bar (348 lbf/in2),
Refer to Section 250-0060, ACCUMULATOR. depending on the current output fom the hydraulic
ECU. This pilot pressure then selects the main spool
The primary accumulator (9) is mounted of the rear left (CT41) in the lift valve section of the main hydraulic
hand side of the tractor exhaust mounting frame. The valve assembly to the raise position.
primary accumulator supports the service brake
system and the body pilot pressure system. The When the main spool (CT41) has been stroked to the
primary accumulator is of the piston type and raise position, oil from the main pump flows through the
precharged with nitrogen to 103 bar (1 493 lbf/in²). It control spool (CT41) out of port 'A' on the main
consists of a charging valve assembly, cylinder hydraulic valve, onto the tip cylinders (1).
assembly and piston. The charging valve is equipped
with a locking feature which, when opened, will allow When oil from the main pump flows through control
precharge to be checked or accumulator charged. spool (CT41), a load sense pressure is fed back to the
load sense port of the main pump via shuttle valves
The piston acts as a separator dividing the cylinder (34,26 & 17). Load sense relief valve (CT20) is set at
assembly into two sections. The section nearest the 210 bar (3045 lbf/in2). This limits the maximum hoist
charging valve contains the nitrogen precharge. load sense pressure. The main pump then increases
Hydraulic oil from the accumulator charge valve flows its displacement and flow passes to port 'A' lifting the
through accumulator check valves in the brake body. Returning flow from the tipping cylinders (1)
manifold valve and into the other section of the passes to Port 'B', through the control spool (CT41)
accumulator. back to tank.
Accumulator pressure is monitored by pressure Body relief valve (43) is located on the raise side of the
switches in the brake lines (Ref. Section 250-0000, circuit and prevents pressure spikes at maximum
BRAKING SYSTEM). extension of the cylinders when the body is raised at
2 SM 2441 Rev1 05-07

Section 230-0000
SM - 3504 The pilot control pressure of 25 bar (362 lbf/in2),

created by pressure reducing valve (CT21) is reduced
by the proportional pressure control valve (CT28) to
between 6 bar (87 lbf/in2) & 24 bar (348 lbf/in2),
depending on the current output from the hydraulic
ECU. This pilot pressure selects the main spool (41) in
the lift valve section of the main hydraulic valve
assembly to the lower position.
When the main spool (41) has been stroked to the

lower position, oil from the main pump flows through
the control spool (41) out of port 'B' on the main
hydraulic valve, onto the tip cylinders (1).
Fig. 2 - Body Control Lever (Operators Cab) When oil from the main pump flows through control
spool (CT41), a load sense pressure is fed back to the
SM - 2867 load sense port of the main pump via shuttle valves
(34,26 & 17). The main pump then increases its
displacement and flow passes to port 'B' lowering the
body. Returning flow from the tipping cylinders (1)
passes to Port 'A', through the control spool (CT41)
back to tank.
During lowering the operator can fully select the body

control lever onto an electric detent within the lever
base which is connected to the body up relay circuit.
This detent holds the lever in the power down position
allowing the operator to drive the vehicle whilst the
body is still lowering.
Located on the chassis is a proximity switch which

supplies a 24 Volt signal to body up relay K52, which in
turn sends a signal to the hydraulic ECU Digital in 'pin
19'. When the body reaches the proximity switch the 24
Volt signal is switched off, this de-energises the
electric detent allowing the lever to spring back to the
mid position. At the same time the hydraulic ECU
ramps back the current to proportional pressure control
valve (28) to de-select the main spool (41) and
energises the coil on the float solenoid valve (29)
allowing the body to float down to the chassis over the
Fig. 3 - Body Control Lever Positions last few centimetres of travel.
maximum engine speed. Relief valve (43) is set at 250 To prevent damage to the body hinge points or the tip
bar (3 625 lbf/in2 ). cylinders (1) the float solenoid valve (29), which is
connected to 'Digital out' 'Pin 49' on the hydraulic ECU
LOWERING THE BODY is energised all the time the body is on the chassis and
When the operator pushes forward on the body control the engine is running. This ensures that the head side
lever a voltage between 0 and 5 volts is sent to the of the tip cylinders (1) is always vented to tank and the
hydraulic ECU, Analogue input, 'Pin 29'. The hydraulic body is sitting firmly on the chassis.
ECU converts this signal to an output current at PWM
Output 'Pin 45' to between 0 and 1000 mA dependent When the body meets the proximity switch on the
upon how far the lever is selected. This current is seen chassis the control spool (41)is de-selected and reverts
at the Electro-Hydraulic Proportional Pressure Control to the neutral position.
Valve (28) that converts this current into a pilot
pressure. When the control spool (41) moves to the neutral
SM 2441 Rev1 05-06 3

Section 230-0000
SM - 3535
1 - Body Cylinders
17 - Shuttle Valve
20 - Relief Valve
21 - Pressure Reducing Valve 17 LOCATED UNDER 20
25 - Shuttle Valve 20
26 - Shuttle Valve
27 - Proportional Control Valve (Raise)
28 - Proportional Control Valve (Lower)
29 - Float Solenoid
30 - Orifice 25
34 - Shuttle
36 - Hoist Load Sense Valve
41 - Control Spool
42 - Anti Cavitation Valve 36
43 - Relief Valve
44 - Check Valve
30
Valve (27 & 28) Coil Rating 27

Ohms Amps Watts
21 0.9 25
Voltage: 24V
28
Valve (29) Coil Rating
Ohms Amps Watts
41 0.6 14
Voltage: 24V
TANK RETURN
43
42
34 41
26 SUPPLY/RETURN
(LOWER SIDE)
SUPPLY/RETURN
(LIFT SIDE)
21
29
Fig. 4 - Main Hydraulic Valve Assembly - Body Control Valve Locations
4 SM 2441 Rev1 05-07

Section 230-0000
position, oil delivery from the main pump is blocked. SM - 3615
To compensate for this over the last few centimeters

of travel, make up check valve (42) opens allowing a 1
2
controlled oil flow via port 'B' to the lower side of the tip 3
4
cylinders (1). The make up check valve (42) opening 5
6
safeguards the system against cavitation when the 9 7
main pump flow is blocked during the lowering 10 8
11
procedure of the body. 12
13
14
CHECKING SYSTEM PRESSURES 15
WARNINGS
To prevent personal injury and property 1 - Front Brake Accumulator 9 - Steering Pressure
damage, be sure wheel blocks and blocking 2 - Rear Brake Accumulator 10 - Transmission Pressure
materials are properly secured and of adequate 3 - Primary Accumulator 11 - DropBox Lube Pressure
capacity to do the job safely. 5 - Rear Brake Pressure 12 - Main Pump (Front)
Hydraulic fluid pressure will remain 7 - Diff-lock Pressure 'TP1' 14 - Pump LS Pressure
within the system after engine shut down. 8 - High / Low Select 'TP2' 15 - Body System Pressure
Operate the brake treadle pedal continuously Fig. 5 - Diagnostic Pressure Check Points Left Hand
until the pressure has dissipated before Fender
carrying out any work on the system or serious
injury could result.
valve (20) on the main hydraulic valve assembly. Relief
valve (20) actually sets the load sense pressure for the
CHECKING MAIN BODY SYSTEM body circuit, controlling the load sense to a maximum
PRESSURE of 210 bar (3045 lbf/in2). This will result in a maximum
main pump delivery pressure for the body raise circuit
1. Position the vehicle in a level work area, apply the of 240 bar (3480 lbf/in2). This is due to the 210 bar
parking brake, switch off the engine and turn steering (3045 lbf/in2) maximum load sense pressure, plus the
wheel in both directions several times to relieve any 35 bar (435 lbf/in2) differential pressure and 240 bar
pressure in the steering circuit. (3480 bf/in2) settings of the main pump. Refer to
Section 230-0050, MAIN HYDRAULIC PUMP. The
2. Operate the brake treadle valve continuously to operator cab will require to be raised to access relief
relieve pressure in the accumulators. Block all road valve (20). Refer to Section 260-0010, CAB AND
wheels, place the steering lock bar in the 'Locked' MOUNTING.
position and the battery master switch in the 'Off'
position. 7. Adjust relief valve (20) until 240 bar (3480 lbf/in2) is
observed on the pressure gauge, while raising the body
3. This following procedure will check that the body over relief.
raise pressure is properly set. Connect a hydraulic
gauge, capable of recording a pressure of 0 - 345 bar 8. Shut off the engine and remove the pressure gauge
(0 - 5 000 lbf/in²), to body system pressure diagnostic from diagnostic check point.
pressure point located on diagnostic plate on left hand
fender at base of cab door (15 Fig. 5) 9. Remove wheel blocks, place the steering lock bar in
the 'Stowed' position, start the engine and check the
4. Place the battery master switch in the 'On' position, body system for proper operation.
start the engine and allow all systems to be charged
normally.
5. Pull back body control lever. Allow body to raise

over relief. The pressure observed on the pressure
gauge should be 240 bar (3480 lbf/in2).
6. Pressure setting can be adjusted by adjusting relief
SM 2441 Rev1 05-06 5

Section 230-0000
CHECKING PILOT CONTROL PRESSURE SM - 1335

FITTING NUT
parking brake, switch off the engine and turn steering
wheel in both directions several times to relieve any TUBE
pressure in the steering circuit.
2. Operate the brake treadle valve continuously to

relieve pressure in the accumulators. Block all road
wheels, place the steering lock bar in the 'Locked'
position. SLEEVE
'O' RING 'O' RING
3. The operators cab has to be raised at this stage so Fig. 6 - Assembly of Typical ORFS Connector
that port 'DL' on the main hydraulic valve can be
accessed. Refer to Section 260-0010, CAB AND 12. Remove wheel blocks, place the steering lock bar
MOUNTING. in the 'Stowed' position, start the engine and check the
body system for proper operation.
4. Remove fitting from port 'DL' on main hydraulic valve
block and connect a Tee-piece connector with diagnostic
coupling. Reconnect original fitting from port'DL' to Tee-
piece. Connect a hydraulic gauge, capable of recording a Where hydraulic lines are fitted with ORFS
pressure of 0 - 345 bar (0 - 5 000 lbf/in2), into diagnostic connections, the following procedure should be carried
coupling on the Tee piece. out during 'Installation'. Refer to Fig. 6.
5. Place the battery master switch in the 'On' position, a. Ensure 'O' ring/seal is in place and that the joining
start the engine and allow all systems to be charged surfaces are clean. If necessary, retain 'O' ring/seal in
normally. place with a light coating of grease or vaseline.
6. A hydraulic pressure of 25 bar (362 lbf/in2) should b. Initially, the nuts should be tightened by hand.
be observed on the pressure gauge.
c. Where a hose is fitted, ensure that it is not twisted
7. Pressure setting can be adjusted by adjusting or kinked when the nuts are tightened so that it is
pressure reducing valve (21) on the main hydraulic allowed to adopt a natural position.
valve. Adjust pressure reducing valve (21) until 25 bar
(362 lbf/in2) is observed on the pressure gauge. d. Where a tube is fitted, ensure that the connection is
aligned correctly.
8. Raise and lower pilot pressures can be checked by
installing a hydraulic gauge, capable of recording a e. Tighten the nut a further 1/4 to 1/2 a turn using the
pressure of 0 - 345 bar (0 - 5000 lbf/in2) ) into port 'TPA' correct size spanner (wrench).
(raise) and port 'TPB' (lower). When the raise or lower
action is requested through the body control lever the f. Check that a satisfactory hose or tube routing has
pressure should read from 0 - 24 bar (0 - 348 lbf/in2) been achieved.
depending on degree of lever action.
HYDRAULIC OIL
9. Check body system for proper operation.
The braking system should be kept filled with hydraulic
10. Shut off the engine, remove pressure gauge and oil as specified in Section 300-0020, LUBRICATION
reinstate connection at port 'DL' to original condition. SYSTEM.
Whenever there is a hydraulic system failure, the oil

11. Operators cab should be lowered and locked into should be drained, the entire system flushed, oil filters
travel position. Check hydraulic lines for any leakage. replaced, oil screens thoroughly cleaned and clean
hydraulic oil added to eliminate all metal particles or
foreign matter.
6 SM 2441 Rev1 05-07

Section 230-0000
SERVICE TOOLS Non-contact Infrared Thermometer

It is recommended that the following service tools are The infrared thermometer, 15269785, can be used to
used when carrying out pressure and temperature spot heat problems early in electrical, mechanical and
checks during maintenance procedures. These tools, hydraulic systems. Hand held and easy to use, you
along with other general service tools, are available simply aim, pull the trigger, and read the temperature.
from your dealer. Refer to Section 300-0070, SERVICE Since there is no need to touch what you are
TOOLS, for part numbers of these tools. measuring, temperatures of hard-to-reach or moving
shocked.
Multi-Gauge
The multi-gauge, 15269784, is basically four pressure O' Ring Face Seals (ORFS) - Seal Kit
are indicated on one of three simultaneously reading The braking system utilizes 'O' Ring Face Seal (ORFS)
gauges through a pressure range of 30 in of vacuum to connectors. An ORFS kit, 15271082, is available. This
5 000 lbf/in². kit contains a minimum stock requirement of all sizes
The following items should be added to the multi-gauge of ORFS type seal.
pressure check points;
15018226 Diagnostic Coupling
00118748 Connector (2 off)
SM 2441 Rev1 05-06 7

Section 230-0000
Body System Trouble Shooting

Body will not lift Pressure Level in the system not high Check pressure at the pump and re-
enough adjust Relief Valve (CT1). Refer to
Section 230-0050, MAIN
HYDRAULIC PUMP.
Relief valve (CT1) stuck open.
No electric current at the proportional Check voltage at the electric

control valve; Body raise solenoid connector of (CT27) when pulling
(CT27) back on the lever in the cab. If no
voltage present refer to
Sections190-0085 HYDRAULIC
ECU and 230-0081, BODY
CONTROL LEVER
Body raise solenoid faulty Replace coil / valve (5)
Check output from lever. Refer to

Control lever in the cab faulty Sections190-0085 HYDRAULIC
ECU and 230-0081, BODY
CONTROL LEVER
Main control spool (41) in the lift Replace lift section of the main
section of the main hydraulic valve hydraulic valve assembly
assembly sticking
Hoist pilot Valve (36) stuck Replace Valve

Orifice (30) blocked Clean orifice
Hoist pilot shuttle (25) stuck Replace shuttle
Main pump faulty Refer to Section 230-0050 MAIN

HYDRAULIC PUMP, for correct
setting procedures
Lift function too slow. Proportional control valve ; body raise Check output from body control
solenoid (27 ) current not high enough lever. Refer to Sections190-0085
HYDRAULIC ECU and 230-0081,
BODY CONTROL LEVER
Main control spool (41) not fully Replace lift section of main
selecting. hydraulic valve assembly.
Contamination in the load sense Clean orifice (30).

orifice (30).
Hoist shuttle (25) sticking Replace shuttle (25)
Main pump faulty. Refer to Section 230-0050 MAIN

setting procedures.
8 SM 2441 Rev1 05-07

Section 230-0000

Lift function too slow (cont.) Control lever in the cab faulty. Check lever outputs. Refer to
Sections 190-0085 HYDRAULIC
ECU and 230-0081 BODY
CONTROL LEVER
Engine RPM too low. Can affect pump delivery. Check

throttle pedal for correct signals.
Check accumulator settings, pre- Priority valve (7) will give pump
charge and charging cycle times demand to accumulator charge
cycle.
Body will not lower. Supply fuse to hydraulic ECU blown. Check power on light at controller
is illuminated. Replace fuse if
required. Refer to Section190-0000
CIRCUIT DIAGRAMS
No electric current at proportional Check link between body control

control valve; body lower solenoid lever and hydraulic ECU and
(28) hydraulic ECU and body lower
solenoid (28). Refer to Sections
190-0085 HYDRAULIC ECU and
230-0081 BODY CONTROL
LEVER
Proportional control valve; body lower Check connections. Replace body

solenoid (28) faulty. lower solenoid (28).
Control lever in the cab faulty. Check for output from control lever.
Refer to Sections 190-0085
HYDRAULIC ECU and 230-0081
BODY CONTROL LEVER
Proximity switch on chassis reading Check connections/replace

LOW (float condition) proximity switch.
Body lowers too slow. Not enough electric current at the Check output from body control
proportional control valve ; body lower lever. Refer to Sections 190-0085
solenoid (28) HYDRAULIC ECU and 230-0081
BODY CONTROL LEVER
Pilot pressure not high enough Re-set pilot pressure at pressure

reducing valve (21). If it cannot be
reset replace pressure reducing
valve (21).
Main control spool (41) sticking. Replace lift section of the main
hydraulic valve assembly.
Faulty main pump. Refer to Section 230-0050 MAIN

setting procedures.
SM 2441 Rev1 05-06 9

Section 230-0000

Body lowers too slow (continued). Contamination in the load sense Clean orifice (30).
orifice(30).
Hoist shuttle valve (25) sticking Replace shuttle
Body will not hold Oil by-pass between control spool Replace lift section of main
(41) and valve body hydraulic valve aseembly
Oil by-pass body lift cylinders (1) Repair lift cylinders (1)
Control spool (41) not centering Check that there is zero pilot
pressure at both ends of control
spool (41). Either of proportional
control valves (27/28) could remain
active
Check body control lever. Should

be zero ouput signal from control
lever when in the neutral position
Control spool (41) damaged.

Replace control spool (41)
Power down available when body is Faulty proximity switch on chassis Check connections. Replace
on the chassis proximity switch. Refer to Section
190-0085 HYDRAULIC ECU, for
check tool
Body fails too slow down when Faulty proximity switch on chassis Check gap between body plate and
reaching the proximity switch on the proximity switch. Max. gap 15mm.
chassis Replace proximity switch
Faulty hydraulic ECU or connections Refer to Section 190-0085

HYDRAULIC ECU for check
procedure.
Main spool (41) sticking Replace main hydraulic valve

assembly
Body fails too go into float and stops Faulty float solenoid valve (29) Check connections. Replace
before it reaches the chassis valve(29). Refer to Section 190-
0085 HYDRAULIC ECU
No voltage at the float solenoid valve Check connections at valve (29)

(29) and hydraulic ECU. Refer to
Section 190-0085 HYDRAULIC
ECU
* * * *
10 SM 2441 Rev1 05-07

Body System - Main Hydraulic Pump
Section 230-0050
SM - 3543
15 14 26 16 2 16 26 14 15
30
23 6 34 34 7
19
22 27
29
12
11
24 5
9,17,33 39 20 13 8 20 39 19 22
2 - Control Valve (2-off) 13 - Splined Hub 26 - 'O' Ring

5 - Cover 14 - Control Piston 27 - 'O'-ring
6 - Front Housing 15 - Piston Rod 29 - Circlip
7 - Rear Housing 16 - Plug 30 - Dowel
8 - Centre Housing 19 - Bearing 34 - Plug
9 - Front Swash Plate 20 - Bearing 39 - Rotating Group
10 - Rear Swash Plate 22 - Stop Ring 40 - Front Control Plate
11 - Front Driveshaft 23 - Spring 41 - Rear Control Plate
12 - Rear Driveshaft 24 - Shaft Seal 45 - Cylinder Block
Fig. 1 - Sectional View Of Hydraulic Pump
DESCRIPTION The pump displaces 325L/Min maximum flow, and the

pressure regulator cut off is set to 240 bar (3 480 lbf/
in2).
The Hydraulic Pump can be identified as item D in
The tandem pump supplies hydraulic oil for the
Section 250-0000, BRAKING SYSTEM SCHEMATIC.
steering, braking and body hoist systems, as well as
the transmission and engine oil cooler fan drive
The hydraulic pump is mounted off the left hand side of
system.
the transmission PTO. It is a 'tandem' axial piston,
variable displacement pump with load sense and
The components of the tandem pump can be divided
pressure regulator to match the flow and pressure to
into three sub-groupings, with each pump side having
the demand. 'Tandem' in the sense that it contains two
the same make-up as that listed:
complete pump assemblies mated together to provide
the desired output levels.
SM 2370 Rev2 05-07 1
Section 230-0050
SM - 2845
42
11 & 12
43
40 & 41 45
A - Outlet Port
B - Outlet Kidney Slot 11 & 12 - Drive shaft 43 - Retaining Plate
C - Inlet Port 40 & 41- Control Plate 45 - Cylinder Block
D - Inlet Kidney Slot 42- Piston Group
Fig. 2 - Pump Rotation and Oil Flow
SM - 603
MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
VIEW A VIEW B VIEW C
Fig. 3 - Variable Displacement Action
Rotating Groups (39) - Provides the main rotary OPERATION

pumping action. Consists of respective driveshafts (11
Numbers in parentheses refer to Figs. 1, 2 & 7. Refer
& 12), cylinder block (45), piston and shoe (42),
to Figs. 4 - 6 for hydraulic schematics of pump.
retaining plate (43), bush (44) and cylinder springs (48).
When the front pump's driveshaft (11) rotates, this
Swash Plate Groups - Varies the pump's delivery flow
causes the rear pump's driveshaft (12) to also rotate.
rate. Consists of respective swash plates (9 & 10),
Due to being linked to each other via splined hub (13).
shoe plate (43), control piston (14), piston rod (15) and
As the cylinder blocks (45) for both front and rear
spring (23)
elements are spline coupled to the respective shafts,
these will also rotate. If the swash plate (9 & 10) has
Valving Cover Groups - Provides the switching of oil been tilted, the pistons and shoes (39) arranged in the
between suction and delivery ports. Consists of front cylinder block (45) due to the shoes being retained on
control plate (40), rear control plate (41), dowel (30), the retaining plate (43) will both rotate with the cylinder
centre housing (8), front housing (6) and rear housing block and reciprocate once per revolution.
(7).
2 SM 2370 Rev2 05-07

Section 230-0050
19 SM - 3545
25
5 7
1 - Cap 14 - Spool 8 11 12 13 14
2 - 'O'-ring 15 - Spring
3 - Nut 16 - Spring
4 - Set screw 17 - Spring Seat
5 - Plug 18 - Spool 24
1 2 3 2 4
6 - Plug 19 - Capscrew
7 - 'O'-ring 20 - Plug
8 - Spacer 21 - Plug
9 - 'O'-ring 20
22 - 'O'-ring
10 - Spacer 23 - 'O'-ring 16 18
6 10 15 17 26
9
11 - Spring 24 -
12 - Spring 25 - Plug
23
13 - Spring Seat 26 - Valve Body 22
21
Fig. 7 - Exploded View Control Valve
Paying attention to one such piston from either front or Regulated Condition - Refer to Fig. 5. Pump pressure
rear pump rotating groups, then it will move away from is still relatively low but the pressure drop across the
the control plate (40 & 41) for half a rotation (suction main hydraulic valve increases. The cut-off pressure
stroke), and move towards the control plate (40 & 41) spool spring (15 & 16) preload still retains the spool
for the second half of rotation (delivery stroke). The (18) in its extreme left position. However, since the
larger the tilt angle of the swash plate (9 & 10), the pressure drop is increased, the pressure on the left
longer the piston (42) stroke and the higher the pump's hand side of the differential pressure spool (14) (pump
displacement. As the swash plate (9 & 10) tilting angle delivery pressure) overcomes the combination of spring
approaches zero, the piston (42) does not stroke and (11 & 12) preload and pressure in the load sense line in
therefore delivers minimum displacement. (Refer to the right hand side of the differential pressure spool
Fig. 3). (14). Therefore the spool (14) moves to the right,
blocking vent line and causing pressure at large side of
Control Valve piston (14, Fig. 1) to increase, overcoming spring (23)
Numbers in parentheses refer to Figs. 1 & 7. force. This reduces the swash plate (9 & 10) angle and
hence pump displacement.
Control Valve (6) is a pilot operated differential
pressure type spool regulator for load sense control. This will continue until the pump flow across the main
The load sense feedback signal from the main hydraulic valve reduces the pressure drop to the value
hydraulic valve is fed to load sense port (X) on top of determined by the differential spool spring (11 & 12)
the control valve body (26) (see Fig. 7). This feedback preload.
signal acts on the spring chamber end of the spool
(14). Standby Condition - Refer to Fig. 6. When no
hydraulic operations are required, the pump standby
Unregulated Condition - Refer to Fig. 4. Pump condition is reached. The load sense line is vented to
pressure is low and the load sense signal is wide open. tank. Differential pressure spool (14) shifts right due to
The cut-off pressure spool spring (15 & 16) preload pump outlet pressure. This allows oil pressure to pass
shifts the cut-off pressure spool (18) to its extreme left through cut-off pressure spool (18) and reach the large
position. Since the pressure drop across the main side of piston (14, Fig.1 ), overcoming spring (23)
hydraulic valve is low, both sides of the differential force and reducing swash plate (9 & 10) angle to zero.
pressure spool (14) see the same pressure and
therefore the spool (14) remains in the extreme left The pump also has a pressure limiting function, used
position. This condition causes the oil at the control for example when steering cylinder reaches the end of
piston (14, Fig. 1) and rod (15, Fig. 1) to be vented, it's stroke. In this condition the delivery pressure will
causing spring ( 23) force to move piston rod and rise, and the load sense control will try to raise delivery
piston (15 & 14) and swash plate (9 & 10) to maximum pressure above the now 'dead head' pressure. This
pump displacement. causes differential pressure spool (14) to shift to the
extreme right, allowing oil pressure to pass through cut-
SM 2370 Rev2 05-07 3

Section 230-0050
off pressure spool (18) and reach the large side of 3. Remove blanking cap from remote drain line at the
piston (14, Fig. 1), overcoming spring (23) force and bottom of the hydraulic tank. Install a length of hose on
reducing swash plate (9 & 10) angle to zero. remote drain fitting, open drain cock and drain
hydraulic oil into a suitable container. Close drain cock,
remove hose and reinstall blanking cap.
REMOVAL
Numbers in parentheses refer to Figs. 1 & 7. 4. Clean pump housing and surrounding area with a
suitable solvent. Ensure all hydraulic lines connected
to pump are identified for ease of installation and, with
WARNINGS suitable containers available to catch leakage,
To prevent personal injury and property disconnect hydraulic lines. Fit blanking caps to all
damage, be sure wheel blocks, blocking open lines and fittings.
secured and of adequate capacity to do the job 5. Support pump assembly with suitable lifting
safely. equipment. It is possible to set up a sling arrangement
using exhaust cradle. Remove bolts (56) and
Hydraulic fluid pressure will remain lockwashers (57) securing pump to transmission.
within the system after engine shut down. Remove pump assembly from transmission.
Operate the treadle pedal continuously until the
pressure has dissipated before carrying out any Note: The pump assembly consists of the main
work on the braking system or serious injury tandem pump and the single stage gear pump
could result. mounted off the end face of the tandem pump.
Once removed, it will be necessary to remove the
1. Position the vehicle in a level work area, apply the gear pump from the tandem pump.
wheel in both directions several times to relieve any 6. Remove 'O' ring from pump. Wash the outside of
pressure in the steering circuit. pump thoroughly with a suitable solvent and move to a
clean area.
2. Operate the treadle valve continuously to relieve
pressure in the braking system. Block all road wheels
and place battery master switch in the 'Off' position.
Place steering lock bar in the 'Locked' position.
4 SM 2370 Rev2 05-07

Section 230-0050
SM - 3542
REAR PUMP
20
37 2
12 30
4
10 21 41
16
26 23
14 39
18
3 15
34 28
7
5 27 33
36 22 19 49
32 48
47
46
38
44 45
43 DETAIL OF 39
42
25 ROTATING GROUP
1
35 2 4
25
13 38 37
3
26 14 15
16
31
34
8
29
22 24 6
19
23
11
17
33
30 FRONT PUMP
21
20
39
40
1 - Pump Assembly 17 - Bearing Shell 33 - Screw

2 - Control Valve 18 - Bearing Shell 34 - Plug
3 - 'O'-ring 19 - Bearing 35 - Pin
4 - Capscrew 20 - Tapered Bearing 36 - Washer
5 - Cover 21 - Shim 37 - Plug
6 - Front Housing 22 - Stop Ring 38 - Plug
7 - Rear Housing 23 - Spring 39 - Rotating Group
8 - Centre Housing 24 - Shaft Seal 40 - Front Control Plate
9 - Front Swashplate 25 - 'O'-ring 41 - Rear Control Plate
10 - Rear Swashplate 26 - 'O'-ring 42 - Piston and Shoe
11 - Front Driveshaft 27 - 'O'-ring 43 - Retaining Plate
12 - Rear Driveshaft 28 - 'O'-ring 44 - Plate
13 - Splined Hub 29 - Circlip 45 - Cylinder Block
14 - Control Piston 30 - Roll Pin 46 - Pressure Pin
15 - Piston Rod 31 - Capscrew 47 - Shim
16 - Plug 32 - Capscrew 48 - Spring
49 - Circlip
Fig. 8 - Exploded View Of Hydraulic Pump
SM 2370 Rev2 05-07 5

Section 230-0050
DISASSEMBLY SM - 3548
Numbers in parentheses refer to Figs. 1 & 7. Unless

otherwise stated.
*
Rear Pump *
*
Note: Discard and replace all 'O' rings and seals
*
removed during disassembly.
1. Remove drain plug (X) and drain oil from pump

housings (6, 7 & 8).
2. Secure the pump assembly (1) in a suitable fixture.

Refer to Fig. 9.
Fig. 11 - Removal of Capscrews
3. Mark the location of the centre housing (8) in relation
to the front and rear housings (6 & 7). Refer to Fig. 9. 6. Using suitable lifting tackle. Secure to assembly
and lift front housing (6) and centre housing (8) from
the rear housing (7) assembly. Refer to Fig. 12.
SM - 3546
Note: Control plate (41) can drop out at this stage.

Ensure this is held secure whilst removing
assembly.
SM - 3549
Fig. 9 - Locating reference for housings
4. Remove 2-off control valves (2) from the respective

housing units. Refer to Fig. 10.
Fig. 12 - Removal of Front pump from Rear pump

SM - 3547
7. Remove bearing ( 20) and shim (21). Ensure not to

damage sealing surface. Refer to Fig. 13.
SM - 3434
Fig. 10 - Control Valve Removal
5. Loosen 8-off capscrews (31). Remove 4-off

capscrews securing the rear pump housing (7) to the
centre housing (8). Refer to Fig. 11. Fig. 13 - Bearing / Shim removal
6 SM 2370 Rev2 05-07

Section 230-0050
SM - 3550 SM - 3553
Fig. 14 - Rotating Group removal Fig. 17 - Bearing shell removal
8. Orientate rear housing (7), to allow removal of the 11. Remove 2-off bearing shells (18) and spring (23)
rotating group (39). Remove rotating group as shown a from the housing (7). As shown in Fig. 17.
in Fig. 14.
12. Remove driveshaft (12) with bearing (19) inner race
9. Remove plug (16) and 'o'-ring (26). Pull out control still fitted to the shaft. Refer to Fig. 18
piston (14) using a suitably sized screwdriver. Refer to
Fig. 15.
1
2
SM - 3551 SM - 3554
3
Fig. 15 - Control Group removal . Fig. 18 - Driveshaft removal
10. Turn swash plate (10) inside of housing along the 13. Pull outer race of bearing (19) out of housing (7)
z-axis. Remove piston rod (15) and swash plate (10) using a suitable bearing puller. Refer to Fig. 19.
from the housing (7) as shown in Fig. 16.
SM - 3552 SM - 3555
4
Fig. 16 - Swash plate / Piston rod removal Fig. 19 - Bearing race removal
SM 2370 Rev2 05-07 7

Section 230-0050
SM - 3556 SM - 3558
Fig. 20 - Shim Removal Fig. 22 - Removal
. Remove shim (22) as shown in Fig. 20. SM - 3559
Front Pump
1. Remove 4-off capscrews (31) securing centre
housing (8) to the front housing (6). Refer to Fig. 21.
SM - 3557
Fig. 23 - Bearing Removal
4. Remove bearing (20) inner race and shim (21).

Ensure not to damage the sealing surfaces. Refer to
Fig. 24.
SM - 3434
Fig. 21 - Housing Removal
2. Using suitable lifting equipment, remove centre

housing (8) from the mating face on the front housing
(6). Refer to Fig. 22.
Note: Control plate (40) can drop out at this stage.

Ensure this is held secure whilst removing
assembly.
2. 'O'-rings (25), control plate (40) and splined hub (13)

should be removed at this stage. Refer to Fig. 22. Fig. 24 - Shim & Brg Removal
3. Pull bearing (20) from centre housing (8) using a 5. Orientate front housing (6) horizontally on a bench to
suitable bearing puller, ensure not to damage sealing allow for removal of the rotating group (39). Remove
surfaces. Refer to Fig. 23. rotating group (39) as shown in Fig. 25.
8 SM 2370 Rev2 05-07

Section 230-0050
SM - 3435 SM - 3560
Fig. 25 - Rotating Group Removal Fig. 28 - Brg Removal
6. Remove control piston (14), plug (16),'o'-ring (26) housing (6), using suitable bearing pullers, as shown in
and piston rod (15). Refer to Fig. 26. Fig. 28.
SM - 3436 SM - 3561
Fig. 26 - Control Piston Removal Fig. 29 - Shim Removal
7. Remove driveshaft (11), bearing (19) inner race 10. Remove shim (22). Refer to Fig. 29.
should be attached to the driveshaft at this stage.
Refer to Fig. 27.
Control Valve
SM - 3438 Numbers in paretheses refer to Fig. X. unless
otherwise stated.
1. If the control valve (2, Fig 1.) has not already been
removed from the front and rear housings (6 & 7, Fig.
1). Do so, by removing 4-off capscrews (19).
Note: The control valve (2, Fig 1) is supplied as a

complete assembly.
2. If it is necessary to disassemble the control valve

(2, Fig. 1), the following steps should be followed.
Fig. 27 - Drive shaft & Brg removal 3. Remove 2-off protective caps (1) and 'o'-rings (2).
8. Remove circlip (29) and shaft seal (24). 4. Unscrew nuts (3), remove nuts (3) and 'o'-rings (2).
9. Pull out outer race of tapered bearing (19) out of 5. Unscrew plugs (5 & 6) . This should allow for careful
SM 2370 Rev2 05-07 9

Section 230-0050
removal of the following items contained within the scratches with 500 grit paper. Remove burrs with an
control valve body (25); 'o'-rings (7 & 9), shims (8 & 9), India stone. Pistons should move freely over their
springs (11,12,15 & 26), spring seats (13 & 16) and respective rods.
spools (14 & 17).
Driveshaft and associated parts

INSPECTION Numbers in parentheses refer to Fig. 8
1. Inspect driveshafts (11 & 12) for wear, chipped
Note: Before inspection of parts, clean all parts with a splines and burrs. Remove burrs with an India stone.
suitable solvent. Inspect contact area of tapered bearings (19 & 20) and
shaft seal (24). Replace driveshaft (11 & 12) if wear or
Note: Rotating group(39) is made up of a cylinder block scoring is greater than 0.127 mm (0.005 in) total
(45), retaining plate (43) and piston assemblies (42). indicator reading (T.I.R.).
2. Inspect inner and outer races of tapered bearings

Rotating Group (19 & 20) for roughness, pitting of rollers and
1. Inspect cylinder block for wear, scratches and/or excessive end play. Make sure the inner race turns
erosion. If cylinder block condition is questionable, freely within the outer race. If the tapered bearing
replace the entire rotating group. needs replacement, both the inner and outer races
must be replaced.
2. Check each cylinder block bore for excessive wear.
Use piston and shoe assemblies for this purpose. The 3. Inspect pump housing (6 & 7) mounting flange for
pistons should be a very close fit and slide in and out nicks and burrs. Remove minor nicks and burrs with an
of the cylinder block bores. No binding can be India stone. Also check pump housing (8) for damaged
tolerated. If binding occurs, clean cylinder block and or stripped threads. If any thread is damaged, replace
piston and shoe assemblies. Lubricate cylinder block the pump housing.
bores with clean hydraulic oil and try again. Even minor
contamination of the oil may cause a piston to seize up 4. Check remaining pump parts for excessive wear,
in a cylinder block bore. damaged threads, burrs, cracks and/or erosion.
3. Inspect retaining plate for heavy wear and/or Replace any part that is in a questionable condition.
cracks. Replace if defective.
Pump Housing and Associated Parts

1. Inspect both pump housing (6 & 7) for erosion,

cracks and burrs. Clean up minor burrs with an India
stone. If erosion or cracks are noted, replace specific
pump housing (6 & 7).
2. Inspect inner and outer races of tapered bearings (19

& 20) for nicks and pitting. Make sure the inner race
turns freely within the outer race. If either of the tapered
bearings need replaced, both the inner and outer races
must be replaced. To remove the outer races from
pump housing (6 & 7) or centre housing (8) do so using
tooling in accordance with manufacturers guidelines.
3. Inspect control plates (40 & 41) for erosion,

excessive wear, heavy scratches and cracks. If any of
the above conditions are found, replace the plate.
4. Inspect spring (23) and rotating group piston parts

for burrs, scratches and cracks. Clean up minor
10 SM 2370 Rev2 05-07

Section 230-0050
ASSEMBLY SM - 3586
Numbers in parentheses refer to Figs. 1 & 8, unless

otherwise stated.
Note: Assembly is largely the reverse sequence to

disassembly.
Note: Where stated, the following assembly steps

apply to both front and rear pump units!
1. For both front and rear housing ( 6 & 7), press in

stop ring (22) and bearing (19) outer race with a
suitable tool. Refer to Fig. (30)
Fig. 32 - Centre housing / Brg Race
2. For both front and rear housing ( 6 & 7), locate o-ring
(X) and plug (34) into housing. Torque plug (34) to a 4. Ensure splined hub (13) is located inside bore of
value of 127 Nm (93.7 Ibf-ft). Refer to Fig. (30). centre housing (8).
3. For both front and rear housing (6 & 7), assemble 5. Press in outer races of bearings (20) into centre
respective driveshafts (11 & 12) in correct position. housing (8). Refer to Fig. 32
Ensure bearing outer race is seated fully on the
driveshaft. Refer to Fig. (31). 6. Assemble front and rear pump to centre housing.
Note: Take care not to damage shaft seal (24) during Ensure points marked during disassembly match up.
steps 1 -3.
SM - 3585
SM - 3418
(21) (21)
'A' 'B' 'A' 'B'

'C' 'C'
Fig. 33 - Measurement for bearing preload.

Fig. 30 - Pump Assembly
7. Tighten 8-off screws (X) , to a value of XX Nm.
SM - 3419
8. Refer to Fig. 33. For both front and rear housing (6 &
7), measure the dimension between the end face 'A' of
the housing and the front face 'B' of the centre housing
(8).
Dimension: 'A' to 'B' = 'C'
'C' should be within the tolerance of 0 - 0.05mm.
Note: If dimension 'C' is out with the specified

tolerance, machine shim (21) to obtain the desired
value.
Fig. 31 - Pump Assembly ; Driveshaft
SM 2370 Rev2 05-07 11

Section 230-0050
9. Assemble rear housing (7) with 'o-ring (27), cover (5) 13. Both front and rear pump housing ( 6 & 7),
and screw (32). Refer to Fig. 34. assemble swash plate (9 & 10) and piston rod (15) into
the bore of correct bore of the housing. Refer to Fig.
SM - 3587
37.
SM - 3424
Fig. 34 - Rear Housing Assembly
10. Assemble the shaft seal (24) using a suitable driver

t tap the seal into place.. Ensure sealing ring is
greased and that the surface the seal is running on is Fig. 37 - Rear Housing Assembly
not damaged. Refer to Fig. 35.
14. Both front and rear pump housing ( 6 & 7);
11. Secure circlip (29) in place using suitable pliers. Assemble control piston (14), 'o'-ring (26) and plug (16)
into the housing. Use loctite 242 on threads of plug
SM - 3422 (16) prior to securing. Torque plug (16) to a value of
190 Nm (140 Ibf-ft).
15. Assemble pressure pins (46) using a suitable

assembly aid. Taking a suitable combination of bolt,
nut and washer type to allow the spring and pins to be
enclosed and compressed in tightening of the bolt / nut
combination. Do so sufficiently enough to allow the
circlip to be locked in place. On removal of assembly
aids, the spring face will be held against full extension
by the inner face of the circlip, similarly the pins will be
held on the inner shoulder of the piston housing, thus
retaining the assembly. Refer to Fig. 38.
SM - 3425
Fig. 35 - Front Housing Assembly
12. Both front and rear housings ( 6 & 7) , fit in bearing
shells (17 & 18) and spring (23). Ensure ample grease
is used. Refer to Fig. 36.
3
8
SM - 3423
4
2
7
5
Fig. 38 - Rear Housing Assembly
16. A Oil pistons and shoes (42). Assemble pistons

(42) with retaining plate (43).
Fig. 36 - Assembly
12 SM 2370 Rev2 05-07

Section 230-0050
17. Both front and rear pump housing ( 6 & 7), fit the SM - 3588
rotary group. It may be necessary to use a suitably
sized 'o'-ring to aid the assembly. Refer to Fig. 39.
SM - 3427
Fig. 39 - Insert Rotating Group

Fig. 41 - Centre Housing assembly
18. Both front and rear pump housing ( 6 & 7), 20. Assemble centre housing (8) to front pump housing
assemble bearing (20) and adjustment shim (21) to (6), secure using 4-off screws (31). Torque screws (31)
respective driveshafts (11 & 12). Refer to Fig. 40. to a value of 165 Nm (122 Ibf-ft). Refer to Fig. 42.
SM - 3428 SM - 3589
Ensure
marks match
Fig. 40 - Driveshaft Assembly Fig. 42 - Secure Centre & Front Pump Housing
19. Insert splined hub (13) into centre housing (8) bore. 21. Using suitable slings to lift the sub assembled front
Assemble control plates (40 & 41), dowels (30) and 'o'- pump and centre housing elements. Orientate these to
rings (25) to housing. Ensure 'o'-rings are greased prior facilitate assembly into the rear housing unit. Refer to
to being inserted in grooves. Note: maintain correct Fig. 43.
location through dowels. Refer to Fig. 41.
Note: Ensure marked positions on all housing

components are matched correctly as they were
created at the disassembly stage.
SM 2370 Rev2 05-07 13

Section 230-0050
SM - 3590 INSTALLATION

where used.
WARNING
safely.
1. Install new 'O' ring to pump.
2. Push pump inward to engage with coupling in

transmission. Secure pump assembly to transmission
with bolts (56) and lockwashers (57). Tighten bolts (56)
Fig. 43 - Assembly to Rear Pump
22. Ensure correct position of the control plate ( 41) 3. Remove caps and connect outlet, inlet and load
and 'o'-ring (25) is fitted in the groove. sense lines to pump. Before connecting case drain
line, fill pump casing through drain port with clean
23. Secure front assembly to the rear pump unit with 4- hydraulic oil as used in the hydraulic tank. Connect the
off screws (31). Torque screws (31) to a value of 165 case drain line to pump. Fill hydraulic tank with oil
Nm (122 Ibf-ft). Refer to Fig. 44. specified in Section 300-0020, LUBRICATION
SYSTEM.
SM - 3591
Note: It is very important that pump casing is

completely filled with hydraulic oil. This will ensure
Front pump proper lubrication of the internal parts of pump when it
is initially operated. Fill the pump casing through the
drain port. Filling only the suction line is totally
insufficient.
4. Refer to 'PUMP STARTING PROCEDURE' for

proper start-up procedure.
Rear pump
PUMP STARTING PROCEDURE
1. Be sure the pump case drain line is free from
obstructions that restrict the pump case drain flow
back to tank and cause high case drain pressure which
can lead to an early pump failure.
2. Ensure that all hydraulic controls are set to a neutral

position, the steering lock bar is in the 'Locked' position
Fig. 44 - Securing Pump Assembly and place the battery master switch in the 'On'
24. Assemble control valves (2) to both pumps. using position. Start the engine and allow the pump to run
screws (4). unloaded for a period to ensure that all residual air
within the system is released.
3. Check for external leakage, abnormal noise and

vibrations.
14 SM 2370 Rev2 05-07
Section 230-0050
4. Remove wheel blocks and place the steering lock SM - 3615
bar in the 'Stowed' position. Start the engine and check
hydraulic systems for proper operation. 1
2
3
4
5
PRESSURE CHECKS 6
9 7
To check pump delivery pressure (cut-off pressure) the 10 8
11
steering should be operated full lock against the stops. 12
13
The pump is checked against the steering system as 14
this is the highest pressure requirement in the hydraulic 15
circuit.

WARNING 2 - Rear Brake Accumulator 10 - Transmission Pressure
3 - Primary Accumulator 11 - DropBox Lube Pressure
Machine has to fully articulate to check pump 4 - Front Brake Pressure 'TP3'
pressures, therefore steering lock bar cannot be 5 - Rear Brake Pressure 12 - Main Pump (Front)
'Locked'. To prevent personal injury and 6 - Parking Brake Pressure 13 - Main Pump (Rear)
property damage, exercise extreme caution 7 - Diff-lock Pressure 'TP1' 14 - Pump LS Pressure
while working around articulation and
oscillation pivot area. Fig. 45 - Diagnostic Pressure Check Points Left Hand
Fender
Delivery Pressure (cut-off pressure)
Install a pressure gauge capable of at least 240 bar (3 If the difference (∆P) between delivery pressure and
480 lb/in2) into main pump front section diagnostic load sense pressure is equal todesired value proceed
checkpoint in diagnostic pressure point (12, Fig. 45) on to 'Pump Setting Procedure - Pump Delivery Pressure
the left hand fender. When steering against stops, Setting'.
pressure should be 240 bar (3 480 lb/in2).
Repeat procedure with pressure gauge installed in main However, if ∆P is not equal to desired value carry out
pump rear section diagnostic pressure point (13, Fig. complete 'Pump Setting Procedure'.
45). When steering against stops pressure should be
240 bar (3480 lb/in2). PUMP SETTING PROCEDURE
Note: It is very important that pump casing is
Differential Pressure (load sense pressure) completely filled with hydraulic oil before pump is
operated. Fill the pump casing through the drain port.
Note: There are two compensators fitted to the unit. Filling only the suction line is totally insufficient.
Each compensator must have the differential pressure
set. Both compensators differential pressure setting is
35 bar (507 lb/in2). Install a pressure gauge capable of Differential Pressure Setting
measuring 240 bar (3480 lb/in2) into main pump front Numbers in parentheses refer to Figs. 30 & 31, unless
section diagnostic checkpoint (12, Fig.45). Install a otherwise stated.
pressure gauge capable of at least 240 bar (3 480 lb/
in2) into pump load sense diagnostic checkpoint on the 1. Install a pressure gauge capable of at least 240 bar
left hand fender (14, Fig. 45). With steering in neutral (3 500 lb/in2) into main pump front diagnostic
position, pressure at main pump front section gauge checkpoint in diagnostic pressure point (12, Fig. 45) on
should be 35 bar (507 lb/in2) greater than pressure at the left hand fender. to measure pump delivery
pump load sense gauge. pressure (cut-off pressure) (Gauge A).
Repeat procedure with pressure gauge installed in main
pump rear section diagnostic checkpoint (13, Fig. 45). 2. Install a pressure gauge capable of at least 240 bar
(3 480 lb/in2) into pump load sense diagnostic
If these pressures are not observed, then pump may checkpoint on the left hand fender (14, Fig. 45) to
need to be reset (refer to Troubleshooting). measure load sense pressure setting (Gauge B).
TROUBLESHOOTING 3. Ensure that all hydraulic controls are set to a neutral
If steering cannot be operated or is excessively heavy, position, the steering lock bar is in the 'Locked' position
then pump delivery pressure is likely to be low and and place the battery master switch in the 'On' position.
pump setting should be checked. Start the engine and allow to run at low idle. This
SM 2370 Rev2 05-07 15

Section 230-0050
SM - 3639 control valve. Protective cap should be replaced and
Pressure values are for one full Clockwise (CW) or Counter- tightened to 21 Nm (15.5 Ibf / ft).
Clockwise (CCW) rotation of the set screw.
8. The differential pressure is now set.
1
Repeat procedure with gauge A connected to main
pump rear section diagnostic checkpoint (13, Fig. 45).
+ 16 bar
Both differential pressure settings of both sections of
- 16 bar the main are now set.
Switch off the engine and relieve system pressures as
+ 50 bar
described in 'Removal'.
- 50 bar
9. Remove pressure gauges from diagnostic
checkpoints.
2
Pump Delivery Pressure Setting
1 - Differential Pressure (LS pressure) Numbers in parentheses refer to Figs. 7 unless
2 - Delivery Pressure (Cut-off pressure) otherwise stated.
Fig. 46 - Pressure Adjustments at Control Valve WARNING

Machine has to fully articulate to set pump,
allows the pump to run unloaded for a period to ensure therefore steering lock bar cannot be 'Locked'.
that all residual air within the system is released. To prevent personal injury and property
Check for external leaks. damage, exercise extreme caution while
working around articulation and oscillation
4. Check readings on both pressure gauges. Pump pivot area.
delivery pressure (Gauge A) should always be greater
than load sense pressure (Gauge B). This differential There should be no requirement to adjust the set screw
pressure (∆P) should be equal to 35 bar (507 lb/in2). If (2, Fig. 46) at delivery pressure (cut-off pressure) port
the ∆P pressure differs from the desired value, then as this is factory set. The cut-off pressure sets the
adjustment may be necessary. pump delivery pressure. If the set screw (2, Fig. 46) or
nut (3) has been moved, to reset the pump delivery
Note: If pump delivery pressure (Gauge A) is less than pressure follow the procedure below:
desired value disconnect either LHS combination cooler
or RHS cooler fan disconnect solenoids, causing the 1. Install a pressure gauge capable of at least 240 bar
solenoid valve to default to an open position, allowing (3 480 lb/in2) into main pump front section diagnostic
hydraulic oil to the fan motor. This will place a demand checkpoint on the left hand fender (12, Fig. 45) to
on the pump causing pump delivery pressure to measure pump delivery pressure (cut-off pressure).
increase.
2. Start the engine and run at full throttle. Steer full
5. At differential pressure (load sense) port (1, Fig. 9) lock against the stops. Observe pressure on gauge.
unlock cap (1, Fig 7) to allow nut (3, Fig. 7) to be This cut-off pressure should be 240 bar (3 480 lb/in2). If
unlocked. turn set screw (1, Fig. 9) CW (looking the pressure reading differs or the steering is
straight at set screw) to increase ∆P pressure, or CCW excessively heavy, then carry out steps which follow.
to decrease ∆P pressure.
Note: Steering has to be operated over relief (against
Note: Pressure should always be adjusted on the stops) as this is the maximum pressure the pump
increase. Hence if ∆P pressure is too high, set screw must deliver. Setting pump against any other operation
should be turned CCW first to bring the pressure below would result in the pump being set at a lower maximum
the desired level, then increased to attain desired delivery pressure.
value.
6. Recheck readings on both pressure gauges. Pump 3. At delivery pressure (cut-off pressure) port, unlock
delivery pressure (Gauge A) should be at correct value. nut (3) and turn set screw (2, Fig. 46) clockwise to
increase cut-off pressure, or counter-clockwise to
7. Once correct ∆P pressure is achieved, tighten nut decrease cut-off pressure (adjustment 50 bar (725 lb/
(3, Fig. 7) at differential pressure (load sense) port on in2) per turn).
16 SM 2370 Rev2 05-07

Section 230-0050
Note: Pressure should always be adjusted on the LUBRICATION
increase. Hence if cut-off pressure is too high, set
Refer to Section 300-0020, LUBRICATION SYSTEM,
screw (2, Fig. 46) should be turned counter-clockwise
for recommended periodic oil change periods and oil
to decrease cut-off pressure below 240 bar (3 480 lb/
specifications.
in2), then turn set screw (2, Fig. 46) clockwise to attain
240 bar (3 480 lb/in2).
All pump parts are lubricated by the hydraulic oil
therefore the oil must be kept clean to minimize pump
4. Once correct cut-off pressure has been attained,
wear. Whenever there is a hydraulic system failure, the
revert steering to neutral position, then steer full lock
oil should be drained, the entire system flushed, oil
against the stops. Observe gauge to confirm cut-off
filter replaced and clean hydraulic oil added to eliminate
pressure is set to 240 bar (3 480 lbf/in2).
all metal particles or foreign matter.
Note: A change in pump tone should be heard when
cut-off pressure is reached, as pump de-strokes to PUMP WEAR LIMITS
standby condition.
Before reassembling the pump after disassembly, the
Pump Wear Limits table should be consulted to
5. If no change in pump tone is heard, cut-off pressure establish which components should be replaced.
is too high. Return to step 3 of procedure. If problem
persists, refer to Section 220-0000, STEERING SPECIAL TOOLS
SYSTEM SCHEMATIC.
There are no special tools required for the procedures
6. Once correct pressure is achieved, tighten nut (3, SERVICE TOOLS, for part numbers of general service
Fig. 7) at cut-off pressure port on control valve. tools required. These tools are available from your
Protective cap should be replaced and tightened to 21 dealer.
Nm (15.5 Ibf / ft).
7. The differential pressure (load sense) and cut-off

PUMP TROUBLESHOOTING
pressure are now set. Irregular Noise Rotation Speed too high,
Repeat procedure with pressure gauge connected to air intake, cavitation or
main pump rear section diagnostic checkpoint (13, Fig. mechanical damage
45). Both sections of the main pump are now set.
Switch off the engine and relieve system pressures as No or insufficient Power comparison of engine
described in 'Removal'. flow pump (do outputs match each
other), pump fails to swivel out,
8. Remove pressure gauge from diagnostic inner leakage, dirt specific wear
checkpoints. (stroke limitation on a too small
swivel angle)
No or insufficient Power comparison of engine pump

pressure (do outputs match each other),
pump fails to swivel out,
inner leakage, dirt specific wear
(stroke limitation on a too
small swivel angle)
Pressure / flow Air suction, inner leakage, dirt

specific fluctuation wear, power
unit damage, controller unstable.
* * * *
SM 2370 Rev2 05-07 17

BODY SYSTEM - Body Control Lever
Section 230-0081
DESCRIPTION AND OPERATION SM - 3504
The body control lever is mounted on the right hand

side dash panel, next to the transmission shift
controller.
When the body control lever is operated, a voltage is

sent to the hydraulic ECU, which converts voltage to
current. This current controls the body raise and lower
proportional pressure control valves, producing a pilot
pressure to shift the control spool in the main hydraulic
valve. This allows the flow of oil to reach the body
cylinders, to either raise or lower the body. Refer to
Section 230-0000, BODY SYSTEM SCHEMATIC and
Section 215-0050, MAIN HYDRAULIC VALVE.
The three operating positions of the joystick from front Fig. 1 - Body Control Lever
to rear are as follows:
Power Down - Pushing the lever forward provides

hydraulic force to power-down the body. Pushing the
lever fully forward will engage the electric detent. When WARNING
the body reaches the body proximity switch, the lever Always disconnect body control lever before
springs back to 'NEUTRAL' and power down is ramped welding on the machine.
back to allow the body to float down onto the chassis.
Neutral - If the body is above the body proximity MAINTENANCE

switch, the lever in this position will stop and hold the
The body control lever is a non-serviceable item and
body at any desired height. If the body is below the
should be replaced completely, if damaged, as follows:
proximity switch, the hydraulic ECU defaults the
control spool in the main hydraulic valve to the neutral
position and energises the float solenoid, allowing the
body to float down onto the chassis. The body should
be fully lowered and in the 'NEUTRAL' position while
the machine is in motion. The lever will remain in the
'NEUTRAL' position when released.
WARNINGS
Raise - Pulling the lever back and holding it in this
position directs oil to extend the body hoists and raise
the body. When released, the lever will spring back to
the 'NEUTRAL' position.
safely.
In the event of an engine, hydraulic or hydraulic ECU
failure, the body can be lowered using a manual
within the system after engine shut down.
release on the float vavle solenoid, which is located on
the main valve block.
work on the hydraulic system or serious injury
Note: The body must remain lowered with lever in the
could result.
'NEUTRAL' position until it is necessary to operate the
body again. Failure to comply to this could result in
overheating the hydraulic oil and failure of the hydraulic
system components.
pressure in the hydraulic system.
SM 2418 01-06 1
Body System - Body Control Lever
Section 230-0081
3. Block all road wheels, place the steering lock bar in 9. Place the battery master switch in the 'On' position,
the 'Locked' position and the battery master switch in start the engine and bring hydraulic oil to operating
the 'Off' position. temperature. Operate the body control lever to ensure
correct operation.
4. Disconnect body control lever harness from main
harness. 10. Remove wheel blocks and place the steering lock
bar in the 'Stowed' position.
5. Support body control lever and remove screws
securing body control lever on the right hand dash
panel. TROUBLESHOOTING
A faulty body control lever will cause an input error at
6. Remove body control lever from mounting location. the hydraulic ECU. Refer to Section 190-0085,
HYDRAULIC SYSTEM ECU.
7. Secure new body control lever on the right hand
dash panel with screws.
SPECIAL TOOLS
Note: Ensure harness from body control lever is at the There are no special tools required for procedures
front when lever is installed. outlined in this section. Refer to Section 300-0070,
8. Reconnect main harness to body control lever tools required. These tools are available from your
harness. dealer.
* * * *
2 SM 2418 01-06
BODY SYSTEM - Body Cylinder
Section 230-0130
SM - 3536
11,22
23
11, 22 20,21
10 9 10 9
8
17 16 19 15 5 14 1 2 7 18 3 13 12 3
BODY MOUNTING FRAME MOUNTING
26 24
4 25
24 6
25 4
6 27
1 - Cylinder Body 8 - Pin 15 - 'O'-ring 22 - Cap

2 - Piston Rod 9 - Circlip 16 - Rod Seal 23 - 'O'-ring
3 - Piston 10 - Spherical Bearing 17 - Wiper Ring 24 - Washer
4 - Spacer 11 - Grease Nipple 18 - 'O'-ring 25 - Spring Washer
5 - Seal Bushing 12 - Wear Ring 19 - Backup Ring 26 - Pin
6 - Bolt 13 - Seal 20 - 'O'-ring 27 - Pin
7 - Bushing 14 - 'O'-ring 21 - Plug 28 - End Cap
Fig. 1 - Sectional View Of Body Cylinder and Mounting
DESCRIPTION REMOVAL
There are two single stage, double acting body hoist

cylinders (1), cushioned at both ends of the stroke on WARNINGS
the vehicle. The cylinder base end is connected to the To prevent personal injury and property
trailer frame and piston rod (2) end is connected at the damage, be sure wheel blocks, blocking
body. Single stage double acting means that piston rod materials and lifting equipment are properly
(2) can have oil applied to either side, extending or secured and of adequate capacity to do the job
retracting the piston rod. safely.
Cylinder mounting is by pins (26 & 27), spacers (4) and Hydraulic fluid pressure will remain
spherical bearings (10) are secured in place with within the body hoist system after engine
circlips (9). Spherical bearings (10) permit a limited shutdown. Operate the treadle pedal
amount of cylinder misalignment. continuously until the pressure has dissipated
before carrying out any work on the hydraulic
system or serious injury could result.
SM 2402 01-06 1
Body System - Body Cylinder
Section 230-0130
DISASSEMBLY
WARNING Numbers in parentheses refer to Fig. 1.
Exercise extreme caution when lowering
the cylinders from the body. The cylinders will
swing out sharply as they leave their WARNING
mountings. To prevent personal injury and property
1. Position the vehicle in a level work area, ensure the secured and of adequate capacity to do the job
body is fully lowered, apply the parking brake and safely.
switch off the engine.
1. Ensure clean working conditions, remove any port
2. Press and hold down body hoist bleed down switch plugs thus allowing easy entry of air into cylinder body
and operate the body control joystick continually to (1), preventing a vacuum when parts are withdrawn
relieve pressure in the body hoist system. from cylinder body (1).
3. Block all road wheels, place the steering lock bar in 2. Remove circlips (9) from base end of cylinder body
the 'Locked' position and the battery master switch in (1) and piston rod (2) end. Press out spherical bearings
the 'Off' position. (10).
4. Install a suitable strap around the cylinder and 3. Using suitable tool unscrew end cap (28) until thread
attach to a lifting device. is disengaged from cylinder body (1).
5. Position a suitable container at the base end of one 4. Support piston rod (2) at the rod eye and withdraw
cylinder. Identify and remove the hydraulic lines. Cap piston rod (2) from cylinder body (1). Ensure centre
hydraulic lines and cylinder ports to prevent entry of lines of piston rod (2) and cylinder body (1) remain
dirt. coincidental during removal of piston rod (2).
6. Remove bolt (6), lockwasher (25), washer (24) and 5. Place piston rod (2) on supports which will not
upper pin (26) connecting piston rod (2) end of the damage the piston rod diameter.
cylinder to the body. If due to lack of maintenance the
upper pin can not be removed from the front, there is 6. Remove and discard piston seals (13) and wear
plate on the inside of the body that can be removed to rings (12) from piston (3).
allow access to the rear of the pin to ease removal.
This plate is tack welded in place so a grinder is 7. Remove pin (8) from piston (3).
required to remove it.
8. Provide an anti-torsion device through piston rod (2)
7. Lower cylinder slowly and remove spacers (4). eye to allow unscrewing of piston (3). Using suitable
tool unscrew piston (3) from piston rod (2).
Note: Cylinder will swing out sharply as it leaves its
mounting. 9. Remove bushing (7) from piston rod (2).
8. Remove bolt (6), lockwasher (25), washer (24) and 10. Remove cylinder end cap (28) from piston rod (2).
lower pin (27) connecting base end of the cylinder to Remove and discard bushing (5), rod seal (16), wiper
the frame. ring (17) , 'O' rings (14 & 15) and back up ring (19).
9. Remove spacers (4) and remove cylinder assembly

to a clean area for disassembly.
10. Repeat steps 4 through 9 for opposite cylinder.
2 SM 2402 01-06
Section 230-0130
INSPECTION end cap (3).

9. Sling assembled piston rod (2) in a manner to allow
careful leading of the assembled piston rod into
1. Clean all parts of the cylinder with a suitable solvent
cylinder body (1). Take care not to damage piston seal
and dry with clean, lint-free cloths. Clean all grooves
(3) on cylinder body (1) threads.
carefully to remove any foreign material.
10. After piston (3) is inserted in cylinder body (1), push
2. Check cylinder body (1) and outer diameter of piston
the piston rod assembly into cylinder body (1) maintaining
(3) for scratches, cracks or other defects. Remove
coincidental centre lines of piston rod and cylinder body.
ridges, nicks and scratches with a fine stone and re-
clean. Replace any components which cannot be
11. Before piston rod (2) is fully home and, with slings
repaired.
still taking some of piston rod (2) weight, engage end
cap (28) thread and screw home.
3. Inspect piston rod (2) for distortion, cracks or other
defects. Replace piston rod if defective area is
12. Push piston rod (2) to the fully retracted position and
irreparable.
tighten end cap (28) to a torque of 237 Nm (175 lbf ft).
4. Check spherical bearing (10) for wear and replace if
necessary.
ASSEMBLY INSTALLATION
connections, as described in Section 230-0000, BODY
WARNING
SYSTEM SCHEMATIC. Renew all 'O' rings where used.
WARNING
safely.
1. Press spherical bearing (10) in base end of cylinder
body (1) and piston rod (2) end. Secure spherical
safely.
bearings (10) with circlips (9).
1. Install a suitable strap around the cylinder and
2. Install new bushing (5), '0' -rings (14 & 15), rod seal (16)
position cylinder on unit with base end of cylinder ready
and backup ring (19) into their respective locations on end
for mounting.
cap (28). Load end cap (28) over piston rod (2) thread,
taking care not to damage rod seal (16) on the thread.
2. Install spacers (4) in base end of cylinder and insert
lower pin (27) through mounting bores, spacers (4) and
3. Install new 'O' rings (18) on piston rod (2) and
cylinder. Secure lower pin (27) with washer (24),
replace bushing (7).
lockwasher (25) and bolt (6). Tighten bolt (6) to a torque
of 66 Nm (49 lbf ft).
4. Apply Loctite 243 to first two threads of piston (3).
Using suitable tool screw on piston (3) and tighten to a
3. Install spacers (4) in rod end of cylinder, align
torque of 1 356 Nm (1 000 lbf ft).
spherical bearing (10) with bores in body and install
upper pin (26) through mounting bores, spacers (4) and
5. Ensure bushing (7) is secure to piston (3) end face
cylinder. Secure upper pin (26) with washer (24),
and piston rod (2) face .
lockwasher (25) and bolt (6). Tighten bolt (6) to a torque
of 66 Nm (49 lbf ft).
7. Insert new piston seal (13), wiper (17) and new wear
rings (12) in piston (3).
4. Connect the hydraulic oil lines to the cylinder ports
as tagged during removal.
8. Screw pin (8) into piston (3) torque to a vaule of XX.
5. Lubricate pins at lube fittings (11) with lubricant as
8. Fully grease piston (3) OD and 'O' rings (14 & 15) in
SM 2402 01-06 3
Section 230-0130
specified in Section 300-0020, LUBRICATION SYSTEM. Every 250 hours: Lubricate cylinder pins as described
in Section 300-0020, LUBRICATION SYSTEM. Inspect
6. Check oil level in hydraulic tank and add if low. cylinders for leaks, if leaks are found, replace seals
Refer to Section 230-0040, HYDRAULIC TANK, for with seals contained in the Service Repair Kit, as
correct fill level. Refer to Section 300-0020, specified in the parts book.
LUBRICATION SYSTEM, for the type of oil used.
7. Place the battery master switch in the 'On' position, SPECIAL TOOLS
start the engine, operate the body and check cylinder lines Special tools can be fabricated as shown in Figs. 2 & 3.
for leaks. Tighten lines and fittings as required. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools are
8. Remove wheel blocks from road wheels. available from your dealer.
MAINTENANCE

TORQUE
1 3 End Cap 237 175
1 12 Piston 1 356 1 000
1 15 Grub Screw 49 36
1 26 Bolt 66 49
4 SM 2402 01-06
Braking System - Braking System Schematic
Section 250-0000
SM - 3613
TO PARKING
Px BRAKE
FROM
TRANSMISSION
ACC1 ACC2 ACC3

P1
A
TO FRONT
SERVICE BRAKES T1
PS4 PS3 PS2
PBP
PB
TS
B1
B2
33
P2
A
TO REAR 10 11
SERVICE BRAKES 32
T2
9
12
E
31
8 13
PS1 14
35
7
P1
15 16
17
19
LSP
D - Main Hydraulic Pump 13 - (CT13) Orifice PS1 - Steering Pressure Switch

E - Brake Treadle Valve 14 - (CT14) Cold Start Solenoid Valve PS2 - ACC2 Pressure Switch
15 - (CT15) Orifice PS3 - ACC1 Pressure Switch
7 - (CT7) Priority Valve 16 - (CT16) Shuttle Valve PS4 - Park Brake Pressure Switch
8 - (CT8) Check Valve 17 - (CT17) Shuttle Valve ACC1 - Front Brake Accumulator
9 - (CT9) Pres. Reduce Valve 19 - (CT19) Orifice ACC2 - Rear Brake Accumulator
10 - (CT10) Check valve 31 - (CT31) Prk Brk Solenoid Valve ACC3 - Primary Accumulator
11 - (CT11) Check Valve 32 - (CT32) Directional Control Valve
12 - (CT12) Brake Charging Valve 33 - (CT33) Orifice
Fig. 1 - Brake System Schematic
DESCRIPTION Service Brakes

Numbers in parentheses refer to Figs. 1, 2 and 9. The service brakes are of the enclosed, forced oil-
cooled multiple disc type. The service brakes are
The hydraulic braking system is of closed centre actuated by hydraulic oil as specified in Section 300-
design wherein constant pressure is stored in 0020, LUBRICATION SYSTEM. DO NOT USE BRAKE
accumulators and is regulated as required to retard or FLUID (J 1703). Multiple discs within the brake
stop the machine. assemblies are cooled by brake cooling oil as specified
in Section 300-0020, LUBRICATION SYSTEM.
A brief description of the individual components used in
the braking system are listed below. Detailed service The brake assembly is bolted to the stub axle and
and operating instructions can be found in the relevant houses a sandwich of friction discs splined to a hub
component sections of this manual. rotor. There are four friction discs in each brake
assembly.
SM 2430 Rev1 05-07 1
Section 250-0000
When the treadle valve is actuated, hydraulic oil enters Brake Coolant / Hydraulic Tank
the brake assembly and forces the brake piston
Refer to Section 230-0040, BRAKE COOLANT /
against the rotating friction discs which react with
HYDRAULIC TANK.
stationary reaction discs. The reaction discs are
retained by scalloped tangs at the outside diameter,
The brake coolant / hydraulic tank as the name reflects
which in turn transfers the reaction torque to the rigid
is a tank assembly comprising of both brake cooling oil
outside housing, slowing or stopping wheel rotation.
tank and hydraulic oil tank in one integral unit fitted in
the left hand tractor fame rail. Looking from the LHS of
In an emergency situation, application of the park/
the tractor unit, the brake cooling tank is to the left and
emergency valve will actuate the service brakes and
the hydraulic tank is to the right. The brake coolant
tank supplies the brake cooling circuit. The hydraulic
condition, a restriction in the 'Px' line from the brake
tank is the common reservoir for the steering, braking,
manifold valve will slow oil flow from the parking brake
body hoist and fan drive system.
allowing the service brakes to actuate momentarily
ahead of the parking brake.
Integral with brake coolant / hydraulic tank assembly
are cap assemblies, suction strainer, Hydraulic filter
When the treadle valve or park/emergency brake is
cover plates and drain valves. Located on the outboard
released, hydraulic pressure against piston is relieved
face of the tank are level gauges and window nut for
and cup springs force the piston to return to its original
checking the fluid levels of both brake cooling oil and
position, thus, relieving the pressure against the brake
hydraulic oil.
disc pack.
Main Hydraulic Pump (D)

Parking Brake
Refer to Section 250-0000, MAIN HYDRAULIC PUMP.
Refer to Section 170-0010, PARKING BRAKE AND
MOUNTING.
The hydraulic pump is mounted off the left hand side of
the transmission PTO. It is an 'tandem' axial piston,
The parking brake consists of a sliding calliper acting
variable displacement pump with load sense and
on a brake disc on a rear driveline and is of 'Inverted
pressure regulator to match the flow and pressure to
Design' i.e. requiring pressure to hold it off.
the demand. 'Tandem' in the sense that it contains two
complete pump assemblies mated together to provide
Operation is by a spring applied/hydraulically released
to desired output levels.
actuator. A push control on the right hand dash panel
activates the park brake solenoid valve (31) on the main
The tandem pump supplies hydraulic oil for the
hydraulic valve assembly, controlling oil pressure from
steering, braking and body hoist systems, as well as
the rear brake circuit accumulator to the actuator.
the transmission and engine oil cooler fan drive
Application of the push control releases oil from the
system.
actuator allowing internal springs in the actuator to apply
the parking brake. Pulling out the push control directs oil Parking Brake Pressure Switch (PS4)
pressure from the rear brake circuit accumulator to the
Located on the main hydraulic valve assembly it
actuator, compressing internal springs, to release the
senses pressure in the parking brake (PB) line. The
parking brake.
pressure switch closes at a pressure of 4.8 bar (70 lb/
in²) and sends a signal to illuminate the parking brake
In an emergency situation, application of the park/ indicator light when the parking brake is applied.
emergency valve will actuate the service brakes and
condition, a restriction in the 'Px' line will slow oil flow Brake Circuit Pressure Switches (PS2
from the parking brake allowing the service brakes to &PS3)
actuate momentarily ahead of the parking brake.
Front and rear brake circuit pressure switches are both
located on the main hydraulic valve assembly. The
pressure switches sense pressure in the front and rear
brake circuits and sends a signal to warning lights on
the dash (a buzzer also sounds) when the pressure
drops below 122 bar (1 769 lbf/in²). The warning lights
will remain illuminated until the pressure rises above
135 bar (1 958 lb/in2).
2 SM 2430 Rev1 05-07
Section 250-0000
Brake Accumulators (ACC1,2 & 3) Brake Treadle Valve (E)

Refer to Section 250-0060, ACCUMULATOR. Refer to Section 250-0070, TREADLE VALVE.
There are three accumulators mounted at the rear left The treadle valve controls the level of hydraulic fluid
hand side of the cab; one for the front brake system pressure applied to front and rear brakes and the
(ACC1) and one for the rear and park brake (ACC2) . maximum pressure available to these circuits.The first
The front and rear brake accumulators are few degrees movement of the brake pedal will acutate
supplemented by a third (primary) accumulator (ACC3). the brake lights on the rear of the vehicle. Continued
The primary accumulator supports the service brake movement will allow pressure to the service brakes. It
system and the body pilot pressure system. All three is operated by a foot pedal in the operators cab and,
accumulators are of the piston type and are precharged with the engine running, is automatically applied by the
with nitrogen, ACC1 and ACC2 to 55 bar (797 lb/in²) park brake solenoid valve (31) through the directional
and ACC3 to 103 bar (1500 lb/in2). It consists of a control valve (32) on the main hydraulic valve to the
charging valve assembly, cylinder assembly and 'px' port on the treadle valve..
piston. The charging valve will allow precharge to be
checked or accumulator charged.
Valves 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
19, 31, 32 & 33
SM - 3614 These valves form part of the brake cuircuit and are an
intregal part of the main hydraulic valve assembly,
mounted on the left hand side of the tractor frame. Ref.
Section 215-0050, MAIN HYDRAULIC VALVE
ASSEMBLY.
OPERATION
Numbers in parentheses refer to Figs. 1, 2 and 3.
Brake Charging
The valves integral of the main hydraulic valve
(F) assembly automatically maintain the brake
PS3
accumulator pressures between a lower and upper
limit.
PS4
PS2 Accumulators (ACC1 & ACC2) are charged from
(R)
accumulator (ACC3) via brake system relief valve (9),
to limit the pressure in these accumulators to 160 bar
(2320 lb/in2) and then via check valves (10 & 11)
respectively.
PS2 - Rear Service Brake Circuit Pressure Switch
PS3 - Front Service Brake Circuit Pressure Switch
PS4 - Park Brake Pressure Switch If the pressure in accumulator (ACC3) is below the
lower charge limit of 165 bar (2390 lbf/in2) the brake
Fig. 2 - Brake System Pressure Switch Locations
system charge valve (12) spring closes the brake
The piston acts as a separator dividing the cylinder system charge valve (12). The pressure then builds up
assembly into two sections. The top section nearest in the load sense line from brake system charge valve
the charging valve contains the nitrogen precharge. (12) to the shuttle valve (16) and onto the priority valve
Hydraulic oil from the main hydraulic pump flows (7) spring chamber where it helps this valve to close,
through check valves in the main hydraulic valve and ensuring flow priority is to the brake charging. At the
into the bottom section of the accumulators. same time it also acts upon the main hydraulic pump
Accumulator pressure is monitored by pressure load sense line via shuttle valve (17) to supply enough
switches (PS2 & PS3)) in the brake lines. flow to charge the accumulators.
As soon as the pressure in accumulator (ACC3)

reaches the upper charge limit of 185 bar (2680 lbf/in2)
the brake system charge valve (12) opens and unloads
SM 2430 Rev1 05-07 3

Section 250-0000
the load sense line to tank. This action unloads the the operators cab.
main hydraulic pump back to its standby pressure of
50 bar (725 lb/in2). When the park/emergency control switch is activated
The accumulators (ACC1 & ACC2) are also (pushed in), the electrical signal between the switch
automatically charged every time the pressure at the and park brake solenoid valve (31) is opened. This
main hydraulic pump rises above the pressure in action de-energises the park brake solenoid valve (31).
accumulator (ACC3). It is therefore possible to achieve Oil flows through park brake solenoid valve (31) and
pressures up to the main hydraulic pump cut off through the directional control valve (32). The oil
pressure of 240 bar (3 480 lb/in2) in this accumulator travels through the directional control valve and into the
(ACC3) (eg. when steering over relief). The brake 'Px' port in the treadle valve for an emergency brake
system relief valve (9) will still limit the pressure in application.
accumulators (ACC1 & ACC2) to 160 bar (2 320 lb/in2).
Return oil from the parking brake circuit enters the
Orifice (35) would protect all three accumulators main hydraulic valve assembly. The oil flows through
against abnormally high pressure spikes. However, park brake solenoid valve (31) and exits the main
accumulator (ACC3) can see system pressure if any of hydraulic valve assembly to the hydraulic tank. With no
the main hydraulic functions are held over relief for a pressure in the parking brake circuit to hold the parking
period of time. brake off, the parking brake is applied by spring
pressure.
Brake Apply
The minimum pressure required at the brake treadle When the emergency brake switch is deactivated
valve is 48 bar (696 lb/in2). (twist and pull out), the electrical signal between the
switch and park brake solenoid valve (31) is closed,
The brake treadle valve controls the level of hydraulic energiszing park brake solenoid valve (31). Oil flows
pressure applied to front and rear brakes and the through park brake solenoid valve (31) and exits the
maximum pressure to these circuits. It is operated by main hydraulic valve assembly pressurising the parking
the foot pedal in the operators cab and in an brake circuit to release the parking brake.
emergency with the engine running, is automatically
applied by the park brake solenoid valve (31) in the Return oil from the 'Px' port on the brake treadle valve
main hydraulic valve assembly (Ref. Park/Emergency flows through the directional control valve (32) through
Brake Function). park brake solenoid cartridge (31) and exits the main
Mounted on the brake treadle valve is a microswitch. hydraulic valve assembly to the hydraulic tank.
This microswitch, when activated, energises K50,
brake lamp relay. Relay is located in operator cab fuse When the engine is shutdown, transmission pilot
box. When the relay is energised an electrical circuit is pressure at directional control valve (32) is lost,
complete to energise the brake lights. causing the directional control valve (32) to move to
The first few degrees movement of the brake pedal the right under the influence of the compressed spring.
activates the rear brake lamps. This movement links the 'Px' port at the brake treadle
valve with the hydraulic tank through the main
Park/Emergency Brake Function hydraulic valve assembly. This action results in a
The park/emergency brake function is designed to controlled bleed down of the applied service brakes to
electrically operate the park brake and with the engine hydraulic tank. This controlled bleed down permits a
running automatically actuates the service brakes also synchronised service brake release/mechanical park
during this operation. brake application.
When the engine is running, a transmission hydraulic When the engine is shutdown, the park brake solenoid
pilot pressure acts against the spring at the directional valve (31) is automatically de-energised (fail safe).
control valve (32). The directional control valve (32) Park brake hold off pressure is allowed to return to tank
creates an open circuit between the main hydraulic through the park brake solenoid valve (31), causing
valve assembly and port 'Px' on the brake treadle park brake to apply (spring applied). The vehicle is now
valve. This permits a flow of oil to either energise the held with park brake only.
'Px' port at the treadle valve, or, exhaust the 'Px' port
through the main hydraulic valve assembly to tank,
dependant on operation of the park brake solenoid
valve (31). The park brake solenoid valve (31) is
controlled by the park/emergency control switch inside
4 SM 2430 Rev1 05-07

Section 250-0000
CHECKING SYSTEM PRESSURES SM - 3615
Numbers in parentheses refer to Figs. 1, 2 and 9, 1

unless otherwise stated. 2
3
4
5
6
WARNINGS 9 7
10 8
To prevent personal injury and property 11
12
damage, be sure wheel blocks and blocking 13
14
materials are properly secured and of adequate 15
capacity to do the job safely0.

within the system after engine shut down. 2 - Rear Brake Accumulator 10 - Transmission Pressure
Operate the brake treadle pedal continuously 3 - Primary Accumulator 11 - DropBox Lube Pressure
until the pressure has dissipated before 4 - Front Brake Pressure 'TP3'
carrying out any work on the system or serious 5 - Rear Brake Pressure 12 - Main Pump (Front)
injury could result. 7 - Diff-lock Pressure 'TP1' 14 - Pump LS Pressure
SM - 3518

Fender
A
P2
P
A2
T T2 parking brake, switch off the engine and turn steering
P wheel in both directions several times to relieve any
P1
T T1
A1
A
2. Operate the brake treadle valve continuously to
relieve pressure in the braking system. Block all road
Px wheels, place the steering lock bar in the 'Locked'
Px
position.
3. Connect a hydraulic gauge, capable of recording a
pressure of 0 - 345 bar (0 - 5 000 lb/in²), to park brake
diagnostic pressure point (6, Fig. 4) on left hand fender
outside cab door.

start the engine and release park/emergency button
(pull out), to energise the park brake line. Monitor
system pressure gauge. Pressure setting should be
160 bar (2 320 lb/in²).This is the pressure at the brake
accumulators.
5. If necessary, pressure setting can be adjusted via

brake system relief valve (9) on the main hydraulic
valve assembly. The operator cab will require to be
P1- Pressure from Rear Brake Accumulator raised to access brake system relief valve (9). Refer to
P2- Pressure from Front Brake Accumulator Section 260-0010, CAB AND MOUNTING.
A1 - Pressure to Rear Brakes
A2- Pressure to Front Brakes 6. Connect a hydraulic gauge, capable of recording a
T1- Tank return, Rear Brakes
T2- Tank return, Front Brakes pressure of 0 - 345 bar (0 - 5 000 lb/in²), to front brake
Px- Emergency / Park Pilot Pressure diagnostic pressure point (4, Fig. 4) on the left hand
fender.
Fig. 3 - Brake Treadle Valve Porting Arrangement
SM 2430 Rev1 05-07 5

Section 250-0000
SM - 1335
start the engine and apply park/emergency brake (push FITTING NUT
button in), to apply service brakes. Monitor system TUBE
pressure gauge. Brake actuating pressure for the front
brake circuit is 48 bar (696 lb/in²).
8. Repeat steps 6 & 7 at rear brake diagnostic pressure

point (5, Fig. 4). Brake actuating pressure for the rear
brake circuit is 48 bar (696 lb/in²).
SLEEVE
'O' RING 'O' RING
Note: When brakes are released, a residual pressure of
no more than 0.2 bar (3 lbf/in²) should remain.
9. If pressure setting at front or rear brake system is

not to specification but pressure input to treadle valve been achieved.
is ok (160 bar, 2320 lb/in2), then the treadle valve HYDRAULIC OIL
should be investigated.
Note: There is no adjustment at the treadle valve. The braking system should be kept filled with hydraulic
oil as specified in Section 300-0020, LUBRICATION
10. Shut off the engine and remove the pressure gauge SYSTEM.
from diagnostic check point.
Whenever there is a hydraulic system failure, the oil
11. Remove wheel blocks, place the steering lock bar should be drained, the entire system flushed, oil filters
in the 'Stowed' position, start the engine and check the replaced, oil screens thoroughly cleaned and clean
braking system for proper operation. hydraulic oil added to eliminate all metal particles or
BLEEDING THE BRAKING SYSTEM

Refer to Section 165-0010, BRAKE PARTS.

Where hydraulic lines are fitted with ORFS
connections, the following procedure should be carried
out during 'Installation'. Refer to Fig. 8.
a. Ensure 'O' ring/seal is in place and that the joining

surfaces are clean. If necessary, retain 'O' ring/seal in
place with a light coating of grease or vaseline.
b. Initially, the nuts should be tightened by hand.
c. Where a hose is fitted, ensure that it is not twisted

or kinked when the nuts are tightened so that it is
d. Where a tube is fitted, ensure that the connection is
aligned correctly.
e. Tighten the nut a further 1/4 to 1/2 a turn using the

correct size spanner (wrench).
f. Check that a satisfactory hose or tube routing has
6 SM 2430 Rev1 05-07

Section 250-0000
foreign matter.
SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, SERVICE
TOOLS, for part numbers of these tools.
Multi-Gauge
The multi-gauge, 15269784, is basically four pressure
are indicated on one of three simultaneously reading
gauges through a pressure range of 30 in of vacuum to
5 000 lbf/in².
The following items should be added to the multi-gauge
pressure check points;
15018226 Diagnostic Coupling
00118748 Connector (2 off)

The infrared thermometer, 15269785, can be used to
spot heat problems early in electrical, mechanical and
hydraulic systems. Hand held and easy to use, you
simply aim, pull the trigger, and read the temperature.
Since there is no need to touch what you are
measuring, temperatures of hard-to-reach or moving
shocked.
O' Ring Face Seals (ORFS) - Seal Kit

The braking system utilizes 'O' Ring Face Seal (ORFS)
connectors. An ORFS kit, 15271082, is available. This
kit contains a minimum stock requirement of all sizes
of ORFS type seal.
SM 2430 Rev1 05-07 7

Section 250-0000
SM - 3616
9
15 14
33
16
32 13 31
17
Valve (14 & 31) Coil Rating

Ohms Amps Watts
41 0.6 14
Voltage: 24V
7 - Priority Valve
8 - Check Valve
9 - Pressure Reducing Valve
10 - Check valve
11 - Check Valve
12 - Brake Charging Valve
13 - Orifice
14 - Cold Start Solenoid Valve
15 - Orifice
16 - Shuttle Valve
17 - Shuttle Valve
19 - Orifice 10
31 - Park Brake Solenoid Valve
32 - Directional Control Valve
33 - Orifice
19
Fig. 6 - Brake System Valves Integral to Main Hydraulic Valve Assembly
8 SM 2430 Rev1 05-07

Section 250-0000
Braking System Trouble Shooting

Front and Rear Brake Accumulators Brake System Relief Valve (9) Re-set valve (9) to the correct
(ACC1 & 2) not reaching the correct not set correctly or faulty setting or replace if faulty
hydraulic charge pressure
Pressure at Primary Accumulator Set the Charge Valve (12) to the
(ACC3) not high enough due to Brake correct setting.
System Charging Valve (12) not being Replace valve (15)
set correctly
Pre-charge gas pressure in the Check Pre-charge gas pressure in

accumulator not at the correct level the accumulator. Refer to Section
250-0060, ACCUMULATOR
Front and Rear Brake Accumulators Check Valves (10) or (11) leaking Replace Check Valves (10) or (11)
(ACC1 & 2) do not hold their charge
pressure Pre-charge gas pressure in the Check Pre-charge gas pressure in
accumulator not at the correct level the accumulator. Refer to Section
250-0060, ACCUMULATOR
Faulty seal in the piston of the Replace the accumulator/seals.

accumulator
Brake Treadle Valve leaking Refer to Section 250-0070,

TREADLE VALVE
Cold Start Solenoid Valve (14) Replace Valve (14). Refer to

Brake Charging System Fails to remains open Section 215-0050, MAIN
charge at initial engine start up HYDRAULIC VALVE ASSEMBLY
Faulty Brake System Charge Valve Replace valve (12)

(12)
Contamination in orifice(13) Replace orifice (13)
Air or contamination in the Load Lift the body of the truck up and
Sense System, especially when first down several times to purge the
running the truck after new main system.
hydraulic valve is fitted.
Front and Rear Brake Accumulators See previous symptoms.

Primary Accumulator (ACC3) does (ACC1 & 2) are not holding their
not hold its charge pressure. charge.
Check Pre-charge gas pressure in
Pre-charge gas pressure in the the accumulator. Refer to Section
accumulator not at the correct level 250-0060, ACCUMULATOR
Leakage across the Valves (8,12) is Replace each valve one at a time
too high. (in order stated) until the fault is
found.
Accumulator Piston Seal leaking Replace the accumulator
SM 2430 Rev1 05-07 9

Section 250-0000

Ineffective Park Brake Fault with Park Brake caliper Refer to Section 170-0010,
PARKING AND MOUNTING
Check if there is hydraulic pressure
Park Brake Solenoid Valve (31) not at the Park Brake port. If there is
functioning. Sticking in the selected pressure present, replace
position Valve(31).
Park Brake fails to release. No voltage at Park Brake Solenoid Check park/emergency switch in
Valve (31) when the switch is operators cab.
activated in the cab.
Check wiring between park/
emergency switch and park brake
solenoid (31).
Park Brake Solenoid Valve(31) fails to Replace valve(31).

operate due to fault.
Insufficient hydraulic charge pressure Check warning lights in cab and

in rear brake accumulator pressure at the Park Brake
diagnostic check point.
See trouble-shooting Brake
Accumulator Charging
Service brakes fail to come on when Faulty Brake Treadle Valve. Spool not Refer to Section 250-0070,
Parking Brake is selected when the stroking when pressure at port 'Px'. TREADLE VALVE.
engine is running.
No transmission pressure at Port TS Check piping and see instructions
on main hydraulic valve assembly. for the transmission.
Directional Control Valve (32) not Replace Valve (32)

selecting.
Fault with Park Brake System See previous trouble-shooting
Service Brakes come on when Directional Control Valve (32) sticking Replace Valve (32)
Parking Brake is selected and Engine in the selected position.
is not running.
Inadequate Braking. Low system pressure. Check hydraulic oil level.
Check oil condition.
Check for major leakage.
Check accumulator pressures.

Refer to Section 250-0060,
ACCUMULATORS
10 SM 2430 Rev1 05-07

Section 250-0000

Inadequate Braking (cont.) Brake treadle valve delivery pressure Check front and rear brake pressure
below normal setting.
Check brake treadle valve
operation. Refer to Section 250-
0070, TREADLE VALVE
Insufficient brake surfaces. Check brake disc/pads for wear.

Refer to Section 165-0010, BRAKE
PARTS.
Replace seals and pistons as

required. Refer to Section 165-
0010, BRAKE PARTS.
* * * *
SM 2430 Rev1 05-07 11

BRAKING SYSTEM - Brake Coolant / Hydraulic Tank
Section 230-0040
SM - 3845
26
10 SEC.
47 190-0270
11 AT HEADER TANK
21 12
46 44
28
'B' 16 AT L.H. 29
45 14 RADIATOR GUARD 35
12 34
15 17,18,19,20 36
38 35
9 14 28
43 30
27 15 29
14 44 6 41
31
15 13
6 30
13
1 31
49 56
2,3 32
48
55 53
'A'
39
5,37 23 33
25
4 24
8
5,37 42
7 40 'B'
22 28
25 51 'A' BREATHER LINES
24 54 50
52
1 - Brake coolant / Hydraulic tank 14 - Bolt 28 - Bushing 42 - Adaptor

assembly 15 - Lockwasher 29 - Nipple 43 - Gasket
2 - Cap assembly 16 - Gasket 30 - Breather Bracket 44 - Cap Assy
3 - Gasket 17 - Hydraulic Filter 31 - Connector 45 - Gasket
4 - Suction Strainer 18 - Filter Element 32 - Hose 46 - Gasket
5 - Drain Valve 19 - Spigot Element 33 - Hose 47 - Quick Drain Plug
6 - Cover Plate 20 - Spring 34 Bolt 48 - Plug
7 - Sight Gauge 21 - Filter-Cover Plate 35 Washer 49 - Plug
8 - Window Nut 22 - Front Mount 36 - Nut 50 - Anticirculation Plate
9 - Screw 23 - Rear Mount 37 - Bonded Seal 51 - Locking Plate
10 - Bolt 24 - Bolt 38 - Cover Plate 52 - Bolt
11 - Washer 25 - Washer 39 - Anti Slip mat 53 - Hydraulic Tank
12 - Breather 26 - Cover Plate 40 - Connector 54 - Brake Coolant Tank
13 - Gasket 27 - Washer 41 - Spacer
Fig. 1 - Exploded View of Hydraulic Tank and Mounting
DESCRIPTION
The brake coolant / hydraulic tank assembly (1) Integral with brake coolant / hydraulic tank assembly
comprises of both brake cooling oil tank (54) and (1) are cap assemblies (2), suction strainer (4),
hydraulic oil tank (53) in one integral unit. Looking from Hydraulic filter (17) cover plates (6, 38) and drain
the LHS of the tractor unit, the brake cooling tank (41) valves (5). Located on the outboard face of the tank
is to the left and the hydraulic tank (53) is to the right. are level gauges and window nut (8) for checking the
The brake coolant tank (54) supplies the brake cooling fluid levels of both brake cooling oil and hydraulic oil.
circuit. The hydraulic tank (53) is the common reservoir
for the steering, braking, body hoist and fan drive
system. The tank is mounted off the frame at the rear
right hand side of the tractor.
SM 2447 Rev2 07-07 1

Section 230-0040
OPERATION Hydraulic Tank

Numbers in parentheses refer to Fig.1.
Every 10 Hours
Oil is added to the hydraulic tank section through
hydraulic fill. The hydraulic oil is drawn from hydraulic Check oil level, add if low. Refer to Checking oil level
tank by main hydraulic pump and pumped to the main paragraph.
hydraulic valve to supply the various hydraulic
systems. Refer to Section 215-0050, MAIN Hydraulic filter restriction - check, replace element if
HYDRAULIC VALVE ASSEMBLY. required.
Emergency steering oil is drawn from hydraulic tank

section by emergency pump, mounted off the rear of Every 1000 Hours
the dropbox, and is also pumped to the main hydraulic Hydraulic tank breather - replace element.
valve. Should a failure occur at the main hydraulic
pump the emergency pump will supply the steering Every 2000 Hours
system with oil to enable the vehicle to be brought to a Hydraulic tank - Drain oil and refill. "Refer to replacing
safe halt. Refer to Section 220-0000, STEERING hydraulic oil"
SYSTEM SCHEMATIC.
OCDB Strainer - Clean strainer and refit, assuming ther
Return oil from the hydraulic systems flows through e are no signs of damage to the strainer.
hydraulic oil cooler and filter before entering the tank
storage area. The filter assembly has a bypass valve Note: Tighten all fasteners without special torques
which allows oil to bypass element (18) when it is cold specified to standard torques listed in Section
or when the filter element is plugged. Filter restriction 300-0080, STANDARD BOLT AND NUT TORQUE
will be displayed on the VDU display on the main SPECIFICATIONS.
instrument panel to alert the operator that it is time to
replace the element when the pressure differential
reaches 2.0 bar (29 lbf/in2 ).Should the filter remain WARNING
restricted, the bypass valve will open at a pressure To prevent personal injury and property
differential of 3.0 bar (43.5 lbf/in2). damage, be sure wheel blocks, blocking
MAINTENANCE secured and of adequate capacity to do the job
Numbers in parentheses refer to Fig. 1. safely.
Brake Coolant Tank

Checking Hydraulic Tank Oil Level
Every 1000 Hours 1. Operate the body hoist and steering systems
several times to bring the oil to correct operating
OCDB tank breather -replace breather. temperature.

Every 1500 Hours body is fully lowered, apply the parking brake and
OCDB tank - drain of cooling oil and refill. Refer to switch off the engine. Turn steering wheel in both
section 300-0020, LUBRICATION SYSTEM for directions several times to relieve any pressure in the
specifications of oils to be used. steering circuit. Operate treadle valve continuously to
discharge accumulators.
Every 2000 Hours
OCDB filter - Replace filter. 3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in
OCDB Strainer - Clean strainer and refit, assuming the 'Off' position.
there are no signs of damage to the strainer.
4. Check oil level and add if low. Oil should be visible
in the window nut (8) which is below the sight gauge
(7). This tells the operator that there is sufficient oil in
the hydraulic tank to allow the operator to run the
2 SM 2447 Rev2 07-07

Section 230-0040
vehicle to heat the oil up to operating temperatures. breathers should be replaced.
5.Once running the operator should check the oil level
in the sight gauge (7) located above the widnow nut (8) 1. Position the vehicle in a level work area, ensure the
on the hydraulic tank (53). The oil should be within the body is fully lowered, apply the parking brake and
'max' and 'min' marked lines. Should more oil be switch off the engine. Turn steering wheel in both
required, remove filler cap (44) from hydraulic tank (40) directions several times to relieve any pressure in the
and fill hydraulic tank (53) with hydraulic oil specified in steering circuit. Operate treadle valve continuously to
Section 300-0020, LUBRICATION SYSTEM, through discharge accumulators.
the fill neck.
2. Block all road wheels, place the steering lock bar in
6. Install filler cap (44) on hydraulic tank (53) and the 'Locked' position and the battery master switch in
tighten. the 'Off' position.
3. Unscrew breather s (12) and remove from respective

Replacing Hydraulic Oil tanks (1). If necessary remove hoses (32 & 33) and
Hydraulic oil should be changed every 2 000 hours. constituent fittings from the breather lines and tanks.
Refer to Section 300-0020, LUBRICATION SYSTEM,
for hydraulic oil used in the system.
Replacing Hydraulic Filter Element
Note: When replacing the hydraulic oil due to a Every 2 000 hours of operation or when hydraulic filter
hydraulic failure, or at recommended change interval, restriction warning symbol displays on the instrument
filter (17) must be replaced and hydraulic tank (53) panel VDU warning screen, whichever comes first,
cleaned thoroughly using a suitable solvent. clean filter (17) and install new element (18).

Checking Brake Coolant Tank Oil Level body is fully lowered, apply the parking brake and
1. Operate the body hoist and steering systems switch off the engine. Turn steering wheel in both
several times to bring the oil to correct operating directions several times to relieve any pressure in the
temperature. steering circuit. Operate treadle valve continuously to
discharge accumulators.
body is fully lowered, apply the parking brake and 2. Block all road wheels, place the steering lock bar in
switch off the engine. Turn steering wheel in both the 'Locked' position and the battery master switch in
directions several times to relieve any pressure in the the 'Off' position.
steering circuit. Operate treadle valve continuously to
discharge accumulators. 3. Remove drain valve (5) on the bottom of hydraulic
tank (1). Install a hose adaptor on drain fitting, open
3. Block all road wheels, place the steering lock bar in drain cock and drain hydraulic oil into a suitable
the 'Locked' position and the battery master switch in container. Close drain cock, remove hose and reinstall
the 'Off' position. drain valve (5).
4. Check oil level and add if low. Oil should be visible 4. Remove bolts (10) and washers (11) securing cover
in the sight gauge (7) integral to the brake coolant tank plate (26) to and filter cover plate (12) to the top of
(54). This tells the operator that there is sufficent brake hydraulic tank (40). Remove plates (12 & 26) and
cooling oil in the system. gasket (16) from hydraulic tank (53). Discard gasket
(16).
Replacing Brake Coolant Oil 5. Remove filter assembly (17) from hydraulic tank
Brake coolant oil should be changed every 15000 (53).
hours. Refer to Section 300-0020, LUBRICATION
SYSTEM, for brake coolant oil used in the system. 6. Remove and discard element (18) from filter
assembly (17).
Replacing Breathers
Every 1 000 hours of operation, or sooner if the vehicle 7. Remove bolts (14) and lockwashers (15) securing
is being operated in extremely dusty conditions, the cover plates (6 & 38) to tank (53). Remove cover
hydraulic tank (53) and brake coolant tank (54) plates (6 & 38) and discard gaskets (13).
SM 2447 Rev2 07-07 3

Section 230-0040
WARNING switch off the engine. Turn steering wheel in both
Splashing liquid. Wear a suitable face shield directions several times to relieve any pressure in the
when using compressed air to dry hydraulic steering circuit. Operate treadle valve continuously to
tank and components. discharge accumulators.
8. Clean out the inside of hydraulic tank (53) with a 2. Block all road wheels, place the steering lock bar in
suitable solvent and dry with compressed air. the 'Locked' position and the battery master switch in
the 'Off' position.
9. Install new element (18) in filter assembly (17),
ensure spigot (19) and spring (20) are installed 3. Ensure all lines connected to tank assembly (1) are
correctly. identified for ease of installation and, with suitable
containers available to catch leakage. Fit blanking
10. Install filter assembly (17) in tank (53), complete caps and plugs to all open lines and fittings.
with new 'gasket (16) and cover plate (12).
4. Place a suitable container beneath the drain port on
11. Secure cover plate (12) and plate (26) to top of tank the hydraulic tank (40). Remove drain valve (5) from
with bolts (10) and washers (11). hydraulic tank (40) and drain the hydraulic oil into the
container.
12. Install new gaskets (13) prior to securing cover
plates (6 & 38) in place. 5. Place a suitable container beneath the drain port on
the brake coolant tank (54). Remove drain valve (5)
13. Secure cover plates (6 & 38) using bolts (14) and and drain brake coolant oil into the container.
washers (6 & 15).
6. Prior to removing the tank assembly (1) from the
14. Replace gasket (3) beneath the filler cap (2). fender. Ensure it is securely supported for lifting.
15. Remove filler cap (44) from hydraulic tank (53) and 7. Remove three bolts (24) and washers (25) securing
fill hydraulic tank with hydraulic oil specified in Section the brake coolant / hydraulic tank assembly (1) to the
300-0020, LUBRICATION SYSTEM. Install filler cap fender support bracket.
(44) on hydraulic tank (53) and tighten.
8. Carefully remove tank assembly (1) assembly from
14. Place the battery master switch in the 'On' position the unit to a clean work area for inspection.
and the steering lock bar in the 'Stowed' position,
remove all wheel blocks, start the engine and operate Inspection
the steering, braking and body hoist systems to Numbers in parentheses refer to Fig. 1.
circulate the oil.
15. Switch off the engine, check for leaks and check WARNING
oil level as described under 'Checking Oil Level'. Splashing liquid. Wear a suitable face shield
when using compressed air to dry hydraulic
tank and components.
TANK ASSEMBLY
1. Clean tank assembly (1) and components with a
Removal suitable solvent and dry with compressed air.
2. Inspect tank assembly (1) for weld cracks and
security of internal pipes and weld fitments. Ensure
WARNING both brake coolant tank (54) and hydraulic tank (53)
To prevent personal injury and property sections are thoroughly inspected.
materials and lifting equipment are properly 3. Inspect breathers (21) and filter assembly (17) for
secured and of adequate capacity to do the job damage. Replace if required.
safely.
4 SM 2447 Rev2 07-07

Section 230-0040
Installation 4. Remove filler cap (44) and fill hydraulic tank (53)
with hydraulic oil specified in Section 300-0020,
LUBRICATION SYSTEM. Install filler cap (44) on
hydraulic tank (53) and tighten.
5. Place the battery master switch in the 'On' position
and the steering lock bar in the 'Stowed' position,
SPECIFICATIONS.
remove all wheel blocks, start the engine and operate
the steering, braking and body hoist systems to
circulate the oil.
connections, as described in Section 230-0000, BODY
SYSTEM SCHEMATIC. Renew all 'O' rings where
6. Switch off the engine, check for leaks and check oil
used.
levela as described under 'Checking Oil Level'.
WARNING Note: Oil level in both sections of the tank

assembly should be checked in accordance with
the 'checking levels' procedure listed in the body of
the text.
safely.
SPECIAL TOOLS
1. Using a suitable lifting device, position tank
There are no special tools required for the procedures
assembly (1) in position on the vehicle, secure with
bolts (24) and washers (25).
2. Remove any eyebolts that were installed to lift the
dealer.
tank assembly (1).
3. Install all hydraulic lines and fittings to tank

assembly (1), as tagged at removal.
* * * *
SM 2447 Rev2 07-07 5

BRAKING SYSTEM - Motor/Triple Pump Assembly
Section 250-0045
DESCRIPTION SM - 3523
Numbers in parentheses refer to Fig. 1. The motor/ 1

triple pump (1) can be identified as item 7 in Section 3
210-0005, COOLING SYSTEM SCHEMATIC. 4
Mounted off brackets on the left hand frame rail, 5

adjacent to the brake coolant tank, the motor/triple
6
pump assembly consists of three pump elements
coupled to a single direction hydraulic motor. The 7
hydraulic motor within the assembly is protected by a
relief valve, which is intergral to the externally mounted 2
OCDB relief unloader valve (3, Fig.2)
OPERATION 1 - Motor/triple pump 3 - Bolt 6 - Lockwasher

Numbers in parentheses refer to Fig. 1,2 & 3. 2 - Mounting bracket 4 - Lockwasher 7 - Washer
5 - Bolt
The motor is supplied with hydraulic oil from the brake Fig. 1 - Motor/Triple Pump
cooling section of the triple gear pump, via the disc
brake oil cooler. The motor and pump elements are
connected by a common shaft, therefore motor TO BRAKE PACKS SM- 3524A
rotation causes pump elements to draw brake cooling FRONT CENTRE REAR
oil from brake coolant tank. Cooling oil is then pumped

to brake packs via manifold blocks on front, centre and 1
rear axles.
Note: A filter is fitted between motor/triple pump and

2 3
front axle brake packs.
A
A solenoid integral to ocdb relief unlaoder valve (3) FROM BRAKE
controls the output of the motor/triple pump by COOLANT TANK
controlling the flow of hydraulic oil to the motor side of

4
the assembly Refer to Section 250-0075 OCDB
RELIEF UNLOADER VALVE for specific details. When
FROM
brake cooling oil is below 50oC (122oF) solenoid (A) is HYDRAULIC
VALVE
TO HYDRAULIC
OIL TANK
energised, which stops any flow from the main
Fig. 2 - Motor/Triple Pump- Solenoid energised.
hydraulic valve from entering the relief unloader. There
will be no cooling from the pumps to the brake packs.
TO BRAKE PACKS SM- 3524B
Refer to Fig. 3. When brake cooling oil reaches 50oC FRONT CENTRE REAR
(122oF) solenoid (A) is de-energised, thereby directing

all of the hydraulic oil through the motor, increasing 1
motor speed therefore increasing pump output.
A sealing arrangement within the assembly prevents

2 3
cross contamination of hydraulic oil from triple gear
pump with brake cooling oil from brake coolant tank. A
The relief valve within the OCDB relief unloader valve FROM BRAKE
limits the pressure through the motor to 26 bar (377 COOLANT TANK
lbf/in2) at a flow rate of 10 l/min.

4
Note: Direction of rotation is clockwise as viewed from

FROM
shaft end, and is indicated by an arrow. HYDRAULIC
VALVE
TO HYDRAULIC
OIL TANK
Fig. 3 - Motor/Triple Pump- Solenoid de-energised.
SM 2422 04-06 1
Braking System - Motor/Triple Pump Assembly
Section 250-0045
SM - 3527
15 22
2
15
5 16 18
17
7
5
4 16
18 20
13 24
11 13 12
9
14
14
19 8
14 21
23
14
3 23
8 6
10
6
14 21
24
14
25
8 6
10
6
24
3
6
10
6
1 - Motor / Triple Pump 6 - Thrust Plate 11 - Screw 16 - Seal 21 - Coupling

2 - Body 7 - Drive Gear 12 - Nut 17 - Q-ring 22 - Coupling
3 - Body 8 - Drive Gear 13 - Washer 18 - Anti-estrusion 23 - Plate - support
4 - Rear Cover 9 - Driven Gear 14 - 'O'-ring 19 - Flange 24 - Dowel Pin
5 - Thrust Plate 10 - Driven Gear 15 - 'O'-ring 20 - Flange
Fig. 2 - Motor/Triple Pump Exploded View
REMOVAL 1. Position the vehicle in a level work area, apply the

Numbers in parentheses refer to Fig. 1. parking brake and switch off the engine.

switch in the 'Off' position. Place steering lock bar in
WARNINGS the 'Locked' position.
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the 3. Remove blanking cap from remote drain line at the
treadle valve continuously until the pressure bottom of the hydraulic tank. Install a length of hose on
has dissipated before carrying out any work on remote drain fitting, open drain cock and drain
the braking system or serious injury could hydraulic oil into a suitable container. Close drain
result. cock, remove hose and reinstall blanking cap.
To prevent personal injury and property 4. Remove blanking cap from remote drain line at the
damage, ensure wheel blocks, blocking bottom of the brake coolant tank. Install a length of
materials and lifting equipment are properly hose on remote drain fitting, open drain cock and drain
secured and of adequate capacity to execute brake cooling oil into a suitable container. Close drain
the job safely. cock, remove hose and reinstall blanking cap.
2 SM 2422 04-06
Section 250-0045
5. Clean motor/triple pump assembly and surrounding ASSEMBLY
area with a suitable solvent. Identify and tag all
hydraulic lines connected to motor/triple pump, to aid
in 'Installation'.
1. From seal kit, replace seals on motor section and
pump elements prior to re-assembly.
6. With suitable containers available to catch leakage,
disconnect hydraulic lines. Fit blanking caps to all
2. Lightly oil parts prior to re-assembly.
open lines.
3. Assemble three pump elements together and locate
7. Remove 4-off bolts (7), washers (8) and nuts (9)
with threaded screws (11). Secure assembly with
securing motor/triple pump to mounting plate (1).
washers (13) and nuts (12). Torque nuts (12) to a
value of 25 Nm (18.4 Ibf ft).
8. If necessary remove brackets (2 & 3) from the
chassis frame, by removal of 4-off bolts (6), washers
4 Install hydraulic connectors and adaptors to correct
(5) and washers (4). This should allow removal of
ports and orientation.
mounting plate (1).
DISASSEMBLY INSTALLATION
1. Place motor/triple pump assembly in a soft-jawed
vice, and clamp on body. Match mark pump sections
and motor to aid in assembly.
Note: Do not clamp vice on machined surfaces of the
assembly at any time.
where used.
2. Note location of all hydraulic connectors and
adaptors and remove from motor/triple pump.
1. Secure motor/triple pump assembly to brackets
with mounting hardware as removed at 'Removal'.
3. Remove 4-off nuts (12) and washers (13) from
pump end of the assembly.
2. Remove blanking caps from hydraulic lines and
install lines to motor/triple pump as identified during
Note: Do not attempt to pry the motor/triple pump (1)
'Removal'.
assembly apart with a large screwdriver or pry bar.
The machined surfaces of the assembly may be
3. Fill brake coolant tank with oil as specified in
damaged.
Section 250-0025, BRAKE COOLANT TANK, for oil
4. Remove constituent parts of the assembly from
levels. Install filler cap on brake coolant tank filler
pump end, through to the motor end and rear cover
neck.
(4).
4. Fill hydraulic tank with hydraulic oil as specified in
5. Remove and discard seals that are to be replaced
with new seals in kit.
Section 230-0040, HYDRAULIC TANK, for oil levels.
Install filler cap on hydraulic tank filler neck.
INSPECTION
temperature.
1. Clean all parts in a suitable solvent and dry with
compressed air.
6. Check motor/triple pump and hydraulic line
2. Check ports threads and make sure they are not
damaged or stripped.
steering lock bar in the 'Stowed' position.
SM 2422 04-06 3
Section 250-0045
FAULT DIAGNOSIS SPECIAL TOOLS

Numbers in parenthesis refer to Fig. 1. There are no special tools required for procedures
Refer to following fault diagnosis chart. As stated SERVICE TOOLS, for part numbers of general service
previously, it is not recommended that the relief valve tools required. These tools are available from your
(B) cartridge assembly is disassembled for dealer.
maintenance purposes. Ensure that motor/triple pump
is cleaned off prior to removal of any components and
that no contaminant is allowed to enter the internal
galleries.
If investigation shows that the relief valve (B) is in

good clean condition and fit for use, the seals should
be replaced prior to re-assembly. Any damage to the
motor section or any of the pump elements would
necessitate a new motor/triple pump assembly.
FAULT DIAGNOSIS
CONDITION REASON ACTION
Non rotation of shaft No oil supply. Check pressure at motor section of triple gear pump.
Pressure should be 26 bar (377 psi) at 2 100rpm,
when oil is at operating temperature.
Relief valve faulty. Check - refer to Section 250-0120, OCDB RELIEF

UNLOADER VALVE.
Brake packs overheating No brake cooling oil supply. Check oil level in brake cooling tank.
Pump elements damaged. Replace motor/triple pump.
* * * *
4 SM 2422 04-06
BRAKING SYSTEM - Brake Manifold Valve
Section 250-0050
SM - 3611
(XXX) - PORT DESIGNATIONS
7,8
12 9,10
(TS2)
2,3
(B3) (TS1)
16 4
5 (B2)
(C1)
(B1) 13
(A2)
2,3
(PS)
1 (A1)
(Y)
2,3
(C)
(X) (C2)
11 11 (T)
2,3 15
14 6
1 - Manifold Block 5 - Connector 9 - O-ring 13 - Temp. Sender

2 - O-ring 6 - Connector 10 - Elbow 14 - Connector
3 - 45 Elbow 7 - O-ring 11 - Check Valve. 15 - O-ring
4 - O-ring 8 - 45 Elbow 12 - Pressure Sw. 16 - O-ring
Fig. 1 - Exploded View of Brake Manifold Valve
DESCRIPTION
The brake manifold valve can be identified as item 10 controller, which commands the OCDB relief unloader
in Section 210-0005, BRAKE COOLING SYSTEM valve to de-energise, allowing hydraulic oil to flow from
SCHEMATIC. port 'WB' on the main hydraulic valve assembly, to
supply the motor side of the triple pump/motor unit.
There are three brake manifold blocks within brake The three pumps will then draw brake cooling oil from
cooling circuit. Each is mounted on the respective the brake coolant tank and distribute it to the
axle. The manifold valve distributes hydraulic oil flow front,centre and rear hubs via the 3 manifold valve.
from the ocdb motor/pump to the brake cooling circuit.
Oil from the accumulators passes through the treadle Hydraulic oil from the motor/triple pump enters the
valve is then distributed to front,centre and rear brakes brake manifold valve at port 'A1'. Oil is distributed to
via each manifold block. the hubs via ports 'X' and 'B1'.
Check Valve
OPERATION
Numbers in parentheses refer to Fig. 1,2 & 3. An integral check valve (11) set to relieve at 1bar is
contained within each manifold block. Any excess
At temperatures below 50deg C, Oil from the brake pressure built up will be sent back to the brake coolant
coolant tank is not drawn by the motor/triple pump. tank via this valve.
When the oil in the brake hubs reaches 50deg C.
temperature sender sends a signal to the IFM
SM 2456 04-06 1
Braking System - Brake Manifold Valve
Section 250-0050
SM - 3612
TO
SERVICE PRESS. TO BRAKE
BRAKES SWITCH HUBS
C2 PS1 X Y
FROM B3 CT1
TREADLE
VALVE TANK RELIEF
TS2
BLANKED
TS1
TEMP. SW. / SENDER
D
C1 A1 B1 B2 A2
TO FROM RETURN TO
SERVICE TRIPLE TO BRAKE TANK VIA
BRAKES PUMP HUBS COOLER
Fig. 2 - Brake Manifold Valve - Schematic
Pressure Switch Temperature Sw. / Sender
Pressure switch 'PS1' is located in the 'PS' port on top The temperature switch monitors brake cooling oil
of the manifold. This monitors brake cooling oil temperature. Two temperature conditions will generate
pressure. Should the brake pressure reach 1.5 bar a response to the system. 50Deg C signalling the
(21.8 lbf/in²) a brake pressure warning symbol will be OCDB relief unloader to allow flow to the triple pump/
displayed on the VDU screen to inform the operator of motor and bringing the engine cooling fan on. The 60
irregular pressure in the system, refer to Fig. 3. deg condition will signal a warning symbol to be
displayed on the VDU screen, refer to Fig. 3
SM - 3613
REMOVAL
WARNINGS
system after engine shut down. Operate the
1
2 STOP P treadle valve continuously until the pressure
has dissipated before carrying out any work on
20 30 15
30
40
50
10 20 the braking system or serious injury could
mph
10 20
km/h
60
70
40
5
r / min x100
25 result.
10
80
0 0000000
50 L H 0 30
0000
˚C 100
70 135˚C 165
40
105
150 210
˚F 250
120 60
140
275 320
˚F 390
200
safely.
Fig. 3 - VDU Warning Symbols
2 SM 2456 04-06
Section 250-0050
1. Position the vehicle in a level work area, apply the 4. If removed, install hydraulic line connectors in
parking brake, switch off the engine and turn steering manifold block (1) as noted during disassembly.
wheel in both directions several times to relieve any
pressure in the steering circuit. INSTALLATION
Note: Tighten all fasteners to torques listed in
2. Operate the treadle valve continuously to relieve Section 300-0080, STANDARD BOLT AND NUT
pressure in the braking system. Block all road wheels, TORQUE SPECIFICATIONS.
place the steering lock bar in the 'Locked' position and the
battery master switch in the 'Off' position. Note: Tighten all hydraulic lines fitted with ORFS
3. Remove and tag electrical connections to pressure BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
switch (12). where used.
4. Clean brake manifold valve assembly and 1. Position brake manifold valve assembly onto the
surrounding area with a suitable solvent. Ensure all respective axle, and secure.
hydraulic lines connected to the brake manifold valve
are identified for ease of installation and, with suitable 2. Remove blanking caps from hydraulic lines and
containers available to catch leakage, disconnect connect to brake manifold valve as noted during
hydraulic lines. Fit blanking caps to all open lines. removal.
5. Release and remove mounting hardware securing 3. Connect electrical connection to pressure switch
brake manifold valve to cradle assembly at rear of cab. (13) as noted during removal.
Remove assembly from the vehicle.
4. Check oil level in the hydraulic tank and add oil if
required. Refer to Section 230-0040, HYDRAULIC
DISASSEMBLY TANK for correct fill level, and, Section 300-0020,
Numbers in parentheses refer to Fig. 1. LUBRICATION SYSTEM for oil specification.
Disassembly of the manifold assembly should only be 5. Place the battery master switch in the 'On' position,
carried out if there is the need to replace one of the remove wheel blocks, start the engine and bring
elements. In any case, remove the specific fitting / hydraulic oil to operating temperature.
switch from the respective port and note this for the
assembly stage. 6. Check brake manifold valve and hydraulic line
Replace any components which have failed.
7. Shut off engine and make sure a full service brake
1. Clamp manifold block (1) lightly in a soft jawed application is made followed by a parking brake
vice.Do not overtighten jaws. This will allow for removal application.
of any of the elbows (3,8 & 10) or pressure switch (13).
8. Repeat all braking and engine shut down cycles
2. Where any 'o'-rings (2,4,7,9,15 & 16) have been several times and check for appropriate application/
discarded, replace with new at the assembly stage. release cycle several times.
9. Check all connections again for leaks and tighten as

ASSEMBLY required.
10. Place steering lock bar in the 'Stowed' position.
1. Fit new 'o'ring(s) to any ports where they have been
removed from.
2. Similarly replace any broken / failed component with

new.
3. Follow the torque values listed in 'special torques'.
SM 2456 04-06 3
Section 250-0050
MAINTENANCE SPECIAL TOOLS

Inspect the brake manifold valve regularly for any signs There are no special tools required for procedures
of leakage or damage and repair/replace as required. outlined in this section. Refer to Section 300-0070,
Note: Limited repair of the brake manifold valve is by tools and adhesives required. These tools, and
replacement of parts only. adhesives are available from your dealer.

TORQUE
1 3 Elbow (C port) 60 44
1 3 Elbow (B1 & B2) 110 81
1 3 Elbow (X & Y port) 110 81
1 6 Connector (C2 port) 60 44
1 8 Elbow (A1 port) 160 118
1 10 Elbow (A2 port) 160 118
1 12 Pressure Sw. (PS) 30 22
1 13 Temp sw. (TS1) 30 22
1 14 Connector (T port) 160 118
* * * *
4 SM 2456 04-06
BRAKING SYSTEM - Accumulator
Section 250-0060
SM - 3277
19
18
17 20
16
15 21
14
13
12
11
24 25 27 28 10
23 22
26 9
Charge Valve Assembly
7
6
5
4
8
3
2
1
1 - Nut 8 - Cylinder Body 15 - 'O'-Ring 22 - Nut

2 - Washer 9 - Piston 16 - Backup Ring 23 - Washer
3 - Chargin valve Assembly 10 - Seal Ring 17 - End Cap 24 - Cap
4 - O-ring 11 - Washer 18 - Mounting Bracket 25 - Valve Core
5 - Cylinder Cap 12 - 'O'-Ring 19 - Bolt 26 - Locknut
6 - Backup Ring 13 - Washer 20 - Elbow 27 - 'O'-Ring
7 - 'O'-Ring 14 - Seal Ring 21 - Bolt 28 - Valve Body
Fig. 1 - Exploded View of Accumulator Assembly
DESCRIPTION assembly (3), end cap (17), cylinder (8) and piston (9).
Charging valve (3) is equipped with a locking feature.
Loosening locknut (26) will open the valve so that the
precharge can be checked or the accumulator charged.
The accumulators can be identified as items
ACC1through ACC3 in Section 250-0000, BRAKING OPERATION
SYSTEM SCHEMATIC.
There are three accumulators mounted off exhaust
Piston (9) acts as a separator dividing cylinder (8) into
mounting cradle located at the rear of the cab; one for
two sections. The bottom section nearest charging
the front brake system and one for the rear. The front
valve (3) contains the nitrogen precharge. Hydraulic oil
and rear brake accumulators are supplemented by a
from the main hydraulic pump flows through check
third (primary) accumulator. Refer to Fig. 2.
valves in the main hydraulic valve and into the top
section of the accumulators.
The primary accumulator supports the service brake
system and the body pilot pressure system. All three
Accumulator pressure is monitored by pressure
accumulators are of the piston type and are precharged
switches located in the main hydraulic valve, which
with nitrogen. The primary accumulator (1, Fig 2) is
send a signal to illuminate warning lights in the dash
precharged to 103 bar (1494 Ibf/in²). The other two
panel when the pressure drops below 122 bar (1 769
accumulators (2,3 Fig.2) are precharged to 55 bar (798
lbf/in²).
lbf/in²). Each accumulator consists of a charging valve
The warning lights will remain illuminated until the
pressure rises above 135 bar (1 958 lbf/in²).
SM 2431 03-06 1
Braking System - Accumulator
Section 250-0060
SM - 3537
P - Primary Accumulator F
F - Front Brake Accumulator R 4
R - Rear Brake Accumulator 3
5
3
5
1
5
3
6
5
3 7
8
9
1 - U-bolt 6 - Locknut
2 - Accumulator Guard 7 - Washer
3 - Lockwasher 8 - Washer 1 P
4 - Partition Plate 9 - Bracket Cradle
5 - Bolt
Fig. 2 - Accumulator Mounting
TESTING Testing Charging Valve For Leakage

WARNING
To prevent personal injury and property 1. Remove cover plate from bottom of battery box.
2. Remove cap (24) from charging valve (3) and loosen
locknut (26). Coat open end of charging valve (3) with
safely.
soapy water. Bubbles indicate leaky valve core (25).
WARNINGS
3. Attempt to reseat the valve core by depressing and
releasing it quickly once or twice. Recheck for leakage.
The service pressure in the primary
If leakage continues, discharge the accumulator as
accumulator is 103 bar (1494 lbf/in²) and in the
described under 'Discharging Nitrogen' in this section.
Front and Rear Brake accumulators is 55 bar
(798 lbf/in²) at 20° C (68o F). To prevent personal 4. Replace valve core (25). Tighten locknut (26) to
injury and property damage do not attempt to 11 Nm (100 lbf in) and replace valve cap (24) finger
remove any valves or fittings until all nitrogen tight.
pressure is completely relieved.
Testing Precharge Pressure

Note: The nitrogen pressure in an accumulator is
work on the braking system or serious injury
directly affected by changes in nitrogen temperature.
could result.
The cylinder pressure will increase or decrease
2 SM 2431 03-06
Section 250-0060
SM - 1273 down on the valve. Loosen locknut (26, Fig. 1) by

turning anticlockwise one to two turns.
5. Turn 'T' handle clockwise until charging valve core is

depressed. Be sure bleeder valve (10) is tight and does
not leak, and valves (4 & 6) are closed.
WARNING
Precharge values are different for the Primary
accumulator and front & rear brake
accumulators. Ensure pressures are correct to
the required value for each type!
6. To read accumulator precharge pressure, slowly

open cylinder valve (4). Pressure gauge (5) will register
precharge pressure, it should be 55 bar (798 lbf/in²) for
the front and rear accumulators; 103 bar (1494 lbf/in²)
for the Primary accumulator, all measured at 20° C (68°
F) ambient temperature. Refer to the table at the end of
1 - Line 6 - Tank Valve
2 - Valve Chuck 7 - Gland Fitting this section for nitrogen pressures at ambient
3 - Valve Extension 8 - Gland Nut temperatures of other than 20° C (68° F).
4 - Cylinder Valve 9 - Cylinder Adaptor
5 - Pressure Gauge 10 - Bleeder Valve 7. Close cylinder valve (4) and open bleeder valve (10)
Fig. 3 - Charging Assembly Kit to dissipate gauge pressure. Close bleeder valve (10)
after pressure is relieved. If the accumulator needs
charged, leave line (1) and valve chuck (2) attached to
proportionally with temperature changes. An charging valve (3 , Fig. 1)). Charge the accumulator as
accumulator pressure reading can vary about 4.3 bar described under 'Charging The Accumulator'.
(62 lbf/in²) with 22° C (72° F) temperature change. Such
temperature changes could easily occur between noon 8. If precharge pressure is correct, rotate 'T' handle
and midnight of the same day. Refer to the table at the anticlockwise until it stops. Tighten locknut (26, Fig. 1)
end of this section for nitrogen pressures at ambient on charging valve (3, Fig. 1) to 11 Nm (100 lbf in).
temperatures of other than Loosen the swivel nut and remove gauging head.
20° C (68° F).
9. Install cap (24, Fig. 1) on charging valve (3, Fig. 1)
To test accumulator precharge pressure or to charge and tighten finger tight.
the accumulator, a charging assembly kit can be used.
Refer to Fig. 3. 10. Remove wheel blocks and place the battery master
switch in the 'On' position.
wheel in both directions several times to relieve any CHARGING THE ACCUMULATORS
2. Operate the treadle valve continuously to relieve WARNING

pressure in the braking system. Block all road wheels Precharge values are different for the Primary
and place battery master switch in the 'Off' position. accumulator and front & rear brake
accumulators. Ensure pressures are correct to
3. Check accumulator mountings to be sure the the required value for each type!
accumulator is held tightly in position.
4. Remove cap (24, Fig. 1) from accumulator charging otherwise specified.
valve (3, Fig. 1). Attach charging line (1) to charging
valve by rotating 'T' handle of valve chuck (2)
anticlockwise until it stops then screw the swivel nut
SM 2431 03-06 3
Section 250-0060
Note: Either oil or water pumped nitrogen can be used 8. Check charging valve (3, Fig. 1) for leakage using
to charge the accumulator. Both types are readily soapy water. Reinstall valve cap (24, Fig. 1) and
available from a local compressed gas dealer. tighten finger tight.
WARNINGS DISCHARGING NITROGEN

Do not use Oxygen or any gas other than Numbers in parentheses refer to Fig. 1.
Nitrogen to charge an accumulator. Oxygen
under pressure coming into contact with oil or Make sure charging valve (3) is closed internally by
grease will cause a violent explosion. Always turning locknut (26) clockwise. Remove cap (24) and
double check to make sure you are using core (25) from charging valve (3). Slowly turn locknut
Nitrogen to prevent personal injury and (26) anticlockwise to open charging valve (3).
property damage.
Do not remove charging valve (3) until all the gas has
A high pressure nitrogen pressure 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 charging valve core (25).
1. Attach line (1) and the swivel nut to charging valve
(3, Fig. 1) as described in steps 1 through 4 under the
heading 'Testing Precharge Pressure'. Be sure valves REMOVAL
(4 & 6) are closed.
WARNINGS
2. Attach gauging head to nitrogen bottle by screwing To prevent personal injury and property
down on gland nut (8). damage, be sure wheel blocks, blocking
3. Open tank valve (6) slowly; pressure shown on secured and of adequate capacity to do the job
pressure gauge (5) is tank pressure. safely.
4. Open cylinder valve (4) slowly and charge
accumulator to the desired value, depending on which WARNINGS
accumulator is being chearged. i.e. the Primary Accumulators are charged with Nitrogen.
accumulator 103 bar (1 494 lbf/in2) or the front and rear The service pressure in the primary
brake accumulators 55 bar (798 lbf/in2) at 20° C (68° F) accumulator is 103 bar (1494 lbf/in²) and in the
ambient temperature, closing valve occasionally. Refer Front and Rear Brake accumulators is 55 bar
to the table at the end of this section for nitrogen (798 lbf/in²) at 20° C (68o F). To prevent personal
pressures at ambient temperatures of other than 20° C injury and property damage do not attempt to
(68° F). remove any valves or fittings until all nitrogen
pressure is completely relieved.
5. To check accumulator charge, close tank valve (6),
relieve pressure between tank and pressure gauge (5) Numbers in parentheses refer to Fig. 2. unless
by opening bleeder valve (10) momentarily. This will otherwise stated.
allow gauge needle to settle, thus giving correct
pressure reading of accumulator charge. 1. Position the vehicle in a level work area, apply the
6. When the correct pressure for the ambient wheel in both directions several times to relieve any
temperature has been reached, close valves (4 & 6) pressure in the steering circuit.
tightly. Bleed pressure off pressure gauge (5) by
opening bleeder valve (10). Close bleeder valve when 2. Operate the treadle valve continuously to relieve
all pressure is bled off from the gauge and unscrew pressure in the braking system. Block all road wheels
gland nut (8) from the nitrogen bottle. and place battery master switch in the 'Off' position.
7. Rotate 'T' handle of valve chuck (2) anticlockwise 3. Remove accumulator guard (2) a nd partition plate
until it stops, tighten locknut (26, Fig. 1) to 11 Nm (100 (4) if necessary to gain adequate access to remove the
lbf in), loosen the swivel nut and remove gauging head. accumulators; by removal of bolts and washers (5 & 3)
4 SM 2431 03-06
Section 250-0060
4. Discharge nitrogen from the accumulators as INSPECTION
described under 'Discharging Nitrogen'.
5. Disconnect hydraulic lines from bottom of 1. Wash metal components with a suitable solvent and
accumulators and plug accumulators to prevent oil thoroughly air dry.
spillage. Cap open lines and fittings to prevent entry of
dirt. 2. Inspect piston (9) for cracks or burrs. Replace piston
(9) if excessively scored or worn.
6. Support accumulators with an adequate sling and 3. Use an inspection lamp to check the bore of
lifting device. Remove bolts (19, Fig.1 ), u-bolts (1), accumulator cylinder (8) for scratches or scoring.
locknuts (6), lockwashers (7) and washers (8) securing Minor nicks, scratches or light scoring of the bore can be
accumulators to the bracket (9). Remove accumulators removed by using crocus cloth. Dress the bore until all
and drain oil from top section into a suitable container. apparent imperfections have been removed. Replace
complete accumulator assembly if the inside of cylinder
7. Remove accumulators to a clean area for (8) is excessively scored or worn.
disassembly.
4. Inspect threads in end cap (17) and threads in
DISASSEMBLY cylinder (8) for damage. Replace all parts worn or
damaged beyond repair.
ASSEMBLY
WARNINGS
The service pressure in the primary 1. Lubricate ‘O’ rings (7,11 & 15), Backup rings (6 &
accumulator is 103 bar (1494 lbf/in²) and in the 16), Seal rings (10 & 14) and Washers (11 & 13) and
Front and Rear Brake accumulators is 55 bar inside of cylinder body (8) with hydraulic oil prior to
(798 lbf/in²) at 20° C (68o F). To prevent personal assembly.
injury and property damage do not attempt to
remove any valves or fittings until all nitrogen 2. Install 'O'- ring (15) and Backup ring (16) on the End
pressure is completely relieved. cap (17).
1. Make sure all nitrogen gas has been released before 3. Install End cap (17) on cylinder body (8).
starting to disassemble the accumulator. Refer to
section on 'Discharging Nitrogen'. 4. Install new Seal rings (10 & 14), Washers (11 & 13)
and 'O'-Ring (12) on grooves of Piston (9).
2. Remove charging valve assembly (3) from end cap
(17). 5. Insert Piston (9) into bore of Cylinder body (8) with
the cupped end facing the open end of the cylinder
3. With accumulator lying horizontal, hold accumulator body (8). Taking care not to damage any components
cylinder (8) with a strap wrench. on the threadfs of the Cylinder body (8) on insertion.
Use a hammer and wood block to carefully tap the
4. Install pins in three equally spaced holes in end cap Piston (9) into place until the Piston (9) is 50.8mm (2.0
(17), then use a long bar working against the pins to in) below the beginning of the honed bore. Keep
remove end cap from cylinder (8). Remove and discard pressure against the Piston (9) while tapping into place
Backup ring (6) and 'O' ring (7). to ensure the Piston (9) does not resist movement and
force its way back.
5. Grip cast web of piston (9) with pliers and, while
rotating, pull piston from cylinder (8). Remove and 6. Install 'O'-ring (7) and Backup ring (6) onto the
discard Seal rings (10 & 14), Washers (11 & 13) and Cylinder cap (5) and install the Cylinder cap into the
'O'-Ring (12). bore of the Cylinder body (8). Tighten the Cap so that it
is flush with the end of the Cylinder body (8), within
1.6-2.4mm (0.062 - 0.094in) above or below.
SM 2431 03-06 5
Section 250-0060
7. Install the Chargin valve assembly (3). Torque 3. Remove caps installed at removal and install
tighten Locnut (26) clockwise to 11Nm (100 Ibf in) to hydraulic lines securely to the oil inlet ports at the
close the Charging valve (3). Insert Valve core (25) and bottom of the accumulators.
torque to 0.5 Nm ( 5 Ibf in), replace Valve cap (24) and
tighten hand tight. 4. Charge the accumulator with Nitrogen gas as
described under 'Charging the Accumulator' in this
section.
INSTALLATION
Note: Tighten all fasteners without special torques 5. If removed install partition plate (4) with washers (3 )
specified to torques listed in Section 300-0080, and bolts (5).
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 6. Install accumulator guard (2) securely with bolts (5)
Note: Tighten all hydraulic lines fitted with ORFS and washers (3).
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings 7. Check oil level in hydraulic tank and add oil as
where used. required. Refer to Section 230-0040, HYDRAULIC
TANK, for correct fill level and Section 300-0020,
LUBRICATION SYSTEM, for oil specification.
WARNING
To prevent personal injury and property 7. Place the battery master switch in the 'On' position,
damage, be sure lifting equipment is properly start the engine and check for leaks. Tighten lines and
secured and of adequate capacity to do the job fittings as required. Remove wheel blocks.
safely.
MAINTENANCE
Numbers in parentheses refer to Fig. 2. unless Inspect accumulator assembly for leaks. If leaks are
otherwise stated. found, disassemble and replace all 'O' rings and seals.
Inspect hydraulic lines for wear and leaks. Replace/
1. Position accumulators onto their respective tighten lines as required.
mounting brackets (18, Fig. 1) and secure in place
using bolts (19).
SPECIAL TOOLS
2. Attach u-bolts (1) securely with washers (8), Refer to Section 300-0070, SERVICE TOOLS, for part
lockwashers (7) and locknuts (6). numbers of the charging assembly kit and other
6 SM 2431 03-06
Section 250-0060

TORQUE
FIG. NO. ITEM NO. Nm Ibf in
1 26 11 100
AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE

AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE
o o
C F bar lbf/in2
-20 -4 81.9 1188
-10 14 85.6 1241
0 32 88.8 1288
10 50 91.3 1324
20 68 95 1380
30 86 97.9 1420
40 104 101 1465
50 122 104.4 1514
60 140 107.9 1565
70 158 111.8 1621
80 176 114.5 1661
90 194 117.3 1701
100 212 120.2 1743
110 230 123.4 1789
120 248 126.6 1836
WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the vehicle or cylinders by any method while
cylinders are charged. For shipment, contact the appropriate agency in the country involved. Consult
your dealer for further permit information.
* * * *
SM 2431 03-06 7
Braking System - Treadle Valve
Section 250-0070
SM - 3517
50 39
13
49 14
48
46 29
47 38 28 16
27 15 10
45
44 12
37
26 11 12
42 43 36
35 25
24 51,52
34 22 9
33 23 12
41 11
32 20
12 8
40
31 22 19
9 12
6
20 21 5
30 7 4
3
19
18
2
17 12
1
1 - Pedal 14 - Bolt 27 - 'O'-Ring 40 - Spool

2 - Pin 15 - Clevis 28 - Backup Ring 41 - 'O'-ring
3 - Push Rod 16 - Cam 29 - Piston 42 - Plug
4 - Boot 17 - Boot 30 - Spring 43 - 'O'-ring
5 - Spring 18 - Push Rod 31 - Spring 44 - Valve Housing
6 - Retainer 19 - Cap Screw 32 - Spring 45 - Washer
7 - Cap Scew 20 - Washe 33 - Shim 46 - Cap Screw
8 - Washer 21 - Spring 34 - Retainer 47 - Spool
9 - Pin 22 - Cap Screw 35 - Cup 48 - Spring
10 - Base 23 - Pilot Housing 36 - Seal 49 - 'O'-ring
11 - Pin 24 - Backup Ring 37 - 'O'-ring 50 - End Plug
12 - 'e'-ring 25 - 'O'-ring 38 - Valve Housing 51 - Cap Screw
13 - Spring Washer 26 - 'O' Ring 39 - 'O'-ring 52 - Nut
Fig. 1 - Exploded View of Treadle Valve Assembly
DESCRIPTION brake solenoid valve within the main hydraulic valve.

Numbers in parentheses refer to Fig. 1. Refer to Section 215-0050, MAIN HYDRAULIC VALVE
ASSEMBLY.
Note: The treadle valve can be identified as item E in
Section 250-0000, BRAKING SYSTEM SCHEMATIC. In the normal position, brake pedal assembly is in the
up position. In this condition the regulated pressure
The tandem circuit modulating treadle valve is a closed outlet ports of the valve 'A1' and 'A2' are directly linked
centre controller which controls the level of hydraulic oil to the hydraulic tank ports 'T1' and 'T2'. While the pedal
pressure applied to the front and rear brakes and the is in this position the brakes are released.
maximum pressure available to these circuits. It is
operated by a foot pedal in the operators cab and with
the engine running, is automatically applied by the park
SM 2427 04-06 1
Section 250-0070
SM - 2875 SM - 2876
9 9
PP PP
SUPPLY SUPPLY
FROM FROM
P1 P1
TO FRONT A1 MAIN HYDRAULIC FROM FRONT A1 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC1 BRAKES VALVE, PORT ACC1
T1 T1
SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
T2 T2
Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release
OPERATION Normal Service Brake Release

Numbers in parentheses refer to Fig. 1. Refer to Fig. 3. When the operator releases pedal (1)
assembly, spools (40 & 47) will become unbalanced
Normal Service Brake Application and move downwards, opening outlet ports 'A1' and
Refer to Fig. 2. When the operator depresses pedal 'A2' to tank. At this point, oil in the 'A1' and 'A2' lines is
assembly, push rod (18) is moved up and pushes on released to tank through tank ports 'T1' and 'T2',
pistons (26 & 29) which in turn, pushes spools (40 & releasing the brakes.
47) up. As spools (40 & 47) move up, the metering
notches move out of the tank cavity and close outlet
ports 'A1' and 'A2' off to tank ports 'T1' and 'T2'. Spools
Emergency Stop Brake Application/
(40 & 47) continue to move upwards until the metering Release
notches become exposed to the inlet pressure ports. Refer to Fig. 4. Pushing in the park/emergency control
This movement opens inlet ports 'P1' and 'P2' to outlet results in the de-energization of the park brake
ports 'A1' and 'A2' respectively. As hydraulic pressure solenoid valve within the main hydraulic valve. This
builds in the brake, oil flows through the small orifice in allows full pressure to enter the 'PP' port in the treadle
spools (40 & 47) and into the cavities above the valve simulating a full and immediate depression of
spools. As pressure rises in the brake it also rises in pedal (1) assembly, i.e. pushing spools (40 & 47)
the cavities above the spools forcing spools (40 & 47) upwards and thereby applying maximum braking
downwards closing outlet ports 'A1' and 'A2'. Spools action.
(40 & 47) are now balanced between the brake
pressure and the pressure of springs (30 - 32) Refer to Fig. 5. Pulling out the park/emergency control
generated by the operators force on pedal (1) will energise the park brake solenoid valve within the
assembly. Spools (40 & 47) have closed off the inlet main hydraulic valve, allowing the pressure in the 'PP'
ports, outlet ports and the tank ports and will remain in line to fall via the return to tank port opened within the
this position as long as pedal (1) assembly is not park brake solenoid valve. Outlet ports 'A1' and 'A2' are
moved. If the operator further depresses pedal (1) opened to tank ports 'T1' and 'T2' allowing oil in the 'A1'
assembly, spools (40 & 47) will move up and build and 'A2' lines to return to tank, releasing the brakes.
more pressure in the brake until it balances the pedal
force.
2 SM 2427 04-06
Section 250-0070
SM - 2877 SM - 2878
9 9
SUPPLY
FROM TO TANK VIA
PP PP MAIN HYDRAULIC
MAIN HYDRAULIC
VALVE, PORT PBP VALVE, PORT PBP
SUPPLY
SUPPLY FROM
P1 P1
TO FRONT A1 FROM FROM FRONT A1 MAIN HYDRAULIC
BRAKES MAIN HYDRAULIC BRAKES VALVE, PORT ACC1
T1 VALVE, PORT ACC1 T1
SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
T2 T2
Fig. 4 - Park/Emergency Brake Application Fig. 5 - Park/Emergency Brake Release
REBUILD CRITERIA REMOVAL

Inspect the valve regularly for any signs of leakage or
damage and replace components if necessary.
WARNINGS
The treadle valve should be rebuilt if one or more of the To prevent personal injury and property
following conditions exist: damage, be sure wheel blocks are properly
1. Any sign of external leakage. safely.
Note: Check all hydraulic lines and fittings to ensure Hydraulic oil pressure will remain
leakage is not coming from there. within the system after engine shut down.
2. Failure of the pedal to return to full upright position. pressure has dissipated before carrying out any
work on the braking system or serious injury
3. Treadle valve holds pressure when in the neutral could result.
position.
4. Varying output pressure with the pedal fully parking brake, switch off the engine and turn steering
depressed. wheel in both directions several times to relieve any
5. Output pressure does not remain constant between
circuits. 2. Operate the treadle valve continuously to relieve
pressure in the braking system. Block all road wheels
and place battery master switch in the 'Off' position.
3. Pull on handle to release hood catch and lift up

hood.
4. Remove blanking cap from remote drain line at the

SM 2427 04-06 3
Section 250-0070
SM - 3518
50
49
48 A
P
P2
P2 T
A2 T2
44
P
P1
T2
T T1
47 A1
A
41 39
P1 Px
40 Px
T1
34
33
30
38
36 37
35
32
46
29
31
28
27
21 23
26
25
24
18 17
P1 - Pressure from main hydraulic valve, port ACC2 A2 - Pressure to front brakes
P2 - Pressure from main hydraulic valve, port ACC1 T1 - Tank return, rear brakes
A1 - Pressure to rear brakes T2 - Tank return, front brakes
Fig. 6 - Treadle Valve Porting / Exploded View Detail
oil into a suitable container. Close drain cock, remove catch leakage, disconnect hydraulic lines. Fit blanking
hose and reinstall blanking cap. caps to all open lines and treadle valve ports.
5. If necessary remove engine air intake tube to gain 7. Disconnect electrical connection from the brake
access to treadle valve on front of cab. Alternatively, pedal potentiometer.
tilt the cab to gain access. Refer to Section 260-0010,
CAB AND MOUNTING. 8. Separate pedal (1) from base (10) by removing one
'e'-ring (12) from each pin (9 & 11) and sliding pin (11)
6. Clean treadle valve assembly and surrounding area from clevis (15) and pin (9) from base (10).
with a suitable solvent. Ensure all hydraulic lines
connected to the treadle valve are identified for ease of 9. Remove boot (4) and spring (5) from base (10).
installation and, with suitable containers available to
4 SM 2427 04-06
Section 250-0070
10. Inspect pin (2) and push rod (3), make sure push 12. Separate housing halves (38 & 44) by removing
rod is in good working order and moving freely. cap screws (46) and washers (45). Remove 'o'-rings (39
& 41) from housing halves.
11. Inspect pins (9 & 11), clevis (15) and cam (16) to
make sure clevis and cam are in good working order 13. Carefully remove spools (40 & 47) from housing
and moving freely. halves (38 & 44). Note: Be careful not to damage
spools or housing bores.
12. Any further disassembly is unneccessary unless
there is damage to the assembly.
WARNINGS
13. Separate valve assembly from base (10) by Do not intermix spools and housings. Spools
removing cap screws (7) and washers (8). and housings are matched sets.
DISASSEMBLY ASSEMBLY
1. Remove blanking caps from treadle valve ports and Lubricate all new rubber components with clean
drain all oil from valve body ports by rotating the valve hydraulic oil used in the braking system. Refer to
over a suitable container. Section 300-0020, LUBRICATION SYSTEM.
2. Remove treadle valve from mounting plate and 1. Clean all parts thoroughly before assembly.
secure the valve assembly upright in a table vice.
2. Install new 'o'-rings (39 & 41) in proper pockets on
3. Remove circlips to allow cam assembly to be housings (38 & 44).
disassembled.
3. Lubricate spool (40) with hydraulic oil used in the
4. Remove boot (17) from push rod (18), then remove braking system. Carefully slide into bottom end of
push rod (18) and spring (21) from pilot housing (23) valve housing half (38) bore. Ensure correct orientation
bore. of spool.
5. Separate pilot housing (23) and valve housing half
(44) by removing screws (37). Remove 'O' ring (17) Note: Spool must slide frelly into bore. If either part is
from valve housing (38). damaged, a new spool/ housing assembly may be
required.
6. Remove piston (26) from pilot housing (23). Piston
must be removed trhough bottom end of housing. 4. Reassemble valve housing halves (38 & 44) using
Note: Be careful not to scratch or mar housing bore. A cap screws (46) and washers (45). Use loctite 242 on
wooden dowel will help in this procedure. cap screws and torque to a value of 29.8 - 33.9 Nm (22
- 25 Ibf ft).
7. Remove 'O' rings (25 & 27) and back-up rings (24 &
28) from piston (26), being careful not to damage 'O' Note: Make sure valve housing halves line up correctly
ring and back-up ring grooves. and that 'o'-rings (39 & 41) remain in their pockets
during assembly.
8. Remove piston (29), springs (30, 31 & 32) and
shim(s) (33) from valve housing bore. Note: Be aware 5. Install new 'o'-ring (49) on plug (50) and install in
of the number of shim(s) being removed from housing. valve housing half (44). Tighten securely.
9.Carefully remove cup (35) and seal (36) from valve 6. Lubricate spool (47) with hydraulic oil used in the
housing half (44) bore. Note: Be careful not to scratch braking system. Carefully slide into valve housing half
or mar housing bore. (44) bore. Ensure correct orientation of spool.
10. Remove end plug (50) and spring (48) from valve Note: Spool must slide frelly into bore. If either part is
housing half (44). Remove 'o'-ring (49) from end plug. damaged, a new spool/ housing assembly may be
required.
11. Remove plug (42) from valve housing half (44).
Remove 'o'-ring (43) from plug. 7. Install new 'o'ring (49) on end plug (50).
SM 2427 04-06 5
Section 250-0070
2. Connect electrical connection to the brake pedal
8. Install new spring (48) and end plug (50) into valve potentiometer.
half housing (44). Torque to a value of 47.5 - 54.2 Nm
(35-40 Ibf ft). 3. Remove blanking caps and connect hydraulic lines
to the treadle valve assembly as noted at 'Removal'.
9. Carefully install new seal (36) and new cup (35) into
valve housing half (38) bore. 4. If previously removed install engine air intake tube,
or if applicable, lower the cab. Refer to Section 260-
Note: Direction and order of cup and seal. Be careful 0010, CAB AND MOUNTING.
not to scratch or mar bore.
5. Fill hydraulic tank with oil specified in Section
10. Assemble springs (30, 31 & 32), shim(s) (33) and 300-0020, LUBRICATION SYSTEM.
retainer assembly (34) in piston (29).
11. Carefully install piston (29) assembly into valve start the engine and bring hydraulic oil to operating
housing half (38) bore. temperature.
12. Install new 'o'-rings (25 & 27) and new back-up 7. Apply the brakes and check for oil leaks. Tighten
rings (24 & 28) on piston (26). line connections and fittings as necessary.
Note: Ensure correct order of 'o'-rings & back-up rings. Note: When performing Step 8, make sure that parking
brake applies and releases appropriately.
13. Install piston (26) into pilot housing (23) through the
bore of the bottom end. Be sure to install piston as far 8. Check brake operations by actuating pedal and park/
as it will go into pilot housing bore. emergency control. Ensure that the pedal assembly is
14. Install new 'o'-ring (37) on valve housing half (38). free to operate.
15. Carefully attach pilot housing (23) to valve housing 9. Shut off engine and check hydraulic tank oil level.
half (38) using cap screws (22). Torque cap screws to Replenish as necessary.
a value of 27.1 - 33.9 Nm (20 -25 Ibf ft).
16. Install spring (21) and push rod (18) into pilot CHECKING SYSTEM PRESSURES
housing (23) bore.
17. Install new boot (17) on push rod (18) and over pilot WARNINGS
housing (23). To prevent personal injury and property
damage, be sure wheel blocks and blocking
18. When reinstalling pdeal actuated valve, use hex materials are properly secured and of adequate
cap screws (7), Torque cap screws to a value of 24.4 - capacity to do the job safely.
29.8 Nm (18 - 22 Ibf ft).
INSTALLATION Hydraulic fluid pressure will remain

Operate the brake treadle pedal continuously
carrying out any work on the system or serious
injury could result.
wheel in both directions several times to relieve any
where used.
1. Secure treadle valve and mounting plate assembly
pressure in the braking system. Block all road wheels,
to front of cab using four bolts removed previously.
6 SM 2427 04-06
Section 250-0070
place the steering lock bar in the 'Locked' position and MAINTENANCE
the battery master switch in the 'Off' position.
General
3. Connect a hydraulic gauge, capable of recording a Check all hydraulic brake lines and fittings at treadle
pressure of 0 - 345 bar (0 - 5 000 lb/in²), to front brake valve for leaks and damage. Tighten/replace as
diagnostic pressure point (4, Fig. 7) located on the left required.
hand fender directly outside the cab door.
4. Place the battery master switch in the 'On' position, Every 1 000 Hours
start the engine and apply park/emergency brake (push Check front and rear brake pressures at remote
button in), to apply service brakes. Monitor system diagnostic test points. If the pressures are outwith the
pressure gauge. Brake actuating pressure for the front specified pressure range, refer to Troubleshooting table
brake circuit is 48 +/- 2.4 bar (700 +/- 35 lbf/in²). for treadle valve and Section 250-0000, BRAKING
SYSTEM SCHEMATIC.
Note: When brakes are released, a residual pressure of
0.3 bar (5 lb/in²) will remain.
SPECIAL TOOLS
5. Repeat steps 1 through 4 at rear brake diagnostic There are no special tools required for the procedures
pressure point (5, Fig. 7) located outside the cab door. outlined in this section. Refer to Section 300-0070,
Note: Actuating pressure for the front and rear brake tools and adhesives required. These tools and
circuits is 48 +/- 2.4 bar (700 +/- 35 lbf/in²), however, adhesives are available from your dealer.
system pressure is 240 bar (3 480 lbf/in²) and can be
checked at the steering diagnostic pressure point (9,
Fig. 7) located on the left hand fender directly outside
the cab door . System pressure is checked against
steering pressure as this is the highest pressure
requirement in the hydraulic circuit. Refer to Section
230-0050, MAIN HYDRAULIC PUMP.
6. If the pressures to the brake circuits have been
determined as high or low, refer to Troubleshooting
table for treadle valve and Section 250-0000,
BRAKING SYSTEM SCHEMATIC.
SM - 3615
1
2
3
4
5
6
9 7
10 8
11
12
13
14
15

3 - Primary Accumulator 11 - DropBox Lube Pressure
5 - Rear Brake Pressure 12 - Main Pump (Front)
7 - Diff-lock Pressure 'TP1' 14 - Pump LS Pressure

Fender
SM 2427 04-06 7
Section 250-0070
TREADLE VALVE TROUBLESHOOTING

Brakes slow to apply No or improper accumulator Check accumulator pre-charge pressure.

pre-charge pressure Refer to Section 250-0060,
ACCUMULATOR
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
BRAKE PARTS
Inoperative brakes Check brakes. Refer to Section 165-0010,
BRAKE PARTS
Hydraulic lines/fittings leaking Check for leaks and repair
Damaged hydraulic brake lines Check lines for restrictions
Air in system Bleed air from system. Refer to Section
165-0010, BRAKE PARTS
Brakes will not release Pedal angle out of adjustment Check for proper pedal angle
BRAKE PARTS
Inoperative treadle valve. Replace treadle valve
Binding spools (40 & 47),
piston (29) binding

Insufficient brakes Low hydraulic oil level Top up hydraulic oil
BRAKE PARTS
Oil or grease on brake pads Clean or replace brake pads. Refer to
Section 165-0010, BRAKE PARTS
Hydraulic lines damaged Check hydraulic lines
No or improper accumulator Check accumulator pre-charge pressure.
ACCUMULATOR
BRAKE PARTS
Broken spring (31). Boot (17)
cut, allowing dirt under piston
(29) flange.
Excessive braking Inoperative brakes Check brakes. Refer to Section 165-0010,
BRAKE PARTS
Excessive shims (33) fitted
8 SM 2427 04-06
Section 250-0070
TREADLE VALVE TROUBLESHOOTING

Brakes will not release Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
completely BRAKE PARTS
BRAKE PARTS
Pedal angle out of adjustment Check for proper pedal angle
Air in system Bleed air from system. Refer to Section
165-0010, BRAKE PARTS
Piston (29) sticking, spring
(32) broken
Back pressure on return line Remove restriction
excessive
No brakes No oil in hydraulic system Add oil to tank
Broken/damaged hydraulic line Replace broken/damaged line
BRAKE PARTS
No accumulator Check accumulator pre-charge pressure.
ACCUMULATOR
No pump pressure Check pump operation
Worn brakes Replace brake pads and discs
Piston (29) binding, broken
spring (32)
Pedal kickback when brakes Air in system Bleed air from system. Refer to Section
are applied 165-0010, BRAKE PARTS

TORQUE
1 7 Cap Screw 24.4 - 29.8 18 - 22
1 22 Cap Screw 27.1 - 33.9 20 -25
1 46 Cap Screw 29.8 - 33.9 22 - 25
1 50 End Plug 47.5 - 54.2 35 - 40
* * * *
SM 2427 04-06 9
Braking System - OCDB Relief Unloader Valve
Section 250-0075
SM - 3609
6 6
1
2
8
7
11 12
10 5
4 3 13 14
6 6
1 - Valve Body 5 - Spool 10 - O-ring

2 - Relief valve 6 - O-ring 11 - O-ring
3 - Flow regulator 7 -O-ring 12 - O-ring
4 - Solenoid Coil 8 - O-ring 13 - O-ring
9 - O-ring 14 - O-ring
Fig. 1 - OCDB Relief Unloader Valve Exploded View
DESCRIPTION SM - 3516
TO MOTOR /
The OCDB relief unloader valve can be identified as TRIPLE PUMP
item 2 in Section 210-0005, BRAKE COOLING
SYSTEM SCHEMATIC. Numbers in parentheses refer RETURN FROM
MOTOR /
to Fig. 1. TRIPLE PUMP
Located on the left hand side of the hydraulic tank, the P1 T

relief unloader valve comprises of an aluminium valve
body (1) with relief valve (2), flow regulator (3) and
solenoid valve (5).
TheOCDB relief unloader valve receives hydraulic (B)
supply pressure from the 'WB' port of the integrated

(A)
control valve Refer to Section 215-0050, MAIN
HYDRAULIC VALVE ASSEMBLY. This is then fed to
the inlet side of the motor part of the motor/ triple
pump assembly and back to tannk via a return line (C)
filter. Refer to Section 250-0045 MOTOR / TRIPLE

PUMP ASSEMBLY. P T
FROM HYD RETURN

VALVE ASSY.
OPERATION TO TANK

Fig. 2 - Relief Unloader Valve Schematic
The priority unloader valve forms part of the brake
actuation circuit. Main hydraulic supply pressure is valve (B). The relief unloader connects to the inlet side
delivered from the main hydraulic valve assembly, via of the motor unit and drives the motor, which in turn
the 'WB' port. drives the three individual pump elements which
supply cooling oil to the brake packs.
The relief unloader valve limits the supply pressure to
the motor section of the motor/ triple pump assembly When there is no need to supply the cooling demands,
to 26 bar (377 Ibf/in ²). This is achieved by the relief the supply to the motor unit is closed off due solenoid
SM 2426 04-06 1
Section 250-0075
valve(A) being energised. (d) Re-start engine and allow pressures to rise with
engine at low idle, until all warning lights are
FUNCTIONAL CHECK extinguished.
Numbers in parentheses refer to Fig. 1. (e) Turn setting screw clockwise (CW) until correct
pressure is observed on gauge.
The relief unloader valve, although adjustable, should
be preset to 26 bar (377 lbf/in²). Refer to following (g) Re-tighten lock nut.
procedure for valve pressure check and adjustment.
REMOVAL
WARNING Numbers in parentheses refer to Fig. 1.
system after engine shut down. Operate the
treadle valve continuously until the pressure WARNING
has dissipated before carrying out any work on To prevent personal injury and property
the braking system or serious injury could damage, ensure wheel blocks, blocking
result. materials and lifting equipment are properly
secured and of adequate capacity to execute
WARNING the job safely.
damage, be sure wheel blocks are properly 1. Position the vehicle in a level work area, apply the
secured and of adequate capacity to do the job parking brake and switch off the engine. Operate
safely. treadle valve continuously to relieve pressure in the
braking system.
1. Attach appropriate pressure gauge to the diagnostic
check point on the brake manifold valve (Port P1). 2. Block all road wheels and place the battery master
switch in the 'Off' position. Place the steering lock bar
2. Start truck and allow pressures to increase with in the 'Locked' position.
engine at low idle, until all warning lights are
extinguished. 3. Remove blanking cap from remote drain line at the
3. Take note of the gauge reading; this is the pressure remote drain fitting, open drain cock and drain
setting of the relief unloader valve. Valve should be set hydraulic oil into a suitable container. Close drain
at 26 bar (377 lbf/in²). cock, remove hose and reinstall blanking cap.
4. If pressure setting is too low after following steps 1 4. Clean priority unloader valve body (1) and
through 3: surrounding area with a suitable solvent. Identify and
(a) Ensure engine is operating at low idle. tag all hydraulic lines connected to the priority
unloader valve, to aid in 'Installation'.
(b) Loosen lock nut on unloader relief valve (2).
(c) Turn setting screw on unloader relief valve (2) 5. With suitable containers available to catch leakage,
clockwise (CW) until correct pressure is observed on disconnect hydraulic lines. Fit blanking caps to all
gauge. open lines.
(d) Re-tighten lock nut.
6. Remove bolts and lockwashers securing the priority
Note: Always adjust hydraulic pressure on the unloader valve to the hydraulic cradle. Remove priority
increase. unloader valve.
5. If pressure setting is too high after following steps 1

through 3: DISASSEMBLY
(a) Stop engine and operate treadle valve continuously Numbers in parentheses refer to Fig. 1.
to dissipate pressure in brake accumulators.
It is not recommended that any of the cartridge
(b) Loosen lock nut on unloader relief valve (2).
assemblies (2 & 3)are disassembled for maintenance
(c) Turn setting screw on unloader relief valve (2) purposes. Ensure that valve assembly is cleaned off
counter clockwise (CCW) 2 to 3 full turns. prior to removal of any components and that no
2 SM 2426 04-06
Section 250-0075
contaminant is allowed to enter the internal galleries. 2. Remove blanking caps from hydraulic lines and
1. Note location and position of all hydraulic install lines to the priority unloader valve as identified
connectors and adaptors prior to removing them from during removal.
valve body (1).
3. Fill hydraulic oil tank with hydraulic oil as specified
2. Remove unloader relief valve. Check for wear, in Section 300-0020, LUBRICATION SYSTEM. Refer
scoring or contamination. to Section 230-0040, HYDRAULIC TANK, for hydraulic
oil levels. Install filler cap on hydraulic tank filler neck.
3. Remove relief valve (2). Check for wear, scoring or
contamination. 4. Place the battery master switch in the 'On' position,
4. If necessary, remove solenoid valve assembly. temperature.
Check for wear, scoring or contamination.
5. Check priority unloader valve and hydraulic line
5. If necessary, remove flow regulator (3). Check for connections for leaks and tighten as required.
wear, scoring or contamination.
6. Ensure all o-rings are checked and replaced when steering lock bar in the stowed position.
re-assembly is carried out. Check parts book for
relevant kit information.
FAULT DIAGNOSIS
Refer to following fault diagnosis chart. As stated
ASSEMBLY previously, it is not recommended that any of the
Numbers in parentheses refer to Fig. 1. cartridge assemblies are disassembled for
maintenance purposes. Ensure that valve assembly is
1. Replace all 'O' rings on hydraulic connectors and cleaned off prior to removal of any components and
adaptors. that no contaminant is allowed to enter the internal
galleries.
2. Replace all seals on unloader relief valve body (1),
relief valve (2), solenoid coil/spool (4 &5) and flow If investigation shows that the cartridge assemblies
regulator (3) valve prior to assembly. are in good clean condition and fit for use, the seals
should be replaced prior to re-assembly. Damage to
3. Install hydraulic connectors (15) and adaptors to the cartridge assemblies or valve body would
correct ports and orientation. Torque each to 35Nm necessitate a new priority unloader valve assembly.
(25.8 Ibf-ft)
4. Fit relief valve (2), flow regulator (3) and solenoid SPECIAL TOOLS
valve assembly to valve body (1) at correct ports. There are no special tools required for procedures
INSTALLATION tools required. These tools are available from your
Numbers in parentheses refer to Fig. 1. dealer.


where used.
1. Secure priority unloader valve to hydraulic cradle

with bolts and lockwashers.
SM 2426 04-06 3
Section 250-0075
PRIORITY UNLOADER VALVE FAULT DIAGNOSIS

CONDITION REASON ACTION
Rapid switching of High leakage in brake circuit. Check brake circuit for leakage.
unloader relief valve.
Internal leakage to priority Replace priority unloader valve assembly.
unloader valve.
Check valve leaking or not Replace priority unloader valve assembly.

seating properly.
Circuit does not load or Unloader relief valve sticking. Replace priority unloader valve assembly.
unload.
Worn or damaged unloader Replace priority unloader valve assembly.
relief valve.
* * * *
4 SM 2426 04-06
OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010
SM - 3571
11 20,21
12
13
19
14,18 13
12
11
20,21
15
3, 35, 36, 37
16
17
CAB -
R.H.S.
23, 24
LH 25, 26 RH
31
R H - HINGED LH
32 22
34
38 1 6
33 4
5 40
27
41
29
5 28
2 39
10
LH
29
39 39
39
30 9 7 8
RH 30
1 - Locating Pin 12 - Mirror - Exterior 22 - Storage Box 30 - Locknut

2 - Hinge Pin 13 - Mirror - Wide Angle 23 - Mat (front floor) 31 - Mud flap (cab RHS)
3 - Nut 14 - Ball 24 - Mat (left rear) 32 - Bolt
4 - Bushing 15 - Washer 25 - Mat (right rear) 33 - Bolt
5 - Spring Pin 16 - Spring 26 - Mat (under seat) 34 - Washer
6 - Bolt 17 - Locknut 24 - Cab Pin 35 - Heat Shield
7 - Cab Safety Prop 18 - Grease 25 - Bolt 36 - Bolt
8 - Pin Assembly (EMS19014) 26 - Locknut 37 - Washer
9 - Bolt 19 - Window Guard 27 - Support Block 38 - Lockwasher
10 - Nut 20 - Bolt 28 - Isolation Mount 39 - Washer
11 - Mirror Arm 21 - Washer 29 - Bolt
Fig. 1 - Cab and Mounting
DESCRIPTION The cab assembly can be tilted to improve accessibilty

Numbers in parentheses refer to Fig. 1. to components below the cab, including transmission
and main hydraulic valve. A hydraulic hand pump (1,
The cab is fully insulated and mounted on cab supports Fig. 2), located under the hood on the left hand fender
(23) to damp structure-borne noise and vibration. It side of the tractor frame and a cab raise cylinder (7,
conforms with ISO/SAE, ROPS (Roll Over Protective Fig. 2) are used to raise the cab.
Structure) and FOPS (Falling Object Protective
Structure) requirements as standard.
WARNING
ROPS - ISO 3471, SAE J1040 APR 88 Never operate the machine while the cab is
FOPS - ISO 3449, SAE J231 tilted. Always ensure the cab is fully lowered
and properly secured before operating the
machine.
WARNING
The protection offered by the roll over and Cab assembly is spacious and offers outstanding
falling object protective structure may be visibility through large areas of tinted safety glass.
impaired if it has been subjected to any Access to cab assembly is from the left hand side with
modification or damage. open tread steps, platform and handrail.
SM 2388 01-06 1
Operators Compartment - Cab and Mounting
Section 260-0010
SM - 2882
11
9
8 CAB BRACKET
10 5
13
3 9 12
6
BRACKET IN 11
1 BATTERY BOX
FRAME BRACKET
12 13
16
2
15
14
1 - Hand Pump 6 - Lever 11 - Bolt

2 - Hydraulic Tank 7 - Cab Raise Cylinder 12 - Washer
3 - Elbow 8 - Hose Assy 13 - Nut
4 - Flow Control Valve 9 - Elbow 14 - Bolt
5 - Adaptor 10 - Clamp 15 - Washer
16 - Nut
Fig. 2 - Cab Tilt Mechanism
The cab interior, trimmed with noise-absorbent

material, is extensively thermally insulated and a WARNINGS
heater/filter/pressurizer and demisting unit keeps To prevent personal injury and property
internal air fresh and dust free. Sliding windows provide damage, be sure wheel chocks, blocking
additional ventilation. Air conditioning is fitted as materials and lifting equipment are properly
standard. Refer to Section 260-0130, AIR secured and of adequate capacity to do the job
CONDITIONING. safely.
Note: Access from the cab, in the case of an emergency, Hydraulic fluid pressure will remain within
can be gained by breaking any of the windows using the the system after engine shutdown. Operate the
hammer provided (mounted on back pillar). brake pedal continuously until the pressure has
dissipated before disconnecting any hoses.
REMOVAL
Numbers in parentheses refer to Fig. 1. parking brake and switch off the engine.
Note: Identify and tag all cables, harnesses, lines and 2. Operate the brake pedal continuously to relieve
linkages disconnected from cab assembly during pressure in the system.
removal to aid in installation.
3. Block all road wheels, place the battery master
switch in the 'Off' position and lift the hood assembly.
2 SM 2388 01-06
Section 260-0010
4. Disconnect the electrical cables in the following Disconnect earth strap at rear right hand cab support
order to prevent damage to the electrical components: (40).
a. Battery earth cable. 11. Lower cab safety prop (7) and place in the stowed
b. Battery supply cable. position, then using lifting equipment, slowly lower cab
c. Alternator earth cables. until horizontal.
d. Alternator supply cables.
e. Electrical harnesses at cab bulkhead. 12. Remove spring pins (5) to allow right hand pins (2)
to be driven out using a suitable driver.
WARNING 13. Check to make certain that all necessary

Before disconnecting any air conditioner lines, disconnections have been made, before lifting cab
refer to Section 260-0130, AIR CONDITIONING. assembly. Taking care to prevent damaging the
Refrigerant will rapidly freeze all objects with insulating material, lift cab assembly from the frame
which it comes into contact. It can cause and place on suitable stands.
serious and permanent damage to the eyes and
skin.
INSTALLATION
5. Evacuate the refrigerant from the air conditioning Numbers in parentheses refer to Fig. 1.
system and disconnect the lines. Refer to Section
260-0130, AIR CONDITIONING. Fit blanking caps to all Note: Tighten all fasteners without special torques
open lines and fittings. specified to standard torques listed in
6. Ensure heater lines are identified for ease of TORQUE SPECIFICATIONS.
installation and with suitable containers available to
catch leakage, disconnect heater lines. Fit blanking
caps to open line ends and fittings. WARNING
7. Remove the front right hand tyre and rim assembly damage, be sure blocking materials and lifting
for access. Refer to Section 160-0050, WHEEL RIM equipment are properly secured and of
AND TYRE. adequate capacity to do the job safely.
1. Inspect cab supports (27 & 40) for damage and

WARNINGS replace if necessary.
To prevent damage, always ensure hood is
raised before tilting or lowering the cab. 2. Attach suitable slings to the cab lifting points and
raise and position cab on frame.
Never work near or under an unblocked
or unsupported cab. Always use the cab safety 3. Secure cab assembly to right hand cab supports
prop. (23) with pins (2) and spring pins (5), as shown in Fig.
1.
8. Tilt cab to allow access to steering valve below cab,
and secure with cab safety prop (7). Ensure lines are 4. Using lifting equipment, raise cab and secure cab
identified for ease of installation and with suitable raise cylinder (7, Fig. 2) to bracket on cab floor using
containers available to catch leakage, disconnect and bolt (11, Fig. 2), washer (12, Fig. 2) and nut (13, Fig.
remove steering valve hoses. Fit blanking caps to open 2). Secure cab in raised position with cab safety prop
line ends and fittings. (7).
9. Attach suitable slings to the cab lifting points and 5. Install and connect steering valve hoses as noted on
raise lifting equipment to take up the slack. Disconnect removal. Connect earth strap at rear right hand cab
cab raise cylinder (7, Fig. 2) from cab floor by removing support.
bolt (11, Fig. 2), washer (12, Fig. 2) and nut (13, Fig.
2). 6. Connect and secure any other harnesses and hoses
that were previously removed.
10. Tag and disconnect any other harnesses and
hoses that may be affected by cab removal. 7. Place cab safety prop (7) in the stowed position.
SM 2388 01-06 3
Section 260-0010
Using hand pump (1, Fig. 2) to control lowering of cab, SM - 3572
gently lower cab until cab brackets align with cab
supports (40). Install pins (1) and secure with bushes
(4) and bolts (6).
8. Install front right hand tyre and rim assembly. Refer

to Section 160-0050, WHEEL RIM AND TYRE.
9. Secure the heater hoses to the front of the cab as

identified at removal.
10. Connect air conditioning lines and charge air 1

conditioning system. Refer to Section 260-0130, AIR
CONDITIONING.
3
11. Connect electrical harnesses at cab bulkhead as
identified at removal.
12. Connect cables to alternator (earth cable last).
13. Connect cables to battery terminal posts (earth

cable last). 2
start the engine and check for leaks. Tighten fittings if
necessary. Allow engine to warm up and recheck all
1 - Cab Safety Prop 3 - Cab Raise Cylinder
connections for leaks. Ensure electrical systems and 2 - Cab Support
gear shift are functioning properly.
Fig. 3 - Cab Secured In Raised Position
15. Ensure parking brake is applied and remove wheel
blocks from all road wheels. 4. Insert lever (6), located under the hood on the left
hand fender side of the tractor frame, into cab hand
pump (1).
TILTING THE CAB
Numbers in parentheses refer to Fig. 2, unless 5. Using hand pump (1), charge the cab raise cylinder
otherwise stated. (7) sufficiently to allow left hand pins (1, Fig. 1) to be
removed. Hold cylinder (7) in this position by locking
hand valve on hand pump (1).
WARNINGS
To prevent damage, always ensure hood is 6. Remove bolts and bushes (6 & 4 Fig. 1), then drive
raised before tilting or lowering the cab. out pins (1, Fig. 1). Carefully raise or lower the cab as
necessary to facilitate removal of pins (1, Fig. 1).
Never work near or under an unblocked
or unsupported cab. Always use the cab safety 7. Once pins (1, Fig. 1) have been safely removed,
prop. continue to raise the cab using hand pump (1) until the
cab safety prop (1, Fig. 3) can be fitted.
parking brake and switch off the engine. 8. Remove pin assembly (8, Fig. 1) to allow cab safety
prop (1, Fig. 3) to swing down to a vertical position on
2. Operate the brake pedal continuously to relieve top of the front left hand cab leg.
pressure in the hydraulic system.
9. Lock the cab safety prop (1, Fig. 3) in position using
3. Block all road wheels, place the battery master pin assembly (8, Fig. 1), locating through holes on
switch in the 'Off' position and lift the hood assembly. bracket at front left hand cab leg.
4 SM 2388 01-06
Section 260-0010
10. Lock off hand valve on hand pump (1). Remove 1. Support mirror arm bracket (11) and remove locknuts
lever (6) from pump (1) and place in the stowed (17), hardened washers (15) and springs (16) securing
position. mirror arm assembly to mounting brackets.
2. Remove mirror arm bracket (11) and ball bearings

LOWERING THE CAB (14) from mounting brackets.
otherwise stated. 3. Repeat steps 1 and 2 for other mirror arm bracket
(11).
WARNINGS
To prevent damage, always ensure hood is MIRROR ARMS
raised before tilting or lowering the cab.
Installation
Never work near or under an unblocked Numbers in parentheses refer to Fig. 1.
or unsupported cab. Always use the cab safety
prop. Note: Tighten all fasteners without special torques
specified to standard torques listed in
1. Remove pin assembly (8, Fig. 1) from bracket at Section 300-0080, STANDARD BOLT AND NUT
front left hand cab leg. Place cab safety prop (1, Fig. 3) TORQUE SPECIFICATIONS.
in stowed position by locating pin assembly (8, Fig. 1)
in bracket under cab.
WARNING
2. Slowly open hand valve on hand pump (1) to allow To prevent personal injury and property
cab to gently lower. Rate of descent is controlled by damage, be sure blocking materials and lifting
the hand valve on pump (1). equipment are properly secured and of
3. Lower cab until holes in cab brackets line up with
holes in cab supports (2, Fig. 3). Hold cylinder (7) in 1. Coat ball bearings (14) with grease (18) and locate in
this position by locking hand valve on hand pump (1). mounting brackets.
4. Install pins (1, Fig. 1) through cab brackets and cab 2. Locate mirror arm bracket (11) to mounting brackets
supports (2, Fig. 3). Secure pins in position with bush and install hardened washers (15), springs (16) and
(4, Fig. 1) and bolts (6, Fig. 1). locknuts (17) as shown in Fig. 1.
5. Lower the hood and place the battery master switch 3. Set mirror bracket spring (16) pressure as follows;
in the 'On' position before closing the battery box. a. rotate mirror arm (11) until ball bearings (14) are
out of their detent.
6. Ensure parking brake is applied and remove wheel b. tighten locknut (17) until spring (16) is almost
blocks from all road wheels. completely compressed (typical two places).
c. swing arm until it seats in detent.
d. check the other two detent positions
MIRROR ARMS
4. Repeat steps 1, 2 and 3 for other mirror arm bracket
Removal (11).
REPLACING GLASS
WARNING Note: When replacing broken glass, it is the user’s
To prevent personal injury and property responsibility to ensure that the replacement glass
damage, be sure blocking materials and lifting meets the required specifications. Replacement glass
equipment are properly secured and of can be purchased from your dealer.
The rear glass, left and right hand side glasses and
front windscreen are held in place by a bonding
adhesive.
SM 2388 01-06 5
Section 260-0010
To replace a glass assembly, proceed as follows: 8. Ensuring the glass is adequately supported, allow
the sealing adhesive to set properly.
Note: Ensure the glass is supported adequately before
starting to cut the adhesive seal. 9. Clean off any excess adhesive using a suitable
solvent.
1. Using a pointed tool, pierce a hole in the adhesive
seal, it is advisable to start at the top edge of the
glass. Unscrew one handle of the special tool and feed Water Leaks
the wire through the opening. Pierce a second hole in Test for leaks by directing a stream of water along the
the adhesive on the side directly opposite the first. adhesive seal, while an assistant marks the spot of
leakage inside the cab. Care should be taken to note
2. From inside the cab pull the wire through and feed it whether the leak is between adhesive and glass. Then
back out through the second hole. apply a sealing compound from the outside. Start from
a point near the leak and continue applying the sealer
3. Re-fit the handle on the special tool. Pull both until well beyond the suspected point of entry.
handles outwards until wire is taut.
This should stop the leak immediately, but since some
4. Manoeuvre the special tool around the edge of the sealing compounds should be allowed to set before
glass, keeping the wire taut, to cut the adhesive seal. getting wet, wait a few minutes before testing.
Ensure the glass is supported adequately before
completing the cut.
MAINTENANCE
5. Clean the remains of the adhesive from the edge of
the panel opening using a suitable solvent.
General
Ensure that hand pump hydraulic tank (2, Fig. 2) is
6. Coat the edge of the replacement glass with primer filled with clean hydraulic oil as specified in Section
and apply adhesive around the lip of the window 300-0020, LUBRICATION SYSTEM. Capacity is 0.75
aperture, as per the manufacturers recommendations. litre (0.2 US gallon).
7. Position glass onto panel opening, pressing firmly

so that adhesive bonds sufficiently to allow the glass
SERVICE TOOLS
to be moved or straightened up as required. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the glass removal tool, adhesive bonding
kit and other general service tools required. These
tools are available from your dealer.
* * * *
6 SM 2388 01-06
OPERATORS COMPARTMENT - Driver Seat and Mounting
Section 260-0090
SM - 2884
1 - Seat Assembly 12 - Armrest LH 23 - Air Hose

2 - Backrest Cushion 13 - Armrest RH 24 - Lever
3 - Seat Cushion 14 - Suspension Assembly 25 - Cable
4 - Seat Belt 15 - Shock Absorber 26 - Shock Absorber - Vertical
5 - Headrest 16 - Locking Lever Kit 27 - Suspension Kit - Upper
6 - Cover LH 17 - Cable Assembly 28 - Level Controller
7 - Cover RH 18 - Operation Unit 29 - Swing Arm
8 - Backrest 19 - Operation Unit Handle 30 - Air Spring
9 - Bushing 20 - Horizontal Isolator 31 - Wear Kit
10 - Seat Pan 21 - Compressor 32 - Bolt
11 - Adjustment Rails 22 - Connecting Cable 33 - Lock Washer
Fig. 1 - Exploded View of Driver Seat
DESCRIPTION pan (10). Seat pan (10) is attached to a cab seat base
by means of a suspension assembly (14). The air seat
only reacts when the driver sits on the seat. When
WARNING unoccupied, the seat sinks to the lowest position to
allow easier access.
By Law, seat belts must be provided. Always
wear seat belts when travelling in the vehicle.
A retractable seat belt (4) is secured to the seat
assembly using nuts and spacers. A push button
The seat assembly consists of a seat cushion (3) and
allows quick release of seat belt (4).
backrest cushion (2) mounted to backrest (8) and seat
SM 2400 11-05 1
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
SM - 2885 the seat position in now engaged properly.
34 - Bolt (x4)
35 - Washer (x4)
36 - Lock Washer (x4)
6 3. Pull up horizontal adjustment handle (2) and move
37 - Nut (x4) seat forwards or backwards, release handle when
required position is achieved.
4. Pull up (or push down) height and weight adjustment

(1) handle and hold until the require height position is
10 achieved, release handle - 'bounce' lightly until a 'click'
is heard, the seat position in now engaged properly.
5. Pull handle (8) to adjust seat cushion fore and aft

4
11 position. Hold and pull handle (8) until desired position
5
is achieved.
8
9 6. Pull handle (9) to adjust seat cushion rake angle,
7
2 hold and pull until desired angle is achieved. Ensure
34 cushion is locked into position. This procedure is better
1 3 35 performed when operator is off seat.
36
37 7. Pull up handle (5) and adjust backrest to the required
angle, release handle when required position is
Fig. 2 - Operator Seat Controls
achieved.
The following is the list of controls to adjust the seat: 8. Pull up (or push down) backrest (6) to the required
1. Height and weight adjustment. height.
2. Horizontal adjustment (sliderails).
3. Fore/aft isolator (forward position - unlocked, 9. Turn lumber support adjustment (10) until desired
rearmost position - locked). pressure if felt on operators back.
4. Seat belt.
5. Backrest angle adjustment. 10. Set damper adjustment (7) position to suit driving
6. Backrest height adjustment. conditions, (4 positions; forward position - hardest
7. Damper adjustment (4 positions; forward position - setting, rearmost position - softest setting).
hardest setting, rearmost position - softest setting).
8. Seat cushion - Fore/aft adjustment. 11. Set fore/aft isolator (3) position to suit driving
9. Seat cushion - Rake adjustment conditions, (forward position - unlocked, rearmost
10.Lumber support adjustment position - locked).
11.Armrest adjustment.
12. Turning armrest adjustment (11) alters the height of
armrests.
WARNING
Do not attempt to adjust the seat or seat belt 13. Engage seat belt (4).
while the machine is moving. Loss of control
may result. Stop the machine; apply the brakes; NOTE: All controls should be set to operators own
then adjust. personal comfort.
OPERATION REMOVAL
To achieve the most comfortable driving position, Numbers in parentheses refer to Fig. 2.
adjust the seat as follows;
WARNINGS
1. Sit in seat. To prevent personal injury and property
damage, be sure wheel chocks, blocking
2. Pull up and release height and weight adjustment (1) materials and lifting equipment are properly
handle - this will reset the seat to the predetermined secured and of adequate capacity to do the job
height setting - 'bounce' lightly until a 'click' is heard, safely.
2 SM 2400 11-05
Section 260-0090
1. Position the vehicle in a level work area, apply the Horizontal Shock Absorber
Note: Remove seat assembly as described in
'Disassembly'
3. Disconnect harness connector at the rear of the
1. Remove pop-out buttons (1) and remove access
seat.
cover (2) to allow access to suspension assembly.
4. Push down height and weight adjustment (1) handle
2. Unclip hooked end of shock absorber (4) from
to release the air from the seat air suspension system.
horizontal spring assembly.
5. Remove bolts (34), washers (35), lock washers (36)
3. Remove circlip (3) and lever out shock absorber (4)
and nuts (37) securing complete seat assembly to the
from rocker shaft and slide off of mounting pin.
cab seat base. Remove seat assembly from vehicle
using suitable lifting equipment.
4. Remove spacer (5) from mounting pin.
DISASSEMBLY 5. Reassembly is done in the reverse order.

Numbers in parentheses refer to Fig. 1. SM - 2487
Note: The disassembly and assembly procedures will

cover only basic sub-assemblies due to the multitude
of parts. If a sub-assembly must be disassembled, use
the exploded view in Fig. 1 for reference.
1. Remove covers (6 & 7) from seat assembly.

Remove nuts and spacers securing lap belt (4) to seat
assembly. Remove lap belt (4).
2. Pull up and remove headrest (5) from seat frame (1).
3. Remove screws securing backrest cushion (2) to

seat frame (1). Remove backrest cushion (2).
4. Remove screws securing seat cushion (3) to seat

Fig. 3 - Exploded View of Horizontal Shock Absorber
frame (1). Remove seat cushion (3).
5. Pull up horizontal adjustment (2, Fig. 2.) lever and

Vertical Shock Absorber
slide seat assembly rearwards. Hold captive nuts using Numbers in parentheses refer to Fig. 4.
a suitable spanner and remove front allen screws.
Note: Remove seat assembly as described in
6. Pull up horizontal adjustment (2, Fig. 2.) lever and 'Disassembly'
slide seat assembly forwards. Hold captive nuts using
a suitable spanner and remove rear allen screws. 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly.
7. Remove seat assembly from suspension base.
2. Unhook Bowden wire (5) and damper adjuster (6)
assembly from the top of shock absorber (7).
3. Remove circlips (3) and lever out shock absorber (7)

from mounting pins (4).
4. Remove spacers (8) from lower mounting pin (4).
5. Reassembly is done in the reverse order.
SM 2400 11-05 3
Section 260-0090
Note: Inscription must face upwards when assembling 3. Remove pressurised airline (5) from compressor (6).
shock absorber (7).
4. Identify and tag and disconnect electrical plug
SM - 2488 connections (7 & 8). Unfasten cable tie on the rocker.
5. Pull suspension assembly up to its highest position

and block securely.
6. Unscrew lower nut (9) and remove micro

encapsulated cylinder screw (10) and retaining clamp
(11).
7. Remove compressor (6) and felt mat (12) from

suspension base.
8. Reassembly is done in the reverse order.
Note: Replace micro encapsulated cylinder screw (10).
Note: Centralise compressor (6) and felt mat (12)

Fig. 4 - Exploded View of Vertical Shock Absorber
between rocker arms.
SM - 2489 SM - 2490
Fig. 5 - Exploded View of Compressor and Mounting Fig. 6- Exploded View of Level Controller and Mounting
Compressor Level Controller

Note: Remove seat assembly as described in Note: Remove seat assembly as described in
'Disassembly' 'Disassembly'
1. Remove pop-out buttons (1) and remove access 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly. cover (2) to allow access to suspension assembly.
2. Remove pop-out buttons (3) and push down 2. Remove pop-out buttons (3) and push down
suspension skirt (4) to allow further access to suspension skirt (4) to allow further access to
suspension assembly. suspension assembly.
4 SM 2400 11-05
Section 260-0090
3. Pull suspension assembly up to its highest position slide seat assembly rearwards. Hold captive nuts using
and block securely. a suitable spanner and install front allen screws.
Tighten allen screws to a torque of 25 Nm (18 lbf ft).
4. Unhook bowden wires (5 & 6) from level controller (7).
3. Install seat cushion (3) to seat frame (1) and secure
5. Identify and tag and disconnect electrical plug using screws.
connections (8 & 9).
4. Install backrest cushion (2) to seat frame (1) and
6. Identify and tag and disconnect pressurised airlines secure using screws.
(10) from air suspension unit (11). Unfasten cable tie on
the rocker. 5. Refit headrest (5) to seat frame (1).
7. Remove screw (12), push out pin (13) and release 6. Position lap belt (4) to seat assembly and secure
roll up belt (17). using nuts and spacers as removed at 'Disassembly'.
Tighten nuts to a torque of 50 Nm (36 lbf ft). Refit
8. Remove nuts (14) and manoeuvre level controller (7) covers (6 & 7).
until studs are free from mounting holes.
9. Remove screws (15) and remove bowden wire (16) INSTALLATION

retainer from level controller (7). Numbers in parentheses refer to Fig. 2.
10. Remove level controller (7) from suspension base. Note: Tighten all fasteners without special torques
11. Reassembly is done in the reverse order. STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Note: Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).
WARNINGS
INSPECTION To prevent personal injury and property
Numbers in parentheses refer to Fig. 1. damage, be sure wheel chocks, blocking
1. Inspect air lines, shock absorbers (15 & 26), secured and of adequate capacity to do the job
compressor (21), level controller (28) and air spring safely.
(30) for leaks and damage and replace if required.
2. Check all brackets and frame for cracks and/or 1. Using suitable lifting equipment, position seat
damage. Repair or replace as necessary. assembly on the cab seat base and secure using bolts
(34), washers (35), nuts (37) and lock washers (36).
3. Check springs for fatigue or damage and replace as
required. 2. Reconnect harness at the rear of the seat.
3. Place battery master switch in the 'On' position, start

ASSEMBLY the engine and charge the air system. Check seat for
Numbers in parentheses refer to Fig. 1. proper operation, refer to 'Operation'.
Note: Tighten all fasteners without special torques 4. Remove wheel chocks from road wheels.
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. Position seat assembly onto suspension base. Hold

captive nuts using a suitable spanner and install rear
allen screws. Tighten allen screws to a torque of 25
Nm (18 lbf ft).
2. Pull up horizontal adjustment (2, Fig. 2) lever and
SM 2400 11-05 5
Section 260-0090

TORQUE
1 # Nut 50 36
1 # Allen Screw 25 18
5 14 Nut 25 18
MAINTENANCE
The care of the upholstery on seat cushion (3) and

backrest cushion (2) is a relatively simple, but
important matter. Accumulation of dirt on the surface
eventually turns into a hard gritty substance which cuts
into the surface of the upholstery.
To clean seat cushion (3) and backrest cushion (2),

use warm water and a mild soap, such as Castile.
Work up thin soap suds on a piece of soft cloth and
rub the upholstery briskly. Remove the suds with a
damp cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.
Lap belt (4) assembly should be inspected by the user

on a regular basis. Replace lap belt (9) immediately if
hardware is worn or damage, straps are nicked or
frayed, buckle is not functioning correctly, loose
stitching is found, or if the strap material has lost
strength due to the effects of ultraviolet rays.
Note: Regardless of appearance, lap belt (4) must be

removed and replaced at least once every three years.
* * * *
6 SM 2400 11-05
OPERATORS COMPARTMENT - Air Conditioning
Section 260-0130
SM - 2430
1 3 IN
D
S OUT
4
5
1 - Compressor 3 - Receiver Drier 5 - Evaporator

2 - Condenser 4 - Expansion Valve
Fig. 1 - Typical Air Conditioning Flow Diagram
DESCRIPTION Compressor Drive Clutch

The R-134a compressor systems use an electronically
Temperature Control Switch actuated clutch to engage and disengage drive to the
A thermostat switch senses the temperature of the compressor. The drive belt pulley is mounted on a bearing
evaporator and engages or disengages the and is free to rotate without turning the compressor
compressor clutch. The control for this switch is crankshaft any time electrical power is disconnected. The
located in the cab. compressor is not operating when the pulley is
freewheeling. The field coil is energized by supplying
electrical current to the exposed wire. The other end of the
Compressor coil winding is grounded to the compressor and equipment
The compressor is designed to compress vapour and frame. Energizing the coil creates a magnetic force that
can be damaged by non-compressibles such as dirt, locks the driven disk to the pulley and drives the
moisture, liquid refrigerant (R-134a), etc. The compressor.
compressor draws vaporized R-134a from the
evaporator (which maintains the low pressure
necessary for proper evaporation) and compresses Condenser
the vapour to a high pressure, which is necessary for The purpose of the condenser is to radiate enough heat
condensation. The high pressure vapour then moves energy from the compressed high pressure vaporized
into the condenser where heat can be radiated to R-134a so that the R-134a changes from vapour to
change the R-134a back to liquid. liquid. During normal operation all the high pressure
section of the system will be warm or hot, but large
Note: R-134a designates the type of refrigerant used quantities of heat should be radiating from the
in heavy duty vehicle air conditioning systems. condenser. Nothing should be permitted to stop or slow
SM 2460 Rev1 07-07 1
Operators Compartment - Air Conditioning
Section 260-0130
down this radiation of heat. Cooling fins are located on Thermostatic Expansion Valve
the condenser tubes and fans are used to circulate
An expansion valve is installed in the system to lower
cool air around the condenser tubes. Keep all leaves,
the pressure before the R-134a enters the
paper, dirt, etc. clear from the condenser and
evaporator. The reduction in pressure is done by
condenser filter. The cooling fins should be straight to
passing the R-134a through a small hole (orifice).
permit free flow of air. The condenser is sometimes
The size of the orifice must be controlled to
located ahead of the engine radiator and blockage of air
compensate for changes in pressure and
flow through the radiator also affects the condenser.
temperature. The temperature of R-134a leaving the
Bent fan blades, slipping fan drive, inoperable
evaporator is sensed by a thermostatic sensor that
condenser fan motors, or any other fault that lessens
moves the valve seat via a diaphragm and actuating
the amount of cool air circulated through the
pin.
condenser, should be corrected. The oil, dirt, or
antifreeze will act as an insulator that will inhibit the
radiation of heat. Evaporator - Heat/Cool
The evaporator is the low pressure, low temperature
Since the purpose of the condenser is to radiate heat
component where liquid R-134a absorbs heat from
energy, anything that prevents or inhibits this action
surrounding air. The expansion valve bleeds high
may affect cooling, but the temperature and pressure
pressure R-134a into the low pressure evaporator.
of the R-134a raise and lower together. Heat energy
The R-134a expands rapidly in the evaporator and its
that has not been radiated will remain in the R-134a
temperature is quickly reduced. The R-134a absorbs
and the result will be pressure that is too high. The
heat from the air when the blower fan circulates air
condenser, hoses, connections and seals can be
over the evaporator coil fins. The exchange of heat
damaged by the high pressure. Pressure sensing
from the air to the R-134a depends upon the
safety switches may be activated by the high
difference in temperature. During high heat load, such
pressure caused by the condenser not radiating
as usually encountered when the system is first
enough heat.
turned on, the temperature difference is great and the
R-134a will absorb heat quickly. The blower fan can
Receiver Drier be set at its highest setting to circulate large
quantities of warm air around the evaporator. After
The high pressure liquid R-134a moves from the
the cab has cooled, the fan speed should be reduced
condenser to the receiver drier, where the R-134a is
so that the already cool air will have a longer time to
stored and filtered. Moisture is the major enemy of
yield heat to the R-134a as it passes the evaporator
the air conditioning system and the desiccant inside
coils. The heater circuits utilize engine coolant at
the receiver drier will absorb only a small amount.
approximately 82° C (180° F).
The container of desiccant inside the receiver drier
may break open and contaminate the system if any
attempt is made to dry the desiccant, or, if more High Pressure and Low Pressure Switches
moisture is inside the system than the desiccant can
The pressure switches are electric switches that
absorb.
monitor air conditioner operation. The high pressure
and low pressure switches are activated at preset
Every effort should be made to remove all moisture
pressures and engage and disengage the compressor
from the system and install a new receiver drier if its
clutch.
condition is questionable. Installation of a new
receiver drier is recommended each time any part of
the R-134a system is open to the atmosphere.
Bubbles are observed in the sight glass on top of the
receiver drier during the charging procedure.
A filter screen is located in the receiver drier to stop

solid contaminates from leaving the unit. Blockage of
the filter will result in a drop in pressure that will be
indicated by a drop in temperature. Connections of
the new receiver drier should be securely capped
before installation to prevent the entrance of moisture
(air) while in storage.
2 SM 2460 Rev1 07-07

Section 260-0130
REMOVAL 5. When satisfied that the system is completely

discharged, tag refrigerant hoses (2 &3) to aid in
installation and carefully disconnect hoses from cab
otherwise stated.
firewall. Cap fittings at front of cab and refrigerant
hoses (2 &3) to prevent foreign matter from entering
the system.
WARNINGS
Always wear goggles or glasses to protect your
6. Remove screws (3, Fig. 3) securing front cover (34,
eyes when working around R-134a.
Fig. 3) to main weldment (35, Fig. 3).
R-134a boils at sea level temperatures of
-29.8° C (-21.6° F), which means that direct
7. Remove heater hoses from front of cab, which
contact with your skin will produce frostbite.
connect to water inlet manifold (22, Fig. 3) and water
Exercise extreme care when handling R-134a. If
outlet manifold (23, Fig. 3). Cap open ports and hoses
R-134a contacts your skin, wash immediately
to prevent foreign matter from entering the system.
with plenty of warm water. Remove any
contaminated clothing with caution as it may
8.If necessary to remove main weldment (35, Fig. 3)
adhere to the skin. If blistering or continued
from cab, be sure to disconnect harness (24) and any
irritation occurs obtain immediate medical
remaining hoses or ducting before withdrawing main
attention.
weldment (35, Fig. 3) from cab.
If you get the slightest trace of R-134a in
Note: The blower assembly mounting (25, Fig. 3),
your eye, flood the eye immediately with cool
thermostat (23, Fig. 3) and heat exchanger (19, Fig. 3)
water; then treat with mineral oil or clear
can be accessed without removing the main weldment
petroleum jelly followed by boric acid rinse.
(35, Fig. 3) from cab.
Report to a hospital or doctor as soon as
possible.
10. Tag refrigerant hoses (1 & 4) to aid in installation
and carefully disconnect hoses from receiver/drier (12).
The chemicals of R-134a when burned
produce gases that will damage the respiratory Cap receiver/drier (12) fittings and refrigerant hoses (1
system if inhaled. NEVER SMOKE in an area & 4) to prevent foreign matter from entering the
where R-134a is used or stored. Use hot water system.
or an approved heated charge cylinder as a heat
source if required to force R-134a into the 11. Support receiver/drier (12) and remove clamps
system. If using water, do not exceed 52° C securing receiver/drier (12) to mounting bracket (11).
(125° F). Never use direct flame or electric
heaters in direct contact with the R-134a 12. Tag refrigerant hoses (1 & 4) to aid in installation
container. High temperatures may result in and carefully disconnect hoses at condenser (10). Cap
raising the pressure to a dangerous level. condenser (10) fittings and refrigerant hoses to prevent
ingress of foreign matter.
13. If required, support air conditioner condenser (23)
securing condenser (10) to radiator assembly. Remove
condenser (23) from vehicle.
safely.
14. Tag refrigerant hoses (3 &4) to aid in installation
and carefully disconnect hoses from compressor (10).
Cap compressor (10) fittings and refrigerant hoses (3 &
4) to prevent foreign matter from entering the system.
2. Toggle the hood switch located beneath the
15. Disconnect electrical connection from compressor
passenger seat to raise the hood.
(10) clutch.
18. Support compressor (10) and remove bolts (17) and
washers (17) securing compressor (1) to engine.
Remove compressor (10) from the vehicle.
4. Discharge the air conditioning system as described
under 'Discharging The System'.
SM 2460 Rev1 07-07 3

Section 260-0130
SM - 3636
21 5
9
19
CAB 3
FIREWALL 6 9
20 18
16
24
7
17
8
10
8
23
14 18
21
7
23
15
11
12 7
4
14
7 22
1 - Refrigerant Hose 7 - 'O'-Ring 13 - P-Clip 19 - P-Clip

2 - Refrigerant Hose 8 - 'O'-Ring 14 - Lockwasher 20 - P-Clip
3 - Refrigerant Hose 9 - 'O'-Ring 15 - Clamp 21 - Bolt
4 - Refrigerant Hose 10 - Compressor 16 - Bolt 22 - Bolt
5 - P- clip 11 - Bracket 17 - Washer 23 - Condenser
6 - Nut 12 - Receiver/Drier 18 - Clamp 24 - Bracket
Fig. 2 - Air Conditioner Lines and Mounting
INSTALLATION 1. If main weldment (35, Fig. 3) was removed, install in

cab and reconnect harnesses, hoses and air ducting as
noted during removal.
otherwise stated.
2. Reconnect heater hoses to front of cab and connect
Note: Tighten all fasteners to standard torques
to water inlet manifold (22, Fig. 3) and water outlet
specified in Section 300-0080, STANDARD BOLT AND
manifold (21, Fig. 3), as identified at removal.
NUT TORQUE SPECIFICATIONS.
4. Once all necessary connections have been made,
Note: Renew all 'O' rings where necessary (7, 8 & 9).
secure front cover (34, Fig. 3) to main weldment (35,
Fig. 3) using fasteners previously removed.
WARNING
5. Remove caps from end of refrigerant hoses (2 & 3)
and ports at front of cab and connect hoses to ports as
tagged at removal.
6. Route refrigerant hoses (2 & 3) along the LH side of
safely.
the engine securing with clamps removed during
removal.
4 SM 2460 Rev1 07-07

Section 260-0130
SM - 3637
24
4
23
7 20
10 22
2
12
17
13 21
11
65 15
16 25
18
9
14 26
19
27 1
28,30
31,32
2 3
1 28,30
31,33
28,29,30,31
1 - Filter Assembly 10 - Binary Switch 19 - Coil Assembly 28 - Knob

2 - Grommet 11 - Screw 20 - Top Seal 29 - Potentiometer Assy
3 - Screw 12 - Bolt 21 - Manifold 30 - Nut
4 - Grommet 13 - Plate 22 - Manifold 31 - Washer
5 - 'O'-Ring 14 - Water Hose 23 - Thermostat 32 - Air Con Switch
6 - 'O'-Ring 15 - Plate 24 - Harness 33 - Blower Switch
7 - Grommet 16 - Water Outlet Pipe 25 - Blower Assy Mounting
8 - Vent 17 - Valve 26 - Water Valve Assy
9 - Clamp 18 - Water Hose 27 - Drain Tube Assy
Fig. 3 - Air Conditioner Lines and Mounting
7. If removed, install receiver/drier (12) to mounting Note: If fan guard and compressor drive belt were
bracket (11) and secure with clamps. removed, proceed with steps 12 & 13.
8. Remove caps from end of refrigerant hoses (1 & 2) 12. Install new drive belt onto engine pulley and fit to
and ports on receiver/drier (12) and connect hoses to groove on compressor (10).
ports as tagged at removal.
13. Adjust tension of compressor drive belt with nut on
9. If removed, install condenser (23) to radiator adjuster bolt until there is approximately an inward
assembly and secure. deflection of 10 mm (0.4 in) at the centre of drive belt
(3). Fully tighten all mounting hardware.
10. Remove caps and connect refrigerant hoses
(1 & 8) to condenser (23) ports as tagged at removal. 14. Remove caps from end of refrigerant hoses (3 & 4)
and ports on compressor (10) and connect hoses to
11. Fit compressor (10) to engine and secure with bolts ports as tagged at removal.
(16) and washers (17). Do not fully tighten at this
stage. 15. Connect electrical connection to compressor (10)
clutch.
SM 2460 Rev1 07-07 5

Section 260-0130
16. Secure all lines with clips and clamps as removed 2. If the system has a heater in the same location as
during removal. Ensure no lines are chaffing on sharp the air conditioning evaporator core, heater valves
edges or resting against areas where heat will be should be closed.
evident.
3. To check the refrigerant level, run the engine at
17. Charge the air conditioning system as described 1 200 rev/min with fans on high speed and thermostat
under 'Charging Procedure'. fully open for a minimum of five minutes. If the clutch
is engaged in this situation, there should be very few
18. Switch the battery master switch to the 'On' bubbles visible in the receiver-drier sight glass.
position, start up the engine and check for correct
operation of the air conditioning system. Note: Unit can operate with some bubbles visible, but
not milky looking.
19. Lower hood and remove wheel blocks from all road
wheels. 4. Ensure all hoses and hose clamps are free from
contact with sharp metal, moving parts or near to
manifolds.
MAINTENANCE
5. Inspect condensation drain lines for debris, sharp
bends or breaks.
WARNINGS
Always wear goggles or glasses to protect your 6. Inspect the clutch wire from the thermostat for bare
eyes when working around R-134a. R-134a boils spots.
at sea level temperatures of -29.8° C (-21.6° F),
which means that direct contact with your skin 7. Inspect bolts and nuts on the compressor and
will produce frostbite. Exercise extreme care mounting bracket for proper tightness.
when handling R-134a. If R-134a contacts your
skin, wash immediately with plenty of warm 8. Check for any air blockages within the system.
water. Remove any contaminated clothing with Clean recirculation filter periodically, by shaking off
caution as it may adhere to the skin. If blistering dust or by washing in soapy water.
or continued irritation occurs obtain immediate
medical attention. 9. If the refrigerant system is broken into following gas
loss due to mechanical damage or there is any other
If you get the slightest trace of R-134a in reason to suspect foreign material ingress, then the
your eye, flood the eye immediately with cool receiver/drier should be replaced.
water; then treat with mineral oil or clear
petroleum jelly followed by boric acid rinse. 10. Every 4 000 hours, drain, flush and refill the
Report to a hospital or doctor as soon as compressor with refrigerant oil specified in Section
possible. 300-0020, LUBRICATION SYSTEM. Also see
'Refrigerant Oil'.
The chemicals of R-134a when burned
produce gases that will damage the respiratory
system if inhaled. NEVER SMOKE in an area
where R-134a is used or stored. Use hot water or
an approved heated charge cylinder as a heat
source if required to force R-134a into the
system. If using water, do not exceed 52° C
(125° F). Never use direct flame or electric
heaters in direct contact with the R-134a
container. High temperatures may result in
raising the pressure to a dangerous level.
1. Periodically clean the condenser coil of debris and

dirt using water or air pressure. A partially blocked
condenser coil can reduce the life of the compressor
belt and/or clutch.
6 SM 2460 Rev1 07-07

Section 260-0130
Maintenance of drive belts Refrigerant Oil

1. Listen for 'ticking' sound - they mean interference
with the belts. Visually inspect for bent or damaged
belt guards. WARNINGS
To prevent personal injury always wear rubber
2. Replace all belts in a mismatched set at one time to gloves when handling refrigerant oils.
ensure even load distribution.
Too much refrigerant oil will dampen the
3. Periodically check tension and keep belts tight. cooling effect and too little refrigerant oil may
lead to compressor failure. If in doubt flush the
- The ideal tension is the lowest tension at which the system.
belt will not slip under peak load conditions.
- Check belt tension frequently during the first 24 - 48 Oil is required to lubricate the compressor. The oil
hours of run-in operation. mixes with the refrigerant and is carried around the
- Initial belt tension should be 533 N (120 lbf) system. The compressor is supplied with an oil
dropping to 422 N (95 lbf) after the first 48 hours. charge. However, additional oil is required, the
- There should be a freeplay of 10 mm in the belt. amount depending on the length of refrigerant hose
- Do not over tension belts. being used. The quantity added should be calculated
- Keep belts free from foreign material that may using the following equation:
cause slippage.
- Inspect the drive periodically. Re-tension belts if Amount of oil to add in fl oz. =
they are slipping. (0.47 x total length of hoses in m) - 2.15
- Maintain sheave alignment with a strong straight If any component is replaced the following amount of
edge tool while tensioning belts. oil should be added to the system;
4. Never attempt to correct belt slippage by using a Condenser add 1 fl oz (28.4 ml)
belt dressing. The dressing may cause softening and Drier add 1 fl oz (28.4 ml)
deterioration. Evaporator add 3 fl oz (85.2 ml)
Compressor add 4.4 fl oz (125 ml)
5. If belt slips, even when properly tensioned, check for
overload, worn sheave grooves or oil or grease on the The oil should be added to the oil filling port of the
belts. compressor before the evacuation procedure is started
or by using an oil injector when the system is being
6. Never pry a drive belt or force it into the sheave charged, observing the following good practises:
groove. Loosen the drive belt tightener prior to
installation. a. Only pour the amount required from the container
straight into a CLEAN measuring jug and
7. A belt that has operated while rolled over in the immediately pour the oil into the compressor.
sheave groove may be damaged - replace it. b. Re-cap container tightly as soon as the required
amount has been taken (never leave an oil container
8. Store belts in a cool, dry place. If stored on a open).
machine, relieve all belt tension by loosening the c. Do not mix different oils.
drive belt tightener.
Only new oil should be used, because oil that has
9. Never attempt to check or adjust belts while they are been exposed to the air will have absorbed water
running. (hygroscopic).
Use only refrigerant oil as specified in Section

SM 2460 Rev1 07-07 7

Section 260-0130
System Leak Testing system is empty before connecting the vacuum so that
refrigerant does not enter the pump.
Recommended Equipment Required:
Electronic Leak Detector
5. Tighten down (turn clockwise) both high and low side
valves on the gauge manifold to the closed position.
Switch off the engine and check all connections
Remove protective caps from the service ports on the
throughout the system for leaks. A large leak point will
compressor.
have an oily or greasy appearance. The refrigerant
carries compressor oil with it and deposits it around the
6. Connect both service hoses from the two fittings (2
leak area. Check all such points for loose connections
& 3) in the bottom of the manifold to the two service
and tighten.
ports on the compressor. High side (red) to compressor
discharge valve, low side (blue) to compressor suction
Using a suitable leak detector, search for leaks around
valve.
all joints, connections, seals and control devices. If a
leak is located, purge the system of refrigerant and
7. Switch vacuum pump on, open vacuum pressure
repair. Fully evacuate and charge the system to make
valve (1) until less than 6 mb is reached on vacuum
it operational.
gauge (A). The vacuum gauge (A) should remain at
this value when vacuum pressure valve (1) is closed
DISCHARGING THE SYSTEM to indicate that there are no leaks.
Note: Refer to all WARNINGS listed under
8. Open the low side hand valve on the manifold and
'Maintenance' prior to discharging the system.
vacuum pressure valve (1) and watch that the
gauges start to register that a vacuum is being drawn.
Recommended Equipment Required:
If the gauges do not register the vacuum thena
Portable High Vacuum Charging Station
blockage is present. Open the high side and pump
Suitable Canister
down until a vacuum of 10 mb is achieved.
or Standard Service Manifold (Refer to Fig. 4)
To eliminate system contaminants from an air
9. After 10 - 15 minutes close vacuum pressure valve
conditioning system requires discharging the entire
(1) and allow the system to settle, vacuum gauge (A)
system. This means removing all of the refrigerant
should not alter. If the vacuum is held, no leaks or
and cleansing all contamination (air and moisture) from
refrigerant contaminated oil is present. If not, open the
the system components. If any of the major system
vacuum pressure valve (1) and continue pumping,
components are to be repaired or replaced, the system
checking at regular intervals. If there is a leak, check
must also be completely discharged.
all fittings and tighten if necessary.
WARNING 10. Tighten down (turn clockwise) both high and low
The vehicle must not be running during this side valves on the gauge manifold to the closed
procedure. Be sure to have adequate ventilation position, remove the service hose (yellow) from the
during this operation. Do not discharge vacuum connection (6) on vacuum pump and switch
refrigerant near an open flame. the pump 'Off'.
Numbers and letters in parentheses refer to Fig. 4. 11. Connect the service hose (yellow) to the R-134a
cylinder. Open the cylinder valve and then purge air
1. Position the vehicle in a level work area, apply the from the hose at the manifold connection.
12. Open the low side hand valve on the manifold
2. Block all road wheels and place the battery master slowly, until low pressure gauge (B) is at bottle
switch in the 'Off' position. pressure. Watch the high side manifold gauge (C) rise
to ensure that no blockage is present. Close the
3. Pull on handle to release hood catch and raise the manifold valve and cylinder, then disconnect the hose
hood. from the cylinder.
4. Connect the service hose (yellow) to the centre 13. Connect the service hose (yellow) to the Nitrogen
access port on the manifold gauge and to the vacuum cylinder. Open the neck valve on the cylinder and set
connection (6) on vacuum pump. Ensure that the the regulator pressure such that it is higher than the
8 SM 2460 Rev1 07-07

Section 260-0130
system pressure then purge the hose. Open the low 9. Run vacuum pump for approximately 30 minutes.
side hand valve on the manifold, as the pressure rises Ideal gauge readings should be 29.92 inches of
open the high side hand valve on the manifold and mercury. The pressure will vary with altitude; it will be
allow a system pressure of 10 bar (150 psig) to be approximately 0.03 bar (0.5 lbf/in²) less for each 305 m
reached. Close all the valves. Using a suitable (1 000 ft) of elevation.
electronic leak detector, check all joints in the air
conditioning system for leaks. Tighten any loose 10. Before disconnecting power supply from vacuum
joints and re-test if necessary. pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
14. Vent the refrigerant mix to atmosphere by R-134a source.
removing the service hose (yellow) from the Nitrogen
cylinder and opening the low side hand valve on the 11. Open R-134a source. Loosen, but do not remove,
manifold. Re-evacuate the system to below 6 mb yellow supply hose at manifold on gauges to remove all
(steps 7 to 10). air in the yellow supply hose, replacing the air with R-
134a. This is done in a few seconds. Tighten yellow
15. Lower hood assembly and remove wheel blocks. supply hose.
12. Open low side of R-134a gauges slowly. When

CHARGING THE SYSTEM gauge reads zero open both sides completely. Vacuum
Note: Refer to all WARNINGS listed under in the system will draw R-134a gas into the system.
'Maintenance' prior to charging the system. Hold until both gauge readings equalize.
Recommended Equipment Required: Note: Never charge with liquid R-134a. Charge on the
Portable High Vacuum Charging Station low pressure side only.
Electronic Leak Detector
or Standard Service Manifold (Refer to Fig. 4)
Final Charging Of The System
For New Or Completely Empty System 1. Start the engine and run at engine idle speed.
Note: The charging procedure must be done in ambient
temperatures above 15.5° C (60° F) with the R-134a 2. Turn the air conditioning system on with the
canister temperature equal to the outside ambient thermostat set on maximum cooling and fan on high
temperature. speed.
1. Shut off engine and block all road wheels. 3. At this point a visual inspection must be made of
the sight glass on top of the receiver-drier. Allow
2. Pull on handle to release hood catch and raise the charging to continue until 1.1 kg (2.43 lbs) of refrigerant
hood. has been added. The charging process can be speeded
up by running the engine at a fast idle.
3. Remove protective caps from 'quick coupler' valves
on rear of compressor. 4. The sight glass on top of the receiver/drier will be
substantially free of bubbles.
4. Connect low pressure gauge hose (blue hose and
gauge) to suction side or low side fitting on Note: It is normal for bubbles to increase during clutch
compressor. The suction side can be identified by the cycling or system start-up.
size of the hose connected to the fitting. This will be
the largest diameter hose of the system. 5. With the system completely charged, shut off the
engine. Close the valve on the R-134a canister and
5. Connect the high pressure gauge hose (red hose and remove the yellow supply hose. Remove both the low
gauge) to discharge or high side fitting on compressor. pressure (blue) hose and high pressure (red) hose from
6. Connect yellow supply hose to suction port on the filling ports on the compressor.
vacuum pump.
Note: Some R-134a will escape as the hoses are being
7. Open both sides of gauges, low and high, completely. removed.
8. Start vacuum pump to evacuate the complete air The system is completely charged when;
conditioning system.
SM 2460 Rev1 07-07 9

Section 260-0130
a. the suction pressure on the gauge is approx. 2. Turn the blower control to setting 1.
20 - 30 psig at 25° C ambient.
b. the correct weight of refrigerant has been added i.e. 3. Turn on the air conditioning unit on for 5 seconds
1.1 kg (2.43 lbs). then off for 5 seconds.
c. the correct sub-cooling can be measured at the
condenser, approx. 5 - 7° C. 4. Repeatedly switch the air conditioning on and off for
at least 1 minute. This should be at least 12
6. Replace protective caps on hoses and valve fittings. repetitions.
7. Lower hood assembly and remove wheel blocks. 5. Commissioning the air conditioning unit is complete
and ready for use.
Air Condition Commissioning Procedure
If the machine has been idle overnight or for an TROUBLESHOOTING

extended period of time, the refrigerant in the air
conditioning unit converts from a gas to a liquid. This Preliminary Checks
puts the compressor unit is under a great deal of strain Before any checks are carried out on the refrigerant
trying to compress a liquid instead of a gas and could circuit the following checks should be made:
cause a failure in the air conditioning unit. The following
commissioning procedure allows the air conditioning 1. Check the compressor drive belt is serviceable and
unit to achieve normal operating parameters. correctly tensioned.
1. Start the machine and allow it to run until the engine 2. Check the condenser and engine radiator are not
is at a normal operating temperature of 80°C (176°F) blocked by debris. Clean with compressed air or water
if necessary.
3. Check that the condenser fins are not flattened or

SM - 2424
damaged, the fins must allow air to pass freely.
B C D
4. Check the cab fresh air inlet filter for blockage.
5. Check that, with the ignition switch on (engine not

4 running), the blower operates over whole speed range
2 3
SUC DIS R 6. Check that, with the ignition switch on (engine not
ACCESS E running), the blower and air conditioning switched on,
F
PORT R the compressor clutch engages.
I
G
E Charge level:
A R Note: It is not possible to check refrigerant charge
A
N level with R134a systems. Any bubbles seen at the
T sight glass on the receiver drier may be bubbles of oil
and are perfectly normal.
VACUUM PUMP
Fault finding:
Refer to Troubleshooting table
6
1 5 Important: Refer to appropriate removal and installation
procedures before working on any system component.
Gauges: Valves:
A - Vacuum Gauge 1 - Vacuum Pressure
B - Low Pressure Gauge 2 - Suction Line SPECIAL TOOLS
C - High Pressure Gauge 3 - Discharge Line
D - Charging Cylinder 4 - Refrigerant Gas
Pressure Gauge 5 - Refrigerant Liquid numbers of special tools referenced in this section and
Port: general service tools and sealants required. These
6 - Vacuum Connection tools and sealants are available from your dealer.
Fig. 4 - Standard Service Manifold
10 SM 2460 Rev1 07-07

Section 260-0130
AIR CONDITIONING TROUBLESHOOTING

CONDITION PROBLEM REMEDY
1. Belt Trouble
Slipping Loose Adjust belt to 10 mm (0.39 in)

depression
Overcharge Correct the charge
Air in system Evacuate and re-charge
Excessive wear Pulley not aligned Align pulley
Belt too tight Adjust or replace
Bad idler bearing Replace idler bearing
Belt wrong width Replace with correct belt
2. Vibration/Noise in Compressor
area
Vibration/noise Stuck compressor or clutch Replace
Vibration Overcharge Correct the charge
Air in system Evacuate system and re-charge
Compressor mounting or belts loose Tighten
Drive pulley loose Tighten
Belt tension incorrect Correct tension
Faulty compressor Replace compressor
Noise with clutch engaged Faulty clutch bearing Replace bearing
Noise with clutch engaged or Clutch loose Tighten

disengaged
Noise Clutch rubbing field coil Align clutch
Faulty belt Replace belt
Compressor oil level low Add oil
Chatter/Knock Valve plate broken Repair or replace
3. Noise - Evaporator
Rubbing/scraping Fan blade or blower Repair or replace
Hissing Low charge/leak Correct charge/repair leak
Chatter/Knocking Expansion valve Replace
Noisy case Loose brackets/screws Tighten
Motor squeal Dry bearings Replace
SM 2460 Rev1 07-07 11

Section 260-0130
AIR CONDITIONING TROUBLESHOOTING (CONTINUED)

4. Air Conditioning Inadequate
After Short Period Of Operation
Cooling quits Loss of refrigerant Charge system/check for leaks
Moisture in system Replace drier
Thermostat Replace thermostat
Clutch Check pull-in of clutch or replace
Cooling intermittent Moisture in system Replace drier
5. Electrical Trouble
Blower motor or condenser fan Defective circuit breaker or bad Replace. Clean and tighten
motor inoperable wiring connections connections
Tight motor bearing Repair or replace motor
Switch open or shorted Repair or replace switch
Blown fuse Check fuse, replace if necessary
Motor seized Check rotors are free to turn
Loose wire/connection Check connectors at blower. Check

there is power across terminals
Motor failure Remove and replace blower
Faulty control Check system with replacement
Module damaged Check system with replacement

module inside main weldment
Slow running blower Shaft binding Replace motor - worn bearings
Wheel misaligned Replace
Bad blower switch Replace blower
Insufficient current Install larger alternator
Clutch inoperable Defective relay Replace
Loose connection Clean and tighten connection
Broken wire - ground Repair wire
Shorted or open field Replace field
Blown fuse Check fuse, replace if necessary
Faulty freeze protection thermostat When temperature is above cut-off

temp, thermostat should be closed.
If faulty, replace thermostat
12 SM 2460 Rev1 07-07

Section 260-0130
AIR CONDITIONING TROUBLESHOOTING (CONTINUED)

Clutch inoperable (continued) Faulty compressor If compressor clutch is being fed
power then it should be engaged. If
not, check wiring. Replace
compressor if faulty
Faulty pressure switch If the binary pressure switch

detects pressure within range,
circuit should be closed. If switch
is not closed circuit, indicates
incorrect pressure or faulty switch.
6. Air Conditioning System

Trouble - Gauges must be
connected
High head pressure Overcharge of refrigerant Purge system as necessary
Air in system Evacuate and re-charge
Condenser clogged Clean condenser
Low head pressure Undercharge of refrigerant Complete charge
Bad compressor valve plate or Repair or replace

gasket
Restriction in drier Replace drier
Low suction pressure Restriction in lines Clean lines
Restriction in expansion valve Replace expansion valve and drier
Improper expansion valve in charge Replace expansion valve
Refrigerant leak Inspect lines and fittings. Tighten,

repair or replace
* * * *
SM 2460 Rev1 07-07 13

Section 260-0130
14 SM 2460 Rev1 07-07

BODY - Body and Mounting
Section 270-0010
SM - 3522
14
1 37 7
1 4
15
16 3
6 1
5
26
27
25 11
13
18 20 21
12
24 32
23 9
28 34
29 30 31
33 10
36 17
19
22 29 2
35
38
1 - Body 11 - Shim 19 - Proximity Switch 27 - Washer

2 - Bushing 12 - Shim 20 - Bolt 28 - Locknut
3 - Body Hinge Pin 13 - Locknut 21 - Washer 29 - Bolt
4 - Shim 14 - Spacer 22 - Locknut 30 - Nut
5 - Bolt 15 - Plate 23 - Bolt 31 - Bolt
6 - Washer 16 - Plate 24 - Washer 32 - Pin Assembly
7 - Grease Fitting 17 - Bracket 25 - Cover Plate 33 - Chain
8 - Bolt 18 - Plate 26 - Body Prop 34 - Pin Spring
9 - Washer 35 - Pin Assembly.
10 - Body Pad
Fig. 1 - Body and Mounting
DESCRIPTION OPERATION
The standard body is an all welded construction with all A body control joystick, mounted on the right hand
wear plates fabricated from high hardness dash panel, actuates the body control valve by means
(min. 360 BHN) 10 150 bar (145 000 lbf/in²) yield of electrical signals to the solenoid valves, which in
strength material. Angled lower body sides reduce turn operate the body hoist cylinders. The four
body impacts when loading and a tailshute angle of operating positions of the joystick from front to rear are
25° provides good load retention when travelling as follows:
without a tailgate. Refer to Section 000-0000,
GENERAL INFORMATION for body capacities. 'FLOAT' - The joystick should be moved to this
position while the body is lowering by gravity and
The body is pivoted at the rear of the trailer frame and should remain in this position until the body must be
is operated by two single stage, double acting body operated again. The control joystick should always be
cylinders which are cushioned at both ends of the kept in 'FLOAT' while the machine is in motion.
stroke to reduce impact shocks. The body cylinders
raise the body to a tipping angle of 65° in 'LOWER' - Pushing the joystick forward and holding it
16 seconds and powerdown the body in 12 seconds. in this position provides hydraulic force to power-down
the body. It is needed when the body cannot be started
SM 2429 03-06 1
Body - Body and Mounting
Section 270-0010
downward from the fully raised position by gravity. 2. Block all road wheels and place the battery master
When the body starts lowering by gravity, the joystick switch the 'Off' position.
can be released and internal valve springs will move
the joystick to the 'HOLD' position. 3. Remove upper pins securing the body cylinders to
body (1) and secure body cylinders clear of the body.
'HOLD' - Moving the joystick to this position while the Refer to Section 230-0130, BODY CYLINDER.
body is being raised or lowered traps the oil in the
body hoists to stop and hold the body at any desired 4. Using suitable lifting equipment, sling body (1)
height. The joystick will remain in the 'HOLD' position assembly at the four lifting points and take an initial
when released. strain.
Note: Approximate weight of body (1) assembly is

'RAISE' - Pushing the joystick back and holding it in
5 400 kg (11 905 lb).
this position directs oil to extend the body hoists and
raise the body. When released, the joystick will be
spring-returned to the 'HOLD' position. 5. Remove bolts (5) and washers (6) securing body
hinge pins (3) through body (1) and pin mounting
bores.
Note: The body control lever must remain in the
'FLOAT' position until it is necessary to operate the
body again. Failure to comply to this could result in 6. Remove body hinge pins (3) and shims (4) from
overheating the hydraulic oil and failure of the body (1) and remove body (1) assembly from the
hydraulic system components. vehicle. If necessary, remove bushing (2) from pin
mounting bores.
Note: A proximity sensor (19) prevents the body (1)
being fully powered down onto the chassis. At a Note: Do not remove body pads (10) and shims (11 &
predetermined height, the sensor automatically 12) unless body pads are being replaced.
defaults the body control valve to the detented
'FLOAT' condition. 7. If required, remove locknuts (13), washers (9) and
Note: If the body-up warning light goes out while the bolts (8) securing body pads (10) and shims (11 & 12)
body is being raised, the 'POWER DOWN' operation to body (1) assembly. Remove and discard body pads
will not be available and the body control valve will (10) and shims (11 & 12).
automatically default to the detented 'FLOAT'
condition. The cause of the electrical fault must be INSTALLATION
investigated and corrected.

REMOVAL
Numbers in parentheses refer to Fig. 1. TORQUE SPECIFICATIONS.
WARNINGS WARNING
damage, be sure wheel chocks and lifting damage, be sure wheel chocks and lifting
equipment are properly secured and of equipment are properly secured and of
adequate capacity to do the job safely. adequate capacity to do the job safely.
Exercise extreme caution when lowering 1. If removed, install bushing (2) to pin mounting
the cylinders from the body. The cylinders will bores.
swing out sharply as they leave their
mountings. 2. Using suitable lifting equipment, sling body (1)
assembly and position over the trailer frame.
body is fully lowered, apply the parking brake and Note: Approximate weight of body (1) assembly is
switch off the engine. Turn steering wheel several 5 400 kg (11 905 lb).
times to relieve any pressure in the steering circuit.
3. Align body hinge pin (3) bores in body (1) with bores in
2 SM 2429 03-06
Body - Body and Mounting
Section 270-0010
the trailer frame. Install body hinge pins (3) and shims (4) of the load, resulting in uneven load distribution along
and secure with bolts (5) and washers (6). the chassis.
4. Secure body cylinders to body (1) assembly with 1. Raise body (1) clear of the trailer frame and lay body
pins and mounting hardware removed during removal. pads (10) (metal face down) roughly in position on the
Refer to Section 230-0130, BODY CYLINDER. frame.
5. Lubricate body hinge pins (3) and body cylinder pins 2. Lower body (1) onto body pads (10).
with lubricant specified in Section 300-0020,
LUBRICATION SYSTEM. Lubricate slowly until 3. Centralise body (1) to the frame and place shims
excess lube is seen. (11 & 12) under the front two body pads (10) until all
other pads are clear of body (1).
6. If removed, install body pads (10) and body guide
plates (15) on body (1) as described under 'Body 4. Slide shims (11 & 12) under the other body pads
Shimming Procedure'. (10) until they just make contact with body (1).
7. Remove lifting equipment from body (1) and wheel 5. Raise body (1) and install body pads (4) and shim
chocks from all road wheels. packs (11 & 12) to their relative brackets on body (1)
securing with bolts (8), washers (9) and locknuts (13).
8. Start the engine and check for correct operation of
body (1) assembly. 6. Lower body (1) and check shimming.
7. Install body guide plates (15) with spacers (14) to

BODY SHIMMING PROCEDURE mounting brackets on body (1) setting gap between
Numbers in parentheses refer to Fig. 1. plate (15) and the frame at 5 - 10 mm (0.2 - 0.4 in).
Secure plate (15) and spacers (14) to mounting
Note: Tighten all fasteners to standard torques listed brackets with bolts (8) and washers (9).
MAINTENANCE
Note: When it becomes necessary, body pads (10) Every 50 Hours: Lubricate body hinge pins and body
should be replaced as a set to maintain load cylinder pins with lubricant specified in Section
distribution along the chassis. Existing body pads will 300-0020, LUBRICATION SYSTEM. Lubricate slowly
have taken a compression 'set' and a new pad until excess lube is seen.
shimmed to match existing pads will not carry its share
* * * *
SM 2429 03-06 3
Miscellaneous - Lubrication System
Section 300-0020
LUBRICATION AND SERVICE

SAFETY PRECAUTIONS
Do not allow unauthorised personnel to service or
maintain this vehicle. Study the Operators Handbook WARNING
and Maintenance Manual before starting, operating or These vehicles are equipped with engine and
servicing this vehicle. Always follow procedures and transmission oil pans which permit operation at
safety precautions detailed throughout this manual. maximum gradeability as designated in the
'Performance Data' section of the relevant Sales
Always attach a DO NOT OPERATE or similar warning Specification Sheet.
sign to the ignition switch or a prominent control before
cleaning, lubricating or servicing the vehicle. Lubrication is an essential part of preventive
maintenance. It is important that the instructions
Never allow anyone to work on the vehicle while it is regarding lubricant specifications, and the frequency of
moving. Make sure there is no one on the vehicle their application, be followed to prolong the useful life
before working on it. of the vehicle. Periodic lubrication of moving parts
reduces to a minimum the possibility of mechanical
Do not work under or near an unblocked or unsupported failures.
body. Always use the body prop. The body prop must only
be used when the body is empty. All change periods are recommendations based on average
operating conditions. Lubricants showing evidence of
Always install the steering lock bar before making excessive heat, oxidation or dirt should be changed more
adjustments or servicing the vehicle with the engine frequently to prevent these conditions.
running.
Lubricant change and service periods must be
Do not work under or near any unblocked or established on the basis of individual job conditions
unsupported linkage, part or vehicle. utilizing oil sampling and recommendations from
lubricant suppliers.
Always relieve pressure before servicing any
pressurized system. Follow the procedures and safety Thoroughly clean all fittings, caps, plugs etc., to
precautions detailed in the relevant Maintenance prevent dirt from entering any system while carrying
Manual section. out servicing procedures. Lubricants must be at normal
operating temperature when draining.
When changing oil in the engine, transmission and
hydraulic system, or removing hydraulic lines, Note: Do not operate any system unless oil level is
remember that the oil may be hot and can cause burns within the recommended operating levels as indicated
to unprotected skin. on oil level dipstick, sight gauge or level plug.
When working on or around exhaust components, Small circles on the following illustration represent
remember that the components may be hot and can points at which lubrication and/or servicing must take
cause burns to unprotected skin. place, at the intervals indicated on the left hand side of
the lubrication and service chart.
Always deflate the tyre before trying to remove any
embedded objects or removing the tyre and rim The numbered circles on the illustration contain
assembly from the vehicle. reference numbers which correspond to the reference
numbers in the 'Ref. Points' column of the lubrication
Always use a self-attaching chuck with a long airline, and service chart.
and stand to one side while inflating the tyre. Refer to
Section 160-0050, WHEEL RIM AND TYRE.
SM 2435 Rev4 05-07 1

Section 300-0020
SM - 3526
24 35 28 27 13 11 9 12 21 16 18 22 19 25 22 16 20 10 16 23
1 33 32 5 4 3 7 15 2 12 21 14 34 22 26 22 17 10 20 8 23
Lubrication and Servicing Points
LUBRICATION AND SERVICE CHART

Interval Ref. No. of Service
Hours Points Identification Service Instructions Points Lubricant Quantities
1 Engine Check oil level. Add if low. 1 EO As required.
10 2 Transmission Check oil level. Add if low 1 TranSynd / As required.
(Daily) TES 295*
3 Hydraulic Tank Check oil level. Add if low 2 HO / Textran HD10 As required.
4 Radiator Header Tank Check coolant level. Add if low 1 Ethylene Glycol As required.
5 Primary Fuel Filter / Check. Drain as required. 1 - -
Water Separator
1 Drive Belts Check for damage. See engine Manual
27 Fuel Tank Check fuel level. Add if low. 1 - As required.
1 Engine Crankcase Breather Inspect and clean if required. - -
24 Cooling Fans Check for damage.
6 Hydraulic Filter Restriction Check. Replace element if required. 1
Indicator
Tyres Check condition and pressure. 6
General Walk round vehicle, check for debris, - Refer to chart.
leaks and damage.
50 7 Battery Electrolyte Check level. Add if low. 2 - As required.

(Weekly) 8 Wheel rim nuts Check Torque. 138 - 600 Nm (442 Ibf ft)
9 Cab Ventilation Filter Inspect and clean if required. 1
10 Panhard Rod Bearings Lube. 4 EP, NLGI See Note 1.
150 1 Engine Air Cleaner Check inlet screen. Clean 1
19 Oscillation Bushed Lube. 2 EP, NLGI See Note 1.

20 Suspension Beam Bushings Lube. 2 EP, NLGI See Note 1.
23 Body Hinge Pins Lube. 2 EP, NLGI See Note 1.
250 21 Steering Cylinder Pins Lube. 4 EP, NLGI See Note 1.
(Monthly) 22 Body Cylinder Pins Lube. 4 EP, NLGI See Note 1.
16 Differential Breathers Clean if required. 3
19 Oscillation Pivot Check end float. Adjust if required. 2
18 Articulation Bearings Lube. 2 See Note 2.
25 Parking Brake Pads Check wear. Replace if required. 2
2 SM 2435 Rev4 05-07

Section 300-0020
LUBRICATION AND SERVICE CHART (Continued)

Interval Ref. No. of Service
Hours Points Identification Service Instructions Points Lubricant Quantities
2 Transmission Breather Clean if required. 1
250 24 Radiator and Coolers Clean and inspect fins. See Note 6.
(Monthly)
26 OCDB Plate Check wear. Replace if required.
1 Engine Drain oil and refill. 1 EO 32 Litres
13 Engine Oil Filter Replace. 1
14 Dropbox Check oil level. Add if low 1 EO As required.
15 Secondary Fuel Filter Replace 1
17 Wheel planetaries Check oil level. Add if low 6 EPL As required.
16 Differentials Check oil level. Add if low 3 EPL & LZ See Note 4.
5 Fuel Filter / Water Separator Replace 1
27 Fuel Tank Clean filler neck, screen and cap. 1

500 11 Engine Air Cleaner Clean inlet screen. 1
(3 14 Dropbox Oil Filter Replace. 1
Monthly)
14 Dropbox Drain oil and refill. 1 EO 13 Litres (3.4 US Gal.)
11 Engine Air Cleaner Replace Element. 1

1000 17 Wheel Planetaries Drain oil and refill. 6 EPL 9 Litres (2.4 US Gal.)
(6 16 Differentials Drain oil and refill. 3 EPL & LZ See Note 6.
Monthly) 9 Cab Ventilation Filters Replace. 1
28 Coolant Additive Replace. 1
29 Fuel Tank Breather Replace. 1
30 Hydraulic Tank Breather Replace. 1
31 OCDB Tank Breather Replace. 1
1500 32 OCDB Tank Drain oil and refill. 1 Textran TDH

Premium
33 OCDB Filter Replace. 1
33 OCDB Strainer Clean. 1
1 Engine Steam Clean. 1

1 Engine Mtg. Bolts Check torque. (Torque seal) 2 330 Nm (239 Ibf ft)
1 Drive Belts Replace all belts.
3 Hydraulic Tank Drain oil and refill. 1 HO / Textran 275 Litres (73 US Gal.)
HD10
2000 34 Articulation Pivot Nut Check torque. 1
(Annually) 3 Hydraulic Filter Replace. 1
2 Transmission Mtg. Bolts Check Torque. (Torque Seal). 2 921 Nm (680 Ibf ft).
1 Turbocharger Mtg. Nuts Check Torque. (Torque Seal). 2 921 Nm (680 Ibf ft).
24 Cooling System Check concentrate, add booster. - Ethylene 67 Litres (18 US Gal.)
Glycol
3000 2 Transmission Oil Filter Replace. 1

2 Transmission Lube Oil Filter Replace. 1
4000 35 Air Conditioning Compressor Drain flush and refill 1 PAG Oil 0.125 Litres.
1 Thermostats and Seals Replace.
6000 2 Transmission Drain oil and refill. 1 TranSynd / 61 Litres (16 US Gal.)
TES 295*
* - When determining whether a fluid is TES 295 approved or not look and/ or ask for one of two things - The
Allison TES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on the
following page. If uncertain if a fluid is approved, consult Allison Transmission for confirmation.
Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and
'Miscellaneous Servicing' contained on the following pages.
SM 2435 Rev4 05-07 3

Section 300-0020
Notes on 'Lubrication and Service Chart' MISCELLANEOUS SERVICING

Note - Capacities given are approximate - work to
dipstick, sight gauges or level plugs. WHEN REQUIRED
Seat Belts - Inspect for damage and replace if
Note 1 - Lubricate slowly until excess lube is seen. required.
Note: Replace seat belts at least once every three
Note 2 - Remove plugs and fit lube fittings. Lubricate years, regardless of appearance.
slowly until excess lube is seen. Remove
fittings and refit plugs. Windscreen Wipers and Washers - Inspect wiper
blades and replace if damaged. Top up washer
Note 3 - Check with the engine idling and the reservoir.
transmission at its normal operating
temperature. Wheel Rim Nuts - After first 10 hours of operation
re-torque nuts to 600 Nm (442 lbf ft). Note torque
Note 4 - When refilling centre axle ensure that 3rd should be applied in 3 stages. Nuts to be torqued
differential unit is primed with 1 litre (1.75 UK crosswise (i.e. opposing pairs). Check torque every
pints) of oil before filling drive head. 50 hours (weekly) thereafter.
Note 5 - Remove plug from port on underside of

oscillation hub. Plug is removed to drain the
cavity of any oil that enters the cavity when EVERY 10 HOURS OF OPERATION (DAILY)
filling. Remove grommet and level plug on Walk Around Inspection - Inspect the vehicle as
side of oscillation hub. Add oil if required. described in Section 4 of the Operator's Handbook.
Refit all plugs.
Engine - Visually check engine for damage, loose or
Note 6 - Clean radiator, condenser and cooler fins frayed belts and listen for any unusual noises.
more often when operating under extremely
dusty conditions. Engine Air Cleaner - Change air cleaner element
only when the yellow band of the air restriction gauge
EO - Engine Oil. Refer to 'Recommended locks up in the orange. Service vacuator valve daily.
Lubricants'. Inspect and remove any obstructionsfrom the
vacuator valve lips which should be open and pliable
*- Refer to chart under 'Recommended with the engine stopped.
Lubricants'. Note: Service air cleaners more often when operating
under extremely dusty conditions.
HO - Hydraulic Oil. Refer to 'Recommended
Lubricants'.
Engine Crankcase - Check oil level and add if low.
EPL - Extreme Pressure Lubricant specification A cold level check should always be done prior to
MIL-L-2105 D. starting the vehicle. To ensure that sufficient oil is in
the system to allow the unit ot be run to operating
EP, NLGI - Extreme Pressure, Lithium No. 2 temp to perform a hot level check.
Grease (which may, or may not,
contain Molybdenum). Transmission - Check oil level and add oil if low.
Refer to Section 120-0010, TRANSMISSION AND
*EP, NLGI - Extreme Pressure, Lithium No. 2 MOUNTING, for correct oil level check procedure.
Grease (without Molybdenum).
LZ - Lubrizol 6178 Hydraulic Tank - Check oil level and add oil if low.
PAG Oil - Polyalklene Glycol (PAG) Compressor Brake Coolant Tank - Check oil level and add if low.
Lubricating Oil - Low Viscosity (ISO46).
Radiator - Check coolant level and add if low. Fill the
radiator header tank with coolant until coolant
reaches the bottom of the filler neck and holds at
that level.
4 SM 2435 Rev4 05-07

Section 300-0020
added, the coolant inhibitor MUST be checked. If the EVERY 500 HOURS OF OPERATION
concentration is low, engine damage will result. Dropbox Oil Filter - Remove and replace.
Conversely, over-inhibiting antifreeze solutions can Dropbox - Drain oil and refill.
result in silicate dropout. Refer to Section
210-0000, COOLING SYSTEM. EVERY 1 000 HOURS OF OPERATION (6 MONTHS)
Service Brakes - Check indicator wear pins for
signs of wear and replace friction plates where
AFTER FIRST 100 HOURS OF OPERATING NEW OR necessary. Test for proper function .
REBUILT COMPONENTS
Note: This service interval applies to normal driving.
Differentials - Drain lubricant and refill to level plug. Check the pins more frequently under more severe
Note: When refilling centre axle ensure that 3rd conditions. In the fully worn plate condition the
differential unit is primed with 1 litre (1.75 UK pints) indicator pin is flush with the bottom of the
of oil before filling drive head. counterbore.
Planetaries - Drain lubricant and refill to level plug. Hydraulic Oil Filter - Clean filter housing and install
new element when indicated, or after 1 000 hours of
Hydraulic Oil Filter - Clean filter housing and install operation, whichever comes first.
new element at 100 hours of operation, or when
indicated, whichever comes first. Brake Coolant Tank - Replace breather.
Note: A 6 micron filter is used to flush the system.
This is replaced with a 12 micron filter for normal Axles - Drain lubricant and refill to level plug.
use. See vehicle Parts Book for filter part numbers. Note: When refilling centre axle ensure that 3rd
differential unit is primed with 1 litre (1.75 UK pints)
Brake Cooling Oil Filter - Clean filter within brake of oil before filling drive head.
coolant tank after 100 hours of operation.
Parking Brake - Check pads and disc for wear.
Adjust or replace if required. Test for proper function.
EVERY 250 HOURS OF OPERATION Thickness of pad friction material should never be
General Inspection - Check entire vehicle for leaks, allowed to wear below 3 mm (0.12 in).
loose bolts and nuts or damaged parts. Examine the
vehicle, particularly the chassis, for cracks or broken Articulation Vertical Bearings - Remove plugs and
welds. Repair where necessary. fit lube fittings. Lubricate slowly until excess lube is
seen. Remove lube fittings and refit plugs.
Service Brakes - Check indicator wear pins for
signs of wear and replace friction plates where Driveshaft Bearings - Remove plug from port on
necessary. Test for proper function. underside of oscillation hub. Plug is removed to drain
the cavity of any oil that enters the cavity when filling.
Note: This service interval applies to normal driving. Remove grommet and level plug on side of oscillation
Check the pins more frequently under more severe hub. Add oil if required. Refit all plugs.
conditions. In the fully worn plate condition the indicator Grease Points - Grease door hinges.
pin is flush with the bottom of the counterbore.
EVERY 1 500 HOURS
Parking Brake - Check pads and discs for wear and Brake Coolant tank - Replace breather.
replace where necessary. Test for proper function.
Note: This service interval applies to normal driving.
Check the pads more frequently under more severe
EVERY 2 000 HOURS
conditions. Thickness of pad friction material should
never be allowed to wear below 3 mm (0.12 in). Drivelines - Visually check Low Maintenance
drivelines for leaking or damaged seals.
Oil Can Points - Oil working parts with engine oil. Note: Low Maintenance drivelines can be identified
by having plugs fitted to the spiders, not grease
nipples.
Note: When service is required, remove plug and fit
grease nipple. Grease spider and refit plug when
SM 2435 Rev4 05-07 5

Section 300-0020
finished. Use Type K lubricating grease in ENGINES AND TRANSMISSIONS
accordance to DIN 51825-KP2-K-40.
All information contained in the 'Lubrication and Service
g centre axle ensure that 3rd differential unit is
Chart' was extracted from the relevant manufacturers
primed with 1 litre (1.75 UK pints) of oil before filling
Operators Manual and was correct at time of publication.
drive head.
User should ensure that information contained in this
chart, regarding Engines and Transmissions, reflects the
Hydraulic Oil Tank - Drain oil, remove and clean
information shown in the relevant manufacturers
suction screens and strainers. Reinstall suction
Operators Manuals supplied with the vehicle.
screens and strainers and refill hydraulic oil tank.
Maintenance procedures should be carried out in
EVERY 3 000 HOURS conjunction with any additional procedures contained in
the relevant manufacturers 'Operation and Maintenance
Transmission - Replace oil filter and lube oil filter.
Manual', at the intervals specified.
EVERY 6 000 HOURS
Transmission - Drain oil and refill to level.
6 SM 2435 Rev4 05-07

Section 300-0020
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE
Engine Engine Oil with 1.00% 32 litre CH-4 15W-40
(Including Filters) sulphated ash limit is (9.8 US gal)
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission 61 litre See Trans.
(Including Filters) TranSynd / TES 295 (16.1 US gal) TranSynd / TES 295 - TES 295
(dry fill) Oil Table.
Hydraulic System Hydraulic Transmission Oil 330 litre Textran HD10. See Hydraulic Oil Table
(Including Lines) (87 US gal) (See Note 2)
Cooling System Anti-freeze, Ethylene 67 litre

Glycol (18 US gal)
Differential Extreme Pressure 33 litre each MIL-L-2105 D GL-5 80W-90 LS
(Front) Gear Lubricant (8.7 US gal) (See Note 3)
Differential Extreme Pressure 34 litre MIL-L-2105 D GL-5 80W-90 LS
(Centre) Gear Lubricant (8.9 US gal) (See Note 3)
Differential Extreme Pressure 33 litre MIL-L-2105 D GL-5 80W-90 LS
(Rear) Gear Lubricant (8.7 US gal) (See Note 3)
Planetaries - Extreme Pressure 9 litre each MIL-L-2105 D GL-5 80W-90 LS
Gear Lubricant (2.4 US gal) (See Note 3)
Dropbox EO 13 litre ACEA E5/E3 or CH-4 -
(3.4 US gal) Allison C4-27403598 ATF oil
Fuel Tank Diesel Fuel Oil with 481 litre DIN EN590
max. sulphur 0.5% (127 US gal)
Grease Nipples** Extreme Pressure No.2
Lithium Grease Consistency
Driveshaft through Extreme Pressure 1.50 litre MIL-L-2105 D GL-5 80W-90
Bearings Gear Lubricant (0.40 US gal)
Articulation Extreme Pressure EMS 19057
Bearings Lithium Complex
Air Conditioning Polyalklene Glycol (PAG) 0.125 litre ISO46
Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10
Low Viscosity
Brake Cooling Hydraulic Transmission Oil 175 litre MIL-L-2104 E CF,CD,SF
System (42.6 US gal) MIL-L-46152 B/C
TEXTRAN TDH Prem
TES295 APPROVED OILS

Approval Number Approved Maker Product Brand Name
AN-011001 Castrol Heavy Duty Lubricants Transynd
AN-031002 BP Autran Syn 295
AN-031003 Cognis Corporation Emgard 2805
AN-031004 International Truck & Engine Co. Fleetrite Synthetic ATF
AN-031005 Exxon Mobile Lubricants Mobile Delvac Synthetic ATF
and Petroleum Specialities Co.
* - When determining whether a fluid is TES 295 approved or not look and/ or ask for one of two things - The
Allison TES 295 approval number or the Allison approved logo . TES 295 approved fluids are listed on the
following page. If uncertain if a fluid is approved, consult Allison Transmission for confirmation.
SM 2435 Rev4 05-07 7

Recommended Lubricant notes Note 2 - Hydraulic Transmission Oil meeting

Specification EMS19058 is also suitable for use in the
* - Capacities given are approximate, work to dipstick, hydraulic system.
sight gauges or level plugs.
Note 3 - Axles have limited slip differentials. If use of a
** - Refer to the 'Lubrication and Service Chart' for the standard SAE 90 oil results in very loud noise and
different applications. DO NOT use on the Articulation jerking of the wheels when driving slowly round sharp
bearings. corners, an EP oil with limited slip additives should be
used.
Note 1 - Operation below the minimum temperatures
listed for the oil used without proper pre-heat or Note 4 - Automatic Transmission Fluids (ATF) may
warm-up results in greatly reduced transmission life. only be used when the ambient temperature is less
Proper warm-up requires 20 minutes minimum than - 10° C (14° F). Should the temperature increase,
operation in neutral (with engine at part throttle) before it is necessary to switch to engine oil.
operating the transmission in gear.
LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) TEMPERATURE

SM - 637
HYDRAULIC OIL
API
SAE CODE MIL-SPEC
1 - - MIL-H-5606A
2 DEXRON Auto Trans. Fluid
3 10W CC/CD MIL-L-2104 B/C
4 20W/20 CC/CD MIL-L-2104 B/C
5 30 CC/CD MIL-L-2104 B/C
SM - 639
ENGINE OIL
ENGINE OIL
(See Note 4)
Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.
* * * *
MISCELLANEOUS - Service Tools
Section 300-0070
INTRODUCTION Hood
Contained in this section are recommended service For manual wind of the linear actuator a 6mm Ball End
tools and equipment required for maintenance, overhaul Allen key with extension is necessary to gain sufficient
and troubleshooting. In certain instances, both Metric access.
and Imperial equivalents of the same tools are listed.
Series 60 Engine
Note: The Company reserves the right to make General
changes in the design or construction of tools and
equipment without obligation to incorporate such See 'Fabricated tools' detail at end of this section for
changes in tools and equipment previously sold. details of engine support brackets.
Note: A tool may be of one piece construction or DDEC V Electronic Diagnostic

consist of a number of parts. 15501306 - DDDL Complete kit; includes software,
Cables & translator box.
Spares
General 15501455 - Translator Box
*15269784 - Multi-Gauge - Pressure range of 30 in of 15501458 - PC to Translatore Box Cable
vacuum to 5 000 lbf/in² 15501460 - Translator Box to Vehicle Cable
15269785 - Non-contact Infrared Thermometer 15501457 - Vehicle Cable
15268968 - Strap Type Filter Wrench 15501454 - ExtensionCable
15268969 - Socket Type Filter Wrench 15501379 - 6 to 9 Pin adaptor Cable - DDEC V
15268970 - Universal Belt Tension Gauge engines only!
15270180 - Belt Tension Gauge - Poly 'V' Belt 15502457 - DDEC V Card
15269858 - Digital Tachometer
15269859 - Multimeter 15275098 - Detroit Diesel Multi Kit, consisting of PRO-
15269813 - Water Manometer LINK Diagnostic Data Reader and cables,
15269802 - Dial Indicator Gauge - Metric Detroit Diesel 6 pin Adaptor Cable and
15269803 - Dial Indicator Gauge - Imperial Multi-Cartridge.
15269804 - Magnetic Base for Dial Indicator Gauge 15273793 - Detroit Diesel Diagnostic Link (Diskette)
15269805 - Micrometer - 0 to 25 mm 15273794 - Detroit Diesel Diagnostic Link (CD)
15269806 - Micrometer - 0 to 1 in 15269239 - High Impedance Digital Multimeter Kit
15269809 - Internal Micrometer - 50 to 210 mm 15270271 - Diagnostic Jumper Wire Kit
15269810 - Internal Micrometer - 2 to 8 in 15273795 - DDEC Repair Kit
15269860 - 92 Piece Heavy Equipment Tool Kit 15270310 - Detroit Diesel 6 pin Adaptor Cable
15269861 - Torque Wrench - 3/8 in drive, 15269038 - Portable Printer for use with DDR,
20 - 100 Nm (15 - 80 lbf ft) range complete with 110 V AC Adaptor
15269862 - Torque Wrench - 1/2 in drive, 15269039 - Portable Printer for use with DDR,
60 - 330 Nm (45 - 250 lbf ft) range complete with 220 V AC Adaptor
15269863 - Torque Wrench - 3/8 in drive, 15269040 - Printer Paper for use in above
4 - 20 Nm (40 - 180 lbf in) range printers - 5 rolls
15269864 - Torque Wrench - 3/4 in drive, 15273084 - Multi-Cartridge
300 - 1 000 Nm (200 - 750 lbf ft) range 15268971 - PRO-LINK Diagnostic Data Reader and
15269865 - Torque Wrench - 3/4 in drive, cables
700 - 1 500 Nm (500 - 1 000 lbf ft) range
15269866 - Torque Multiplier - 1/2 in to 1 in drive, For a list of service maintenance tools for overhaul of
25:1 Ratio, 3 000 Nm (2 200 lbf ft) range the engine, refer to relevant series 60 engine operation
and overhaul manual. Overhaul should only be carried
* - The following items should be added to the out by approved Detroit Diesel trained service
multi-gauge to enable the gauge to be used on personnel.
diagnostic test points:
15018226 - Diagnostic Coupling
00118748 - Connector (2 off)
15004085 - Hose Assembly (-4 HP, 84 in long)
SM 2437 03-06 1
Miscellaneous - Service Tools
Section 300-0070
Transmission 15269934 - Measuring Shaft.

15500895 - Torque Spanner.
The following tools are recommended for Transmission
15500896 - Driver.
Maintenance Procedures. These tools should be used
15500909 - Driver.
in conjunction with procedures outlined in the
15270121 - Handle.
transmission manufacturers service manual.
15500910 - Compressed Air Connection.
15500911 - Indicator.
4th Gen Electronic Diagnostic
15500897 - Magnetic Stand.
15500898 - Dial Indicator.
15502613 - Allison DOC V 5.0 PC service tool (New
15500899 - Micrometer.
user).
15500912 - Driver.
15502614 - Allison DOc V 5.0 PC service tool
15502331 - Adjusting Screw.
(Currrent user).
15501178 - Lifting equipment.
15502615 - Translator Device (Kit). Includes all
15271107 - Extractor Tool.
relevant cables to interface laptop with the
15500882 - Socket.
transmission and DPA box.
15500883 - Centering Bracket.
15502616 - 9-Pin to DB15 Cable.
15270131 - Pry Bar.
15502617 - USB cable for laptop to DPA box.
15501177 - Mounting Tool.
15269888 - Handle.
General
15502336 - Inner Installer.
15501178 - Chain.
15502618 - Valve Body spring compression tool.
15502404 - Bock Gauge.
15502405 - Lifting Tackle.
Transmission PTO
15501231 - Lifting Tackle.
Stud mounting kit 15502084 is required for installation 15501169 - Spring Balance
of the PTO to the transmission. 15269088 - Helical Gear Tool
15500012 - Large Face Seal Insertion Tool
15500013 - Small Face Seal Insertion Tool
Articulation and Oscillation Pivot 15500014 - Plate Centralising Tool
15500015 - Ring Gear Alignment Tool
15269101 - Thrust Nut Tool
15270104 - Driver
OCDB / Wheel Hub
Axles and Differentials
15502331 - Adjusting Screws.
15271101 - Backup Tool. 15501178 - Lifting Eye.
15500905 - Extractor. 15270145 - Pliers.
15269929 - Lifting Pliers. 15500882 - Socket.
15272560 - Bearing Puller. 15500883 - Centering Bracket.
15500887 - Gripping Insert. 15501170 - Lifting Tackle.
15500888 - Gripping Insert. 15270131 - Pry Bar.
15500889 - Reducer. 15502336 - Inner Installer (Seal locator).
15500890 - Socket. 15269899 - Hot Air Blower (220V).
15270120 - Clamping Yoke. 15269900 - Hot Air Blower (110V).
15500906 - Puller. 15269948 - Straight edge.
15500907 - Fixture. 15270114 - Digital Depth Gauge.
15500908 - Socket. 15502404 - Block Gauges.
15269946 - Puller Set. 15502405 - Lifting Tackle.
15500891 - Socket.
15500892 - Gripping Insert. Front Suspension
15272560 - Bearing Puller. 15269095 - Hydraulic Jack
15270113 - Gauge Blocks. 15269096 - Power Press
15269948 - Straight Edge. 15269097 - Press Tool
15270114 - Digital Depth Gauge.
15500893 - Shims.
15500894 - Shims.
2 SM 2437 03-06
Section 300-0070
Nitrogen Charging Fabricated Tools

09359489 - Charging Assembly The service tools shown on the following pages can be
fabricated as detailed in Fig's.
Cooling and Air Conditioning
15270181 - Coolant Test Strips
15500709 - Pro Cool Test Strips
15269816 - Refractometer - °C Scale
15269817 - Refractometer - °F Scale
15269844 - Portable High Vacuum Charging
Station - R-134a Gas
15269845 - Halogen Leak Tester
Cab
15271016 - Glass Removal Tool
15271017 - Bonding Kit (Quick Dry)
Adhesives and Sealants

15269103 - Loctite 221
09362529 - Loctite 225
09029849 - Loctite 243
15500690 - Loctite 262
09244598 - Loctite 270
09985300 - Loctite 271
15269104 - Loctite 275
15269245 - Loctite 277
15233715 - Loctite Prism 406
15269111 - Loctite Prism 410
15269105 - Loctite 515
09007209 - Loctite 574 (50 ml)
09379518 - Loctite 574 (160 ml)
15269106 - Loctite 577 (Superflex)
15270244 - Loctite 592 - Pipe Sealer with Teflon
15023696 - Loctite 635
09371048 - Loctite 638
15269107 - Loctite 641
15269108 - Loctite Superclean Safety Solvent 706
15229541 - Loctite Activator 'N'
09243825 - Loctite Activator 'T'
09175039 - General Adhesive
15269114 - Tectyl 280 Wax Based Rust Preventive
09380475 - Hylosil RTV Silicone Compound
15303808 - Silicon Grease (Dielectric)
SM 2437 03-06 3
Section 300-0070
140 SM - 3529
ENGINE SUPPORT BRACKET (LHS)
85 43 90
25
" "
50 10 100 Ø 20 4 POS'N
332 245
210 12
75
¾"unc
10 100 50
190
(mm)
Fig. 1 - Engine Support Bracket LHS (Section 110-0030, ENGINE AND MOUNTING)
140 SM - 3530
ENGINE SUPPORT BRACKET (RHS)
10
25
"
43 90
"
5
" "
100 Ø 20
4 POS'N VIEW ON 'A'
"
377 280
50 "
155 70
10 80
'A'
12
5
5 ¾"unc
60
12
225 (mm)
Fig. 2 - Engine Support Bracket RHS (Section 110-0030, ENGINE AND MOUNTING)
4 SM 2437 03-06
MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
Section 300-0080
and to establish a uniform value to which these

WARNING fasteners can be safely tightened, the following torque
Some fasteners are important attaching parts tables have been compiled.
which could affect the performance of vital
components and systems, and/or, could result The torque values listed in the tables have been
in major repair expense. Fasteners should be established over a period of years and cover all
replaced with parts of the same part number, conditions of assembly. The maximum torque values
or with equivalent parts, if replacement for standard bolts and nuts are based on 75% of the
becomes necessary. Do not use replacement specified minimum proof strength of the bolt steel in
parts of lesser quality or substitute design. The order to provide a safety factor to compensate for the
torque values shown in the following tables variation in the accuracy of torque wrenches, skill of
should be used in all cases, unless otherwise the assembler, and variance in fractional conditions.
specified elsewhere in this manual, in order to All torque values are for lubricated threads. The
avoid possible personal injury or property term 'lubricated' includes the application of thread
damage. lubricants, cadmium plating or the use of hardened
washers.
The following torque specification tables are based on
GM Standard Materials for bolts, nuts, studs and self- To provide a quick method for determining the GM
locking fasteners based on SAE bolt steel material classification of a particular standard bolt or
classifications, or, prevailing torque specifications for nut, compare the bolt head markings to those in the
self-locking fasteners. appropriate tables, then locate the maximum torque
value for that bolt size in the column under that
To prevent the threaded bolts and nuts used on this marking.
equipment from being overstressed during assembly,
RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ± 10% TABLE144
SAE Symbol SAE Symbol SAE Symbol SAE Symbol

GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel 12 Point Cap
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8) Screws
Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
0.25 - 20 5 4 8 6 11 8 12 9 14 10
0.25 - 28 7 5 10 7 12 9 14 10 15 11
0.31 - 18 11 8 18 13 22 16 24 18 27 20
0.31 - 24 12 9 19 14 24 18 27 20 30 22
0.38 - 16 20 15 31 23 38 28 43 32 49 36
0.38 - 24 23 17 34 25 43 32 49 36 56 41
0.44 - 14 33 24 47 35 59 43 68 50 75 55
0.44 - 20 37 27 54 40 68 50 79 58 87 64
0.50 - 13 50 37 75 55 94 69 106 78 119 88
0.50 - 20 56 41 88 65 106 78 122 90 134 99
0.56 - 12 75 55 108 80 136 100 156 115 171 126
0.56 - 18 81 60 122 90 149 110 176 130 191 141
0.62 - 11 102 75 149 110 190 140 217 160 237 175
0.62 - 18 115 85 169 125 210 155 244 180 270 199
0.75 - 10 176 130 271 200 332 245 380 280 420 310
0.75 - 16 203 150 298 220 366 270 420 310 472 348
0.88 - 9 169 125 434 320 536 395 610 450 679 501
0.88 - 14 190 140 488 360 590 435 678 500 751 554
1.00 - 8 258 190 651 480 800 590 915 675 1 021 753
1.00 - 12 285 210 719 530 881 650 1 003 740 1 119 825
1.00 - 14 285 210 732 540 902 665 1 030 760 1 148 847
SM 1238 2-98 1
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ± 10% TABLE145
SAE Symbol SAE Symbol SAE Symbol SAE Symbol

GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel 12 Point Cap
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8) Screws
Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
1.12 - 7 366 270 800 590 1 132 835 1 302 960 1 447 1 067
1.12 - 12 407 300 902 665 1 274 940 1 451 1 075 1 624 1 198
1.25 - 7 515 380 1 132 835 1 600 1 180 1 830 1 350 2 043 1 507
1.25 - 12 569 420 1 254 925 1 776 1 310 2 034 1 500 2 267 1 672
1.38 - 6 664 490 1 478 1 090 2 095 1 545 2 400 1 770 2 676 1 974
1.38 - 12 759 560 1 688 1 245 2 393 1 765 2 739 2 020 3 056 2 254
1.50 - 6 881 650 1 966 1 450 2 786 2 055 3 186 2 350 3 556 2 623
1.50 - 8 936 690 2 088 1 540 2 962 2 185 3 390 2 500 3 781 2 789
1.50 - 12 990 730 2 217 1 635 3 145 2 320 3 593 2 650 4 010 2 958
1.75 - 5 - - - - 4 393 3 240 5 016 3 700 5 604 4 133
1.75 - 12 - - - - 5 091 3 755 5 830 4 300 6 497 4 792
1.88 - 8 - - - - 6 006 4 430 6 874 5 070 7 664 5 653
1.88 - 12 - - - - 6 304 4 650 7 213 5 320 8 048 5 936
2.00 - 4.5 - - - - 6 623 4 885 7 565 5 580 8 448 6 231
2.00 - 8 - - - - 7 342 5 415 8 406 6 200 9 367 6 909
2.00 - 12 - - - - 7 687 5 670 8 786 6 480 9 811 7 236
2.25 - 4.5 - - - - 9 701 7 155 11 090 8 180 12 377 9 129
2.25 - 8 - - - - 10 629 7 840 12 148 8 960 13 566 10 006
2.25 - 12 - - - - 11 050 8 150 12 636 9 320 14 102 10 401
2.50 - 12 - - - - 15 280 11 270 17 463 12 880 19 500 14 383
Note: Where materials other than GM Standards are used, refer to the conversion table below.
Types of Steel Rockwell Hardness Range Applicable Torque Values SAE Bolt Head Symbols
Plain Low Carbon

(eg. SAE 1018 or 1020) Rockwell "B" 85-100 GM 260-M
Plain Medium Carbon
(eg. SAE 1035, 1038 & 1045) Rockwell "C" 19-30 GM 280-M
Medium Carbon Alloy
Medium Carbon Alloy
2 SM 1238 2-98
Section 300-0080
RECOMMENDED MAXIMUM TORQUES (METRIC) ± 10% TABLE146
Class 8.8 Class 9.8 Class 10.9 Class 12.9

Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
M 1.6 - 0.35 - - 0.20 0.15 - - 0.20 0.15
M 1.6 - 0.20 - - 0.25 0.20 - - 0.40 0.30
M 2.0 - 0.40 - - 0.25 0.20 - - 0.45 0.30
M 2.0 - 0.25 - - 0.45 0.30 - - 0.45 0.30
M 2.0 - 0.45 - - 0.25 0.20 - - 0.45 0.30
M 2.5 - 0.35 - - 1 0.75 - - 1 0.75
M 3.0 - 0.50 - - 1 0.75 - - 2 1.5
M 3.0 - 0.35 - - 1 0.75 - - 2 1.5
M 3.5 - 0.60 - - 2 1.5 - - 3 2
M 4.0 - 0.70 - - 3 2 - - 4 3
M 4.0 - 0.35 - - 3 2 - - 5 3
M 5.0 - 0.80 - - 5 4 - - 8 6
M 5.0 - 0.50 - - 6 4 - - 9 6
M 6.0 - 1.00 - - 9 6 - - 13 10
M 6.3 - 1.00 - - 10 8 13 10 16 11
M 6.0 - 0.75 - - 10 7 12 9 14 10
M 8.0 - 1.25 - - 21 15 27 20 32 23
M 8.0 - 1.00 - - 23 17 29 21 34 25
M 10.0 - 1.50 - - 42 31 54 39 63 46
M 10.0 - 1.25 - - 45 32 57 41 67 48
M 12.0 - 1.75 - - 74 53 94 68 110 80
M 12.0 - 1.25 - - 81 58 103 74 121 87
M 14.0 - 2.00 - - 118 85 151 109 176 127
M 14.0 - 1.50 - - 128 92 163 118 190 137
M 16.0 - 2.00 169 122 - - 234 169 274 197
M 16.0 - 1.50 181 130 - - 250 180 292 211
M 18.0 - 2.50 234 169 - - 323 234 378 273
M 18.0 - 1.50 263 190 - - 363 262 425 307
M 20.0 - 2.50 330 239 - - 457 330 531 386
M 20.0 - 1.50 367 265 - - 507 366 593 423
M 22.0 - 2.50 451 325 - - 623 450 728 526
M 22.0 - 1.50 495 357 - - 684 494 800 577
M 24.0 - 3.00 571 412 - - 790 570 923 667
M 24.0 - 2.00 623 450 - - 861 622 1 007 727
M 27.0 - 3.00 837 605 - - 1 158 836 1 354 977
M 27.0 - 2.00 903 652 - - 1 250 902 1 461 1 055
M 30.0 - 3.00 1 135 820 - - 1 570 1 134 1 835 1 325
M 30.0 - 2.00 1 258 908 - - 1 740 1 256 2 034 1 468
M 30.0 - 1.50 1 300 939 - - 1 799 1 299 2 102 1 516
M 36.0 - 4.00 1 985 1 433 - - 2 745 1 982 3 208 2 317
M 36.0 - 3.00 2 102 1 517 - - 2 907 2 099 3 398 2 453
SM 1238 2-98 3
Section 300-0080
SELF-LOCKING FASTENERS been used. Do not use a self-locking fastener more

Self-locking fasteners develop a measured gripping than five times.
action or torque and provide a renewed locking action
after being removed and reinstalled to their original The following table shows the minimum torque
mating part. The self-locking fasteners used on this specifications allowed to remove self-locking fasteners
equipment meet specifications necessary to allow the after the initial break-away torque has been achieved.
fasteners to be reused up to five times. Whenever a Any self locking fastener that can be removed with
self-locking fastener is removed, the head of the less than the prevailing torque value shown in the
fastener should be deeply scribed or otherwise table should be discarded, even if the fastener has not
marked to record the number of times the fastener has yet been reused five times.
MINIMUM PREVAILING TORQUE - REMOVAL TABLE537
Lockscrews Locknuts
SAE Grade 5 & 8
and ASTM A-574 SAE Grade 5 SAE Grade 8
Size Nm lbf in Nm lbf in Nm lbf in
0.25 - 20 0.3 3 0.4 3.5 0.5 4.5
0.25 - 28 0.3 3 0.4 3.5 0.5 4.5
0.31 - 18 0.6 5 0.6 5.5 0.9 7.5
0.31 - 24 0.6 5 0.6 5.5 0.9 7.5
0.38 - 16 1.0 9 1.0 8.5 1.3 11.5
0.38 - 24 1.0 9 1.0 8.5 1.3 11.5
0.44 - 14 1.4 12 1.4 12 1.8 16
0.44 - 20 1.4 12 1.4 12 1.8 16
0.50 - 13 1.8 16 1.7 15 2.3 20
0.50 - 20 1.8 16 1.7 15 2.3 20
0.56 - 12 2.5 22 2.4 21 3.2 28
0.56 - 18 2.5 22 2.4 21 3.2 28
0.62 - 11 3.4 30 3.1 27 4.1 36
0.62 - 18 3.4 30 3.1 27 4.1 36
0.75 - 10 5.1 45 4.6 41 6.1 54
0.75 - 16 5.1 45 4.6 41 6.1 54
0.88 - 9 7.3 65 7.0 62 9.3 82
0.88 - 14 7.3 65 7.0 62 9.3 82
1.00 - 8 9.6 85 9.5 84 12.7 112
1.00 - 12 9.6 85 9.5 84 12.7 112
1.00 - 14 - - 9.5 84 12.7 112
* * * *
4 SM 1238 2-98
MISCELLANEOUS - Unit Storage
Section 300-0090
GENERAL 8. ENGINE - Consult the relevant Engine Maintenance

The storage of machines for short periods of time or Manual for complete information on storing the engine
during the off-season is an important item if major for periods shorter than 30 days.
damage to components is to be avoided. Failure to
take the necessary steps to protect the various 9. TRANSMISSION - Fill transmission sumps to the
assemblies while the machine is being stored can proper level.
result in an expensive overhaul job and delay in
returning the machine to work.
EXTENDED STORAGE - Under Six Months
When storing a machine for periods of longer than 30
TEMPORARY STORAGE days, but under six months, the following procedure
When storing a machine for a period of 30 days or must be followed:
less, the following precautions must be taken:
1. INSPECTION AND REPAIR - Same as Step 1
1. INSPECTION AND REPAIR - Thoroughly inspect given under 'Temporary Storage'.
and test the machine and make any necessary repairs
or adjustments which may be necessary to prepare 2. LUBRICATION - Same as Step 2 given under
the machine for service. This will enable you to put the 'Temporary Storage'.
machine back into use immediately at the end of the
storage period. 3. PARKING - Same as Step 3 given under
'Temporary Storage'. Machines should be blocked up
2. LUBRICATION - Lubricate the machine completely so the tyres are off the ground or floor.
according to the instructions given in Section
300-0020, LUBRICATION SYSTEM of this manual. 4. BATTERIES - Remove batteries from the machine
and store them in a suitable place where they can be
3. PARKING - After thoroughly cleaning the entire inspected and charged at least every 30 days or
machine, park it on a hard, dry, level surface that is placed on a trickle charger.
free from grease and oil. The oil and grease would
cause tyre deterioration. Apply the parking brake. 5. RUST PREVENTION - Same as Step 5 given under
'Temporary Storage'.
4. BATTERIES - Where moderate temperatures are
expected, the batteries may be left in the machine. Up 6. SUPPLY TANKS - Same as Step 6 given under
to 30 days, the batteries may require a boost at the 'Temporary Storage'.
end of the storage period. Preferably place the
batteries in the shop where they can be inspected, 7. TYRES - With the machine on blocks, as called for
brought up to full charge and placed on a trickle in Step 3, deflate the tyres to 0.7 bar (10 lbf/in²)
charge to keep them at full charge. In very cold or hot pressure. Remove all traces of grease and oil and
climates, store the batteries where they will be protect the tyres from direct sunlight and water with a
protected from temperature extremes. suitable cover.
5. RUST PREVENTION - Remove all evidence of rust 8. TRANSMISSION - Consult the relevant
from the machine and repaint. In addition, cover all Transmission Maintenance Manual for storage data
exposed machine surfaces with a good rust involving periods longer than 30 days.
preventive.
9. ENGINE - Consult the relevant Engine Maintenance
6. SUPPLY TANKS - Fill fuel and hydraulic tanks to Manual for storage data involving periods longer than
prevent moisture condensation within the tanks. 30 days.
7. TYRES - Inflate all tyres to correct pressure. During 10. VENTS AND BREATHERS - Remove all vents
storage, check inflation pressure approximately once and breathers and plug openings with pipe plugs. If it
every two weeks. is not possible to do this, seal vents and breathers with
waterproof tape.
SM 1239 2-98 1
Miscellaneous - Unit Storage
Section 300-0090
EXTENDED STORAGE - Over Six Months 2. BATTERIES - Install batteries and check for a full
When a machine is to be stored for a period over SIX charge. Charge batteries as required.
MONTHS, the following procedure must be followed:
3. TYRES - Inflate tyres to the proper pressures. Refer
Note: These steps are in addition to those given to Section 140-0040, WHEEL RIM AND TYRE, of this
previously under 'Extended Storage - Under Six manual.
Months'.
4. FUEL AND HYDRAULIC TANKS - Drain off
1. LUBRICATION - Completely lubricate the machine condensation and fill tanks to proper level, remove
according to the instructions contained in Section breather covers and install air breathers. Be sure
300-0020, LUBRICATION SYSTEM of this manual. breathers are clean before installation.
2. WHEEL BEARING - Remove, clean, inspect and 5. VENTS AND BREATHERS - Remove seals and
repack all wheel bearings. plugs from all breather openings, then install all
breathers and vents.
Note: The above steps must be repeated for every Six
Month period the machine is in storage. 6. ENGINES - Consult the relevant Engine
Maintenance Manual for instructions on removing an
engine from storage.
REMOVAL FROM EXTENDED STORAGE
7. PAINT - Check machine for rust. Remove all rust
General spots and repaint rusted areas.
1. LUBRICATION - Completely lubricate the machine
according to the instructions in Section 300-0020, 8. TRANSMISSION - Consult the relevant
LUBRICATION SYSTEM of this manual. Transmission Maintenance Manual for instructions on
removing from storage.
* * * *
2 SM 1239 2-98

Manuel de Maintenance TEREX

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TEREX Equipment Limited Maintenance Manual

Motherwell, ML1 5RY

Tel; +44 (0) 1698 732121

Re-Order Part Number

revision July 2007

Alternatively, please contact;

Customer Support Department

Tel; +44 (0) 1698 732121

No part of this publication may be reproduced, transmitted in any form - electronic,

Please refer to TEREX Specification Sheets or consult Factory Representatives to

Safety Alert Symbol

DANGER indicates an imminently hazardous situation which, if not avoided, will

WARNING indicates an potentially hazardous situation which, if not avoided, could

CAUTION indicates an potentially hazardous situation which, if not avoided, may

Section No. Description SM No.

190 ELECTRICAL SYSTEM

Section No. Description SM No.

220 STEERING SYSTEM

230 BODY SYSTEM

250 BRAKING SYSTEM

260 OPERATORS COMPARTMENT

Fig. 1 - Machine Dimensions

ENGINE Main ................................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

SUSPENSION Braking surface (tractor) ....... 590240 mm2 (914.9 in2)/brake

TYPICAL NOISE LEVELS

*Exterior Sound Rating (ISO 6395) ......................... 109 dbA

Note: Noise Level Exposure to the operator and bystander

Fig. 1 - Machine Dimensions

ENGINE Main ................................. 18.5 + 3.4 bar (269 + 50 lbf/in²)

SM 2436 Rev2 03-07 1

SUSPENSION Braking surface (tractor) ........ 590240 mm2 (914.9 in2)/brake

Inflation Pressures (GoodYear): ELECTRICAL SYSTEM

2 SM 2436 Rev2 03-07

TYPICAL NOISE LEVELS

*Exterior Sound Rating (ISO 6395) ......................... 109 dbA

Note: Noise Level Exposure to the operator and bystander

SM 2436 Rev2 03-07 3

Note: The current from the welding rod always follows

Electric arc welding is recommended for all welded

Fig. 1 - General Arrangement of Frame Assemblies

Straightening d- Battery supply cables

WARNINGS Successfully welded repairs will depend to a great

1 - Pivot Assembly 16 - Lockplate 27 - Lube Fitting 41 - Washer 55 - Lube Fitting

Fig. 1 - Articulation and Oscillation Pivot

9. Disconnect mounting hardware securing protective

WARNINGS 12. Identify the relationship of the driveline caps to

23. If bearing replacement is required, use a suitable

1. Clean all parts with a suitable solvent and let dry.

SHIM AREA 'E' ('D' - 'C')

Fig. 3 - Measurements / various

40. Apply Loctite 638 to the threads of capscrews used WARNINGS

10. Remove upper pin (40). If necessary tap upper pin

Note: It may be necessary to relieve binding between

11. Remove bolt (48) and hardened washer (44)

4. Remove and tag all bearing assemblies (30) with

5. Align steering cylinder bores and mounting pin bores

6. Remove plugs (28) from articulation bearing, grease

Note: Lube fittings (27) are stored on pad on side of

7. Fill bearing housings with Extreme Pressure Lithium

5. Place a suitable container under rear brake yoke (18)

SM - 011 3. Install plug (25) in filler/level hole on pivot assembly

4. Install plug (25) in cavity drain port on underside of

5. Install plugs (28) into oscillation bearing grease

6. Lightly coat 'V' ring (10) and machined surfaces of