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CUSTOMER SUPPORT DEPARTMENT


TEREX EQUIPMENT LIMITED
Part No. 15500771 MOTHERWELL, SCOTLAND ML1 5RY
REF. NO. SM828
SM 2205 Rev 4 08-05
Service
The information contained within this
Alert must not be made available to
third parties not authorised to receive it.
Information
Alert
DATE: April 1994 B168

MODEL: General

SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS

PURPOSE:

To advise potentially hazardous condition.

DETAIL:

It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces a
highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315 C.

The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.

We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.

a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.

b. If this is affirmed - Do Not Touch

c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.

d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.

e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by washing
thoroughly with Limewater (Calcium Hydroxide solution).

f. Any cloths, residue and gloves used MUST be safely discarded after use.

Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.

TEREX SERVICE DEPARTMENT


TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046
TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752
THIS PAGE IS INTENTIONALLY LEFT BLANK
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.

Two types of heading are used in this manual to attract your attention.

1. WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly
followed could result in personal injury or loss of life. Look for this symbol to point out important safety
precautions. It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.

WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardize
the integrity of the machine and could result in property damage or serious personal injury.

SM 222 Rev 1 9-93


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TABLE OF CONTENTS

Section No. Description SM No.


000 GENERAL INFORMATION
0000 Technical Data - TA30 2169 Rev 5
0010 Welding Procedure 2172
100 CHASSIS
0010 Frames 2170
0020 Articulation and Oscillation Pivot 2171
0040 Hood and Mounting 2173
110 ENGINE
0030 Engine and Mounting 2174 Rev 1
0040 Cooling Fan 2175
0050 Air Cleaner 2176
120 TRANSMISSION
0010 Transmission and Mounting 2177
130 DRIVELINES
0010 Front and Rear Drivelines 2178
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 1971 Rev 1
160 REAR AXLE GROUP
0020 Differential Drive Head 1969
0030 Axle Group (Hub) 2194 Rev 1
0050 Wheel Rim and Tyre 2179 Rev 2
165 BRAKE PARTS
0010 Brake Parts - Rear 2180
0020 Brake Parts - Front (Refer to Section 165-0010) -
170 PARKING BRAKE
0010 Parking Brake and Mounting 2181
180 SUSPENSION SYSTEM
0020 Front Suspension 2182
0040 Rear Suspension From A8281011 to A8281563 2183
0040 Rear Suspension From A8281564 2183 Rev 1
190 ELECTRICAL SYSTEM
0000 Circuit Diagrams 2184 Rev 2
0085 Hydraulic System ECU 2200
0270 Switches and Sensors 2185 Rev 1
200 FUEL SYSTEM
0040 Fuel System 2186
0051 Electronic Foot Pedal 2187 Rev 1

SM 2168 Rev8 08-05 1


TABLE OF CONTENTS

Section No. Description SM No.


210 COOLING SYSTEM
0000 Cooling System 2188 Rev 1
0040 Radiator and Mounting 2189
0060 Transmission Oil Cooler 2190 Rev 1
0100 Hydraulic Oil Cooler 2191
215 MAIN HYDRAULIC VALVE
0050 Main Hydraulic Valve Assembly 2192 Rev 2
220 STEERING SYSTEM
0000 Steering System Schematic 2197
0090 Steering Valve 2193
0120 Steering Cylinder 2349
230 BODY SYSTEM
0000 Body System Schematic 2199 Rev 1
0040 Hydraulic Tank 2350
0050 Main Hydraulic Pump 2196
0081 Body Control Lever 2202
0130 Body Cylinder 2207
250 BRAKING SYSTEM
0000 Braking System Schematic 2198
0060 Accumulators 2203
0070 Treadle Valve 2208
260 OPERATORS COMPARTMENT
0010 Cab and Mounting 2209
0090 Driver Seat and Mounting 2210
0130 Air Conditioning 2211 Rev 1
270 BODY
0010 Body and Mounting 2212
300 MISCELLANEOUS
0020 Lubrication System 2204 Rev 3
0070 Service Tools 2206 Rev 2
0080 Axle Bolt and Nut Torque Specifications 1521
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239

* * * *

2 SM 2168 Rev8 08-05


GENERAL INFORMATION - Technical Data
Section 000-0000
SM - 2870

2 685
Max. (8-10)
Body 1 445
Depth (4-9) 2 895
(9-6)

45

6 110
65 (20-0)
SAE Turning Radius 8 470mm (27-9)
Clearing Radius 8 950mm (29-4)

5 010
(16-5)
4 920
(16-2)
3 450
(11-3)
3 420
(11-2)
3 325 2 895
(10-10) (9-6)

2 175
(7-0)
405 725
(1-6) (2-3)
1 580
(5-3)
2 200 2 400 1 310 2 945 1 690 1 410
(7-2) (7-9) (4-4) (9-8) (5-6) (4-9)
2 895 9 755
(9-6) (32-0)
Fig. 1 - Machine Dimensions

ENGINE
overspeed. Blocked filter indicator and filter bypass system
Make/Model .............................................. Cummins QSM11 provide valve block with additional protection from unfiltered
Type .............. Four cycle diesel, turbocharged with air-to-air oil.
charge cooling, water-cooled. Electronic management.
Pressures:
Gross power at 2 100 rev/min ....... 261 kW (350 hp, 355 PS) Main ........................................ 16 + 2 bar (232 + 30 lbf/in)
Net power at 2 100 rev/min ........... 248 kW (333 hp, 338 PS) Lockup (Wk) ........................... 12 2 bar (174 30 lbf/in)
Converter 'IN' .......... 10.5 bar (152 lbf/in) at 2 300 rev/min
Note: Gross power rated to SAE J1995 Jun 90. Engine
Converter 'OUT' .......... 4.8 bar (70 lbf/in) at 2 300 rev/min
emission meets USA EPA/CARB Tier II and EU NRMM
Converter Relief Valve ........................ 8.5 bar (123 lbf/in)
(non-road mobile machinery) Tier II directive.
Retarder ................................................. 5.5 bar (80 lbf/in)
Maximum Torque .... 1 776 Nm (1 310 lbf ft) at 1 400 rev/min Temperatures:
Number of cylinders/configuration ........................... 6, in line Normal ................................... 80 - 110 C (176 - 230 F)
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in) Maximum (Retarder Mode) ....................... 145 C (293 F)
Piston Displacement ............................... 10.8 litres (660 in) Stall Speed .............................................. 1 805 50 rev/min
Air cleaner ..................................... Dry type, double element Ratios:
Starting ....................................................................... Electric Torque Converter .................................................... 1.84:1
Maximum Speed (No load) .............................. 2 350 rev/min Transmission ..................................... Refer to table below
Maximum Speed (Full load) ............................. 2 100 rev/min
Idle Speed ........................................................... 750 rev/min
Safe Operating Angle ................................... 39/81% Grade Forward
Gear 1 2 3 4 5 6
TRANSMISSION
km/h 5.6 8.7 13.6 21.1 31.0 51.0
Make/Model ............................ ZF 6WG 310 RPC Automatic
with manual override. The transmission assembly consists
mile/h 3.5 5.4 8.5 13.1 19.3 31.7
of a torque converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. Automatic Reverse
shifting throughout the range, with kickdown feature. Lockup
action in all forward gears. A torque proportioning output
Gear 1 2 3
differential transmits drive permanently to front and rear km/h 5.6 13.6 31.0
axles. This differential may be locked by the driver for use in mile/h 3.5 8.5 19.3
difficult traction conditions. Standard integral hydraulic
retarder which automatically operates should the engine
SM 2169 Rev 5 08-05 1
General Information - Technical Data
Section 000-0000
AXLES HYDRAULIC SYSTEM
Three axles in permanent all-wheel drive with differential Braking, steering and body hoist systems are controlled by
coupling between each axle to prevent driveline wind-up. a main hydraulic valve mounted on frame. Systems are
Heavy duty axles with fully-floating axle shafts and outboard supplied with oil from a common tank by the main hydraulic
planetary reduction gearing. pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
Automatic limited slip differentials in each axle. Centre axle line.
incorporates a through-drive differential to transmit drive to
the rear axle. Locking of this differential is actuated Pump:
simultaneously with the transmission output differential lock. Type ......................................................................... Piston
Capacity at 2 100 rev/min ....... 4.9 litre/s (77.4 US gal/min)
Ratios:
Differential ............................................................... 3.44:1 Brakes
Planetary ................................................................. 6.35:1
Total Reduction ..................................................... 21.85:1 All hydraulic braking system with dry disc on each wheel
with two heavy-duty callipers per disc. Independent circuits
for front and rear brake systems. Warning lights and audible
SUSPENSION alarm indicate low brake system pressure. Brake system
Front: Axle is carried on the leading arms of a sub-frame conforms to ISO 3450, SAE J1473.
which pivots on the main frame. Suspension is by rubber
elements with four heavy duty hydraulic dampers. Actuating Pressure ............................. 103 bar (1 500 lbf/in)
Rear: Each axle is coupled to the frame by three rubber-
Discs:
bushed links with lateral restraint by a transverse link.
Diameter ................................................. 477 mm (18.8 in)
Pivoting inter-axle balance beams equalise load on each
Thickness ................................................. 16 mm (0.63 in)
axle. Suspension movement is cushioned by rubber/metal
laminated compression units between each axle and
Parking: Spring-applied, hydraulic-released disc on
underside of balance beam ends. Pivot points on rear
rear driveline.
suspension linkages are rubber-bushed and maintenance-
free.
Emergency: Automatic application of driveline brake
WHEELS AND TYRES should pressure fall in main brake hydraulic
system. Service brakes may also be applied
Wheels: ............ 5-piece earthmover rims with 12 stud fixing using the parking-emergency brake control.
Size:
Standard ....................... 25 x 19.50 in for 23.5 R25** tyres Retardation: Hydraulic retarder integral with transmission,
Optional .................... 25 x 22.00 in for 750/65 R25** tyres or optional engine brake.
Tyres:
Standard ........................................................... 23.5 R25** Steering
Optional ........................................................ 750/65 R25**
Hydrostatic power steering by two single-stage, double-
Inflation Pressures (Bridgestone): acting, cushioned steering cylinders. Emergency steering
Front Rear pressure is provided by a ground driven pump mounted on
23.5 R25** ...... 4.75 bar (69 lbf/in) 4.75 bar (69 lbf/in) the rear of the transmission. An audible alarm and warning
750/65 R25** .. 3.25 bar (47 lbf/in) 3.25 bar (47 lbf/in) light indicates should the emergency system activate.
Conforms to ISO 5010, SAE J53.
Inflation Pressures (Michelin):
Front Rear System Pressure ................................ 241 bar (3 500 lbf/in)
23.5 R25** ........... 4 bar (58 lbf/in) 4 bar (58 lbf/in) Steering Angle to either side ............................................ 45
750/65 R25** .... 3.0 bar (44 lbf/in) 3.0 bar (44 lbf/in) Lock to Lock Turns, steering wheel .................................... 4

Inflation Pressures (Pirelli): Body Hoist


Front Rear Two single-stage, double-acting hoist rams, cushioned at
23.5 R25** ........ 4.8 bar (70 lbf/in) 4.8 bar (70 lbf/in) both ends of stroke. Electro servo assisted hoist control.

Inflation Pressures (Continental): System Pressure ................................. 220 bar (3 200 lbf/in)
Front Rear Control Valve ....................... Pilot Operated, Closed Centre
23.5 R25** ........ 5.0 bar (73 lbf/in) 5.0 bar (73 lbf/in) Body Raise Time (loaded) .......................................... 12 sec
Body Lower Time (power down) ................................ 7.5 sec
Inflation Pressures (Marangoni):
Front Rear ELECTRICAL SYSTEM
750/65 R25** .... 3.0 bar (43 lbf/in) 3.0 bar (43 lbf/in) Type .............................................. 24 volt, Negative Ground
Battery ......................................... Two, 12 Volt, 143 Ah each
Note: Tyre pressures should be regarded as nominal only. It Accessories ................................................................ 24 Volt
is recommended that for tyres both listed and unlisted, the Alternator .................................................................. 70 Amp
user should consult the tyre manufacturer and evaluate all
job conditions in order to make the proper selection.

2 SM 2169 Rev 5 08-05


General Information - Technical Data
Section 000-0000
BODY
Of all welded construction, fabricated from high hardness
Vehicle Weights 23.5 R25 Tyres
(min. 360 BHN) 1 000 MPa (145 000 lbf/in) yield strength Standard Vehicle kg lb
steel. 25 tail chute angle provides good load retention Net Distribution
without tailgate.
Front Axle 11 720 25 840
Plate Thicknesses: Centre Axle 5 300 11 685
Floor and Tailchute ................................... 14 mm (0.55 in) Rear Axle 5 400 11 905
Sides ......................................................... 12 mm (0.47 in) Vehicle, Net 22 420 49 430
Front ........................................................... 8 mm (0.31 in) Payload 28 000 61 730
Volume: Gross Distribution
Struck (SAE) .......................................... 13.8 m (18.0 yd) Front Axle 16 800 37 040
Heaped 2:1 (SAE) ................................. 17.5 m (22.9 yd) Centre Axle 16 720 36 860
Rear Axle 16 900 37 360
SERVICE CAPACITIES Vehicle, Gross 50 420 111 260
Fuel tank ........................................... 390 litres (103 US gal) Bare Chassis 17 490 38 560
Hydraulic System ............................. 202 litres (53.4 US gal) Body 4 400 9 700
Engine Crankcase and filters ............. 41 litres (10.8 US gal)
Cooling System .................................. 54 litres (14.3 US gal) Body Hoists (Pair) 530 1 170
Transmission (including cooler) ......... 63 litres (16.6 US gal)
Differentials - Front & Rear (each) ....... 17 litres (4.5 US gal)
Differential - Centre ........................... 18.5 litres (4.9 US gal) Ground Pressures
Planetaries (each) .................................. 3 litres (0.8 US gal)
Hand Pump Tank ................................. 1 litres (0.26 US gal) At 15% sinkage of unloaded radius and specified weights
Air Conditioning Compressor ...... 0.125 litres (0.033 US gal) 23,5 R25 Net Loaded
Front 115 kPa (16.7 psi) 165 kPa (23.9 psi)
TYPICAL NOISE LEVELS Rear 52 kPa (7.5 psi) 165 kPa (23.9 psi)
Operator Ear (ISO 6394) ............................................ 78 dbA
750/65 R25 Net Loaded
*Exterior Sound Rating (ISO 6395) .......................... 110 dbA Front 90 kPa (13.1 psi) 128 kPa (18.6 psi)
* - The above result is for the mode giving the highest Rear 41 kPa (5.9 psi) 111 kPa (18.6 psi)
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 2169 Rev 5 08-05 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 10-02 1
General Information - Welding Procedure
Section 000-0010
3. Pre-heat area to 100 C (212 F), measured 3 - 4" 3 - 4" either side of repair prior to gouging. On
either side of repair. Avoid local overheating. completion of gouging grind to remove thin carbon
layer.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from 2. Apply dye-penetrant check to ensure crack has
moisture pick-ups at all times. been completely removed.

5. Allow repair weld to cool slowly. 3. Pre-heat area to 200 C (392 F), measured 3 - 4"
either side of repair. Avoid local overheating.
6. Grind and blend repair to original contour. Paint
heat damaged areas. 4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the 5. On completion of welding, post-heat repair area to
welds joining steel castings. 400 C (752 F), measure 3 - 4" either side of repair.

1. Completely ARC-AIR gouge or grind out the crack 6. If welding has to be interrupted for any reason, e.g.
until sound metal is reached. If ARC-AIR method is overnight, post-heat immediately as in Step 5.
employed, pre-heat area to 200 C (392 F), measure

* * * *

2 SM 2172 10-02
CHASSIS - Frames
Section 100-0010

SM - 2783

Fig. 1 - General Arrangement of Frame Assemblies

DESCRIPTION thrust faces of the bushes is compensated by


The chassis consists of two separate frame tightening this thrust nut.
assemblies which provide the articulation of the unit.
The front and rear frames are constructed of all
welded high-grade steel fabrications with rectangular INSPECTION AND MAINTENANCE
box section beams forming main, side and cross
members. Inspection
Inspect the frames and attached parts at intervals not
The front frame is fabricated to form a rigid structure exceeding 250 hours for cracked or broken welds and
which carries the cab, power train and suspension bending of the frame. Any defects found should be
system. repaired before they progress into major failures.

The rear frame is fabricated to form a rigid structure


which carries the body, body hydraulics, suspension Straightening
and rear drive axles. Hydraulic straightening or aligning equipment should
be used to straighten bent or twisted frames whenever
Steering is by frame articulation to 45 either side by possible. However, if heat must be applied, never heat
two widely spaced vertical pivot pins in taper roller the metal beyond a dull, cherry red colour, as too
bearings. Oscillation between the front and rear frames much heat will weaken the metal. When it is necessary
is provided by a large diameter cylindrical coupling to heat the metal, apply heat uniformly over the area to
carried on nylon bushes located in the rear frame. be straightened and protect the heated surface from
Longitudinal shocks are absorbed by the thrust faces sudden cooling. Frame parts that cannot be
of the nylon bushes. A large thrust nut, which is straightened should be renewed.
threaded to the end of the coupling and locked to the
frame, secures the coupling in position. Wear on the

SM 2170 9-02 1
Chassis - Frames
Section 100-0010

Welding
WARNING
Welding and flame cutting cadmium plated
metals produce odourless fumes which are
WARNINGS
toxic. Recommended industrial hygiene
Before any welding is done on a machine
practice for protection of the welding operator
equipped with the Quantum Electronic Fuel
from the cadmium fumes and metallic oxides
System, disconnect the following in this order:
requires enclosure ventilation specifically
Battery earth cable, battery supply cable,
designed for the welding process. A respiratory
alternator earth cables, alternator supply
protective device such as the M.S.A. 'Gasfoe'
cables, body hydraulics joystick and electrical
respirator with G.M.A. cartridge will provide
connections at the engine ECM, transmission
protection against cadmium, fumes and
ECU and hydraulics ECU to avoid damage to
metallic oxides. The 'Gasfoe' respirator has
electrical components. Turn off battery master
been approved by the U.S. Bureau of Mines:
switch to isolate the batteries before
Approval number 23B-10, and is designed to
disconnecting any components.
protect against gases, vapours, and/or metal
After welding connect all of the above in the
fumes.
reverse order.
Note: The current from the welding rod always follows
the path of least resistance. If, for example, the ground
clamp is attached to the rear frame when welding is
Before any welding is done ensure all paint has
performed on the front frame, the current must pass a
been removed from the area to be welded.
frame connection to return to the welding machine.
Failure to do so may result in hazardous fumes
Since the pivot coupling offers the least resistance but
being given off from the paint.
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
cause welding blotches on their wearing surfaces and
Note: Always fasten the welding machines ground
increase the wear rate of these components.
cable to the piece/frame being welded if possible.

Electric arc welding is recommended for all welded Reinforcement


frame repairs. Since the nature and extent of damage
Frame reinforcement can be made with channel or
to the frame cannot be predetermined, no definite repair
angle or flat structural stock. Whenever possible, the
procedure can be established. As a general rule
reinforcement should extend well beyond the bent,
however, if parts are twisted, bent or pulled apart, or a
broken or cracked area. The reinforcement stock
frame is bent or out of alignment, no welding should be
thickness should not exceed that of the frame stock
done until the parts are straightened or realigned.
and the material should be of the same tensile
strength.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Customer Support Painting
Department can be consulted regarding the feasibility
A check of the condition of the paint should be made
of welding repairs.
approximately twice a year and chassis repainted if
necessary.

2 SM 2170 9-02
Section 100-0010
To keep rust and corrosion to a minimum, periodic
WARNING painting of abrasions and other exposed metal areas
Welding, burning, heating or dressing surfaces on the frames is highly recommended.
previously painted using polyurethane paint
produces fumes which are toxic. Surfaces must If painting of a frame is required, thoroughly clean the
be prepared using paint stripper prior to area areas to be painted. Apply a primer coat of
being reworked. Recommended Industrial polyurethane red oxide and then a finish coat of
Hygiene and Safety Rules should be followed polyurethane enamel.
for protection of the welding operator from the
fumes.

* * * *

SM 2170 9-02 3
CHASSIS - Articulation and Oscillation Pivot
Section 100-0020

SM - 2784

29 25 60
16 30
59 59
28 61
19 5,6
7
14 20 62
17 63
59
DETAIL A

42 47 25
46
43
44,45
58
36-38
34,35,23

33
26,59 26,62
60,61 63,61 10,26
59
11
2,3,4 2,3,4 57
40,41 32 39 27 1
54,55,56

30 18
DETAIL A 13
15 8,9
30
17 31
19 19
28 28
45,52,53 50 48
16 16
49 31
8,9 29
29 15
36-38
34,35,23 21,22

51 14 24
12
25
45,46,49 48 44,45,58 10,26
1 - Pivot 17 - Front Yoke 33 - Retainer 49 - Retainer
2 - Nylon Bush 18 - Brake Yoke 34 - Bearing Cup 50 - Pin Assembly
3 - Loctite 648 19 - Nut 35 - Bearing Cone 51 - Retainer
4 - Loctite Primer 20 - Washer 36 - Shim 52 - Bolt
5 - Gasket 21 - Hardened Washer 37 - Shim 53 - Washer
6 - Cover Plate 22 - Bolt 38 - Shim 54 - Adaptor
7 - Bolt 23 - EMS19057 Grease 39 - Pin Assembly 55 - Connector
8 - Bearing Cone 24 - EMS19003 EP Oil 40 - Bolt 56 - Elbow
9 - Bearing Cup 25 - Plug 41 - Hardened Washer 57 - Pipe Assembly
10 - 'V' Ring Seal 26 - EMS19014 Grease 42 - 'O' Ring 58 - Loctite 243
11 - Thrust Nut 27 - Lube Fitting 43 - Retainer 59 - Elbow
12 - Lockplate 28 - Lockwasher 44 - Bolt 60 - Hose Assy
13 - Antiseize Compound 29 - 'O' Ring 45 - Lockwasher 61 - Lube Fitting
14 - Driveshaft 30 - 'O' Ring 46 - Spacer 62 - Hose Assy
15 - Seal 31 - Retaining Ring 47 - Lock Nut 63 - Connector
16 - Thrust Washer 32 - 'O' Ring 48 - 'O' Ring

Fig. 1 - Articulation and Oscillation Pivot

DESCRIPTION AND OPERATION connecting the drive between the front and rear
The articulation and oscillation pivot allows the front frames.
and rear frames to rotate horizontally (articulation) and
tilt laterally (oscillation) with respect to each other. It is Articulation bearings, oscillation bushes, pivot
also the main load bearing coupling between the two driveshaft bearings and associated parts can be
frames. The pivot assembly houses the driveshaft removed, inspected and replaced or renewed by

SM 2171 11-02 1
Chassis - Articulation and Oscillation Pivot
Section 100-0020
following the procedures outlined in this section. 8. Place a suitable container under the front of the
pivot and pull front yoke (17) from driveshaft (14).

THRU-DRIVE DRIVESHAFT 9. Disconnect mounting hardware securing protective


Numbers in parentheses refer to Fig. 1, unless guard (if fitted), from beneath the parking brake disc,
otherwise specified. to the rear frame.

Note: The following procedures assume that only thru- 10. Release the parking brake by turning the hex-head
drive components require repair. on the parking brake slack adjuster fully anticlockwise.

Note: Tighten all fasteners without special torques


specified to torques listed in Section 300-0080, WARNING
STANDARD BOLT AND NUT TORQUE Tensioned spring on adjuster.
SPECIFICATIONS.
11. Remove mounting hardware securing parking
brake assembly to mounting bracket on frame, then
WARNINGS secure parking brake assembly clear of brake disc.
To prevent personal injury and property
damage, be sure wheel blocks are properly 12. Identify the relationship of the driveline caps to
secured and of adequate capacity to do the job brake yoke (18). Remove capscrews, disconnect
safely. driveline and secure clear of brake yoke.

When necessary to drive out or drive on 13. Remove mounting hardware securing parking
components during disassembly/assembly, be brake disc to brake yoke (18) and remove brake disc.
sure to use a soft drift to prevent property
damage and personal injury. 14. Withdraw driveshaft assembly (14) from housing
by pulling rearwards on parking brake disc/brake yoke
assembly (18). If necessary, tap front end of driveshaft
Removal and Disassembly (14) to ease removal, take care to avoid damaging
1. Position the vehicle on a level work area and apply threads. Place driveshaft (14) assembly on work
parking brake. bench for further disassembly.

2. Raise body and install body safety prop to secure 15. Prise out and discard seal (15) from front of the
body in partially raised position. housing.

3. Shut down engine and block all wheels securely. 16. Lift out front bearing assembly cup (9) from front of
the housing.
4. Identify the relationship of the driveline caps to the
transmission yoke and front yoke (17). Remove 17. If bearing replacement is required, use a suitable
capscrews and remove driveline from vehicle. Refer to puller to remove front and rear bearing assembly cups
Section 130-0010, FRONT AND REAR DRIVELINES. (9) from the housing.

Note: Take extra care when handling drivelines as any Note: If either bearing assembly cup or cone (9 or 8)
deformity on a rotating mass creates vibration and need replacing, they must be replaced as a set.
excessive wear during any operation.
18. If retaining rings (31) need replacing, use a
5. Remove wheel blocks, start engine and steer suitable drift or puller to remove them from the housing.
vehicle into a full left-hand lock. Shut down engine and
block all wheels securely. 19. Remove front nut (19) then temporarily install front
yoke (17) fully onto front of driveshaft (14) and suitably
6. Remove front nut (19), lockwasher (28) and thrust restrain to resist rotation.
washer (16) from driveshaft (14). Reinstall nut (19)
temporarily onto driveshaft (14) to protect the threads. 20. Remove rear nut (19), lockwasher (28), thrust
washer (16), and brake yoke (18) from driveshaft (14).
7. Remove and discard 'O' rings (29 & 30) from thrust Identify front and rear ends of driveshaft (14).
washer (16).

2 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
21. Remove and discard 'O' rings (29 & 30) from thrust 5. Remove nut (19), thrust washer (16) and brake
washer (16). yoke (18) from driveshaft (14). The distance from the
end of the bearing cone (8) to the end of the spline
22. Remove and discard seal (15) from driveshaft (14). should be 60mm.

23. If bearing replacement is required, use a suitable 6. Install driveshaft (14) through the housing from the
puller or drift to remove rear bearing assembly cone rear.
(8) from driveshaft (14).
7. Using a suitable driver, install front bearing
24. Reinstall nuts (19) on driveshaft (14) to protect the assembly cone (8) on driveshaft (14).
threads.
8. Using a suitable driver, install seals (15) into ends
of housing, ensuring that they butt hard against
Inspection abutment shoulders.
1. Clean all parts with a suitable solvent and let dry.
DO NOT spin bearings with compressed air. Place 9. Install brake yoke (18) on rear of driveshaft (14)
bearings on a clean surface, cover with a lint free cloth until it butts against bearing assembly cone (8).
and allow to dry.
10. Install 'O' rings (29 & 30) to thrust washer (16) and
2. Check bearing assemblies cups and cones (9 & 8) install assembly on rear of driveshaft (14).
for wear or damage. Renew as necessary.
11. Install rear nut (19) temporarily on rear of
Note: If either bearing assembly cup or cone (9 or 8) driveshaft (14) and tighten.
need replacing, they must be replaced as a set.
12. Install front yoke (17) on driveshaft (14) until it
3. Inspect splines of driveshaft (14) and yokes butts against bearing assembly cone (8).
(17 & 18) for nicks, burrs or excessive wear. Replace
if wear is excessive or splines are nicked. Burrs may 13. Install 'O' rings (29 & 30) to thrust washer (16) and
be removed with a fine file or medium India stone. install assembly on front of driveshaft (14).

4. Check yokes (17 & 18) for damage in region 14. Install nut (19) and lockwasher (28) to front
polished by oil seal lip; even slight damage in this area threads of driveshaft (14). Prevent driveshaft (14) from
can cause leakage. Very slight marks may be polished turning by restraining brake yoke (18).
out with fine emery cloth but it is essential that
polishing marks are parallel to the seal lip. 15. Tighten nut (19) and bend at least one lockwasher
(28) tab into nut (19). If required back off nut (19) until
5. Replace all seals and 'O' rings with new parts. the first available tab lines up with a slot in the nut
(19).
Assembly and Installation 16. Tighten nut (19) at rear of driveshaft (14) to a
1. If removed, use a suitable driver and install retaining torque of 250 Nm (180 lbf ft) to seat bearing cup and
rings (31) into housing, ensuring that they butt hard cone assemblies (9 & 8).
against abutment shoulders.
17. Chap driveshaft (14) at both ends with a hide-
2. Using a suitable driver, install front and rear bearing faced hammer. Re-torque nut (19) to 250 Nm (180 lbf
assembly cups (9) into housing, ensuring that they butt ft).
hard against abutment shoulders.
18. Back off nut (19) four flats, and chap rear end of
3. Lightly oil both bearing assembly cones (8) with driveshaft (14) with a hide-faced hammer to remove
EMS19003 E. P. gear oil (24). pre-load from bearing cup and cone assemblies (9 &
8).
4. Using a suitable driver, install rear bearing assembly
cone (8) on rear end of driveshaft (14). Temporarily install 19. Remove nut (19) from rear of driveshaft (14),
brake yoke (18), thrust washer (16) and nut (19) to install lockwasher (28) and reinstall nut (19).
driveshaft (14). Tighten nut (19) until the yoke (18)
bottoms out on the driveshaft (14). 20. Set up dial indicator with pointer positioned on rear

SM 2171 11-02 3
Chassis - Articulation and Oscillation Pivot
Section 100-0020
end face of driveshaft (14). Push and pull on parking pivot assembly (1) of any oil that entered while filling
brake disc to move driveshaft (14) backwards and the driveshaft bearing housing.
forwards, remembering to rotate shaft at the same
time to obtain an accurate reading. Note dial indicator 31. Install plug (25) into filler/level hole on pivot
reading. assembly (1). Install gasket (5) and cover plate (6) on
side of oscillation hub, secure with bolts (7) and
21. Tighten nut (19) until end play on driveshaft (14) washers (20).
can just be felt. Take dial indicator reading of end play.
Tighten nut (19) until end play on driveshaft (14) is 32. Install plug (25) into cavity drain port on underside
0.05 - 0.15 mm (0.002 - 0.006 in). of oscillation hub.

Note: One flat on nut (19) turned is equivalent to 33. Install parking brake disc protective guard (if fitted)
0.025 mm (0.001 in) axial movement. and secure with bolts, washers and nuts.

22. When correct end play is obtained, remove dial 34. Start engine, raise body, lower body safety prop
indicator and secure nut (19) by bending the first and lower body.
available lockwasher (28) tab into nut (19). Recheck
end play. 35. Remove wheel blocks.

23. Install parking brake disc on brake yoke (18) and


secure with bolts and washers. Tighten bolts to a ARTICULATION COMPONENTS
torque of 49 Nm (36 lbf ft). Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
24. Install parking brake assembly to mounting
brackets and secure with bolts, washers and nuts. Note: The following procedures assume that only
Tighten bolts to a torque of 75 Nm (55 lbf ft). Refer to components associated with articulation require repair.
Section 170-0010, PARKING BRAKE AND
MOUNTING. Note: It is essential that the grease used for articulation
components is EMS19057 grease (23), as specified in
25. Apply the parking brake by turning the hex-head Section 300-0020, LUBRICATION SYSTEM.
on the parking brake slack adjuster fully clockwise.
Note: Tighten all fasteners without special torques
26. Apply Loctite 638 to the threads of capscrews specified to torques listed in Section 300-0080,
used to mount driveline to brake yoke (18). Align STANDARD BOLT AND NUT TORQUE
match marks and install driveline. Tighten capscrews SPECIFICATIONS.
to a torque of 153 Nm (113 lbf ft). Refer to Section
130-0010, FRONT AND REAR DRIVELINES.
WARNINGS
27. Apply Loctite 638 to the threads of capscrews To prevent personal injury and property
used to mount driveline between transmission yoke damage, be sure wheel blocks, blocking
and front yoke (17). Align match marks and install materials and lifting equipment are properly
driveline. Tighten capscrews to a torque of 153 Nm secured and of adequate capacity to do the job
(113 lbf ft). Refer to Section 130-0010, FRONT AND safely.
REAR DRIVELINES.
When necessary to drive out or drive on
28. Remove bolts (7), washers (20), gasket (5) and components during disassembly/assembly, be
cover plate (6) from side of oscillation hub to gain sure to use a soft drift to prevent property
access to filler/level hole plug (25) on pivot assembly damage and personal injury.
(1). Remove filler/level plug (25).

29. Add EMS19003 E. P. gear oil (24) through filler/ Disconnecting Front and Rear Frames
level hole in pivot assembly (1) until the oil is level with Note: The front and rear frames can be separated
the bottom of filler/level hole. sufficiently to permit disassembly/assembly of the
articulation components without disconnecting
30. Remove plug (25) from underside of oscillation hydraulic lines or electrical wiring.
hub to drain the cavity between the oscillation hub and

4 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
1. Position the vehicle on a level work area and apply hydraulic and electrical connections could result.
parking brake.
13. Remove blocks from rear wheels and use lifting
2. Raise body and install body safety prop to secure equipment to pull pivot/rear frame assembly clear of
body in partially raised position. the front frame. After moving, block pivot/rear frame
assembly and block the wheels.
3. Shut down engine and block all wheels securely.
14. Remove spacer (46) noting orientation to ensure
4. Identify the relationship of the driveline caps to the correct installation.
transmission yoke and front yoke (17). Remove
capscrews and remove driveline from vehicle. Refer to
Section 130-0010, FRONT AND REAR DRIVELINES. Disassembly
1. Identify retainers (33, 43, 49 & 51) to ensure correct
5. Support tractor frame at front and rear with suitably location on assembly/installation.
placed stands or timbers so the frame will remain level
during and after pin removal. Note: Retainers (33, 43, 49 & 51) are not
interchangeable.
6. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of 2. Remove bolts (44), lockwashers (45), retainers (33,
pivot. Refer to Section 220-0120, STEERING 43, 49 & 51) and upper and lower shims (36, 37 & 38).
CYLINDER.
3. Prise out and discard 'O' rings (32, 42 & 48) from
7. Release the parking brake by turning the hex-head the retainers.
on the parking brake slack adjuster fully anticlockwise.
4. Remove and tag all bearing assemblies (34 & 35)
with spacers to ensure correct assembly/installation.
WARNING
Tensioned spring on adjuster. Note: Bearing assemblies (34 & 35) and spacers are a
matched set, never interchange cups, cones or
8. Attach suitable lifting equipment to pivot/rear frame spacers between sets.
assembly. Lifting equipment must prevent pivot from
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
9. Remove nut (47) securing upper pin (39). Remove bearings on a clean surface, cover with a lint free cloth
bolt (40) and washer (41) securing upper pin (39) to and allow to dry.
tractor frame.
2. Check bearing assemblies (34 & 35) and spacers,
10. Remove upper pin (39). If necessary tap upper pin and pins (39 & 50) for wear or damage. Renew as
(39) to ease removal taking care to avoid damaging necessary.
the threads.
Note: Bearing assemblies (34 & 35) and spacers must
Note: It may be necessary to relieve binding between be renewed as a matched set.
the pin and pin bores by raising or lowering the pivot/
rear frame assembly. 3. Replace all seals with new parts.

11. Remove bolt (52), lockwasher (45) and washer


(53) securing lower pin (50). Assembly
1. Secure retainers (33 & 51) temporarily to pivot bores
12. Remove lower pin (50). If necessary tap lower pin with bolts (44).
(50) to ease removal taking care to avoid damaging
the pin. Note: Bearing assemblies (34 & 35) and spacers are a
matched set, never interchange cups, cones or
Note: Only separate the frames sufficiently to permit spacers between sets.
removal of the articulation bearings or damage to

SM 2171 11-02 5
Chassis - Articulation and Oscillation Pivot
Section 100-0020
2. Using EMS19057 grease (23), pack bearing 4. Remove blocks from rear wheels and blocking from
assemblies (34 & 35), including end faces, and install pivot/rear frame assembly. Using lifting equipment, pull
bearings using a suitable driver. pivot/rear frame assembly to align pivot bearing bores
and front frame pin bores. Block wheels and block
3. Remove bolts (44) and retainers (33 & 51) from pivot/rear frame assembly to remain level and
pivot bores. stationary.

4. Temporarily install retainers (43 & 49) to pivot 5. Freeze upper and lower pins (39 & 50) to ease
bores. Ensure pressure relief hole is opposite the installation.
grease nipple (27). Install retainers (33 & 51) to pivot
bores and secure with bolts (44) and washers (45). 6. Smear upper pin (39) and bearing bores with
Tighten bolts (44) to a torque of 27 Nm (20 lbf ft). EMS19057 grease (23) and install through front frame
and bearing bores. Fit nut (47), with anti-seize
5. Using feeler gauges, as shown in Fig. 2, measure compound, and tighten to pull assembly into position.
the dimension between the top pivot faces and Tighten nut (47) to a torque of 1425 Nm (1050 lbf ft).
retainers (43 & 49). Measure at 3 positions equally
spaced around retainers and determine average Note: It may be necessary to relieve binding between
dimension, this is the size of shims (36 - 38) required. the pin and pin bores by raising or lowering pivot/rear
frame assembly.
6. Remove bolts (44), washers (45) and retainers (43
& 49). 7. Secure upper pin (39) with bolt (40) and hardened
washer (41).
7. Install shims (36 - 38) as calculated at Step 5,
reinstall retainers (43 & 49) and secure with bolts (44), 8. Smear lower pin (50) and bearing bores with
coated with sealant (58), and washers (45). Tighten EMS19057 grease (23) and install through front frame
bolts (44) to 106 - 116 Nm (78 - 86 lbf ft). and bearing bores.

8. Install seals (32, 42 & 48) into retainers (33, 43, 49 9. Secure lower pin (50) with bolt (52), lockwasher (45)
& 51). and washer (53).

Connecting Front and Rear Frames Final Assembly


1. Install spacer (46) in upper outer seal housing (43), 1. Apply parking brake by turning the hex-head on the
as noted on removal. parking brake actuator fully clockwise.

2. Smear bearing and pin bores with EMS19057 2. Remove lifting equipment from pivot/rear frame
grease (23). assembly.

3. Attach suitable lifting equipment to pivot/rear frame 3. Remove stands or timbers from front frame.
assembly. Lifting equipment must prevent pivot from
oscillating and be capable of pulling pivot/rear frame 4. Apply Loctite 270 to the threads of capscrews used
assembly to align pivot bearing bores and front frame to mount driveline between transmission yoke and
pin bores. Raise lifting equipment to support pivot/rear front yoke (17). Align match marks and install
frame assembly. driveline. Tighten capscrews to a torque of 153 Nm
(113 lbf ft).
SM - 008
5. Align steering cylinder bores and mounting pin
bores on pivot, install pins and secure with bolts and
washers.

6. Fill bearing housings with EMS19057 grease (23),


through lube fittings (27), until excess grease starts to
escape from retainers (43 & 49).

7. Start engine, raise body, lower body safety prop and


Fig. 2 - Measuring Shim Thickness lower body.

6 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
8. Remove wheel blocks. capscrews and remove driveline from vehicle. Refer to
Section 130-0010, FRONT AND REAR DRIVELINES.

OSCILLATION COMPONENTS 6. Support tractor frame at front and rear with suitably
Numbers in parentheses refer to Fig. 1. placed stands or timbers so the frame will remain level
during and after pin removal.
Note: The following procedure assumes that only
components associated with oscillation require repair. 7. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of
Note: It is necessary to disconnect the front and rear pivot. Refer to Section 220-0120, STEERING
frames at the articulation point to service the CYLINDER.
oscillation components.
8. Release the parking brake by turning the hex-head
Note: It is essential that the grease used for oscillation on the parking brake slack adjuster fully anticlockwise.
components is EMS19014 grease (26), as specified in
Section 300-0020, LUBRICATION SYSTEM.
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 9. Attach suitable lifting equipment to pivot/rear frame
SPECIFICATIONS. assembly. Lifting equipment must prevent pivot from
oscillating after separation, and, be capable of pulling
pivot/rear frame assembly clear of front frame. Raise
WARNINGS lifting equipment to support pivot/rear frame assembly.
To prevent personal injury and property damage,
be sure wheel blocks, blocking materials and 10. Remove nut (47) securing upper pin (39). Remove
lifting equipment are properly secured and of bolt (40) and washer (41) securing upper pin (39) to
adequate capacity to do the job safely. tractor frame.

When necessary to drive out or drive on 11. Remove upper pin (39). If necessary tap upper pin
components during disassembly/assembly, be (39) to ease removal taking care to avoid damaging
sure to use a soft drift to prevent property the threads.
damage and personal injury.
Note: It may be necessary to relieve binding between
Hydraulic fluid pressure will remain the pin and pin bores by raising or lowering the pivot/
within the braking system after engine shut rear frame assembly.
down. Operate the treadle pedal continuously
until the pressure has dissipated before 12. Remove bolt (52), lockwasher (45) and washer
carrying out any work on the braking system (53) securing lower pin (50).
or serious injury could result.
13. Remove lower pin (50). If necessary tap lower pin
(50) to ease removal taking care to avoid damaging
Disconnecting Front and Rear Frames the pin.
1. Position the vehicle on a level work area and apply
parking brake. 14. 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. 15. Remove spacer (46) noting orientation to ensure
correct installation.
4. Depress and release brake pedal continuously to
relieve the pressure in the braking system.
Disassembly
5. Identify the relationship of the driveline caps to the 1. Remove protective guard (if fitted) from beneath
transmission yoke and front yoke (17). Remove parking brake disc by removing mounting hardware

SM 2171 11-02 7
Chassis - Articulation and Oscillation Pivot
Section 100-0020
securing guard to the rear frame. Refer to SM - 038
Section 170-0010, PARKING BRAKE AND
MOUNTING.

2. Remove mounting hardware securing parking brake


assembly to mounting bracket on frame. Remove and
secure parking brake assembly clear of brake disc.

3. Identify the relationship of the driveline caps to


brake yoke (18). Remove capscrews, disconnect
driveline and secure clear of brake yoke (18).

4. Remove mounting hardware securing parking brake


disc to brake yoke (18) and remove brake disc.
Fig. 3 - Preventing Pivot Assembly From Oscillating
5. Place a suitable container under rear brake yoke
(18) to catch oil released when pulling brake yoke (18)
16. Inspect nylon oscillation bushes (2) as described in
from driveshaft (14).
'Inspection'. If bushes are to be renewed, proceed with
step 17.
6. Remove rear nut (19), lockwasher (28) and thrust
washer (16) from driveshaft (14) and pull brake yoke
17. Remove nylon oscillation bush/es (2) with hammer
(18) from driveshaft (14). Reinstall nut (19) on
and chisel.
driveshaft (14) to protect the threads.
Note: The suggested method is to make an axial cut
7. Remove adaptor (54), connector (55), elbow (56)
along the bush then to lever the bush in order to
and pipe assembly (57) from oscillation hub.
collapse it upon itself.
8. Remove bolts (22) and washers (21) securing
locking plate (12). Remove locking plate (12). Inspection
1. Clean nylon oscillation bushes with a suitable
9. Restrain pivot assembly (1) to prevent it oscillating,
solvent and allow to dry.
by placing a heavy bar between the steering cylinder
mountings. Lock the bar in position using suitable
2. Inspect nylon oscillation bushes for wear, scoring,
trestles or stands. See Fig. 3.
erosion and 'out of round'. Pay particular attention to
the thrust faces of the bushes which should also be
10. Using a suitable tool, remove thrust nut (11). If
inspected for cracking/splitting. Renew if required.
wear area of thrust nut (11) is damaged, replace thrust
nut (11).
3. Replace all seals with new parts.
11. Insert an eyebolt into tapped pad provided on top
of pivot assembly (1) and attach suitable lifting Assembly
equipment. Numbers in parentheses refer to Fig. 1.
12. Remove pivot restraining bar. Note: Tighten all fasteners without special torques
specified to torques listed in Section 300-0080,
13. Using lifting equipment, carefully pull pivot STANDARD BOLT AND NUT TORQUE
assembly (1) clear of oscillation hub. Place pivot SPECIFICATIONS.
assembly (1) in a suitable work area for further
disassembly.
WARNING
14. Reinstall thrust nut (11) on pivot assembly (1) to To prevent personal injury and property
protect the threads. damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
15. Note position of front 'V' ring (10) to aid in safely.
'Installation'. Remove and discard 'V' ring (10).

8 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
1. Wipe bush housing clean using a suitable solvent 12. Install nut (19) at rear of driveshaft (14), and
and allow to dry. tighten to a torque of 250 Nm (180 lbf ft) to seat
bearing cup and cone assemblies (9 & 8).
2. Apply Loctite (3) and Loc Quick Primer (4) and align
new bushes (2) in rear frame with grease holes 13. Chap driveshaft (14) at both ends with a hide-
aligned vertically and identification 'PAINT DOT' at Top faced hammer. Re-torque nut (19) to 250 Nm (180 lbf
Dead Centre. Refer to Fig. 4. Drift bushes (2) into rear ft).
frame using hammer with soft packing for protection.
14. Back off nut (19) four flats, and chap rear end of
3. Install plug (25) in filler/level hole on pivot assembly driveshaft (14) with a hide-faced hammer to remove
(1). Install gasket (5) and cover plate (6) on side of pre-load from bearing cup and cone assemblies (9 &
oscillation hub and secure with bolts (7) and washers 8).
(20).
15. Remove nut (19) from rear of driveshaft (14),
4. Install plug (25) in cavity drain port on underside of install lockwasher (28) and reinstall nut (19).
oscillation hub.
16. Set up dial indicator with pointer positioned on rear
5. Lightly coat 'V' ring (10) and machined surfaces of end face of driveshaft (14). Push and pull on parking
pivot with EMS19014 grease (26) and, install 'V' ring brake disc to move driveshaft (14) backwards and
(10), with lip towards rear, on front of oscillation hub. forwards, remembering to rotate shaft at the same
time to obtain an accurate reading. Note dial indicator
6. Using suitable lifting equipment, and taking care to reading.
prevent damaging bushes (2) or pivot threads, install
pivot assembly (1) into rear frame. 17. Tighten nut (19) until end play on driveshaft (14)
can just be felt. Take dial indicator reading of end play.
7. Thread thrust nut (11) on pivot assembly (1) and Tighten nut (19) until end play on driveshaft (14) is
tighten as follows: 0.05 - 0.15 mm (0.002 - 0.006 in).

a) Restrain pivot assembly (1) to prevent it oscillating, Note: One flat on nut (19) turned is equivalent to
by placing a heavy bar between the steering cylinder 0.025 mm (0.001 in) axial movement.
mountings. Lock the bar in position using suitable
trestles or stands. See Fig. 3. 18. When correct end play is obtained, remove dial
indicator and secure nut (19) by bending the first
b) Secure a special tool, which can be manufactured available lockwasher (28) tab into nut (19). Recheck
as shown in Fig. 5, to pivot thrust nut (11) and tighten end play.
thrust nut (11) until there is no end float/ clearance at
thrust face of either bush. Slacken thrust nut (11) until
pin of the locking plate (12) can be inserted in the first Connecting Front and Rear Frames
available hole in the thrust nut (11). 1. Install spacer (46) in upper retainer (43), as noted
on removal.
c) Secure locking plate (12) with bolts (22) and
lockwashers (21). Torque tighten bolts (22) to 94 Nm 2. Smear bearing and pin bores with EMS19057
(69 lbf ft). grease (23).

8. Install adaptor (54), connector (55), elbow (56) and 3. Attach suitable lifting equipment to pivot/rear frame
pipe assembly (57) to oscillation hub. assembly. Lifting equipment must prevent pivot from
oscillating and be capable of pulling pivot/rear frame
9. Install brake yoke (18) on driveshaft (14) until it assembly to align pivot bearing bores and front frame
butts against bearing assembly cup and cone (9 & 8). pin bores. Raise lifting equipment to support pivot/rear
frame assembly.
10. Install parking brake disc on brake yoke (18) and
secure with bolts and washers. Tighten bolts to a 4. Remove blocks from rear wheels and blocking from
torque of 49 Nm (36 lbf ft). pivot/rear frame assembly. Using lifting equipment, pull
pivot/rear frame assembly to align pivot bearing bores
11. Install thrust washer (16) on rear of driveshaft (14). and front frame pin bores. Block wheels and block
pivot/rear frame assembly to remain level and

SM 2171 11-02 9
Chassis - Articulation and Oscillation Pivot
Section 100-0020
stationary. SM - 011

5. Freeze upper and lower pins (39 & 50) to ease PAINT DOT
installation.

6. Smear upper pin (39) and bearing bores with


EMS19057 grease (23) and install through front frame
and bearing bores. Fit nut (47), with anti-seize
compound, and tighten to pull assembly into position.
Tighten nut (47) to a torque of 1425 Nm (1050 lbf ft).

Note: It may be necessary to relieve binding between


the pin and pin bores by raising or lowering pivot/rear
frame assembly.
Fig. 4 - Installing Oscillation Bushes
7. Secure upper pin (39) with bolt (40) and hardened
washer (41). washers.

8. Smear lower pin (50) and bearing bores with 8. Connect hydraulic lines and electrical wiring as
EMS19057 grease (23) and install through front frame noted on disassembly.
and bearing bores.
9. Remove bolts (7), washers (20), gasket (5) and
9. Secure lower pin (50) with bolt (52), lockwasher (45) cover plate (6) from side of oscillation hub to gain
and washer (53). access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).

Final Assembly 10. Add EMS19003 E. P. gear oil (24) through filler/
1. Install parking brake assembly to mounting brackets level hole in pivot assembly (1) until the oil is level with
and secure with bolts, washers and nuts. Tighten bolts the bottom of filler/level hole.
to a torque of 75 Nm (55 lbf ft).
11. Remove plug (25) from underside of oscillation hub
2. Apply parking brake by turning the hex-head on the to drain the cavity between the oscillation hub and
parking brake actuator fully clockwise. pivot assembly (1) of any oil that entered while filling
the driveshaft bearing housing.
3. Remove lifting equipment from pivot/rear frame
assembly. 12. Install plug (25) in filler/level hole on pivot
assembly (1). Install gasket (5) and cover plate (6) on
4. Remove stands or timbers from front frame. side of oscillation hub, secure with bolts (7) and
washers (20).
5. Apply Loctite 270 to the threads of capscrews used
to mount driveline between transmission yoke and 13. Install plug (25) in cavity drain port on underside of
front yoke (17). Align match marks and install oscillation hub.
driveline. Tighten capscrews to a torque of 153 Nm
(113 lbf ft). 14. Fill bearing housings with EMS19057 grease (23)
through lube fittings (27) until excess grease starts to
6. Align match marks and reconnect driveline to brake escape from retainers (43 & 49).
yoke (18). Tighten capscrews to a torque of
153 Nm (113 lbf ft). 15. Add EMS19014 grease (26) to oscillation bushing
lube fittings (61) on top of oscillation hub. Lube until
Note: Take extra care when handling drivelines as excess grease in seen.
chips, dents, burrs or deformity on any rotating mass
creates vibration and excessive wear during any 16. Install parking brake disc protective guard (if fitted)
operation. and secure with bolts, washers and nuts.

7. Align steering cylinder bores and mounting pin 17. Start engine to charge hydraulic systems, raise
bores on pivot, install pins and secure with bolts and body, lower body safety prop and lower the body.

10 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
18. Bleed the braking system as described in Section 2. Raise body and install body safety prop to secure
165-0010, BRAKE PARTS. body in partially raised position.

19. Remove wheel blocks. 3. Shut down engine and block all wheels securely.

4. Remove protective guard (if fitted) from beneath


MAINTENANCE parking brake disc by removing nuts, washers and
Numbers in parentheses refer to Fig. 1. bolts securing guard to rear frame.

Every 250 hours, oscillation bushes must be 5. Remove bolts (7), washers (20), gasket (5) and
lubricated. Add EMS19014 grease (26) to oscillation cover plate (6) from side of oscillation hub to gain
bushing lube fittings (61) on top of oscillation hub. access to filler/level plug (25) on pivot assembly (1).
Lube until excess grease in seen. Remove filler/level plug (25).

6. Add EMS19003 E. P. gear oil (24) through filler/level


WARNING hole in pivot assembly (1) until the oil is level with the
To prevent personal injury and property bottom of filler/level hole.
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job 7. Remove plug (25) from underside of oscillation hub
safely. to drain the cavity between the oscillation hub and
pivot assembly (1) of any oil that entered while filling
Every 250 hours, check the end float/clearance at the the driveshaft bearing housing.
thrust face of the oscillation bushes. Any clearance
found must be removed by adjustment of the thrust 8. Install plug (25) into filler/level hole on pivot
nut, as described in step 7 of 'Assembly' procedure. assembly (1). Install gasket (5) and cover plate (6) on
side of oscillation hub, secure with bolts (7) and
Note: A practical method of establishing the effective washers (20).
adjustment of the thrust nut is to use movement of the
machines body in the raised position. Move the body 9. Install plug (25) into cavity drain port on underside
from fully raised to almost fully raised while watching of oscillation hub.
the effect of this action on the frame and pivot
arrangement. Any slackness between the thrust nut 10. Fill bearing housings with EMS19057 grease (23)
and thrust faces will be clearly visible by movement of through lube fittings (27) until excess grease starts to
the frame. escape from retainers (43 & 49).

Every 1 000 hours (6 months), follow the procedure 11. Add EMS19014 grease (26) to oscillation bushing
given below to check the oil level in the driveshaft lube fittings (61) on top of oscillation hub. Lube until
bearing housing, and, lubricate the articulation and excess grease in seen.
oscillation bearings.
12. Install parking brake disc protective guard (if fitted)
Note: It is essential that the grease used for and secure with bolts, washers and nuts.
articulation and oscillation components is EMS19057
grease (23), as specified in Section 300-0020, 13. Start engine, raise body, lower body safety prop
LUBRICATION SYSTEM. and lower body.

1. Position the vehicle on a level work area and apply 14. Remove wheel blocks.
parking brake.

SM 2171 11-02 11
Chassis - Articulation and Oscillation Pivot
Section 100-0020
SM - 844

Dimensions in mm (in)
Fig. 5 - Fabrication Details of Thrust Nut Removal and Installation Tool

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 44 Bolt 106 78
1 22 Bolt 94 69
1 47 Nut 1 425 1 050

12 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020

ARTICULATION AND OSCILLATION PIVOT DIAGNOSIS


CONDITION REASON REMEDY
Noise (Pivot Driveshaft) Insufficient lubricant Check seals.
Install proper grade of lubricant.
Out of balance driveshaft assembly Check alignment.
Vibration (Pivot Driveshaft) Backlash due to worn bearings, Renew worn parts.
housings, yokes and trunnions
Yoke not in line Renew driveshaft assembly or
assemble correctly.
Driveshaft out of balance Renew driveshaft assembly.
Noise (Articulation/Oscillation Excessive run out or distorted yokes Dismantle and correct, or renew,
Points) damaged part.
Loose nut on yoke Check splines, if worn, renew shaft.
Check lockwasher is not damaged.
Check for excessive end float.
Insufficient lubricant Lubricate. Investigate/revise lubrication
schedules. Refer to Section 300-0020,
LUBRICATION SYSTEM. Check seals
for lubricant loss/contamination. Renew
as necessary.
Worn bearings/bushes Inspect/renew as necessary.

* * * *

SM 2171 11-02 13
CHASSIS - Hood and Mounting
Section 100-0040

SM - 2785
38
35
35 36 37 19
34 9,10,11
30 29 31 20
31
32
21
31
22
33
18
32
29 28 23
9
24

1 9
10 25
26
16
11

12 IN BATTERY BOX

27 12 15

39
7 14
8 13
6 17
7
4
5
2 3

1 - Hood Assembly 14 - Hood Retaining Strap 27 - Grille


2 - Hinge Assembly 15 - Gas Strut 28 - Bracket
3 - Bolt 16 - Hood Catch Cable 29 - Nut
4 - Nut 17 - Nut 30 - Bolt
5 - Washer 18 - Goalpost Assembly 31 - Washer
6 - Adjustment Rod 19 - Bolt 32 - Plate
7 - Nut 20 - Hood Stop 33 - Cam Plate Assembly
8 - Hardened Washer 21 - Spring 34 - Cam Plate Assembly
9 - Hood Handle 22 - Locknut 35 - Washer
10 - Bolt 23 - Bolt 36 - Bush
11 - Washer 24 - Hardened Washer 37 - Spring
12 - Seal 25 - Washer 38 - Bolt
13 - Washer 26 - Locknut 39 - Bolt

Fig 1 - Hood and Mounting

HOOD 2. Block all road wheels and place the battery master
switch in the 'Off' position.
Removal
Numbers in parentheses refer to Fig. 1. 3. Remove bolts, washers, lockwashers and nuts
securing grille (27) to grille subframe. Secure grille
(27) clear of hood (1).
WARNING
To prevent personal injury and property 4. Pull cable assembly (16), handle inside battery box,
damage, be sure blocking materials and lifting to release hood catch and lift up hood (1). Secure
equipment are properly secured and of hood (1) in raised position using suitable lifting
adequate capacity to do the job safely. equipment.

1. Position the machine on a level surface, apply the 5. Carefully remove bolts, washers and nuts securing
parking brake and switch off the engine. hood retaining straps (14) and gas struts (15).

SM 2173 10-02 1
Chassis - Hood and Mounting
Section 100-0040
Remove fasteners, hood retaining straps (14) and gas GOALPOST SUPPORT ASSEMBLY
struts (15) from hood (1).
Removal
6. Remove bolts (39), washers (13) and nuts (17) Numbers in parentheses refer to Fig. 1.
securing hinge assemblies (2) to frame. Carefully lift
hood (1) assembly from the machine.
WARNING
7. If required, remove mounting hardware securing To prevent personal injury and property
grille subframe to hood (1). Secure grille subframe damage, be sure blocking materials and lifting
clear of hood (1). equipment are properly secured and of
adequate capacity to do the job safely.
8. If required, remove bolts (10) and washers (11)
securing handles (9) to hood (1). Secure handles (9) 1. Position the machine on a level surface, apply the
clear of hood (1). parking brake and switch off the engine.

Installation 2. Block all road wheels and place the battery master
switch in the off position.
Numbers in parentheses refer to Fig. 1.
3. Pull cable assembly (16), handle inside battery box,
Note: Tighten all fasteners to torques listed in to release hood catch and lift up hood (1). Secure
Section 300-0080, STANDARD BOLT AND NUT hood (1) in raised position.
TORQUE SPECIFICATIONS.
4. Remove mounting hardware securing washer bottle
to mounting bracket on the left hand side of goalpost
WARNING support assembly (18). Secure washer bottle clear of
To prevent personal injury and property goalpost support assembly (18).
damage, be sure blocking materials and lifting
equipment are properly secured and of 5. Remove plate and mounting hardware securing
adequate capacity to do the job safely. transmission oil cooler to goalpost support assembly
(18). If required, disconnect transmission oil cooler
1. If removed, secure handles (9) to hood (1) using hoses.
bolts (10) and washers (11).
6. Remove mounting hardware securing air cleaner
2. If removed, secure grille subframe to hood (1) using intake tube to goalpost support assembly (18).
mounting hardware as removed at 'Removal'.
7. With a suitable container available to catch leakage,
3. Using suitable lifting equipment, lift and position remove drain plug from radiator header tank and drain
hood (1) on the machine and align holes in hinge coolant. Apply Loctite 225 to drain plug and reinstall in
assemblies (2) with mounting holes on frame. Secure header tank.
hood (1) using bolts (39), washers (13) and nuts (17).
8. Ensure all cooling lines connected to header tank
4. Carefully install hood straps (14) and gas struts (15) are identified for ease of installation and with suitable
using mounting hardware as removed at 'Removal'. containers available to catch leakage, disconnect
cooling lines. Fit blanking caps to all open lines.
5. With lifting equipment still in place, lower hood (1) to
match with goalpost support assembly (18). Remove 9. Disconnect electrical harness from coolant level
lifting equipment. sensor in header tank. Note routing of all hoses and
harnesses attached to and through goalpost support
6. If required, adjust fitment of hood (1) to frame at assembly (18) and disconnect.
hinge assemblies (2) and adjustment rod (6).
10. Disconnect hood cable (16) ball joint from cam
7. Install grille (27) to hood (1) and secure using bolts, plate assembly (33) and secure cable (16) clear of
washers, lockwashers and nuts. hood catch mechanism.
8. Remove wheel blocks. 11. Check to make certain that all necessary line and

2 SM 2173 10-02
Chassis - Hood and Mounting
Section 100-0040
cable disconnections have been made, before lifting 6. Fit plate and mounting hardware securing
goalpost support assembly (18). transmission oil cooler to goalpost support assembly
(18) as removed during 'Removal'. If necessary,
12. Attach suitable lifting equipment to goalpost reconnect transmission oil cooler hoses. Ensure
support assembly (18). Remove bolts (23), washers transmission oil cooler contains sufficient oil. Refer to
(24 & 25) and locknuts (26) securing goalpost support Section 210-0060, TRANSMISSION OIL COOLER.
assembly (18) to its mounting. Lift goalpost support
assembly (18) from the machine. 7. Install washer bottle to mounting bracket on the left
hand side of goalpost support assembly (18) and
13. If required, remove locknuts (22), bolts (19), hood secure using mounting hardware as removed during
stops (20) and springs (21) from goalpost support 'Removal'.
assembly (18).
8. Secure air cleaner intake tube to goalpost support
14. If required, remove bolts (30), washers (31) and assembly (18) using mounting hardware as removed
nuts (29) securing hood catch mechanism (28 - 38) to during 'Removal'.
goalpost support assembly (18). Remove hood catch
mechanism (28 - 38). 9. Remove blanking caps from all cooling lines and
connect cooling lines to radiator header tank as tagged
at 'Removal'.
Installation
Numbers in parentheses refer to Fig. 1. 10. Connect electrical harness to coolant level sensor
in header tank. Secure all hoses and harnesses to and
Note: Tighten all fasteners to torques listed in through goalpost support assembly (18) following
Section 300-0080, STANDARD BOLT AND NUT routing as noted at 'Removal'.
TORQUE SPECIFICATIONS.
11. Fill radiator header tank with coolant as specified
in Section 210-0000, COOLING SYSTEM.
WARNING
To prevent personal injury and property 12. Lubricate hood catch mechanism. Use grease as
damage, be sure blocking materials and lifting specified in Section 300-0020, LUBRICATION
equipment are properly secured and of SYSTEM.
adequate capacity to do the job safely.
13. Lower hood assembly and check for correct
1. If removed, secure hood catch mechanism (28 - 38) alignment between hood (1) and goalpost support
to goalpost support assembly (18) with mounting assembly (18) and for operation of hood catch
hardware as removed at 'Removal'. mechanism.

2. If removed, secure hood stops (20) and springs (21) 14. Remove wheel blocks.
to goalpost support assembly (18) with bolts (19) and
locknuts (22).
MAINTENANCE
3. Using suitable lifting equipment, lift and position Periodically check bolts (39), washers (13) and
goalpost support assembly (18) on the machine. locknuts (17) and tighten when necessary.
Secure goalpost support assembly (18) to its mounting
with bolts (23), washers (24 & 25) and locknuts (26). Periodically check condition of hood catch mechanism
and adjust and lubricate when necessary.
4. Remove lifting equipment.

5. Connect hood cable (16) ball joint to cam plate SPECIAL TOOLS
assembly (33) and secure cable (16) using clips There are no special tools required for procedures
removed during 'Removal'. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
adhesives are available from your dealer.

* * * *

SM 2173 10-02 3
ENGINE - Engine and Mounting
Section 110-0030

SM - 3373

xx

31
1 39

20
30 29
23
18
19

27
28
21 19
6
2

16 10
9 12
13
16

15

xx
14 xx 14
25 22 xx
8 38
xx 12
17 7 xx xx
24 11 17

INSIDE BATTERY BOX 26


34
36,37
OUT IN
33

ENGINE LEFT HAND SIDE LINES- S.W.E.


FUEL LUBE WATER
OIL 5

MOUNTED TO AIR COND BRACKET -ENGINE LHS


3

35

32

1 - Engine 13 - Bolt 24 - Bolt 35 - Hose Assembly


2 - Alternator Belt 14 - Isolation Mount 25 - Nut 36 - Bolt
3 - Oil Filter 15 - Snubbing Washer 26 - Bracket Assembly 37 - Lockwasher
4 - Fuel Filter 16 - Bolt 27 - Fan Clutch 38 - Snubbing Washer
5 - Coolant Filter 17 - Locknut 28 - Fan 39 - Foam Spacer
6 - Fan Belt 18 - Bolt 29 - Bolt 40 - Cap
7 - Rear Mount 19 - Lockwasher 30 - Washer 41 - Bolt
8 - Front Mounting Bracket 20 - Flywheel Guard 31 - Bracket 42 - Washer
9 - Bolt 21 - Bolt 32 - Hose Assembly 43 - P-Clip
10 - Lockwasher 22 - Bracket 33 - Elbow 44 - Nut
11 - Bolt 23 - Engine Coupling 34 - Elbow 45 - Dipstick Bracket
12 - Washer

Fig. 1 - Engine and Mounting

SM 2174 Rev1 12-04 1


Engine - Engine and Mounting
Section 110-0030

DESCRIPTION correct fuel output and timing for optimum power, fuel
economy and emissions.
Numbers in parentheses refer to Fig. 1.
The Quantum Electronic Fuel System also takes
For engine make, model and specification, refer to
action to prevent damage to the engine and, provides
Section 000-0000, GENERAL INFORMATION. For
the serviceman with diagnostic capabilities so that
engine servicing and repair data refer to the engine
problems can be corrected quickly and easily.
manufacturers service manual.
1. Electronic Control Module (ECM) - Receives
The engine is mounted to the tractor frame at three
electronic inputs from the driver as well as from
points by a mounting bracket at the front of engine (8)
mounted sensors that provide information
and two rear mounts (7). Rubber isolation mounts (14)
electronically, such as oil pressure and temperature
through engine mounts provide sufficient flexibility to
and intake manifold pressure. This information is used
absorb varying engine vibration and torsional loads.
to control both the quantity of fuel injected and injection
timing.
Lube oil filter (3) and fuel filter (4) are remote mounted
in the battery box on the left hand side of machine. The
2. Programmable Read Only Memory (PROM) -
filters are of the throw away, spin-on type. Oil supplied
Located in the ECM and encoded with the operating
by the engine oil pump passes through oil filter (3)
software. Additional information is programmed into the
before reaching the various moving parts of engine (1).
EEPROM. This information controls the horsepower
Fuel drawn from the fuel tank passes through fuel filter
rating, torque curve, maximum engine speed and
(4) before reaching the fuel pump.
engine protection devices. The ECM processes this
information and sends electronic signals to the
Engine coolant filter (5) is a replaceable spin-on type
Electronic Fuel System Injectors where the precise
element mounted on the left hand side of engine (1).
amount of fuel is injected into the engine.
Refer to Section 210-0000, COOLING SYSTEM.
3. Electronic Fuel System Injectors - The injector is
QUANTUM ELECTRONIC FUEL SYSTEM a lightweight, compact unit that injects diesel fuel
directly into the combustion chamber. The amount of
Description fuel injected and the beginning of injection timing is
Refer to Fig. 2. determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.

WARNING The injector performs four functions:


Before any welding is done on a machine
equipped with the Quantum Electronic Fuel a - Creates the high fuel pressure required for efficient
System, disconnect the following in this order: injection.
Battery earth cable, battery supply cable, b - Meters and injects the exact amount of fuel required
alternator earth cables, alternator supply cables to handle the load.
and electrical connections at the engine ECM, c - Atomizes the fuel for mixing with the air in the
transmission ECU, body control lever, combustion chamber.
hydraulics ECU and cab bulkhead to avoid d - Permits continuous fuel flow for component cooling.
damage to electrical components. Turn off
battery master switch to isolate the batteries Electronic fuel system injectors are self compensating
before disconnecting any components. and virtually eliminate engine tune-ups.

After welding connect all of the above in the Note: Never apply 12 V directly to terminals on the
reverse order. injector as it will burn out. Before removing injectors,
the fuel passages must be blown out to prevent fuel
The engine is equipped with Quantum Electronic Fuel flow from entering the cylinder head.
System which controls the timing and amount of fuel
injection by the electronic fuel system injectors. The 4. Batteries - Two 12 volt maintenance free batteries
system also monitors several engine functions using supply the machine with electrical power to operate all
electrical sensors which send electrical signals to the electrical components.
electronic control module (ECM). The ECM then
computes the incoming data and determines the

2 SM 2174 Rev1 12-04


Engine - Engine and Mounting
Section 110-0030

SM - 2787

3 6 7

STOP
STOP

1 2 P

1,2
4

10 11

1 - Electronic Control Module (ECM) 7 - Stop Engine Light


2 - Programmable Read Only Memory (PROM) 8 - Diagnostic Test Point
3 - Electronic Fuel System Injectors 9 - Maintenance Light
4 - Batteries 10 - Engine Diagnostic Switch
5 - Electronic Foot Pedal 11 - Engine Diagnostic Request Switch
6 - Check Engine Light
Fig. 2 - Quantum Electronic Fuel System Components

5. Electronic Foot Pedal - The electronic foot pedal 8. Diagnostic Test Point - Plug in connector for
provides an electrical signal to the engine's fuel control diagnostic data reader (DDR).
system in proportion to the degree of pedal actuation.
9. Maintenance Light - The maintenance light will
Note: The engine MUST be started with foot 'OFF' the illuminate when it is time to change the engine oil. The
electronic foot pedal. maintenance monitor continuously monitors the time
the engine has been operating and the amount of fuel
Do not place engine under full load at full speed burned to determine when it is time to change oil.
immediately after starting. Always allow the engine to
fully circulate lubricant and warm up gradually before Note: Whenever an electrical fault has occurred, the
operating at full speed and full load. Operate engine at maintenance monitor data can be inaccurate.
top rated speed when maximum power is needed for
the load. 10. Engine Diagnostic Switch - To check for active
codes:
6. Check Engine Light - When the 'Check Engine' light
comes on, the computer has detected a fault in the a - turn the ignition key switch to the 'OFF' ('0') position.
engine. The fault should be diagnosed and corrected at
b - press the diagnostic switch to the 'ON' position.
the earliest opportunity.
c - turn the ignition key switch to position '1'.
7. Stop Engine Light - When the 'Stop Engine' light
comes on, the computer has detected a major If no active codes are recorded, both the 'Stop' and
malfunction in the engine that requires immediate 'Check' lights will illuminate and stay on.
attention. It is the operators responsibility to shut down
the engine to avoid serious damage. If active codes are recorded the 'Stop' and 'Check'

SM 2174 Rev1 12-04 3


Engine - Engine and Mounting
Section 110-0030
lights will illuminate momentarily. The amber 'Check' A special diagnostic data reader (INSITE) is available
and red 'Stop' lights will begin to flash the code of the that can be plugged into the engine computer memory
recorded fault. via the diagnostic test point (8). The reader is used to
extract information related to the cause of the problem.
11. Engine Diagnostic Request Switch - When the Once the malfunction has been corrected, the
engine is in diagnostic mode this switch is used to Electronic Fuel System will return the engine to normal
search through a list of fault codes, ie. pressing the top operation. The data reader can now distinguish
of the switch momentarily will advance to the next between active codes and those stored in the historic
active fault code, pressing the bottom of the will go code memory (inactive codes). Inactive codes can only
back to the previous code. If only one code is active, be viewed using the data reader. The fault code
the system will continuously display the same fault recorded in the ECM memory will remain until it is
code. erased by a technician.

Operation WARNING
Numbers in parentheses refer to Fig. 2. The operator of a Quantum-equipped vehicle
must not attempt to use or read a data reader of
When the 'Stop' light on the dash panel illuminates, the any kind while the vehicle is operating. Doing
ECM (1) has detected a major malfunction in the so can result in loss of control, which may
engine that requires immediate attention. It is the cause vehicle damage and may result in
operators responsibility to shut down the engine to personal injury.
avoid serious damage.
The operator can check for active faults by turning the
The machine is equipped with an engine protection ignition key switch to the 'OFF' position, switching the
derate system, which records fault codes and diagnostic switch (10) 'ON' and then turning the ignition
illuminates appropriate warning lights when an out-of- key switch to position '1'.
range condition associated with any of the following
sensors is found: If no active fault codes are recorded, both 'Stop' (7) and
Coolant temperature 'Check' (6) lights will come on and stay on. If active
codes are recorded, both lights will come on
Coolant level momentarily. The amber 'Check' (6) and red 'Stop' (7)
Intake manifold temperature lights will begin to flash the code of the recorded fault.
Oil pressure The fault codes flash in the following sequence: the
Oil temperature amber light flashes once, then there is a pause where
both lights are off. Then the numbers of the recorded
The engine power and speed will be gradually reduced
fault code flash in red. There is a pause between each
depending on the level of severity of the out-of-range
number. When the number is done, the amber light
condition. The operator MUST shut down the engine to
flashes again. e.g. amber flashes once - pause - red
avoid serious damage.
flashes twice - pause - red flashes three times - pause
- red flashes five times - pause - amber flashes once,
The engine should not be restarted after it has been
indicates fault code 235. The number will repeat in the
shut down after activation of the engine protection
same sequence until the the system is advanced to
derate system unless the problem has been diagnosed
the next active fault code by diagnostic request switch
and corrected.
(11), or the diagnostic switch (10) is switched to the
'OFF' position. Refer to 'Electronic Fuel System
Whenever the 'Stop' (7) or 'Check' (6) light comes on,
Diagnostic Codes' table for fault code descriptions.
the Electronic Fuel System 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.

4 SM 2174 Rev1 12-04


Engine - Engine and Mounting
Section 110-0030

ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES


Error Code Description Fault Lamp
111 ECM Hardware Internal Failure - Mission disabling Red
115 Engine Speed Sensor - Both signals lost Red
121 Engine Speed Sensor - One signal lost Amber
122 Boost Pressure Sensor - Component shorted high Amber
123 Boost Pressure Sensor - Component shorted low Amber
131 Throttle Position Sensor - Component shorted high Red
132 Throttle Position Sensor - Component shorted low Red
135 Oil Pressure Sensor - Component shorted high Amber
141 Oil Pressure Sensor - Component shorted low Amber
143 Oil Pressure Sensor - Data below normal range Amber
144 Engine Coolant Temperature Sensor - Component shorted high Amber
145 Engine Coolant Temperature Sensor - Component shorted low Amber
147 Throttle Position Sensor - Circuit low frequency Red
148 Throttle Position Sensor - Circuit high frequency Red
151 Engine Coolant Temperature Sensor - Data above normal range Amber
153 Intake Manifold Temperature Sensor - Component shorted high Amber
154 Intake Manifold Temperature Sensor - Component shorted low Amber
155 Intake Manifold Temperature Sensor - Data above normal range Amber
187 Sensor Supply Voltage #2 - Circuit shorted low Amber
211 Additional OEM/Vehicle Diagnostic Codes have been logged None
212 Oil Temperature Sensor - Component shorted high Amber
213 Oil Temperature Sensor - Component shorted low Amber
214 Oil Temperature - Data above normal range Red
221 Ambient Air Pressure Sensor - Component shorted high Amber
222 Ambient Air Pressure Sensor - Component shorted low Amber
223 Engine Oil Burn Valve Solenoid - Circuit shorted low Amber
227 Sensor Supply Voltage #2 - Circuit shorted high Amber
234 Engine Speed - Data above normal range Red
235 Engine Coolant Level - Data below normal range Amber
237 External Speed Input (Multiple Unit Sychronization) - Data incorrect Amber
241 Vehicle Speed Sensor Circuit - Data incorrect Amber
242 Vehicle Speed Sensor Circuit - Tampering has been detected Amber
245 Fan Clutch - Circuit shorted low Amber
254 Fuel Shutoff Value - Component shorted low Red
255 Fuel Shutoff Value - Component shorted high Amber
285 SAE J1939 Multiplexing PGN timeout error Amber
286 SAE J1939 Multiplexing configuration error Amber
287 SAE J1939 Multiplexing accelerator pedal sensor system error Red
293 Auxiliary Temperature Sensor Input #1 - Circuit shorted high Amber
294 Auxiliary Temperature Sensor Input #1 - Circuit shorted low Amber
295 Ambient Air Pressure Sensor - Circuit data incorrect Amber
297 Auxiliary Pressure Sensor Input #2 - Circuit shorted high Amber
298 Auxiliary Pressure Sensor Input #2 - Circuit shorted low Amber
299 Engine Shutdown - Commanded by J1939 Amber
311 Injector Solenoid Valve Cylinder #1 Circuit - Grounded circuit Amber
312 Injector Solenoid Valve Cylinder #5 Circuit - Grounded circuit Amber
313 Injector Solenoid Valve Cylinder #3 Circuit - Grounded circuit Amber
314 Injector Solenoid Valve Cylinder #6 Circuit - Grounded circuit Amber
315 Injector Solenoid Valve Cylinder #2 Circuit - Grounded circuit Amber
319 Real Time Clock - Power interrupt Maint
321 Injector Solenoid Valve Cylinder #4 Circuit - Grounded circuit Amber
322 Injector Solenoid Valve Cylinder #1 Circuit - Open circuit Amber
323 Injector Solenoid Valve Cylinder #5 Circuit - Open circuit Amber

SM 2174 Rev1 12-04 5


Engine - Engine and Mounting
Section 110-0030

ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES


Error Code Description Fault Lamp
324 Injector Solenoid Valve Cylinder #3 Circuit - Open circuit Amber
325 Injector Solenoid Valve Cylinder #6 Circuit - Open circuit Amber
331 Injector Solenoid Valve Cylinder #2 Circuit - Open circuit Amber
332 Injector Solenoid Valve Cylinder #4 Circuit - Open circuit Amber
341 ECM - Data lost Amber
343 ECM - Warning internal hardware failure Amber
346 ECM - Warning software error Amber
349 Transmission Output Shaft Speed High - Warning Amber
352 Sensor Supply Voltage #1 - Circuit shorted low Amber
386 Sensor Supply Voltage #1 - Circuit shorted high Amber
387 Accelerator Pedal Position Sensor Supply Voltage - Circuit shorted high Amber
415 Oil Pressure Sensor - Data indicates very low oil pressure Red
418 Water in Fuel Indicator High Maint
422 Engine Coolant Level Sensor Signals - Data invalid Amber
426 SAE J1939 datalink - cannot transmit None
428 Water in Fuel Sensor - Circuit shorted high Amber
429 Water in Fuel Sensor - Circuit shorted low Amber
431 Accelerator Pedal Idle Validation Circuit - Data incorrect Amber
432 Accelerator Pedal Idle Validation Circuit - Out of calibration Red
433 Intake Manifold Pressure Sensor - Circuit data incorrect Amber
434 Power Lost without ignition off Amber
435 Engine Oil Pressure Sensor - Circuit data incorrect Amber
441 Battery Voltage Low - Warning Amber
442 Battery Voltage High - Warning Amber
443 Accelerator Pedal Position Sensor Supply Voltage - Circuit shorted low Amber
489 Transmission Output Shaft Speed Low - Warning Amber
527 Auxiliary Input/Output #2 - Circuit shorted high Amber
528 OEM Alternate Torque Validation Switch - Data incorrect Amber
529 Auxiliary Input/Output #3 - Circuit shorted high Amber
551 Acclerator Pedal Idle Validation - Circuit shorted low Amber
581 Fuel Supply Pump Inlet Pressure Sensor - Circuit shorted high Amber
582 Fuel Supply Pump Inlet Pressure Sensor - Circuit shorted low Amber
583 Fuel Supply Pump Inlet Pressure Low - Warning level Amber
596 Electrical Charging System Voltage High - Warning level Amber
597 Electrical Charging System Voltage Low - Warning level Amber
598 Electrical Charging System Voltage Low - Critical level Red
611 Engine Hot Shutdown None
951 Cylinder Power Imbalance between cylinders None

6 SM 2174 Rev1 12-04


Engine - Engine and Mounting
Section 110-0030

Maintenance Monitor 3 seconds, then switch off.


The maintenance monitor uses data received from the
ECM to determine the amount of fuel burned and the 4. Press engine diagnostic switch on/off quickly, twice
time the engine has been operating to determine when (less than 1 second per cycle).
it is time to change the oil. The operator must still be
alert for any indications that the engine needs other 5. Press engine diagnostic switch on for a minimum of
service. 3 seconds, then switch off.

Note: Maintenance monitor is designed to alert the 6. The maintenance light will flash three times. This
operator of the need for a routine maintenance stop. means the maintenance monitor is reset.
Maintenance records must still be maintained for Note: If the maintenance light does not flash as
historical purposes. described, the reset sequence must be performed
again.
Note: Whenever an electrical fault has occurred, the
maintenance monitor data can be inaccurate. 7. Turn key to position '0'.

'Severe' oil drain interval duty cycle is the default 8. Remove blocks from road wheels.
setting for the maintenance monitor, however this can
be adjusted by using diagnostic tools, to suit duty Alternative method of resetting maintenance monitor is
cycle and oil type used. Engine oil drain intervals are as follows:
dependant on working environment and oil type used.
Refer to 'Engine oil drain intervals by duty cycle 1. Park machine on level ground, block road wheels,
(Hours)' table below. Refer to Section 300-0020, apply parking brake and switch off engine.
LUBRICATION SYSTEM for recommended oil type.
2. Turn keyswitch to position '1'.
The maintenance monitor will alert the operator of the
need to change oil by flashing the maintenance light for 3. Press engine diagnostic switch on.
approximately 12 seconds after key-on. The flashing
sequence will be three quick flashes, followed by a 4. Press and hold throttle pedal at 100% for 3 seconds,
pause. This flash sequence will go through five cycles then release.
in the 12 second period. This sequence will occur at
every key-on until the maintenance monitor has been 5. Press throttle pedal 100% on then off quickly, twice.
reset.
Note: The diagnostic switch must be OFF for the 6. Press and hold throttle pedal at 100% for 3 seconds,
flashing sequence to occur. then release.

Resetting the Maintenance Monitor - There are two 7. The maintenance light will flash three times.
ways to reset the maintenance monitor, depending on Note: If the maintenance light does not flash as
the engine ECU calibration. described, the reset sequence must be performed
again.
1. Park machine on level ground, block road wheels,
apply parking brake and switch off engine. 8. Press engine diagnostic switch off.

2. Turn key to position '1'. 9. Turn key to position '0'.

3. Press engine diagnostic switch on for a minimum of 10. Remove blocks from road wheels.

ENGINE OIL DRAIN INTERVALS BY DUTY CYCLE (HOURS)


Severe Heavy Medium Light
Fuel Consumption > 13 gal/hr 10 to 13 gal/hr 8.5 to 10 gal/hr < 8.5 gal/hr
API CF-4 150 200 250 300
API CG-4 250 300 400 500
API CH-4 or ACEA E5 300 350 500 600
CES20076 or CES20077 350 400 550 700

SM 2174 Rev1 12-04 7


Engine - Engine and Mounting
Section 110-0030

REMOVAL the goalpost assembly.


Numbers in parentheses refer to Fig. 1.
9. With a suitable container in position, remove drain
valve on the cooler and drain the oil. Remove
Note: Tag all cables, harnesses, lines and pipes
transmission oil cooler from the vehicle. Refer to
disconnected during removal to aid in installation.
Section 210-0060, TRANSMISSION OIL COOLER.

WARNINGS 10. Support engine sump guard with suitable blocking


and remove mounting hardware securing sump guard to
To prevent personal injury and property
the frame. Remove sump guard from the frame.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job 11. Support guard plate under the engine (1) at the front
safely. of the frame with suitable blocking and remove
mounting hardware securing guard plate to the frame.
High electrical current can cause sparks Remove guard plate from the frame.
and personal injury from burns. Turn battery
master switch to the 'Off' position before 12. Place a suitable container under the engine drain
removing any components. Remove battery port, remove drain plug and drain the oil. After draining,
ground cable first, and reconnect last, to avoid reinstall drain plug in engine sump and tighten
damaging electrical components. securely.

1. Position the vehicle in a level work area, ensure the


WARNING
body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel several Before disconnecting any air conditioner lines,
times to relieve any pressure in the steering circuit. refer to Section 260-0130, AIR CONDITIONING.
Refrigerant will rapidly freeze all objects with
2. Block all road wheels and place the battery master which it comes into contact. It can cause
switch in the 'Off' position. serious and permanent damage to the eyes and
skin.
3. Disconnect battery cables from terminal posts (earth
13. Evacuate air conditioning system and disconnect
cable first).
air conditioner lines at the engine compressor. Refer to
Section 260-0130, AIR CONDITIONING.
4. Pull on handle, inside battery box, to release hood
catch and lift up hood.
14. Remove the radiator assembly from the vehicle.
Refer to Section 210-0040, RADIATOR AND
5. Using hydraulic hand pump inside battery box, tilt
MOUNTING.
cab and secure. Refer to Section 260-0010, CAB AND
MOUNTING.
15. Remove charge air cooler pipes from engine
turbocharger and engine inlet manifold.
6. Remove mounting hardware securing air cleaner
intake tube to goalpost assembly. Remove mounting
16. Disconnect exhaust piping from the engine
hardware securing air cleaner to battery box. Slacken
turbocharger.
mounting clamp at air cleaner intake tube and draw air
cleaner away from intake pipe. Cover open ends to
prevent entry of dirt. 17. Disconnect air cleaner intake pipe from engine
turbocharger and remove from the engine (1).
7. Carefully remove filler cap from header tank. With a
suitable container in position, remove plug and open 18. Identify heater lines for ease of installation and with a
shut-off valve on the radiator assembly and drain the suitable container in position, disconnect heater lines
coolant. from the engine (1). Cap open line ends and fittings.

8. Remove hood and goalpost from the vehicle. Refer 19. Identify fuel lines for ease of installation and with a
to Section 100-0040, HOOD AND MOUNTING. suitable container in position, disconnect fuel lines
from the engine (1). Cap open line ends and fittings.
Note: Radiator header tank will be removed as part of
20. Identify all electrical harnesses and cables for ease

8 SM 2174 Rev1 12-04


Engine - Engine and Mounting
Section 110-0030
of installation and disconnect from the engine (1). 3. If required, remove rubber isolation mounts (14) from
rear mounts (7) and front mounting bracket (8).
21. Disconnect clips securing items to the engine (1)
that cannot be removed with the engine. 4. Loosen air conditioner compressor drive belt and
remove compressor from engine (1). Refer to Section
22. Remove guard from flywheel housing and 260-0130, AIR CONDITIONING.
disconnect driveline from the engine coupling and
secure clear of the engine (1). Refer to Section 5. Loosen alternator adjusting screw locknut (1, Fig. 3).
130-0010, FRONT DRIVELINES.
6. Loosen the adjustment link locking capscrew (2,
23. Attach suitable lifting equipment to the lifting Fig.3).
brackets on the engine and raise lifting equipment to
take up the slack. 7. Loosen the alternator mounting capscrew (3, Fig. 3).

24. Remove locknuts (17), snubbing washers (15 & 38) 8. Turn the adjusting screw (4, Fig. 3) anticlockwise to
and bolts (16) securing engine (1) to the frame through release tension. Remove alternator belt (2).
front mounting bracket (8) and rear mounting brackets
(7). 9. Remove alternator mounting capscrew (3, Fig. 3)
and adjustment link locking capscrew (2, Fig. 3).
25. Check to make certain that all necessary line and Remove alternator.
electrical disconnections have been made before lifting
engine (1). 10. Disconnect the electrical harness to fan clutch (27).

26. Carefully lift engine (1) clear of the frame, remove 11. Remove bolts (29) and washers (30) securing fan
to a suitable work area and mount securely on a work (28) and clutch (27) to engine (1) fan hub.
stand.
12. Remove both fan (28) and clutch (27) together from
the engine (1).
DISASSEMBLY
Numbers in parentheses refer to Fig. 1. 13. Loosen fan idler pulley shaft locknut. Loosen the
adjusting link to slacken the fan belt (6). Remove fan
1. Remove bolts (11 & 13) and washers (12) securing belt (6).
front mounting bracket (8) to engine (1). Remove front
mounting bracket (8). 14. Remove bracket supporting hoses from top of
flywheel housing.
2. Remove bolts (9) and washers (10) securing rear
mounts to engine (1). Remove mounts (7). 15. Remove bolts (21) and washers (19) securing
flywheel guard (20) to flywheel housing, then remove
flywheel guard (20) from engine (1).
SM - 2786

16. Remove bolts (18) and washers (19) securing


engine coupling (23) at rear of engine (1) then remove
engine coupling (23).

17. Remove and discard filters (3, 4 & 5) from engine


(1), as described in 'Maintenance'. Cover engine inlet
ports to prevent entry of dirt.

18. Refer to 'Engine Manufacturers Service Manual' if


engine service or repair is required.

INSPECTION
1 - Locknut 3 - Capscrew Numbers in parentheses refer to Fig. 1.
2 - Capscrew 4 - Adjusting Screw
Fig. 3 - Alternator Mounting 1. Inspect rubber isolation mounts (14) for damage and

SM 2174 Rev1 12-04 9


Engine - Engine and Mounting
Section 110-0030
replace if required. 11. Tighten the adjusting screw locknut (1, Fig. 3)
against the retainer. Tighten the adjustment link locking
2. Check mounting brackets (7 & 8) and mounting capscrew (2, Fig. 3) to 59 lbf ft (80 Nm).
brackets on the front frame for cracks and/or damage.
Repair or replace as necessary. 12. Tighten the alternator mounting capscrew (3, Fig. 3)
to 35 lbf ft (47 Nm).
3. Inspect engine coupling (23) for damage and repair
or replace as required. 13. Install air conditioning compressor and compressor
drive belt on engine (1). Refer to Section 260-0130, AIR
CONDITIONING.
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 14. If removed, install rubber isolation mounts (14) to
rear mounts (7) and front mounting bracket (8).
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section 15. Install rear mounts (7) to engine (1) and secure with
300-0080, STANDARD BOLT AND NUT TORQUE bolts (9) and washers (10).
SPECIFICATIONS.
16. Install front mounting bracket (8) to engine (1) and
1. Remove covers from engine filter ports and install secure with bolts (11 & 13) and washers (12).
new filters (3, 4 & 5) on engine (1), as described in
'Maintenance'.

2. Install engine coupling (23) to rear of engine (1) and INSTALLATION


secure with bolts (18) and washers (19). Tighten bolts Numbers in parentheses refer to Fig. 1.
(18) to a torque of 31 Nm (23 lbf ft).
Note: Tighten all fasteners without special torques
3. Install flywheel guard (20) to flywheel housing and specified to standard torques listed in Section
secure with bolts (21) and washers (19). 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Install bracket supporting hoses to top of flywheel
housing.
WARNING
5. Fit fan belt (6) and tighten adjusting link to tighten To prevent personal injury and property
fan belt (6). Refer to Engine Operation and damage, be sure lifting device is properly
Maintenance Manual for correct fan belt (6) tension. secured and of adequate capacity to do the job
safely.
6. Tighten the fan idler pulley shaft locknut to 140 lbf ft
(190 Nm). Check the belt tension again after the 1. Attach suitable lifting equipment to engine (1) lifting
locknut is tightened. brackets and carefully position engine (1) assembly in
the tractor frame.
7. Install fan (28) and clutch (27) to fan hub and secure
with bolts (29) and washers (30). Tighten bolts (29) to a 2. Secure engine (1) assembly to frame mounting
torque of 31 Nm (23 lbf ft). brackets with bolts (16), snubbing washers (15 & 38)
washers (9) and locknuts (10) as shown in Fig. 1.
8. Connect electrical harness to fan clutch (27). Tighten bolts (16) to a torque of 298 Nm (220 lbf ft).

9. Install alternator on engine (1) and secure with 3. Connect driveline to the engine coupling (23). Install
adjustment link locking capscrew (2, Fig. 3) and guard to flywheel housing. Refer to Section 130-0010,
alternator mounting capscrew (3, Fig. 3). FRONT DRIVELINES.

10. Fit alternator belt (2) between alternator pulley and 4. Install radiator assembly on the vehicle. Refer to
accessory drive pulley. Turn adjusting screw (4, Fig. 3) Section 210-0040, RADIATOR AND MOUNTING.
clockwise to increase belt tension; anticlockwise to
decrease belt tension. Refer to Engine Operation and 5. Install air cooler pipes from engine turbocharger and
Maintenance Manual for correct alternator belt (2) engine inlet manifold to charge air cooler mounted on
tension. the radiator assembly. Refer to Section 210-0040,

10 SM 2174 Rev1 12-04


Engine - Engine and Mounting
Section 110-0030
RADIATOR AND MOUNTING. coolant filter (5) are open to allow flow through the filter.

6. Install air cleaner intake pipe and exhaust piping to 19. Fill the cooling system with coolant. Refer to
engine turbocharger. Section 210-0000, COOLING SYSTEM.

7. Remove caps from heater lines and fittings and 20. Fill the engine with lubricant through oil filler to the
connect heater lines to engine (1) as identified at top mark on dipstick. Refer to Section 300-0020,
removal. LUBRICATION SYSTEM for oil specification.

8. Remove caps from fuel lines and fittings and 21. Fill transmission oil cooler with oil. Refer to Section
connect fuel lines to engine (1) as identified at removal. 210-0060, TRANSMISSION OIL COOLER.

9. Connect all electrical harnesses and cables to 22. Check all line and pipe connections for leaks prior
engine (1) (with the exception of battery connections) to starting the vehicle. Tighten as required.
as identified at removal.
23. Install hood assembly on the vehicle. Refer to
10. Connect air conditioner lines at the compressor as Section 100-0040, HOOD AND MOUNTING.
identified at removal. On completion of engine
installation the air conditioning system will require to 24. Using hydraulic hand pump inside battery box,
be charged. Refer to Section 260-0130, AIR lower cab and secure. Refer to Section 260-0010, CAB
CONDITIONING. AND MOUNTING.

11. Install the goalpost and radiator header tank 25. Switch the battery master switch to the 'On'
assembly on the vehicle. Refer to Section 100-0040, position, start up the engine and check for leaks.
HOOD AND MOUNTING. Tighten lines, pipes and fittings and top up all systems
as required.
12. Ensure all cooling lines to radiator assembly,
engine (1) and radiator header tank are correctly 26. Using suitable lifting equipment position front guard
connected. Refer to Section 210-0040, RADIATOR plate under the engine and secure to the frame with
AND MOUNTING. mounting hardware removed during removal.

13. Remove covers from air cleaner intake pipe and 27. Using suitable lifting equipment position engine
rubber hose on the air cleaner inlet then slide air sump guard under the engine and secure to the frame
cleaner assembly towards the cab locating the rubber with mounting hardware removed during removal.
hose to the inlet pipe.
28. Remove wheel blocks from all road wheels.
14. Secure air cleaner assembly to the battery box,
rubber hose to the inlet pipe and intake tube to
goalpost assembly with mounting hardware removed MAINTENANCE
during removal. Numbers in parentheses refer to Fig. 1.

15. Install transmission oil cooler on the vehicle. Refer Note: Carry out the following maintenance procedures
to Section 210-0060, TRANSMISSION OIL COOLER. in conjunction with additional procedures listed in
Section 300-0020, LUBRICATION SYSTEM.
16. Connect battery positive connections to battery
terminals. Connect battery earth connections to battery
terminals. Every 10 Hours (Daily)
Engine (1) - Visually check engine for damage, loose
17. Ensure all lines, harnesses and cables are secured or frayed belts and listen for any unusual noises.
with clips and clamps as removed during removal. Check coolant level and air cleaner restriction. Check
Ensure no lines are chaffing on sharp edges or resting charge air piping for damage.
against areas where heat will be evident.
Engine (1) Oil Level Check - Position the vehicle on a
18. Ensure shut-off valve at the bottom of the radiator level work area, apply the parking brake, shut off the
assembly and any drain cocks on engine (1) water engine and wait at least five minutes (to allow oil to
jacket are securely closed. Ensure shut off cocks at drain to the oil pan) before checking the oil level. The

SM 2174 Rev1 12-04 11


Engine - Engine and Mounting
Section 110-0030
oil level should be between the low (L) and high (H) area, apply the parking brake and switch off the engine.
marks on the dipstick. Add oil if low. Refer to Section Position a suitable container under the engine oil drain
300-0020, LUBRICATION SYSTEM for oil plug and drain the oil immediately to make sure all the
specification. oil and suspended contaminants are removed from the
engine.
Note: Never operate the engine with oil level below the
low (L) or above the high (H) mark on the dipstick. Clean the area around the lube oil filter head and, using
strap type filter wrench, remove lube oil filter (3).
Fuel Filter/Water Separator (4) - Drain the water and Discard lube oil filter (3) if it is not required for a failure
sediment from the separator daily. Position the vehicle analysis. Clean the gasket sealing surface of the filter
on a level work area, apply the parking brake, shut off head.
the engine and, with a suitable container below the
drain valve to catch spillage, open the drain valve by Note: The 'O' ring can stick on the filter head. Make
hand. Turn the valve anticlockwise approximately sure the 'O' ring is removed and discarded.
1.5 - 2 turns until draining occurs. Drain the filter sump
until clear fuel is visible. Turn the valve clockwise to Note: Fill the filter with clean lubricating oil prior to
close the drain valve. installation. The lack of lubrication during the delay
until the filter is pumped full of oil is harmful to the
Note: Do not overtighten the drain valve as engine.
overtightening can damage the threads.
Apply a light film of clean lubricating oil to the gasket
Cooling Fan (28) - Visually inspect the fan for cracks surface of the new filter and install the filter on the filter
or damaged blades. Check the fan to make sure that head. Turn the filter until the gasket contacts the filter
mounting bolts (29) are secure. Tighten bolts as head surface. Tighten the filter an additional 1/2 to 3/4
required. Replace any fan that is damaged. of a turn, or as specified by the filter manufacturer.

Note: Mechanical tightening of the filter is not


WARNING recommended and may result in seal and/or cartridge
Personal injury can result from a fan blade damage. Tighten filter by hand only.
failure. Never pull or pry on the fan as this can
damage the blades and lead to fan failure. Check and clean the engine oil drain plug threads and
the seal surface. Replace plug if damaged. Install and
Drive Belts - Visually inspect all drive belts daily. tighten the drain plug to a torque of 88 Nm (65 lbf ft).
Replace belts that are cracked or frayed and adjust Fill the engine with clean lubricating oil specified in
belts that have a glazed or shiny surface which Section 300-0020, LUBRICATION SYSTEM. The oil
indicates belt slippage. Correctly installed and level should be between the low (L) and high (H) marks
tensioned belts will show even pulley and belt wear. on the dipstick.

Engine (1) Crankcase Breather - Check and clean the Engine oil pressure must be indicated on the gauge
crankcase breather hose. Remove the breather hose within 15 seconds after starting engine. If oil pressure
and check internally for obstructions or sludge buildup. is not reached within 15 seconds, shut off the engine
Clean or replace breather hose as necessary, to immediately to avoid engine damage. Confirm the
prevent excess crankcase pressure buildup. correct oil level in the oil pan.

Start the engine and operate at idle speed to inspect


Every 500 Hours for leaks at the filter and oil drain plug. Shut off the
Engine Oil and Lube Oil Filter (3) - Replace the engine, wait approximately ten minutes to let the oil
lubricating oil and oil filter (3). drain back to the sump and check the oil level again.
Add oil as necessary to bring the level to the high (H)
mark on the dipstick. Do not overfill the engine with oil.
WARNING
Avoid direct contact of hot oil with your skin.
Hot oil can cause serious personal injury. Every 1 000 Hours
Fuel Filter (4) - Clean the area around the fuel filter
Operate the engine until the water temperature reaches head and replace the fuel filter.
60 C (140 F). Position the vehicle on a level work

12 SM 2174 Rev1 12-04


Section 110-0030
Position the vehicle on a level work area, apply the 3. Clean the filter adaptor with a clean, lint free cloth.
parking brake and switch off the engine. Using a strap
type filter wrench, remove fuel filter (4) and discard the 4. Lightly coat new coolant filter (5) seal with clean
thread adaptor sealing ring. Clean the gasket surface of engine oil as specified in Section 300-0020,
the filter head. LUBRICATION SYSTEM.

Install the new thread adaptor sealing ring (supplied 5. Start coolant filter (5) on the filter adaptor and tighten
with new filter) and apply a film of clean engine oil to it by hand until the seal touches the adaptor filter head.
lubricate the filter seal. Fill the new filter with clean fuel Tighten an additional 1/2 to 3/4 of a turn after contact,
specified in Section 300-0020, LUBRICATION or as specified by the filter manufacturer.
SYSTEM.
Note: Mechanical tightening of coolant filter (5) is not
Install new fuel filter (6) on the filter head and tighten necessary and will distort or crack the adaptor. Tighten
by hand until the gasket contacts the filter head coolant filter by hand only.
surface. Tighten fuel filter (6) per filter manufacturer's
instructions. 6. Open shut off valves at coolant filter (5) inlet and
outlet lines, and install pressure cap on header tank.
Note: Mechanical tightening of the filter is not
recommended and may result in seal and/or cartridge 7. Start the engine and check for leaks. If any leaks are
damage. Tighten filter by hand only. noted, have them corrected. Add coolant as required.
Refer to Section 210-0000, COOLING SYSTEM.
Coolant Filter (5) - Replace coolant filter (5) as
follows:
Every 2 000 Hours
Note: There is a shut off valve at the coolant inlet and Engine Mounting Bolts (16) - Check torque on engine
outlet lines of coolant filter (5). Closing these valves mounting bolts (16). If required, tighten to 298 Nm (220
will enable coolant filter (5) to be replaced without an lbf ft).
excessive loss of coolant.
Engine (1) - Steam clean.

WARNING Engine (1) Overhead Set - Adjust the valves and


Do not remove the pressure cap from a hot injectors. Refer to Engine Operation and Maintenance
engine. Wait until the coolant temperature is Manual for details.
below 50 C (120 F) before removing the
pressure cap. Heated coolant spray or steam Engine (1) Water Pump - Inspect water pump weep
can cause personal injury. hole and ensure it is not blocked.

1. Remove the cooling system pressure cap from Engine (1) Turbocharger Mounting Nuts - Tighten
header tank. nuts to 65 Nm (50 lbf ft).

2. Close shut off valves at coolant filter (5) inlet and


outlet lines and, using filter wrench, remove and SPECIAL TOOLS
discard coolant filter (5) from engine (1). Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of service tools which should be used in
conjunction with procedures outlined in the engine
WARNING manufacturers service manual, and, general service
A small amount of coolant can leak when tools required. These tools are available from your
servicing the coolant filter with the shut off dealer.
valves in the closed position. To avoid personal
injury, avoid contact with hot coolant.

SM 2174 Rev1 12-04 13


Engine - Engine and Mounting
Section 110-0030

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
3 2 Capscrew 80 59
3 3 Capscrew 47 35
1 16 Bolt 298 220
- - Engine Drain Plug 88 65
1 18 Bolt 31 23
1 29 Bolt 31 23

* * * *

14 SM 2174 Rev1 12-04


ENGINE - Cooling Fan
Section 110-0040

SM - 2790

2,3

1
5

ECM ON ENGINE LHS

7
6
SWE

1 - Bolt 5 - EST Fan Drive


2 - Lockwasher 6 - Electronic Control Module (ECM)
3 - Nut 7 - Harness
4 - Fan

Fig. 1 - Typical Layout View of Cooling Fan and Electronic Clutch

DESCRIPTION AND OPERATION further rises in coolant/air intake temperature results in


increased fan speed. The fan speed increases
Numbers in parentheses refer to Fig. 1.
proportionally with the increase in temperature until the
fan is fully engaged.
Note: The rate of fan (4) speed change and maximum
fan speed is preset to the cooling needs of the engine.
Note: The fan is fully engaged when the air
conditioning is switched on.
The electronic sensing technology (EST) fan (5) drive
system uses a pulse width modulated signal from the
When the temperature drops, so the fan speed reduces
engine electronic control module (6) to provide the
proportionally until the idle speed is reached.
appropriate fan speed necessary to satisfy any cooling
demand.
The EST fan drive (5) has a failsafe feature, ie. if the
electrical current to the fan drops to zero, the fan will
At a pre-determined engine coolant temperature or
be automatically engaged.
engine air intake temperature, variable current signals
from the ECM (6) give an increased fan speed. Any

SM 2175 10-02 1
Engine - Cooling Fan
Section 110-0040

REMOVAL
Numbers in parentheses refer to Fig. 1. WARNING
To prevent personal injury and property
damage, make sure blocking or lifting
WARNINGS equipment is properly secured and of adequate
To prevent personal injury and property capacity to do the job safely.
damage, make sure blocking or lifting
equipment is properly secured and of adequate 1. Install EST fan drive (5) on fan (4) mounting surface
capacity to do the job safely. of housing and secure in place with lockwashers (2)
and nuts (3).

Personal injury can result from a fan blade 2. Using suitable lifting equipment, position fan (4)
failure. Never pull or pry on the fan as this can assembly on the machine and secure to engine with
damage the blades and lead to fan failure. bolts (1). Torque tighten bolts (1) to 31 Nm (23 lbf ft).

1. Position the machine on a level work area, ensure Note: Ensure there is even clearance, all the way
the body is fully lowered, apply the parking brake and round, between fan (4) and the fan shroud.
switch off the engine. Operate the steering several
times to discharge the steering system. 3. Connect harness (7) at the connector on the fan
drive (5) braided cable.
2. Block all road wheels and place the battery master
switch in the off position. 4. If removed, install radiator on machine. Refer to
Section 210-0040, RADIATOR, HEADER TANK AND
3. If required, remove mounting hardware securing MOUNTING. Install fan guards to the fan shroud and
hood assembly to the machine and, using suitable secure with mounting hardware, as removed at
lifting equipment, remove hood assembly. Refer to 'Removal'.
Section 100-0040, HOOD AND MOUNTING.
5. If removed, position the hood assembly on the
4. Remove mounting hardware securing fan guards to machine using a suitable lifting device. Secure hood
the fan shroud. Remove fan guards from the machine. assembly on the machine with mounting hardware, as
If required remove radiator from the machine. Refer to removed at 'Removal'. Refer to Section 100-0040,
Section 210-0040, RADIATOR, HEADER TANK AND HOOD AND MOUNTING.
MOUNTING.
6. Start the engine and check for correct operation of
5. Disconnect harness (7) at the connector on the fan the fan. Refer to 'Testing' procedures contained in this
drive (5) braided cable. section.

6. Support fan (4) assembly with suitable lifting 7. Remove wheel blocks.
equipment and remove bolts (1) securing fan (4)
assembly to the engine. Remove fan (4) assembly
from the machine. TESTING

7. Remove nuts (3) and lockwashers (2) securing EST Static Test
fan drive (5) to fan (4) mounting surface of housing. Note: This test will only determine if the fan drive has
Remove EST fan drive (5) from housing. seized or is very close to seizure.

With the engine stopped, the fan should turn smoothly


INSTALLATION
with resistance (viscous) without scraping, scratching
Numbers in parentheses refer to Fig. 1. or grating noise.

Note: Tighten all fasteners without special torques Note: Rotation without resistance indicates a fault.
specified, to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. Basic Dynamic Test - Cut In/Cut Out
Note: This test is carried out with the machine static
and secured at rest.

2 SM 2175 10-02
Engine - Cooling Fan
Section 110-0040
After the machine has stood for approximately 30 2. Maintain engine speed at 2 100 rev/min and
minutes with the engine stopped, start the engine and disconnect harness at the connector on the fan drive
increase engine speed to 2 100 rev/min. braided cable. Fan should automatically engage to full
flow speed.
Initially the fan noise should be loud (cut in), but before
a further minute has elapsed, the fan noise should
significantly reduce (cut out). MAINTENANCE
Every 10 Hours/Daily
Basic Dynamic Test - Fan Drive Operation Check the fan for cracks or damaged blades. Clean or
Note: This test is carried out with the machine static replace as required.
and secured at rest.
Note: This DST fan is a non-serviceable component.
1. Place a cardboard, or alternative material, sheet However, the following instructions must be strictly
over the radiator front with an approximate 100 mm adhered to:
(4 in) diameter hole in the sheet, in line with the centre
of the fan drive. 1. DO NOT clean around fan drive with steam or high
pressure jet.
2. Start the engine and increase engine speed to
2 100 rev/min. 2. DO NOT tamper with modulation control mechanism
for ANY reason.
3. Fan noise should initially be loud and reduce
significantly before 1 minute has elapsed. 3. DO NOT add any fluids or lubricants to the drive.

4. Maintain engine speed at 2 100 rev/min. Fan drive 4. DO NOT restrict fan rotation during engine operation
should 'cut in' (engage) before coolant temperature for ANY reason.
gauge indicates excessive coolant temperature.
5. DO NOT operate a machine with a damaged fan
5. Return engine speed to idle, quickly remove the assembly. Replace a damaged fan as soon as the fault
sheet in front of the radiator and bring engine speed is noted.
back up to 2 100 rev/min. Fan speed should 'cut out'
(disengage) within 1 minute. 6. DO NOT disassemble ANY fan assembly or
associated parts that are still within the warranty
coverage period.
Failsafe Check
Note: This test is carried out with the machine static 7. IMMEDIATELY investigate and correct ANY
and secured at rest. Hood should be raised and operator complaint involving drive or cooling system
secured. performance.

1. Start the engine and increase engine speed to


2 100 rev/min.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 1 Bolt 31 23

* * * *

SM 2175 10-02 3
ENGINE - Air Cleaner
Section 110-0050

SM - 2791

5
1

4 3

1 - Air Cleaner Body


2 - Primary Element
3 - Safety Element
4 - Vacuator Valve
5 - Mounting Band
6 - Cover Assembly
Fig. 1 - Exploded View of Typical Air Cleaner

DESCRIPTION AND OPERATION A mechanical air restriction gauge (2, Fig. 2) is


Numbers in parentheses refer to Fig. 1. mounted on the air cleaner body and shows when the
system air flow is being restricted. A red band
The dual dry element air cleaner is remote mounted gradually rises in the gauge window as air restriction
horizontally on the left hand side of the machine. The increases. The red band is locked when maximum
air cleaner prolongs engine life by removing grit, dust allowable restriction is reached. When the red band
and water from the air as it enters the engine. Grit and locks at the top of the gauge window, primary filter
dust, combined with engine oil, forms a highly abrasive element (2) should be serviced. Air restriction gauge (2,
compound which can destroy the engine in a Fig. 2) should be reset by pushing the button on the
comparatively short period of time. gauge, holding it for several seconds and then
releasing it.
A rubber vacuator valve (4) attached to end cover (6) in
a downward position, ejects grit, dust and water while While air restriction gauge (2, Fig. 2) indicates the need
the engine is running. Vacuator valve (4) minimizes the for servicing, it does not give as precise a
need for daily servicing. Even though vacuator valve measurement as a water manometer or vacuum
(4) is normally under a slight vacuum when the engine gauge. Refer to 'Measuring Air Restriction'.
is running, pulsing of the vacuum opens and closes the
rubber valve, expelling dust and water as they collect. Secondary (safety) element (3) is installed in air
When the engine is stopped, vacuator valve (4) opens cleaner body (1) inside of primary element (2). This
and expels any accumulated grit, dust or water. element increases the reliability of the air cleaners

SM 2176 11-02 1
Engine - Air Cleaner
Section 110-0050

SM - 2792

19 18 1716
24

9 2513 10
15 16
11
14

1 13
12

2
20 8

23

3
4

22 21
18
17 5
19 6

1 - Air Intake Tube 8 - Band Clamp 14 - Retaining Bracket 20 - Clamp


2 - Air Restriction Gauge 9 - Air Intake Tube 15 - Seal 21 - Air Cleaner Bracket
3 - Bolt 10 - Bracket 16 - Bolt 22 - Bolt
4 - Washer 11 - Clamp 17 - Lockwasher 23 - Clamp
5 - Lockwasher 12 - Bolt 18 - Washer 24 - Air Intake Coupling
6 - Nut 13 - Washer 19 - Locknut 25 - Nut
7 - Elbow
Fig. 2 - Exploded View of Typical Air Cleaner Mounting

protection of the engine from airborne dirt. It protects the 'Off' position.
the engine from dirt admitted by a damaged primary
element (2), or dirt that might be dropped into air 3. Pull on handle to release hood catch and lift up the
cleaner assembly while changing primary element (2). hood.

4. Remove bolts (16), washers (13) and nuts (25)


AIR CLEANER securing coupling (24) to air intake tube (1).
Removal 5. Slacken clamps (8 & 23) securing elbow (7).
Numbers in parentheses refer to Fig. 2.
6. Remove bolts (3), washers (4), lockwashers (5) and
1. Position the vehicle in a level work area, apply the nuts (6) securing air cleaner to bracket (21). Using
parking brake and switch off the engine. suitable lifting equipment, support the air cleaner
assembly and draw air cleaner assembly away from
2. Block all road wheels, place the steering lock bar in elbow (7).
the 'Locked' position and the battery master switch in

2 SM 2176 11-02
Engine - Air Cleaner
Section 110-0050
7. Blank off all open ends with tape or cardboard to b. Check that air cleaner mounting bracket (21) is
prevent entry of dirt. secure and that air cleaner is mounted securely.

8. If required, remove bolts (22), lockwashers (17),


washers (18) and nuts (19) securing bracket (21) to the MAINTENANCE
battery box. Remove bracket (21). 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 air restriction gauge (2, Fig. 2) daily (every 10
air cleaner body (1). hours). The air cleaner elements should be serviced
only when the maximum allowable restriction has been
1. Release latches on cover assembly (6) and remove reached, as indicated by air cleaner restriction gauge
cover assembly from air cleaner body (1). (2, Fig. 2). The elements should not be serviced on the
basis of visual observation as this would lead to over
2. Remove primary element (2) and safety element (3) service. When restriction readings finally indicate a
from air cleaner body (1). change, remove primary element (2) carefully and
clean/replace as required. Refer to 'Primary Element'.
3. Open mounting bands (5) and remove from air
cleaner body (1). Never attempt to clean safety element (3). Change
safety element (3) after every third primary element (2)
4. Slacken clamp (20, Fig. 2) and remove air intake service.
tube (1, Fig. 2), complete with retaining bracket (14,
Fig. 2) and seal (15, Fig. 2), from air cleaner body (1). 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 clamps (8 & 23, Fig. 2), elbow
remove tape or cardboard from body outlets. (7, Fig. 2) and air intake tubes (1 & 9, Fig. 2). Tighten/
replace as necessary.
Assembly/Installation
Numbers in parentheses refer to Fig. 2, unless Primary Element
otherwise specified. Numbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners to standard torques listed Although a paper primary element (2) is used, it is
in Section 300-0080, STANDARD BOLT AND NUT possible to remove excess dirt by tapping element.
TORQUE SPECIFICATIONS.
1. Release latches on cover assembly (6) and remove
Assembly and installation of the air cleaner assembly cover assembly from air cleaner body (1).
is the reverse of disassembly and removal. Reset air
restriction gauge (2). 2. Remove primary element (2) from air cleaner body (1)
and clean/replace. It is advised to replace the element
Following installation, but before starting the engine, rather than attempt to clean thoroughly.
the following system checks should be carried out:
3. Using a damp cloth and a suitable solvent, wipe out
a. Check air intake tube (9) for defects and that clamps all excess dust from air cleaner body (1) and allow to
(8 & 23) (and those supplied with the engine) are dry.
securely tightened to ensure that there are no leaks in
the system. 4. Install primary element (2) in air cleaner body (1).

SM 2176 11-02 3
Engine - Air Cleaner
Section 110-0050
5. Install cover assembly (6) on air cleaner body (1) (air cleaner outlet) increases. This vacuum is generally
and secure with latches. measured as 'restriction in mm (inches) of water'.

The recommended maximum allowable intake


Secondary Element restrictions at rated speed and load are as follows:
Numbers in parentheses refer to Fig. 1.
a. 380 mm-H2O (15 in-H2O) with clean filter elements.
Since safety element (3) is protected from b. 635 mm-H2O (25 in-H2O) with dirty filter elements.
contamination by primary element (2), it needs no
periodic cleaning and should be replaced only after While the air restriction gauge sends a signal to
every third primary element (2) service. indicate the need for servicing, it does not give as
precise a measurement as a water manometer or
1. With primary element (2) removed from air cleaner vacuum gauge.
body (1), remove safety element (3).
Water Manometer
2. Remove any dust dislodged into air cleaner body (1) a. Remove air restriction gauge (2) from port in air
outlet and, using a damp cloth and a suitable solvent, cleaner assembly.
wipe out all excess dust from air cleaner body (1) and
allow to dry. b. Hold water manometer vertically and fill both legs
approximately half full of water. Connect one of the
3. Install new safety element (3) followed by primary upper ends to port by means of a flexible hose.
element (2) in air cleaner body (1).
c. With the manometer held vertically and the engine
4. Install cover assembly (6) on air cleaner body (1) drawing maximum air, the difference in height of the
and secure with latches. water columns in the two legs is measured as the air
cleaner restriction.
Recommendations d. If the restriction exceeds the levels indicated, engine
Numbers in parentheses refer to Fig. 2. performance will be affected. Primary filter element
should be cleaned or replaced.
1. Under no condition should the vehicle be operated
without both filter elements in each air cleaner Vacuum Gauge
assembly. a. Remove air restriction gauge (2) from port in air
cleaner assembly.
2. It is very important that elbow (7) and air intake tube
(9) from the air cleaner assembly to the engine be b. Connect the hose from the vacuum gauge to
airtight or the purpose of the air cleaner will be port and, with the engine drawing maximum air, take a
completely defeated. All clamps (8 & 23) (and those note of the reading on the gauge.
supplied with the engine) should be checked frequently
and tightened to prevent leaks. c. 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
MEASURING AIR RESTRICTION numbers of service tools referenced in this section and
Numbers in parentheses refer to Fig. 2. general service tools required. These tools are
available from your dealer.
As a dry air cleaner element becomes loaded with
dust, the vacuum on the engine side of the air cleaner

* * * *

4 SM 2176 11-02
TRANSMISSION - Transmission and Mounting
Section 120-0010

SM - 2793

5 11

3
4 17

16
15
14
10

1 6 8 12 LH
13 RH
8 9
7
16

22

10
21 19
20
18

15 - Lockwasher
1 - Sleeve 8 - Washer 16 - Isolation Mount
2 - Front Bracket 9 - Bolt 17 - Snubbing Washer
3 - Lockwasher 10 - Nut 18 - Dipstick Tube
4 - Bolt 11 - Bolt 19 - Gasket
5 - Front Plate 12 - LH Bracket 20 - Bolt
6 - Centre Bonded Mount 13 - RH Bracket 21 - Lockwasher
7 - Bolt 14 - Bolt 22 - Hardened Washer

Fig. 1 - Exploded View of Transmission and Mounting

DESCRIPTION integral output transfer gearing. Automatic shifting in


Numbers in parentheses refer to Fig. 1. gear ranges 1 to 6, with kickdown feature. Lockup in all
forward gears. A wear-resistant hydrodynamic retarder
For transmission make, model and specification, refer is integral of the transmission.
to Section 000-0000, GENERAL INFORMATION. For
transmission servicing and repair data refer to An engine dependent power takeoff at the rear of the
transmission manufacturers service manual. transmission provides the drive for the main hydraulic
pump which supplies the braking, steering and body
The transmission is supported by front plate (5), LH hoist systems. A ground driven emergency steering
bracket (12) and RH bracket (13) which are bolted to pump is attached at the lower rear left hand side of the
the transmission and attached to front frame mounting transmission.
brackets through centre bonded mount (6) and isolation
mounts (16). Mounts (6 & 16) provide sufficient Mounted off bracket assembly on top of transmission
flexibility to absorb varying transmission vibration and is the diff-lock/retarder valve which houses the retarder
torsional loads. solenoid, axle differential lock solenoid and pressure
reducing valve (refer to Figs. 4 & 5).
The transmission assembly consists of a torque
converter close-coupled to a 6 speed gearbox with

SM 2177 11-02 1
Transmission - Transmission and Mounting
Section 120-0010

SM - 2794
1

2
10 4

11

RHS
8
1 - Oil Temperature Sender (Gauge)
2 - Main Control Valve 7
3 - Transmission Difflock Solenoid
4 - Lockup Solenoid
5 - Engine Speed Sensor
6 - Output Speed Sensor
7 - Central Gear Train Sensor
8 - Turbine Speed Sensor
9 - Trans. Cooler Fan Drive Temp. Sensor
10 - Breather
11 - Retarder Oil Temperature Sensor 3

Fig. 2 - Location of Transmission Switches, Sensors and Solenoids

SWITCHES AND SENSORS The transmission oil temperature is also monitored by


temperature sensors in the main control valve, which
Numbers in parentheses refer to Fig. 2, unless
sends a signal to illuminate the transmission STOP
otherwise specified.
warning light. The light will illuminate to indicate any of
Transmission Oil Temperature the following conditions:
Oil temperature sender (1) sends a signal to indicate
High retarder temperature
transmission oil temperature on the transmission oil
High transmission sump temperature
temperature gauge in the cab. The gauge should read
Engine overspeed
between 80 C (176 F) and 120 C (248 F) during
normal operation and may reach 145 C (293 F) during
retarder operation. If the needle remains at high If the light illuminates during normal operation, a fault
temperatures for extended periods, the machine should code will also register on the display unit (See EST-37
be brought to a stop, transmission shifted to neutral Trouble Shooting tables). Bring the machine to a stop
and engine speed increased to 1 200 - 1 500 rev/min. and investigate the cause.
Under this condition, oil temperature should drop to
normal values in about 2 - 3 minutes. If oil temperature Temperature sensor (9) sends a signal to the hydraulic
does not drop, the cause should be investigated. ECU to operate the transmission cooler fan drive at a
speed proportional to transmission oil temperature.

2 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

SM - 1826

VALVE BLOCK

COVER

Y3 Y4

Y2 Y5 6

Y1 Y6

2 1
HOUSING
SYSTEM PRESSURE FROM
CONTROL UNIT BREATHER

1 - Main Pressure Valve 16+2 bar 5 - Follow-on Slide


2 - Pressure Reduction Valve 9 bar 6 - Proportional Valve (P1 to P6)
3 - Lockup Solenoid 7 - Vibration Damper
4 - Lockup Reduction & Shift Valve 8 - Harness Connection Y1 to Y6 - Pressure Regulators

Fig. 3 - Sectional View of Typical Control Unit with Lockup Clutch (Wk)

Lockup Clutch (Wk) clutches. These clutches are controlled via the six
The transmission lockup clutch is automatically proportional valves (6, Fig. 3). Each proportional valve
engaged. Engine speed is picked up by turbine speed (6, Fig. 3) is composed of a pressure regulator (Y1 to
sensor (8) which sends a signal to energise lockup Y6, Fig.3), follow-on slide (5, Fig. 3) and vibration
solenoid (3, Fig. 3) when turbine speed reaches a damper (7, Fig. 3).
predetermined level. Energising lockup solenoid
(3, Fig. 3) will move lockup valve (4, Fig. 3) across, The control pressure of 9 bar for the actuation of the
allowing oil to flow through the valve to engage lockup. follow-on slides (5, Fig. 3) is created by the pressure
reduction valve (2, Fig. 3). The pressure oil (16+2
bar) is directed via the follow-on slide (5, Fig. 3) to
Gear Selection the respective clutch.
The transmission can be engaged and disengaged
under load by means of hydraulically controlled multi- Due to the direct proportional control with separate
disc clutches. All gears run in antifriction bearings and pressure modulation for each clutch, the pressures to
are constantly meshed. The gears, bearings and the clutches, which are taking place in the gear
clutches are lubricated with cooled oil. change, are controlled. In this way, a hydraulic
intersection of the clutches to be engaged and
The transmission is equipped with six multi-disc disengaged becomes possible. This creates fast

SM 2177 11-02 3
Transmission - Transmission and Mounting
Section 120-0010
shiftings without traction force interruption. move when the vehicle speed is below 20 km/hr. Warning
light will illuminate when differential locks are selected,
NOT attained.
Speedometer Sensor
Speedometer sensor, within the ECU, sends a signal to Note: Before driving in soft or slippery conditions, stop
the speedometer, via the speedometer frequency and engage the differential locks. Spinning wheels can
divider, to indicate travel speed in kilometres per result in damage to the transmission and axle
hour and miles per hour. differentials.

Note: Disengage differential locks when driving on firm


Differential Pressure Switch ground.
The differential pressure switch is located in the
transmission filter head. The switch will close and
record a fault code when the filters become blocked, Retarder Control
indicating a filter change is required. The hydro dynamic retarder is arranged between the
engine and torque converter so that a good braking
Note: The differential pressure switch is not operational effect is obtained in all speeds. The retarder is a
when oil temperature is below 50 C (122 F) or when wear resistant hydrodynamic brake with speed
transmission output speed is greater than 2000 rev/ dependent action.
min.
Retarder solenoid (4, Figs. 4 & 5) is energised on
application of the retarder switch, located on the right
Differential Locks hand switch bank, provided that the lockup clutch is
Note: The transmission differential lock requires engaged and the transmission 'Stop' warning light is
hydraulic pressure to hold it 'Off', whereas, the centre OUT. Energising retarder solenoid will shift retarder
axle differential lock requires pressure to hold it 'On'. solenoid valve and allow oil to flow through the valve to
engage the retarder. Pressure reducing valve (2, Figs.
When the engine is started, hydraulic pressure is 4 & 5) reduces the inlet pressure from 16 bar (232 lbf/
applied to the transmission differential lock to ensure in2) to 5.5 bar (80 lbf/in2).
the differential lock is released. On activation of the
differential lock switch, the transmission differential Pressing the retarder switch OFF will de-energise
lock solenoid is de-energised and hydraulic pressure is retarder solenoid and retarder solenoid valve will shift
released at the transmission differential lock and back to disengage the retarder.
applied at the centre axle differential lock. In this
condition, the differential locks are engaged. Note: Irrespective of speed, the retarder will
automatically disengage when the transmission oil
Note: The differential locks can be preselected when the temperature reaches 150 C (302 F).
machine is moving however, they will only engage on the
SM - 2856 SM - 2857

5 6
A1 B1 A2 B2
3 CT1 CT2
1
INLET
1
CT3 T2
2
2
CT4 TRANS
SUMP
4
3
4
7
TO 'TS' PORT ON
MAIN HYDRAULIC
VALVE
TRANSMISSION
PILOT PRESSURE

1 - Valve 4 - Retarder Solenoid 1 - Valve 4 - Retarder Solenoid


2 - Pressure Reducing Valve 5 - Bolt 2 - Pressure Reducing Valve 6 - Diff-lock
3 - Axle Diff-lock Solenoid 3 - Axle Diff-lock Solenoid 7 - Retarder
Fig. 4 - Diff-lock/Retarder Valve Fig. 5 - Diff-lock/Retarder Valve Schematic

4 SM 2177 11-02
SM 2177 11-02
2nd POWER TAKE-OFF
SCHEDULE OF MEASURING POINTS
CONVERTER
Measurements to be carried out with oil at normal operating 14
RETARDER WK
temperature of 80 C and operating at full speed. KV K1

MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE: 1st POWER TAKE-OFF

51 = Before the Convertor - Opening Pressure 8.5 bar


52 = Behind the Convertor - Opening Pressure 5 bar INPUT
53 = Clutch forward 16+2 bar KV
55 = Clutch reverse 16+2 bar KR KR K2
56 = Clutch 16+2 bar K1 PUMP
57 = Clutch 16+2 bar K2
Fig. 6 - Typical Schedule of Measuring Points and Gear Pattern

58 = Clutch 16+2 bar K3


6 31
60 = Clutch 16+2 bar K4 K4 K3
63 = Temperature 100 C behind the retarder (short time 150 C)
65 = System pressure 16+2
66 = Temperature 100 C behind the converter (short time 120 C)
67 = WK-Control pressure 131 bar 39
OUTPUT OUTPUT

58
56

Transmission - Transmission and Mounting


53 ENGAGEMENT AND DISENGAGEMENT DIFFERENTIAL
DIFFERENTIAL LOCK
60 D C
INDUCTIVE TRANSMITTERS AND SPEED SENSORS
E B 6 = Inductive Transmitter n Turbine
55 14 = Inductive Transmitter n Engine
F A
31 = Speed Sensor n Output and Speedometer
G
39 = Inductive Transmitter n Central Gear Train
J H K
57

66 PRESS REG. UNDER VOLTAGE


51
52 SPEED Y1 Y2 Y3 Y4 Y5 Y6
F1
F2
F3
F4
F5
F6
63 R1
67 65 R2

Section 120-0010
R3
N
CLUTCH KR K4 K1 K3 KV K2
POS. VALVE F E D C B A

SM - 1824
POINTS 55 60 56 58 53 57
5
6

Section 120-0010
Transmission - Transmission and Mounting
SM - 2570
KR K4 K1 K3 KV K2

F 55 E 60 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D
Fig. 7 - Oil Circulation Diagram for Typical Transmission with Lockup Clutch and Retarder

Y1 NFS Y2 NFS Y3 NFS Y4 NFS Y5 NFS Y6 NFS

RV-9
TEMP

No. Denomination of the Position Port


K 65
NOT SCOPE OF SUPPLY ZF
15 To the heat exchanger
WK-M HDV
HYDRAULIC PRESSURE 16 From the heat exchanger
WK-V 28 To the ZF-filter
29 From the ZF-filter
32 Behind the Convertor to heat exchanger
PRESSURE REDUCTION VALVE
33 Before the Convertor to heat exchanger
5.5 bar 34 From heat exchanger to lubrication into Transmission
CONVERTER
67 WK 51 Before the Convertor - Opening Pressure 8.5 bar H
52 Behind the Convertor - Opening Pressure 5 bar
51
53 Clutch forward 16+2 bar KV B
55 Clutch reverse 16+2 bar KR F
H 56 Clutch 16+2 bar K1 D
TO THE RETARDER VALVE WSV 57 Clutch 16+2 bar K2 A
5.5 bar 66 52 58 Clutch 16+2 bar K3 C
60 Clutch 16+2 bar K4 E
29 63 Temp. 100 C behind the retarder (short time 150 C)
WGV 65 System pressure 16+2 K
66 Temp. 100 C behind the converter (short time 120 C)
BYPASS VALVE 67 WK-Control pressure 131 bar
ZF-FINE FILTER
32
WT (SCOPE OF SUPPLY CUSTOMER) 28

16 15

WITH RETARDER
RT-V
LEGEND:
FILLING POSITON IN THE CABIN TRANSMISSION PUMP = MAIN PRESSURE
63 = CONTROLLED MAIN PRESSURE
= PILOT PRESSURE
= CONVERTER INLET PRESSURE
WITHOUT RETARDER = CONVERTER EXIT PRESSURE
= LUBRICATION
= RETURN TO SUMP
SM 2177 11-02

COARSE FILTER
LUBRICATION

33 34

RT OIL SUMP
Transmission - Transmission and Mounting
Section 120-0010

OPERATION
WARNING
EST-37 Automatic Shift Control Before any welding is done on a machine
The EST-37 transmission is equipped with an equipped with an EST-37 shift system,
electronic control unit (ECU) which continually monitors disconnect the following in this order: Battery
the transmission and shift system electrical earth cable, battery supply cable, alternator
components and warns the operator when a problem earth cables, alternator supply cables and
develops. It also takes action to prevent damage to the electrical connections at the engine ECM,
transmission, and provides the serviceman with transmission ECU, body control lever,
diagnostic capabilities so that problems can be hydraulics ECU and cab bulkhead to avoid
corrected quickly and easily. damage to electrical components. Turn off
battery master switch to isolate the batteries
When a fault occurs, a two digit error code will be before disconnecting any components.
displayed on the LCD display on the dash panel. The After welding connect all of the above in the
error code is also recorded in the transmission ECU, reverse order.
and can be accessed by the serviceman by plugging in
a data reader to extract information relating to the fault. VTS-3 Shift Controller - Operation: The shift
The error code recorded in the ECU memory will remain controller has 3 positions the lever can rest in,
until it is erased by a technician. Forward, Neutral and Reverse. Within each of these
positions, the gear can be changed by pushing the
If a major fault is detected, it is the operators lever to the right (+) to upshift or to the left (-) to
responsibility to shut down the machine as soon as it downshift. In the Neutral position, this can be used to
is safe to do so. The machine should not be restarted preselect the starting gear (the default being 2nd gear).
until the fault has been diagnosed and corrected.
The shift controller has a 'Function' button on the top of
Refer to 'EST-37 Trouble Shooting' table for a list of the lever which is used to switch between automatic
fault codes and checks. and manual modes. Press the function button from
'NEUTRAL' and move the lever forward to select
The EST-37 transmission control has been designed to automatic mode, when driving normal upshifting and
provide the driver with maximum operational flexibility downshifting will occur. If required, a gear can be held
by allowing the choice of automatic or manual gear in manual mode by pressing the function button once,
selection to optimize vehicle performance under all to resume full automatic mode the function button
operating conditions. should be pressed again. Manual gears can also be
selected by pushing the lever to the left for lower gears
The rotational pressure compensated (RPC) system or to the right for higher gears, again by pressing the
gives improved shift quality due to more accurate function button once automatic mode will be resumed.
clutch filling, in addition to reduced clutch filling time.
Note: The transmission will only allow gearshifting
The transmission provides six forward gears, three when the predetermined values have been reached.
reverse gears and a neutral position. The gear
positions are indicated on the LCD display located on Note: There is no shift inhibitor in the gear shift
the dash panel. The transmission will only operate in control, therefore, no resistance would be felt while
the gear selected by the operator in the manual moving through the gear ranges.
range, or, when the lever is in the automatic range,
shifts will occur automatically between 1st and 6th The gear lever housing sends a signal to the electronic
gear, depending on operating requirements. The control unit, which in turn will only allow the engine to
reverse gears 1st through 3rd are manual mode only. be started when the gear lever is in the 'NEUTRAL'
position. The gear shift lever must always be placed in
'NEUTRAL' and the parking brake applied when starting
the engine, or whenever the machine is left unattended.

When shifting from 'NEUTRAL' to start from a


standstill, or to reverse direction, decelerate the engine
to idle speed before selecting the proper gear. When
'REVERSE' is selected, the 'Reverse Alarm' sounds
and the 'Reverse Light' illuminates to warn personnel to

SM 2177 11-02 7
Transmission - Transmission and Mounting
Section 120-0010

SM - 2798 SM - 2335

S
T
O
P

1 2 3

1 - Bars show gear ranges and full display (as


IDLE
shown) indicates driving in automatic mode.

FULL LOAD/THROTTLE
2 - Display shows actual driving direction.
KICK/HOLD DOWN 3 - Display shows actual gear in use.

Fig. 8 - Accelerator Load Ranges and Kickdown Position Fig. 9 - Dashboard Display
the rear of the machine that reverse gear has been speed has increased sufficiently to allow this to
selected. happen, and that the shift lever is in the automatic
mode.
During reversing operations it is recommended to
reduce engine speed, use only 1st or 2nd gear and A dashboard display is provided which indicates gear
never exceed 10 km/h (6.2 mile/h). selected and driving direction as follows (See Fig. 9):

The electronic control system distinguishes between Manual Mode - When driving with shift selector in
the throttle position (or load ranges) depending on the manual range, the bars only are shown in position 1,
governor position (injection pump). On a light throttle and, driving direction and gear selected are indicated
opening, the transmission will give earlier upshifts and in positions 2 and 3.
later downshifts than when operating at full throttle.
Automatic Mode - When driving with shift selector in
A kickdown facility (See Fig. 8), which can be used automatic range, a full display of bars and arrows are
when automatic mode is selected, allows for the shown in position 1, and, driving direction and gear
possibility of selecting a lower gear by pressing down selected are indicated in positions 2 and 3.
fully on the throttle pedal and holding. This can be used
to provide a downshift on demand provided that the Under certain conditions the transmission may start
vehicle speed is within the range allowable. That is, the to 'hunt' between gears when in automatic mode. The
vehicle is not travelling at a speed that would result in transmission changes up and down between two
the engine overspeeding in the lower gear. gears at short intervals because there is not
When driving with kickdown, the transmission will give sufficient power to sustain driving in the higher gear,
earlier downshifts and later upshifts. To disengage the but is sufficient for upshifting from the lower gear. By
transmission kickdown, release the throttle pedal and using the shift display, it can be established which
allow it to return to a light throttle position. gears are involved and in these circumstances the
lower gear should be selected using the shift control
When operating in automatic range with the display lever. Automatic mode should be reselected at the
indicating that the transmission has downshifted to 2nd earliest opportunity.
gear, there are two options for providing a further
downshift as conditions indicate. During machine operation, watch for wide deviations
from normal readings on the transmission oil
1. 1st gear can be manually selected by pushing the temperature gauge. If the gauge shows the oil
shift lever to the left. temperature rising above 120 C (248 F) during normal
operation, or above 145 C (293 F) during retarder
2. Kickdown can be selected from 2nd automatic, when operation, the machine must be stopped and inspected
the transmission will downshift to 1st gear, depending for external oil leakage. If no leaks are found, shift to
upon vehicle speed. 'NEUTRAL' and operate the engine at 1 200 - 1 500 rev/
min. If the transmission oil temperature does not
When the kickdown is released the transmission will decrease into the normal zone within 2 or 3 minutes,
upshift to 2nd automatic, provided that the forward the cause of the overheating should be corrected

8 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
before the machine is operated further.
WARNINGS
Note: In cold weather, the transmission oil should be
Never allow the machine to coast with the
warmed up by running the engine at idle speed with the
transmission in 'NEUTRAL'.
gear selector in neutral, since the system will not
operate satisfactorily if the oil is too cold. When running down a gradient the engine
speed should not be allowed to drop below
When temporarily stopped, such as for yielding the 1 200 rev/min, at which point, lockup would
right-of-way to a loaded machine, the transmission disengage preventing retarder operation.
can be left in gear and the machine held stationary with
In the event of a loss of electric power to the
the service brakes.
gear shift control, the transmission will
automatically shift to 'NEUTRAL'. If this occurs,
When stopped for a more extended period with the
stop the machine using the service brakes and
engine left running, shift to 'NEUTRAL' to avoid
apply the parking brake. Do not operate until
unnecessary heat buildup, and apply the parking brake.
the fault has been repaired.
Always select 'NEUTRAL' and apply the parking
WARNING brake before leaving the operators seat.
Always select the correct drive direction and The retarder will automatically disengage when
gear before releasing the parking brake. the oil temperature reaches 150 C (302 F),
irrespective of engine speed.

Display during operation


Symbol Meaning Remarks
1F, 1R Actual gear and direction. Left digit shows
2F, 2R actual gear, right digit shows actual
3F, 3R direction
4F
5F
6F
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing only 6WG:
direction F or R selected while turbine
speed is too high, CAUTION gear will
engage if turbine speed drops
NN not neutral, waiting for neutral after go engage a gear, first move shift
power up or a severe fault selector to neutral position and again
to F or R position
** oil temperature too low, no gear available warm up engine / transmission
*N oil temperature low, only one gear available warm up engine / transmission
1 bar (special symbol) manual mode 1. gear
2 bars manual mode 2. gear
3 bars manual mode 3. gear
4 bars manual mode 4. gear
4 bars and 2 arrows automatic mode
bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed
above a certain limit and lockup clutch
not activated
spanner at least one fault active select neutral to get fault code displayed
fault code see faultcode list

SM 2177 11-02 9
Transmission - Transmission and Mounting
Section 120-0010

Display during operation - Continued


Symbol Meaning Remarks
WS warning sump temperature changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WR warning retarder temperature changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WT warning torque converter temperature changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WE warning high engine speed changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
PN direction F or R selected while parking transmission in neutral until parking
brake engaged brake is released CAUTION: vehicle
starts to move after release of parking
brake
F or R flashing direction F or R selected while turbine
speed is to high, CAUTION gear will
engage if turbine speed drops
EE flashing no communication with display checked wiring from TCU to display

The AEB-Starter is a tool to start the AEB (automatic filling parameter adjustment) of ergopower transmissions
with ease. Connect AEB-Starter to plug X25 located below dash adjacent to TCU.

Display during AEB-Mode


Symbol Meaning Remarks
PL AEB - Starter is plugged at the diagnostic
plug
ST AEB-Starter-button is pressed
K1..K4,KV,KR calibrating clutch K1..K4,KV,KR
_ and Kx wait for start, initialization of clutch Kx,
x: 1, 2, 3, 4, V, R
and Kx fast fill time determination of clutch Kx
= and Kx compensating pressure determination of
clutch Kx
OK calibration for all clutches finished Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
after removing AEB-Starter
STOP AEB cancelled (activation stopped) Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx cant be calibrated Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
Spanner and Kx Kx couldnt be calibrated, AEB finished Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
E engine speed too low, -> raise engine
speed
E engine speed too high, -> lower engine
speed
T transmission oil temperature too low,
-> heat up transmission

10 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

Display during AEB-Mode - Continued


Symbol Meaning Remarks
T transmission oil temperature too high
-> cool down transmission
FT transmission temperature not in defined Transmission stays in neutral, you
range during calibration have to restart the TCU (ignition off/on)
FB operating mode not NORMAL or Transmission stays in neutral, you
transmission temperature sensor defective have to restart the TCU (ignition off/on)
or storing of Calibrated values to
EEPROM-has failed.
FO Outputspeed_not_zero Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
FN Shift lever not in Neutral position Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
FP Parkbrake_not_applied Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
STOP AEB - Starter was used incorrect or is Transmission stays in neutral, you
defective have to restart the TCU (ignition off/on)

TABLE OF FAULT CODES


Fault MEANING OF CODE TCU reaction Checks Remarks
Code possible reason for fault detection
(hex)
11 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to check cables from TCU to Failure cannot be
TCU detected a wrong signal combination for the neutral shift lever detected in systems
gear range OP-Mode: transmission check signal combinations with DW2/DW3 shift
cable from shift lever to TCU is broken shutdown of shift lever positions for lever
cable is defective and is contacted to battery voltage gear range
or vehicle ground
shift lever is defective
12 LOGICAL ERROR AT DIRECTION SELECT SIGNAL TCU shifts transmission to check cables from TCU to
TCU detected a wrong signal combination for the neutral shift lever
direction OP-Mode: transmission check signal combinations
cable from shift lever to TCU is broken shutdown of shift lever positions
cable is defective and is contacted to battery voltage F-N-R
or vehicle ground
shift lever is defective
13 LOGICAL ERROR AT ENGINE DERATING DEVICE after selecting neutral, check engine derating This fault is reset
TCU detected no reaction of engine while TCU changes to device after power up of
derating device active TCU

15 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2 TCU shifts transmission check cables from TCU Fault is taken back if
SHIFT LEVER to neutral if selector to shift lever 2 TCU detects a valid
TCU detected a wrong signal combination for the active check signal neutral signal for the
direction OP-Mode: transmission combinations of shift lever direction at the shift
cable from shift lever 2 to TCU is broken shutdown if selector positions F-N-R lever
cable is defective and is contacted to battery active
voltage or vehicle ground
shift lever is defective
16 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal check cables from TCU
feedback axle connection measured by TCU to feedback axle
and output signal axle connection don't fit connection switch
axle can't be connected/disconnected due to check signals of the
mechanical problem feedback axle connection
one of the cables from feedback axle connection -
switch to TCU is broken

SM 2177 11-02 11
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
17 S.C. TO GROUND AT customer specific check cables from TCU See figure 10
TCU detected a wrong voltage at the output pin, to device
that looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle TCU to device
ground check the resistance of
device has an internal defect device
connector pin is contacted to vehicle ground
18 S.C. TO BATTERY VOLTAGE AT ADM4 no reaction check cables from TCU See figure 10
TCU detected a wrong voltage at the output pin, to relay
that looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery TCU to relay
voltage check the resistance of
relay has an internal defect relay
connector pin is contacted to battery voltage
19 O.C. AT ADM4 no reaction check cable from TCU See figure 10
TCU detected a wrong voltage at the output pin, to relay
that looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU relay to TCU
relay has an internal defect check resistance of
connector has no connection to TCU relay
25 S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION SUMP no reaction, check cable from TCU to
TEMPERATURE SENSOR INPUT TCU uses default temp. sensor
the measured voltage is too high: OP-Mode: normal check connectors
cable is defective and is contacted to battery voltage check temperature sensor
cable has no connection to TCU
temperature sensor has an internal defect
connector pin is contacted to battery voltage or is
broken
26 S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE SENSOR no reaction, check cable from TCU to
INPUT TCU uses default temp. sensor
the measured voltage is too low: OP-Mode: normal check connectors
cable is defective and is contacted to vehicle ground check temperature sensor
temperature sensor has an internal defect
connector pin is contacted to vehicle ground
27 S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER no reaction, check cable from TCU to
TEMPERATURE SENSOR INPUT TCU uses default temp. sensor
the measured voltage is too high: OP-Mode: normal check connectors
cable is defective and is contacted to battery voltage check temperature sensor
cable has no connection to TCU
temperature sensor has an internal defect
connector pin is contacted to battery voltage or is
broken
28 S.C. TO GROUND AT RETARDER TEMPERATURE SENSOR INPUT no reaction, check cable from TCU to
the measured voltage is too low: TCU uses default temp. sensor
cable is defective and is contacted to vehicle ground OP-Mode: normal check connectors
temperature sensor has an internal defect check temperature sensor
connector pin is contacted to vehicle ground
31 S.C. TO BATTERY VOLTAGE OR O.C. AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage higher than 7.00 V at speed control sensor
input pin check connectors
cable is defective and is contacted to battery voltage check speed sensor
cable has no connection to TCU
speed sensor has an internal defect
connector pin is contacted to battery voltage or has
no contact

12 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
32 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed input control sensor
pin check connectors
cable/connector is defective and is contacted to check speed sensor
vehicle ground
speed sensor has an internal defect
33 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a engine speed over a threshold and the control sensor power up to TCU
next moment the measured speed is zero check connectors
cable / connector is defective and has bad contact check speed sensor
speed sensor has an internal defect check sensor gap
sensor gap has the wrong size
34 S.C. TO BATTERY VOLTAGE OR O.C. AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage higher than 7.00 V at speed control sensor
input pin if a failure is existing at check connectors
cable is defective and is contacted to battery voltage output speed, check speed sensor
cable has no connection to TCU TCU shifts to neutral
speed sensor has an internal defect OP-Mode: limp home
connector pin is contacted to battery voltage or has
no contact
35 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed control sensor
input pin if a failure is existing at check connectors
cable / connector is defective and is contacted to output speed, check speed sensor
vehicle ground TCU shifts to neutral
speed sensor has an internal defect OP-Mode: limp home
36 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a turbine speed over a threshold and control sensor power up of TCU
at the next moment the measured speed is zero if a failure is existing at check connectors
cable / connector is defective and has bad contact output speed, check speed sensor
speed sensor has an internal defect TCU shifts to neutral check sensor gap
sensor gap has the wrong size OP-Mode: limp home
37 S.C. TO BATTERY VOLTAGE OR O.C. AT INTERNAL SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage higher than 7.00 V at speed control sensor
input pin check connectors
cable is defective and is contacted to battery voltage check speed sensor
cable has no connection to TCU
speed sensor has an internal defect
connector pin is contacted to battery voltage or has
no contact
38 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch check cable from TCU to
TCU measures a voltage less than 0.45V at speed input control sensor
pin check connectors
cable / connector is defective and is contacted to check speed sensor
vehicle ground
speed sensor has an internal defect
39 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute clutch check cable from TCU to This fault is reset after
TCU measures a internal speed over a threshold and at control sensor power up of TCU
the next moment the measured speed is zero check connectors
cable / connector is defective and has bad contact check speed sensor
speed sensor has an internal defect check sensor gap
sensor gap has the wrong size

SM 2177 11-02 13
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
3A S.C. TO BATTERY VOLTAGE OR O.C. AT OUTPUT SPEED INPUT special mode for gear check cable from TCU to
TCU measures a voltage higher than 12.5 V at speed selection sensor
input pin OP-Mode: substitute clutch check connectors
cable is defective and is contacted to battery voltage control check speed sensor
cable has no connection to TCU if a failure is existing at
speed sensor has an internal defect turbine speed,
connector pin is contacted to battery voltage or has TCU shifts to neutral
no contact OP-Mode: limp home
3B S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear check cable from TCU to
TCU measures a voltage less than 1.00V at speed input selection sensor
pin OP-Mode: substitute clutch check connectors
cable / connector is defective and is contacted to control check speed sensor
vehicle ground if a failure is existing at
turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3C LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear check cable from TCU to This fault is reset after
TCU measures a output speed over a threshold and at selection sensor power up of TCU
the next moment the measured speed is zero OP-Mode: substitute clutch check connectors
cable / connector is defective and has bad contact control check speed sensor
speed sensor has an internal defect if a failure is existing at check sensor gap
sensor gap has the wrong size turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3E OUTPUT SPEED ZERO DOESNT FIT TO OTHER SPEED SIGNALS special mode for gear check sensor signal of This fault is reset after
if transmission is not neutral and the shifting has selection output speed sensor power up of TCU
finished, OP-Mode: substitute clutch check sensor gap of output
TCU measures outputspeed zero and turbine speed or control speed sensor
internal speed not equal to zero. if a failure is existing at check cable from TCU to
speed sensor has an internal defect turbine speed, sensor
sensor gap has the wrong size TCU shifts to neutral
OP-Mode: limp home
56 ENGINE CONF TIMEOUT OP-Mode: substitute clutch check engine controller
Timeout of CAN-message ENGINE CONF from engine control check wire of CAN-Bus
controller check cable to engine
interference on CAN-Bus controller
CAN wire/connector is broken
CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
57 EEC1 TIMEOUT OP-Mode: substitute clutch check EEC controller
Timeout of CAN-message EEC1 from EEC controller control check wire of CAN-Bus
interference on CAN-Bus check cable to EEC
CAN wire/connector is broken controller
CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
58 EEC3 TIMEOUT OP-Mode: substitute clutch check EEC controller
Timeout of CAN-message EEC3 from EEC controller control check wire of CAN-Bus
interference on CAN-Bus check cable to EEC
CAN wire/connector is broken controller
CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
65 ENGINGE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for engine torque is defective control check wire of CAN-Bus
engine controller is defective check cable to engine
interference on CAN-Bus controller
66 KICKDOWN SIGNAL no reaction check engine controller
CAN signal for kickdown is defective check wire of CAN-Bus
engine controller is defective check cable to engine
interference on CAN-Bus controller

14 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
69 REFERENCE ENGINE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for reference of engine torque is defective control check wire of CAN-Bus
engine controller is defective check cable to engine
interference on CAN-Bus controller
6A ACTUAL ENGINE TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for actual engine torque is defective control check wire of CAN-Bus
engine controller is defective check cable to engine
interference on CAN-Bus controller
6B NOM FRICTION TORQUE SIGNAL OP-Mode: substitute clutch check engine controller
CAN signal for nominal friction torque is defective control check wire of CAN-Bus
engine controller is defective check cable to engine
interference on CAN-Bus controller
6E EEC2 TIMEOUT no reaction check EEC controller
Timeout of CAN-message EEC2 from EEC controller TCU uses default signal check wire of CAN-Bus
interference on CAN-Bus accelerator pedal in idle check cable to EEC
CAN wire/connector is broken position controller
CAN wire/connector is defective and has contact to OP-Mode: normal
vehicle ground or battery voltage
6F ACCELERATOR LOW IDLE SWITCH SIGNAL no reaction check EEC controller if this signal is not
CAN signal for manual downshift is defective TCU uses default signal check wire of CAN-Bus transmitted via CAN,
EEC controller is defective accelerator pedal in idle check cable to EEC TCU uses default
interference on CAN-Bus position controller signal
OP-Mode: normal
71 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K1 valve is too high. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending TCU to gearbox
battery voltage TCU shifts to neutral check regulator resistance 1)
cable / connector is defective and has contact to OP-Mode: TCU shutdown check internal wire
another regulator output of the TCU harness of the gearbox
regulator has an internal defect
72 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K1 valve is too low. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
vehicle ground TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
73 O.C. AT CLUTCH K1 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit. if failure at another check connectors from
cable / connector is defective and has no contact to clutch is pending gearbox to TCU
TCU TCU shifts to neutral check regulator resistance 1)

regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
74 S.C. TO BATTERY VOLTAGE AT CLUTCH K2 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K2 valve is too high. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
battery voltage TCU shifts to neutral check regulator resistance 1)
cable / connector is defective and has contact to OP-Mode: TCU shutdown check internal wire
another regulator output of the TCU harness of the gearbox
regulator has an internal defect

SM 2177 11-02 15
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
75 S.C. TO GROUND AT CLUTCH K2 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K2 valve is too low. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
vehicle ground TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
76 O.C. AT CLUTCHK2 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit. if failure at another check connectors from
cable / connector is defective and has no contact to clutch is pending gearbox to TCU
TCU TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
77 S.C. TO BATTERY VOLTAGE AT CLUTCH K3 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K3 valve is too high. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
battery voltage TCU shifts to neutral check regulator resistance 1)
cable / connector is defective and has contact to OP-Mode: TCU shutdown check internal wire
another regulator output of the TCU harness of the gearbox
regulator has an internal defect
78 S.C. TO GROUND AT CLUTCH K3 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K3 valve is too low. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
vehicle ground TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
79 O.C. AT CLUTCHK3 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit. if failure at another check connectors from
cable / connector is defective and has no contact to clutch is pending gearbox to TCU
TCU TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
81 S.C. TO BATTERY VOLTAGE AT CLUTCH K4 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K4 valve is too high. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
battery voltage TCU shifts to neutral check regulator resistance 1)
cable / connector is defective and has contact to OP-Mode: TCU shutdown check internal wire
another regulator output of the TCU harness of the gearbox
regulator has an internal defect
82 S.C. TO GROUND AT CLUTCH K4 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K4 valve is too low. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
vehicle ground TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
83 O.C. AT CLUTCH
K4 TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit. if failure at another check connectors from
cable / connector is defective and has no contact to clutch is pending gearbox to TCU
TCU TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox

16 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
84 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at KV valve is too high. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
battery voltage TCU shifts to neutral check regulator resistance 1)
cable / connector is defective and has contact to OP-Mode: TCU shutdown check internal wire
another regulator output of the TCU harness of the gearbox
regulator has an internal defect
85 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at KV valve is too low. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
vehicle ground TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
86 O.C. AT CLUTCH KV TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit. if failure at another check connectors from
cable / connector is defective and has no contact to clutch is pending gearbox to TCU
TCU TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
87 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at KR valve is too high. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
battery voltage TCU shifts to neutral check regulator resistance 1)
cable / connector is defective and has contact to OP-Mode: TCU shutdown check internal wire
another regulator output of the TCU harness of the gearbox
regulator has an internal defect
88 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at KR valve is too low. if failure at another check connectors from
cable / connector is defective and has contact to clutch is pending gearbox to TCU
vehicle ground TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
89 O.C. AT CLUTCH KR TCU shifts to neutral check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit. if failure at another check connectors from
cable / connector is defective and has no contact to clutch is pending gearbox to TCU
TCU TCU shifts to neutral check regulator resistance 1)
regulator has an internal defect OP-Mode: TCU shutdown check internal wire
harness of the gearbox
91 S.C. TO GROUND AT RELAY REVERSE WARNING ALARM backup alarm will be on check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that until TCU power down backup alarm device
looks like a s.c. to vehicle ground even if fault vanishes check connectors from
cable is defective and is contacted to vehicle ground (loose connection) backup alarm device to
backup alarm device has an internal defect OP-Mode: normal TCU
connector pin is contacted to vehicle ground check resistance 1) of
backup alarm device
92 S.C. TO BATTERY VOLTAGE AT RELAY REVERSE WARNING ALARM no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal backup alarm device
looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery voltage backup alarm device to
backup alarm device has an internal defect TCU
connector pin is contacted to battery voltage check resistance 1) of
backup alarm device

SM 2177 11-02 17
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
93 O.C. AT RELAY REVERSE WARNING ALARM no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal backup alarm device
looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU backup alarm device to
backup alarm device has an internal defect TCU
connector has no connection to TCU check resistance 1) of
backup alarm device
9A S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal converter clutch solenoid
looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle ground converter clutch solenoid
converter clutch solenoid has an internal defect to TCU
connector pin is contacted to vehicle ground check resistance 1) of
converter clutch solenoid
9B O.C. AT CONVERTER LOCK UP CLUTCH converter clutch always check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that open, retarder not converter clutch solenoid
looks like a o.c. for this output pin available check connectors from
cable is defective and has no connection to TCU OP-Mode: normal converter clutch solenoid
converter clutch solenoid has an internal defect to TCU
connector has no connection to TCU check resistance 1) of
converter clutch solenoid
9C S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP CLUTCH no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal converter clutch solenoid
looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery voltage converter clutch solenoid
converter clutch solenoid has an internal defect to TCU
connector pin is contacted to battery voltage check resistance 1) of
converter clutch solenoid
9D S.C. TO GROUND AT RETARDER no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal retarder solenoid
looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle ground retarder solenoid to TCU
retarder solenoid has an internal defect check resistance 1) of
connector pin is contacted to vehicle ground retarder solenoid
9E O.C. AT RETARDER no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal retarder solenoid
looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU retarder solenoid to TCU
retarder solenoid has an internal defect check resistance 1) of
connector has no connection to TCU retarder solenoid
9F S.C. TO BATTERY VOLTAGE AT RETARDER SOLENOID no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal retarder solenoid
looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery voltage retarder solenoid to TCU
retarder solenoid has an internal defect check resistance 1) of
connector pin is contacted to battery voltage retarder solenoid
A1 S.C. TO GROUND AT DIFFLOCK SOLENOID no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal difflock solenoid
looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle ground difflock solenoid to TCU
difflock solenoid has an internal defect check resistance 1) of
connector pin is contacted to vehicle ground difflock solenoid
A2 S.C. TO BATTERY VOLTAGE AT DIFFLOCK SOLENOID no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal difflock solenoid
looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery voltage difflock solenoid to TCU
difflock solenoid has an internal defect check resistance 1) of
connector pin is contacted to battery voltage difflock solenoid
A3 O.C. AT DIFFLOCK SOLENOID no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal difflock solenoid
looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU difflock solenoid to TCU
difflock solenoid has an internal defect check resistance 1) of
connector has no connection to TCU difflock solenoid

18 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
A4 S.C. TO GROUND AT WARNING SIGNAL OUTPUT no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal warning device
looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle ground warning device to TCU
warning device has an internal defect check resistance 1) of
connector pin is contacted to vehicle ground warning device
A5 O.C. AT WARNING SIGNAL OUTPUT no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal warning device
looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU warning device to TCU
warning device has an internal defect check resistance 1) of
connector has no connection to TCU warning device
A6 S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-Mode: normal warning device
looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery voltage warning device to TCU
warning device has an internal defect check resistance 1) of
connector pin is contacted to battery voltage warning device
B1 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral check pressure at clutch K1
TCU calculates a differential speed at closed clutch K1. OP-Mode: limp home check main press. in system
If this calculated value is out of range, TCU interprets if failure at another check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
low pressure at clutch K1 TCU shifts to neutral check sensor gap at output
low main pressure OP-Mode: TCU shutdown speed sensor
wrong signal at internal speed sensor check signal at internal
wrong signal at output speed sensor speed sensor
wrong size of the sensor gap check signal at output
clutch is defective speed sensor
replace clutch
B2 SLIPPAGE AT CLUTCH K2 TCU shifts to neutral check pressure at clutch K2
TCU calculates a differential speed at closed clutch K2. OP-Mode: limp home check main press. in system
If this calculated value is out of range, TCU interprets if failure at another check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
low pressure at clutch K2 TCU shifts to neutral check sensor gap at output
low main pressure OP-Mode: TCU shutdown speed sensor
wrong signal at internal speed sensor check signal at internal
wrong signal at output speed sensor speed sensor
wrong size of the sensor gap check signal at output
clutch is defective speed sensor
replace clutch
B3 SLIPPAGE AT CLUTCH K3 TCU shifts to neutral check pressure at clutch K3
TCU calculates a differential speed at closed clutch K3. OP-Mode: limp home check main press. in system
If this calculated value is out of range, TCU interprets if failure at another check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
low pressure at clutch K3 TCU shifts to neutral check sensor gap at output
low main pressure OP-Mode: TCU shutdown speed sensor
wrong signal at internal speed sensor check signal at internal
wrong signal at output speed sensor speed sensor
wrong size of the sensor gap check signal at output
clutch is defective speed sensor
replace clutch
B4 SLIPPAGE AT CLUTCH K4 TCU shifts to neutral check pressure at clutch K4
TCU calculates a differential speed at closed clutch K4. OP-Mode: limp home check main press. in system
If this calculated value is out of range, TCU interprets if failure at another check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
low pressure at clutch K4 TCU shifts to neutral check sensor gap at turbine
low main pressure OP-Mode: TCU shutdown speed sensor
wrong signal at internal speed sensor check signal at internal
wrong signal at turbine speed sensor speed sensor
wrong size of the sensor gap check signal at turbine
clutch is defective speed sensor
replace clutch

SM 2177 11-02 19
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
B5 SLIPPAGE AT CLUTCH KV TCU shifts to neutral check pressure at clutch KV
TCU calculates a differential speed at closed clutch KV. OP-Mode: limp home check main press. in system
If this calculated value is out of range, TCU interprets if failure at another check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
low pressure at clutch KV TCU shifts to neutral check sensor gap at turbine
low main pressure OP-Mode: TCU shutdown speed sensor
wrong signal at internal speed sensor check signal at internal
wrong signal at turbine speed sensor speed sensor
wrong size of the sensor gap check signal at turbine
clutch is defective speed sensor
replace clutch
B6 SLIPPAGE AT CLUTCH KR TCU shifts to neutral check pressure at clutch KR
TCU calculates a differential speed at closed clutch KR. OP-Mode: limp home check main press. in system
If this calculated value is out of range, TCU interprets if failure at another check sensor gap at internal
this as slipping clutch. clutch is pending speed sensor
low pressure at clutch KR TCU shifts to neutral check sensor gap at turbine
low main pressure OP-Mode: TCU shutdown speed sensor
wrong signal at internal speed sensor check signal at internal
wrong signal at turbine speed sensor speed sensor
wrong size of the sensor gap check signal at turbine
clutch is defective speed sensor
replace clutch
B7 OVERTEMP SUMP no reaction cool down machine
TCU measured a temperature in the oil sump that is OP-Mode: normal check oil level
TCU measured a temperature in the oil sump that is OP-Mode: normal check oil level
over the allowed threshold. check temperature sensor
B8 OVERTEMP RETARDER TCU disables retarder cool down machine
TCU measured a temperature in the retarder oil that is OP-Mode: normal check oil level
over the allowed threshold. check temperature sensor
B9 OVERSPEED ENGINE retarder applies - not used
OP-Mode: normal
BA DIFFERENTIAL PRESSURE OIL FILTER no reaction check oil filter
TCU measured a voltage at differential pressure switch OP-Mode: normal check wiring from TCU to
out of the allowed range. differential pressure switch
oil filter is polluted check differential pressure
cable/connector is broken or cable/connector is switch (measure resistance)
contacted to battery voltage or vehicle ground
differential pressure switch is defective
BB SLIPPAGE AT CONVERTER LOCKUP CLUTCH check pressure at
TCU calculates a differential speed at closed converter converter lockup clutch
lockup clutch. If this calculated value is out of range, check main pressure in the
TCU interprets this as slipping clutch. system
low pressure at converter lockup clutch check sensor gap at engine
low main pressure speed sensor
wrong signal at engine speed sensor check sensor gap at turbine
wrong signal at turbine speed sensor speed sensor
wrong size of the sensor gap check signal at engine
clutch is defective speed sensor
check signal at turbine
speed sensor
replace clutch
BD S.C. TO GROUND AT ENGINE BRAKE SOLENOID no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-mode: normal engine brake solenoid
looks like a s.c. to vehicle ground check connectors from
cable is defective and is contacted to vehicle ground engine brake solenoid
engine brake solenoid has an internal defect to TCU
connector pin is contacted to vehicle ground check the resistance 1) of
engine brake solenoid

20 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
BE S.C. TO BATTERY VOLTAGE AT ENGINE BRAKE no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-mode: normal engine brake solenoid
looks like a s.c. to battery voltage check connectors from
cable is defective and is contacted to battery voltage engine brake solenoid
engine brake solenoid has an internal defect to TCU
connector pin is contacted to battery voltage check the resistance 1) of
engine brake solenoid
BF O.C. AT ENGINE BRAKE no reaction check cable from TCU to 1)
see figure 10
TCU detected a wrong voltage at the output pin, that OP-mode: normal engine brake solenoid
looks like a o.c. for this output pin check connectors from
cable is defective and has no connection to TCU engine brake solenoid
engine brake solenoid has an internal defect to TCU
connector has no connection to TCU check the resistance 1) of
engine brake solenoid
C3 OVERTEMP TORQUE CONVERTOR OUTPUT no reaction cool down machine
TCU measured an oil temperature at the OP-mode: normal check oil level
converter output that is over the allowed threshold check temperature
sensor
CA ENGINE_RETARDER CONFIG_TIMEOUT OP-mode: substitute check EEC controller
Timeout of CAN message clutch control check wire of CAN-Bus
ENGINE_RETARDER CONFIG from EEC check cable to EEC
controller controller
inteference on CAN-Bus
CAN wire/connector is broken
CAN wire/connector is defective and has contact
to vehicle ground or battery voltage

CB ERC1 TIMEOUT OP-mode: substitute check EEC controller


Timeout of CAN-message ERC1 from EEC clutch control check wire of CAN-Bus
controller check cable to EEC
inteference on CAN-Bus controller
CAN wire/connector is broken
CAN wire/connector is defective and has contact
to vehicle ground or battery voltage

D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 check cables and fault codes no. 21
TCU measures more than 6V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
check power supply at
pin AU1 (should be
approx. 5V)
D2 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS see fault codes no. 21 check cables and fault codes no. 21
TCU measures less than 4V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
check power supply at
pin AU1 (should be
approx. 5V)
D3 LOW POWER AT BATTERY shift to neutral check power supply
measured voltage at power supply is lower OP-Mode: TCU shutdown battery
than 18 V check cables from
batteries to TCU
check connectors from
batteries to TCU
D4 HIGH POWER AT BATTERY shift to neutral check power supply
measured voltage at power supply is higher OP-Mode: TCU shutdown battery
than 32.5 V check cables from
batteries to TCU
check connectors from
batteries to TCU

SM 2177 11-02 21
Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF CODE TCU reaction Checks Remarks


Code possible reason for fault detection
(hex)
D5 ERROR AT SWITCH 1 FOR VALVE POWER SUPPLY VPS1 shift to neutral check fuse
TCU switched on VPS1 and measured VPS1 is off or OP-Mode: TCU shutdown check cables from
TCU switched off VPS1 and measured VPS1 is still on gearbox to TCU
cable or connectors are defect and are contacted to check connectors from
battery voltage gearbox to TCU
cable or connectors are defect and are contacted to replace TCU
vehicle ground
permanent power supply KL30 missing
TCU has an internal defect
D6 ERROR AT SWITCH 2 FOR VALVE POWER SUPPLY VPS2 shift to neutral check fuse
TCU switched on VPS2 and measured VPS2 is off or OP-Mode: TCU shutdown check cables from
TCU switched off VPS2 and measured VPS2 is still on gearbox to TCU
cable or connectors are defect and are contacted to check connectors from
battery voltage gearbox to TCU
cable or connectors are defect and are contacted to replace TCU
vehicle ground
permanent power supply KL30 missing
TCU has an internal defect
E3 S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT no reaction check cable from TCU
TCU sends data to the display and measures always a OP-Mode: normal to the display
high voltage level on the connector. check connectors at
cable or connectors are defect and are contacted to the display
battery voltage change display
display has an internal defect
E4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction check cable from TCU
TCU sends data to the display and measures always a OP-Mode: normal to the display
high voltage level on the connector. check connectors at
cable or connectors are defect and are contacted to the display
vehicle ground change display
display has an internal defect
F1 GENERAL EEPROM FAULT no reaction replace TCU often shown
TCU cannot read non volatile memory OP-Mode: normal together with fault
TCU is defective code F2
F3 APPLICATION ERROR transmission stay neutral replace TCU fault occurs only if
something of this application is wrong OP-Mode: TCU shutdown a test engineer did
something wrong in
the application of
the vehicle
F5 CLUTCH FAILURE transmission stay neutral check clutch TCU shows also the
AEB was not able to adjust clutch filling parameters OP-Mode: TCU shutdown affected clutch on
One of the AEB-Values is out of limit the Display
F6 CLUTCH ADJUSTMENT DATA LOST TCU shifts to neutral execute AEB
TCU was not able to read correct clutch adjustment OP-Mode: limp home
parameters
interference during saving data on non volatile
memory
TCU is brand new or from another vehicle

22 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

8.1 Actuator:
1

2
G

open circuit: R12 R1G R2G


short cut to ground: R12 R; R1G 0, R2G R or R1G R, R2G 0 (for s.c. to ground, G is connected to
vehicle ground)
short cut to battery: R12 R; R1G 0, R2G R or R1G R, R2G 0 (for s.c. to battery, G is connected to
battery voltage)

8.2 Cable: UBat

P (power supply)
TCU

1 2 Actuator / Sensor

C (chassis)

Gnd

open circuit: R12 R1P R1C R2P R2C


short cut to ground: R12 0; R1C R2C 0, R1P R2P
short cut to battery: R12 0, R1C R2C , R1P R2P 0

Fig. 10 - Measuring Resistance at Actuator/Sensors and Cable

Retarder - the service brakes should be employed for this


The retarder is engaged when the bottom of the switch purpose.
is pressed and provided that the transmission 'Stop'
warning light is OUT and the transmission is in 'lockup'. Before the vehicle starts down the grade, release
To disengage retarder, press the top of the switch. The accelerator, slow the vehicle with the service brakes,
retarder will also be selected by the brake pedal. The select the required gear, and apply the retarder. For
first 5 of pedal travel engages the retarder, provided maximum retardation, oil circulation and cooling, the
that the transmission 'Stop' warning light is OUT, the vehicle downgrade speed (retarder applied) in the gear
transmission is in 'lockup' and oil temperature is within selected should be high enough to keep the engine
operating range. Further depression of pedal applies operating at governed speed. Generally the gear used
service brakes in addition to retarder. Retarder will be to ascend a grade is also correct for its descent. If the
disengaged when the brake pedal is released, or when rate of descent is too slow, the transmission should be
any of the conditions are out of range. upshifted to the next highest gear. If the rate of
descent is too fast, the service brakes should be
The retarder is used to apply a continuous braking applied and the transmission shifted into a lower gear
force to hold the truck to a safe steady speed when which will allow a safe descent and efficient retarder
descending grades, to reduce the need for service operation.
brake applications, thus reducing service brake wear
and preventing overheating. The retarder may be used Frequent use of the retarder will result in higher
anytime to slow down. If additional braking is required transmission oil temperatures. Therefore, the oil
apply the service brakes. The retarder is not meant for temperature gauge should be checked frequently.
bringing the vehicle to a halt, or for sudden deceleration During normal operation the gauge should read between

SM 2177 11-02 23
Transmission - Transmission and Mounting
Section 120-0010
80 C (176 F) and 120 C (248 F). However, during 1. Position the vehicle in a level work area, ensure the
retarder operation the gauge may reach 145 C (293 body is fully lowered, apply the parking brake and
F). Provided the vehicle is not in an overspeed switch off the engine. Operate steering right and left
condition, the transmission 'Stop' warning light will several times to relieve any pressure in the steering
illuminate when the transmission oil temperature system.
reaches 140 C (284 F). The retarder will automatically
disengage when the oil temperature reaches 150 C 2. Operate the treadle valve continuously to discharge
(302 F) irrespective of engine speed. The speed must the accumulators, block all road wheels, place the
be reduced by using the service brakes so that the oil steering lock bar in the 'Locked' position and the
is cooled down. Reduce downgrade travel speed to battery master switch in the 'Off' position.
avoid the oil overheating and possible damage to the
transmission. 3. Disconnect the following cables and connectors in
the order given, to prevent serious damage to the
If the vehicle is approaching an overspeed condition, vehicles electrical components.
the transmission upshifts automatically through the
gears (to 6th) to decrease the engine speed, whether in a- Battery earth cables
manual or automatic mode. The service brakes should b- Battery supply cables
be applied to reduce travel speed. With the accelerator c- Alternator earth cables
pedal released, the retarder will automatically engage d- Alternator supply cables
when the engine speed reaches 2 000 rev/min and it e- Transmission ECU (Est-37) connector
will disengage at 1 850 rev/min to prevent engine f- Engine ECM connectors
overspeeding. g- Body control lever
h- Hydraulics ECU
With the accelerator pedal depressed, the retarder is
automatically engaged at 2 600 rev/min to decrease 4. Place a suitable container under the transmission
the engine speed. The retarder is disengaged at 2 450 drain port, remove drain plug and drain oil. After
rev/min. A fault code will be displayed and recorded by draining, reinstall drain plug and tighten securely.
the ECU. If the oil temperature reaches 150 C (302F)
the retarder is disengaged and a fault code will be 5. Remove blanking cap from remote drain line at the
displayed and recorded by the ECU. bottom of the hydraulic tank. Install a length of hose on
remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
REMOVAL hose and reinstall blanking cap.
Numbers in parentheses refer to Fig. 1.
6. Remove cab from the machine. Refer to Section
Note: Tag all lines, cables and linkages disconnected 260-0010, CAB AND MOUNTING. Ensure all
during removal to aid in installation. connections and lines connected to cab are
disconnected.

WARNINGS 7. Disconnect all drivelines connected to the


To prevent personal injury and property transmission and secure clear of the transmission.
damage, be sure wheel blocks, blocking Refer to Section 130-0010, DRIVELINES.
materials and lifting equipment are properly
secured and of adequate capacity to do the job 8. Identify and tag oil filter hose assemblies (5, 6 & 7,
safely. Fig. 11) to aid installation. Disconnect hose assemblies
(5, 6 & 7, Fig. 11) and cap open ends and adaptor (8,
Hydraulic oil pressure will remain within Fig. 11) and elbows (9, 10 & 11, Fig. 11) to prevent
the braking system after engine shutdown. entry of dirt.
Operate the treadle valve continuously until the
pressure has dissipated before removing any 9. Remove filter bracket (1, Fig. 11) from exhaust
brake lines or serious injury could result. cradle. Remove all exhaust tubes, silencer, exhaust
stack and exhaust cradle. Remove engine air intake
High electrical current can cause sparks tube if required.
and personal injury from burns. Turn battery
master switch to the 'Off' position before 10. Disconnect all electrical harnesses and
disconnecting any components. connections not previously disconnected on removal of

24 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010

SM - 2795

8
12
13
14
5

7 10 2
3
1 4

11 8

1 - Filter Bracket 6 - Hose Assembly 11 - Elbow


2 - Bolt 7 - Hose Assembly 12 - Bolt
3 - Washer 8 - Adaptor 13 - Lockwasher
4 - Locknut 9 - Elbow 14 - Washer
5 - Hose Assembly 10 - Elbow

Fig. 11 - Transmission Oil Filter Lines

the cab assembly. hydraulic tank. Cap lines and ports to prevent entry of
dirt.
11. Identify and tag all hydraulic lines at the hydraulic
pump. Disconnect hydraulic lines and cap lines and 16. Identify and tag diagnostic hose assemblies (22 &
ports to prevent entry of dirt. 23, Fig. 12) to aid in installation. Disconnect hose
assemblies (22 & 23, Fig. 12) and cap open ends and
Note: The transmission can be removed from the tee (21, Fig. 12) and adaptor (26, Fig. 12) to prevent
vehicle without removing the hydraulic pump. entry of dirt.

12. Identify, tag and disconnect hydraulic lines at the 17. Identify, tag and disconnect all remaining lines and
main hydraulic valve. Cap lines and ports to prevent fixtures necessary to allow removal of the transmission
entry of dirt. from the vehicle.

13. Identify, tag and disconnect transmission oil cooler 18. Attach suitable lifting equipment to the lifting points
lines from the transmission. Cap lines and ports to on transmission and raise lifting equipment to take up
prevent entry of dirt. the slack.

14. Identify, tag and disconnect hydraulic lines (6, 7, 8, 19. Remove locknut (10), hardened washer (22), bolt
9 & 10, Fig. 12) at the diff-lock/retarder valve. Cap (11) and snubbing washer (17) securing LH bracket (12)
lines and ports to prevent entry of dirt. to frame mounts.

15. Identify, tag and disconnect hydraulic lines at the 20. Remove locknut (10), hardened washer (22), bolt

SM 2177 11-02 25
Transmission - Transmission and Mounting
Section 120-0010

SM - 2796

21 13
5
12
23
11 6
1
11
7
17 2
1

22 26
18 10
3,4
8 25
19 20

TO DIAGNOSTIC
MANIFOLD PLATE

TO 'TS' PORT
ON HYD. VALVE
9 TO AXLE DIFF-LOCK
24
27
15 16
MANIFOLD
(REAR OF FRONT FRAME)

MANIFOLD
14 (REAR FRAME)

1 - Diff-lock/Retarder Valve 10 - Hose Assembly 19 - Adaptor


2 - Pressure Reducing Valve 11 - Adaptor 20 - Bracket Assy
3 - Cartridge 12 - Elbow 21 - Tee
4 - Coil 13 - Plug 22 - Diagnostic Hose
5 - Bolt 14 - Elbow 23 - Diagnostic Hose
6 - Hose Assembly 15 - Adaptor 24 - Hose Assembly
7 - Hose Assembly 16 - Manifold Plate 25 - Elbow
8 - Hose Assembly 17 - Tee 26 - Adaptor
9 - Hose Assembly 18 - Adaptor 27 - Adaptor

Fig. 12 - Transmission Retarder And Diff-Lock Lines

(11) and snubbing washer (17) securing RH bracket DISASSEMBLY


(13) to frame mounts.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
21. Remove locknuts (10), washers (8) and bolts (9)
securing front bracket assembly to frame mounts.
1. Remove bracket assembly (20, Fig. 12) complete
with diff-lock/retarder valve (1, Fig. 12). Remove bolts
22. Check to make certain that all necessary line and
(5, Fig. 12) securing diff-lock/retarder valve to bracket
cable disconnections have been made before lifting the
assembly and remove valve.
transmission.
2. If required, pressure reducing valve (2, Fig. 12),
23. Carefully raise the transmission ensuring that no
solenoid cartridges (3, Fig. 12) and coils (4, Fig. 12)
lines, cables or components foul during removal. The
can be removed from diff-lock/retarder valve.
transmission may have to be pushed forward to allow
output yoke to clear rear of frame. When the
3. Remove bolts (14), lockwashers (15) and LH bracket
transmission is clear of the frame assembly, move to a
(12) from the transmission. Remove isolation mount
suitable work area and mount securely on a work
(16) from LH bracket (12) and replace if required.
stand.
4. Remove bolts (14), lockwashers (15) and RH bracket

26 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
(13) from the transmission. Remove isolation mount (16) Note: Tighten all fasteners without special torques
from RH bracket (13) and replace if required. specified to standard torques listed in Section 300-
0080, STANDARD BOLT AND NUT TORQUE
5. Remove bolts (4) and lockwashers (3) securing front SPECIFICATIONS.
bracket (2) and front plate (5) to transmission.
1. Install new gasket (19) on dipstick tube (18)
6. Remove mounting hardware securing front plate (5) assembly and secure assembly to the transmission
to front bracket (2). Press out centre bonded mount (6) with bolts (20) and lockwashers (21). Secure dipstick
from front plate (5) and remove sleeve (1). tube (18) to support bracket with fasteners previously
removed.
7. Remove mounting hardware securing hydraulic pump
to the transmission power takeoff. Refer to Section 2. If removed, install oil temperature sender (gauge) (1,
230-0050, HYDRAULIC PUMP. Fig. 2), transmission oil cooler fan drive temperature
switch (9, Fig. 2) and retarder oil temperature sender
8. If required, identify and tag electrical connections to (11, Fig. 2) in top of the transmission. Tighten electrical
engine speed sensor, output speed sensor, central connections securely.
gear train sensor and turbine speed sensor (5, 6, 7 & 8,
Fig. 2) and remove sensors from the transmission. 3. If removed, install engine speed sensor, output
speed sensor, central gear train sensor and turbine
9. If required, identify and tag electrical connections to speed sensor (5, 6, 7 & 8, Fig. 2) in the transmission
oil temperature sender (gauge) (1, Fig. 2), transmission as shown in Fig. 2. Tighten electrical connections
oil cooler fan drive temperature switch (9, Fig. 2) and securely.
retarder oil temperature sender (11, Fig. 2) and remove
from the top of the transmission. 4. Install hydraulic pump to the transmission power
takeoff and secure using mounting hardware removed
10. Remove fasteners securing dipstick tube (18) at Disassembly. Refer to Section 230-0050, MAIN
support bracket. Remove bolts (20), lockwashers (21), HYDRAULIC PUMP.
dipstick tube (18) assembly and gasket (19) from the
transmission. 5. Install centre bonded mount (6) and sleeve (1) to
front plate (5). Secure front plate assembly to front
11. Refer to transmission manufacturers service bracket (2) with bolt (7), washer (8) and nut. Tighten
manual if transmission service or repair is required. bolt (7) to 920 Nm (679 lbf ft).
Note: Clean, prime and seal joint using Loctite 7063
cleaner, Loctite T primer and Loctite 648 retaining
INSPECTION compound.
Numbers in parentheses refer to Fig. 1.
6. Secure front bracket assembly to transmission using
1. Check front bracket assembly (1, 2, 5 - 8), LH bolts (4) and lockwashers (3). Tighten bolts (4) to 225
bracket (12), RH bracket (13) and frame mounting Nm (166 lbf ft).
brackets for cracks and damage. Repair or replace as
required. 7. Secure LH bracket (12) and RH bracket (13) to the
transmission with bolts (14) and lockwashers (15).
2. Check general condition of transmission assembly Tighten bolts (14) to 410 Nm (302 lbf ft).
for wear and damage. Check for worn or damaged Note: Clean, prime and seal joint using Loctite 7063
driveline flanges and excessive wear on mounting cleaner, Loctite T primer and Loctite 648 retaining
holes and isolation mounts (16). compound.

3. Check condition of all electrical harnesses and 8. Secure diff-lock/retarder valve (1, Fig. 12) to bracket
connections and repair/replace as required. Check assembly (20, Fig. 12) with mounting hardware
condition of all hydraulic lines on the transmission removed during Disassembly.
and replace if damaged.
9. Mount bracket assembly (20, Fig. 12) and diff-lock/
retarder valve (1, Fig. 12) to transmission with
ASSEMBLY fasteners removed during Disassembly.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.

SM 2177 11-02 27
Transmission - Transmission and Mounting
Section 120-0010

INSTALLATION (6, 7, 8, 9 & 10, Fig. 12) and ports at diff-lock/retarder


valve. Connect hose assemblies to the diff-lock/
Numbers in parentheses refer to Fig. 1, unless
retarder valve.
otherwise specified.
9. Remove blanking caps from transmission oil cooler
Note: Tighten all fasteners without special torques
lines and retarder ports and connect oil cooler lines.
specified to standard torques listed in Section
Refer to Section 210-0060, TRANSMISSION OIL
300-0080, STANDARD BOLT AND NUT TORQUE
COOLER.
SPECIFICATIONS.
10. Remove blanking caps and connect lines to main
Note: Tighten all hydraulic lines fitted with ORFS
hydraulic valve, as identified at removal.
connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
11. Remove blanking caps and connect hydraulic lines
where used.
to the hydraulic pump, as identified at removal.

WARNING 12. Connect all electrical cables, harnesses and


connections to the transmission, as identified at
To prevent personal injury and property
removal.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job 13. Install air intake tube (if removed), exhaust tubes,
safely. exhaust cradle, exhaust silencer and exhaust stack.
Install filter bracket (1, Fig. 11) to cradle.
1. Lubricate isolation mounts (16) with water or a
suitable rubber lubricant and install in front frame 14. Connect all drivelines to the transmission and
mounts, with spigots to the underside of the mounts. secure with mounting hardware removed during
removal. Refer to Section 130-0010, DRIVELINES.
2. Attach suitable lifting equipment to transmission
lifting points and carefully position the transmission 15. Prior to installing the cab, ensure that all connections
assembly in the frame. Take care to avoid snagging to the transmission, other than cab connections, are
any lines, harnesses or components attached to the connected securely and properly clipped.
transmission.
16. Install the cab assembly on the front frame. Refer
3. Secure rear mounting brackets (12 & 13) to frame to Section 260-0010, CAB AND MOUNTING.
mounts with bolts (11), snubbing washers (17), hardened
washers (22) and locknuts (10), as shown in Fig. 1. 17. Connect all harnesses and electrical connections at
Tighten bolts (11) to a torque of 920 Nm (679 lbf ft). front of the cab.

4. Secure front bracket assembly to frame mounts with 18. Fill hydraulic tank with hydraulic oil specified in
bolts (9), washers (8) and locknuts (10). Tighten bolts Section 300-0020, LUBRICATION SYSTEM. Refer to
(9) to a torque of 920 Nm (679 lbf ft). Section 230-0040, HYDRAULIC TANK for fill level
and procedure.
5. Remove lifting equipment from lifting points on
transmission. 19. Fill transmission with engine oil specified in Section
300-0020, LUBRICATION SYSTEM. Check the oil
6. Remove blanking caps from hose assemblies level as described under 'Oil Level Check'.
(22 & 23, Fig. 12), tee (21, Fig. 12) and adaptor (26, Note: Transmission oil cooler should be primed when
Fig. 12) and connect hose assemby (22, Fig. 12) to refilling transmission. Refer to Section 210-0060,
adaptor (26, Fig. 12), and hose assembly (23, Fig. 12) TRANSMISSION OIL COOLER.
to tee (21, Fig. 12).
20. Connect the following cables and connectors in the
7. Remove blanking caps from hydraulic tank hose order given to prevent serious damage to the engines
assemblies and ports, and connect hose assemblies to electrical components.
the hydraulic tank.
a - Hydraulics ECU
8. Remove blanking caps from hose assemblies b - Body control lever
c - Engine ECM connectors

28 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
d- Transmission ECU (Est-37) connector SM - 2797
e- Alternator supply cables HOT COLD FILL
f- Alternator earth cables COLD FILL LEVEL
LEVEL LEVEL
BAND - MINIMUM -
g- Battery supply cables MINIMUM -
ENGINE OFF
ENGINE ENGINE
RUNNING RUNNING
h- Battery earth cables
MAX MIN

21. Turn the battery master switch to the 'On' position,


152mm (6") Min
start the engine and make an operational check of all
lines and electrical connections disconnected during
removal. Check for leaks and tighten lines and fittings
Fig. 13 - Transmission Dipstick Markings
as required. Allow transmission to warm up and
recheck all connections for leaks.
overheat. It is absolutely necessary that the oil put into
the transmission is clean.
22. Ensure parking brake is applied, disconnect
steering lock bar and secure in the 'Stowed' position.
Cold Oil Level Check - Engine Off
Remove wheel blocks from all road wheels.
This check is made only to determine if the transmission
contains sufficient oil for safe starting. Oil level should
23. Check for correct operation of the transmission,
show at least 6" (152 mm) above the hot oil maximum
shift selector and warning lights.
(MAX 80 C) mark on the dipstick. Add oil if low.

MAINTENANCE Cold Oil Level Check - Engine Running


This cold check is valid only when transmission oil
Periodic Inspections temperature is below 40 C (104 F).
For easier inspection, the transmission should be kept
clean. Make periodic checks for loose mounting bolts 1. Position the vehicle on a level work area, apply the
and leaking oil lines. Check the condition of electrical parking brake and block all road wheels securely.
harnesses and connections regularly.
2. With parking brake applied, gear selector in neutral
Transmission breather (10, Fig. 2) should be checked and engine idling, check the oil level on dipstick. Oil
on a regular basis (every 250 hours), and as frequently level should be up to the 'COLD MIN' mark on the
as necessary, depending on operating conditions. A dipstick. Add oil if low.
badly corroded or plugged breather restricts proper
breathing and causes a buildup of condensation and Hot Oil Level Check - Engine Running
subsequent oil deterioration. This hot check is valid for normal operating oil
temperature of 80 C (176 F).

Oil Level Check 1. Position the vehicle on a level work area, apply the
parking brake and block all road wheels securely.

WARNING 2. With the transmission in neutral and the engine


When checking the oil level, be sure that the running, allow the machine to idle until normal operating
parking brake is applied and all road wheels are temperature of 80 C (176 F) is achieved.
securely blocked.
3. With parking brake applied, foot on service brake,
Check the transmission oil level and add oil if low, engine idling and transmission operating at normal
every 10 hours/daily. Use only oil specified in temperature, select each gear position in turn. Allow
Section 300-0020, LUBRICATION SYSTEM. the transmission to remain in each gear for 5 - 10
seconds.
Because the transmission oil cools, lubricates and
transmits hydraulic power it is important that the 4. Return gear selector to neutral and, with the engine
proper oil level be maintained at all times. If the oil idling, check the oil level on dipstick. Oil level should
level is too low, the converter and clutches will not be between the 'MAX 80 C' upper mark and the 'MIN
receive an adequate supply of oil. If the oil level is 80 C' lower mark on the dipstick. Add oil if low.
too high, the oil will aerate and the transmission will

SM 2177 11-02 29
Transmission - Transmission and Mounting
Section 120-0010

Topping Up Oil with mineral spirits at each oil and filter change. Metal
particles in the oil (except for the minute particles
If transmission oil level has to be topped up, according
normally trapped in the oil filters) indicate damage has
to dipstick, oil should be added through the filler on the
occurred in the transmission. When these particles are
transmission oil cooler. Bleed plug on top of
found in the filters, the cause must be established and
transmission oil cooler should be opened while adding
rectified immediately to prevent damage to the
oil. Allow oil to drain into system then recheck level.
transmission.

Oil and Filter Change At each oil change, examine the used oil for evidence
of dirt or water. A normal amount of condensation will
emulsify in the oil during transmission operation.
However, if there is evidence of water or engine coolant
WARNING
in the oil, the cause must be established and rectified
When changing filter cartridges, it is imperative
immediately to prevent damage to the transmission. Oil
that new filter cartridges are the same part
should be added to transmission as described in
number and colour as the original cartridges.
'Topping Up Oil'.
The transmission oil and filter cartridges should be
changed every 1 000 hours, or sooner, depending on AEB Starter
operating conditions. Clean oil filter head when
The AEB Starter is an electronic tool used to calibrate
changing filter cartridges. Also, the oil must be
the transmission to ensure optimum shift comfort. It is
changed whenever there are traces of dirt or evidence
recommended to run the AEB Starter after the first 500
of high temperature indicated by discoloration or strong
hours of transmission operation. The AEB Starter
odour.
should also be run if shift quality deteriorates, or
whenever the transmission, electronic control unit
The internal filter and finger magnet at the lower front
(ECU) or shift lever are replaced. The procedure for
left hand of the sump should be removed and cleaned

AEB Starter Procedure


ACTION DISPLAY MESSAGE REMARK
1 warm up transmission normal operating messages
2 turn off ignition nothing
3 plug in AEB - Starter
4 move shift lever to N position
engage parkbrake
5 start engine PL TCU must recognise PL for at
least 2 seconds before you
can press the button
6 set engine speed to idle PL if start conditions are OK
7 press button of the AEB-Starter ST if start conditions are OK The button must not be
released before TCU has
started the AEB or quit with
an error code (see display
table)
8 hold button until AEB has started K1 (Information about the AEB TCU has started the AEB,
state) and goes on adjusting K1, K2,
, KR. (Button may be
released)
9 wait until AEB has finished OK (AEB has been successful)
10 turn off ignition and unplug nothing
AEB-Starter

30 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
running the AEB Starter is detailed in the table on Lock-Up Solenoid
previous page. Refer to table on page 10 for typical The solenoid can be checked at plug X9, pins 7 & 8
codes displayed during AEB mode. (located below the right hand dash panel).
Resistance: 60 - 80 ohms
Note: Connect the AEB Starter to plug X25 located
below the right hand dash panel, adjacent to the ECU. Current: 0.25 - 0.35 A
Voltage: 24 V
Pressure can also be checked (see Fig. 6).
TROUBLESHOOTING
Numbers in parentheses refer to Fig. 2, unless
otherwise specified. Temperature Sensors
The sump temperature sensor, located in the main
control valve (2) can be checked at plug X8, pins 14 &
Transmission Sensor Checks 15. Resistance should be 1 000 - 1 500 ohms.
The engine (5), turbine (8), central gear train (7) and
output (6) speed sensors can be checked by The retarder temperature sensor (11) can be checked
measuring their resistance at plug X8 (located below at plug X9, pins 15 & 16. Resistance should be 800 - 1
the right hand dash panel). 500 ohms.

1. Engine speed sensor (5). Check across pins 1 & 2. The transmission oil cooler fan drive temperature
Resistance should be 945 - 1 155 ohms at a sensor (9) can be checked by measuring resistance
temperature of 20 C (68 F). across terminals:
At 20 C (68 F), resistance should be 1 020 - 1 280
2. Turbine speed sensor (8). Check across pins 3 & 4. ohms.
Resistance should be 945 - 1 155 ohms at a At 60 C (140 F), resistance should be 219 - 261
temperature of 20 C (68 F). ohms.
At 90 C (194 F), resistance should be 82 - 96 ohms.
3. Central gear train speed sensor (7). Check across At 120 C (248 F), resistance should be 36.3 - 40.7
pins 5 & 6. Resistance should be 945 - 1 155 ohms at ohms.
a temperature of 20 C (68 F).

4. Output speed sensor (6). Check across pins 21 & Shift Controller
22. Resistance should be 5 mega ohms. To troubleshoot the shift controller, continuity checks
can be easily done by removing plug X2, selecting
The installation of the speed sensors can also be position and measuring across following pins:
checked by measuring the gap between the sensor and Neutral - Pins 2 & 5
the gear tooth:
Forward - Pins 2 & 4
Engine speed sensor (5) and turbine speed sensor (8) - Reverse - Pins 2 & 6
gap should be 0.5 - 0.8 mm. Up - Pins 2 & 7
Down - Pins 2 & 8
Central gear train speed sensor (7) - gap should be 0.3 Button - Pins 2 & 10
+
/- 0.1 mm.

Output speed sensor (6) - gap should be 1.0 - 1.5 mm.

Measuring CAN-Bus Resistance At Plug X4 (Ignition OFF)


Measurement between Specified Value (ohms) Actual Value (ohms) Possible Cause
CAN H (X4 pin 1) 40 0 Short circuit from CAN H to CAN L
and 40 60 or 120 Connections to one or two ends of
CAN L (X4 pin 2) resistors are damaged or cut off
40 Infinity End resistors damaged or cut off

SM 2177 11-02 31
Transmission - Transmission and Mounting
Section 120-0010

Measuring CAN-Bus Voltage At Plug X4 (Ignition ON)


Measurement between Specified Value (Volts) Actual Value (volts) Possible Cause
CAN H (X4 pin 1) 24 Short circuit from CAN H to battery
and 2.4 - 2.9 0 Short circuit from CAN H to ground
Ground 0 - 2.3 Intermittent short circuit from
3.0 - 24 CAN H to another component
CAN L (X4 pin 2) 24 Short circuit from CAN L to battery
and 2.2 - 2.7 0 Short circuit from CAN L to ground
Ground 0 - 2.1 Intermittent short circuit from
2.8 - 24 CAN L to another component

Transmission To Engine CAN-Bus Differential Pressure Switch


The communication link between the transmission and When oil is at operating temperature, the switch can be
the engine can be electrically checked by measuring checked at plug X9, pins 17 & 18. With the harness
resistance and voltage. Refer to tables. connected to the switch, resistance should be 500
ohms.

Solenoid Coil Ratings


The following data should be referenced when Pressure Checks
checking solenoids: Refer to Fig. 6 for measurement points and pressures.
The system pressure, convertor pressure and retarder
1. Centre axle diff-lock solenoid (3, Figs. 4 & 5) (at
pressure can be measured at the diagnostic test points
valve on top of transmission)
in the battery box. If other pressures are to be
Resistance: 41 ohms
measured, then diagnostic connectors on main control
Current: 0.6 A
valve (2) should be moved to required point, so
2. Transmission diff-lock solenoid (at transmission pressure can be read from diagnostic test point.
output to front axle)
Resistance: 30 ohms
Current: 0.8 A SERVICE TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
3. Retarder solenoid (4, Figs. 4 & 5) (at valve on top of
number of AEB Starter and other service tools which
transmission). The solenoid can be checked at plug
should be used in conjunction with procedures outlined
X9, pins 9 & 10.
in the transmission manufacturers service manual,
Resistance: 41 ohms
and, general service tools required. These tools are
Current: 0.6 A
available from your dealer.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 4 Bolt 225 166
1 7 Bolt 920 679
1 9 Bolt 920 679
1 11 Bolt 920 679
1 14 Bolt 410 302

* * * *
32 SM 2177 11-02
DRIVELINES - Front and Rear Drivelines
Section 130-0010

SM - 2799

15

13 14
12

15 2 3
ENGINE

TRANSMISSION

10
1
10

5 9 8
6
TO
TRAILER

FRONT AXLE

11 11 10 10
4 7
1 - Driveline Assembly 6 - Screw 11 - Capscrew
2 - Universal Joint 7 - Driveline Assembly 12 - Anti-flail Guard
3 - Screw 8 - Universal Joint 13 - Bolt
4 - Driveline Assembly 9 - Screw 14 - Washer
5 - Universal Joint 10 - Capscrew 15 - Bracket

Fig. 1 - Front Drivelines and Mounting

DESCRIPTION generated during operation, preventing tension or


Numbers in parentheses refer to Fig. 1, unless compression loads from causing serious damage to the
otherwise specified. components.

The function of the driveline is to transmit rotating Note: Extra care should be taken when handling the
power from one point to another in a smooth and drivelines since chips, dents, burrs or deformity on any
continuous action while allowing a degree of rotating mass creates vibration and excessive wear
movement or misalignment of the components it during any operation.
connects.
There are three driveline assemblies installed between
The drivelines must operate through constantly various components in the tractor frame as follows:
changing relative angles between the components
they are mounted to and must also be capable of Driveline assembly (1) is connected between the
changing length while transmitting torque. engine drive and transmission input drive.

A typical driveline consists of universal joints which Driveline assembly (4) is connected between the front
allow some misalignment and permit the driveline to axle drive flange and transmission final drive.
pivot in any direction, and, a light rigid hollow slip yoke
and splined shaft assembly forming a slip joint. Driveline assembly (7) connects the rear final drive of
the transmission to the articulation and oscillation
The slip joint accommodates length variations pivot.

SM 2178 11-02 1
Drivelines - Front and Rear Drivelines
Section 130-0010

SM - 2800

CENTRE AXLE REAR AXLE


2,3 5,6
2,3 5,6

1 4
7 8
7 8
OSCILLATION
PIVOT

1 - Driveline Assembly 4 - Driveline Assembly 7 - Capscrew


2 - Universal Joint 5 - Universal Joint 8 - Capscrew
3 - Screw 6 - Screw

Fig. 2 - Rear Drivelines and Mounting

There are two driveline assemblies connecting the 1. Position the vehicle in a level work area, apply the
centre and rear axles to the drive supplied from the parking brake and switch off the engine.
transmission, through the pivot drive arrangement, as
follows: 2. Block all road wheels and place the battery master
switch in the 'Off' position.
Driveline assembly (1, Fig. 2) is connected between
the oscillation pivot drive arrangement and the centre Note: Access to remove driveline assembly (1) can be
axle. obtained by tilting the cab. Refer to Section 260-0010,
CAB AND MOUNTING.
Driveline assembly (4, Fig. 2) is connected between
the centre axle and the rear axle. 3. Remove bolts (13) and washers (14) securing anti-
flail guard (12) to bracket (15). Remove anti-flail guard
(12).
REMOVAL
Numbers in parentheses refer to Fig. 1, unless 4. Remove bracket (15) over driveline assembly (1)
otherwise specified. from engine flywheel housing.

Note: Extra care should be taken when handling 5. Match mark universal joint (2) and their mating
drivelines since carelessness can result in premature surfaces to ensure correct mating alignment when
failure of the components. Chips, dents, burrs, or any installing driveline assembly (1).
other deformity of universal joints will prevent accurate
mating. This will cause misalignment which is 6. Support driveline (1) with suitable lifting equipment
accompanied by vibration and excessive wear. and remove capscrews (10) securing universal joints
(2) to their mating components. Remove driveline
assembly (1). If necessary tap driveline assembly (1)
WARNINGS from its mating components with a soft faced hammer.
To prevent personal injury and property
damage, be sure wheel blocks, blocking Note: Access to driveline assemblies (4 & 7) can be
materials and lifting equipment are properly obtained from underneath the vehicle.
secured and of adequate capacity to do the job
safely. 7. Match mark universal joints (5 & 8) and their mating
surfaces to ensure correct mating alignment when
installing driveline assemblies (4 & 7).
To prevent serious injury or death, DO NOT go
under the vehicle when the engine is running. 8. Remove capscrews (11) securing universal joints (5)
Rotating shafts can be dangerous. You can to their mating components and remove driveline
snag clothes, skin, hair, hands, etc.. assembly (4). If necessary tap driveline assembly (4)

2 SM 2178 11-02
Drivelines - Front and Rear Drivelines
Section 130-0010
from its mating components with a soft faced hammer. SM - 088

9. Remove capscrews (10) securing universal joints APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
(8) to their mating components and remove driveline
assembly (7). If necessary tap driveline assembly (7)
from its mating components with a soft faced hammer.
STRAIGHT EDGE
Note: Access to driveline assemblies (1 & 4, Fig. 2)
can be obtained from underneath the vehicle.

10. Match mark universal joints (2 & 5, Fig. 2) and their


mating surfaces to ensure correct mating alignment
REMOVE ALL
when installing driveline assemblies (1 & 4, Fig. 2).
BURRS AND
PAINT FROM
11. Remove capscrews (7, Fig. 2) securing universal THESE SURFACES
joints (2, Fig. 2) to their mating components and
remove driveline assembly (1, Fig. 2). If necessary tap
driveline assembly (1, Fig. 2) from its mating
components with a soft faced hammer.
Fig. 3 - Checking Parallelism
12. Remove capscrews (8, Fig. 2) securing universal
joints (5, Fig. 2) to their mating components and splines are nicked. Burrs may be removed with a fine
remove driveline assembly (4, Fig. 2). If necessary tap file or medium India stone.
driveline assembly (4, Fig. 2) from its mating
components with a soft faced hammer. 3. Check the surfaces of the components that universal
joints mate against for parallelism. Refer to Fig. 3.

DISASSEMBLY 4. Check condition of mounting capscrews and replace


if required.
Universal Joint
Numbers in parentheses refer to Fig. 1.
ASSEMBLY
1. Place the yoke end of driveline assembly (1) in a
soft jawed vice, clamping on the tube of shaft. Universal Joint
Numbers in parentheses refer to Fig. 1.
Note: Do not distort the tube with excessive grip.
1. Place the yoke end of driveline assembly (1) in a
2. Remove screws (3) and universal joints (2) from soft jawed vice, clamping on the tube of shaft.
driveline assembly (1).
Note: Do not distort the tube with excessive grip.
3. Place the shaft end of driveline assembly (1) in a
soft jawed vice. 2. Install universal joint (2) to yoke end of driveline
assembly (1) and secure with screws (3).
4. Remove screws (3) and universal joints (2) from
driveline assembly (1). 3. Place the shaft end of driveline assembly (1) in a
soft jawed vice.
5. Repeat steps 1 to 4 for drivelines (4 & 7) and
(1 & 4, Fig. 2) 4. Install universal joint (2) to shaft end of driveline
assembly (1) and secure with screws (3).

INSPECTION 5. Repeat steps 1 to 4 for drivelines (4 & 7) and


1. Clean all metal parts in a suitable solvent, and dry (1 & 4, Fig. 2)
all parts with compressed air.

2. Inspect splines of shaft and yoke for nicks, burrs INSTALLATION


and excessive wear. Replace if wear is excessive or Numbers in parentheses refer to Fig. 1, unless

SM 2178 11-02 3
Drivelines - Front and Rear Drivelines
Section 130-0010
otherwise specified. 8. Secure anti-flail guard (12) to bracket (15) with bolts
(13) and washers (14).
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section 9. Position driveline assembly (1, Fig. 2) on the vehicle
300-0080, STANDARD BOLT AND NUT TORQUE as shown and align match marks on universal joints (2,
SPECIFICATIONS. Fig. 2) with those on its mating surfaces.

Note: Extra care should be taken when handling 10. Apply Loctite 648 to the threads of capscrews
drivelines since carelessness can result in premature (7, Fig. 2) and secure universal joints (2, Fig. 2) to its
failure of the components. Chips, dents, burrs, or any mating surfaces with capscrews (7, Fig. 2). Tighten
other deformity of wing bearings will prevent accurate capscrews (7, Fig. 2) to a torque of 153 Nm
mating. This will cause misalignment which is (113 lbf ft).
accompanied by vibration and excessive wear.
11. Position driveline assembly (4, Fig. 2) on the
vehicle as shown and align match marks on universal
WARNINGS joints (5, Fig. 2) with those on its mating surfaces.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 12. Apply Loctite 648 to the threads of capscrews
materials and lifting equipment are properly (8, Fig. 2) and secure universal joints (5, Fig. 2) to its
secured and of adequate capacity to do the job mating surfaces with capscrews (8, Fig. 2). Tighten
safely. capscrews (8, Fig. 2) to a torque of 153 Nm
(113 lbf ft).
To prevent serious injury or death, DO
NOT go under the vehicle when the engine is 13. Lower the cab, place the battery master switch in
running. Rotating shafts can be dangerous. the 'On' position, ensure the parking brake is applied
You can snag clothes, skin, hair, hands, etc.. and start the engine. Remove wheel blocks from all
road wheels.
1. Position driveline assembly (7) on the vehicle as
shown in Fig. 1 and align match marks on universal
joints (8) with those on its mating surfaces. MAINTENANCE
Every 500 hours, check the universal joints for wear
2. Apply Loctite 648 to the threads of capscrews (10) and replace if required.
and secure universal joints (8) to its mating surfaces
with capscrews (10). Tighten capscrews (10) to a Every 2 000 hours, check drivelines for leaks and
torque of 153 Nm (113 lbf ft). damage, and replace if required.

3. Position driveline assembly (4) on the vehicle as


shown in Fig. 1 and align match marks on universal Periodic Inspection
joints (5) with those on its mating surfaces. Use a small pry bar to check the companion flange
yokes for looseness. If loose, drop one end of the
4. Apply Loctite 648 to the threads of capscrews (11) driveline and twist the yoke to check the backlash
and secure universal joints (5) to its mating surfaces between the splines and yokes. Replace any yoke that
with capscrews (11). Tighten capscrews (11) to a does not fit snugly.
torque of 153 Nm (113 lbf ft).
With the pry bar, check the universal joints for play. If
5. Position driveline assembly (1) on the vehicle as loose, replace the universal joints. Check the splines at
shown in Fig. 1 and align match marks on universal the slip joint and replace the yoke if excessively worn.
joints (2) with those on its mating surfaces.

6. Apply Loctite 648 to the threads of capscrews (10) SERVICE TOOLS


and secure universal joints (2) to its mating surfaces There are no special tools required for the procedures
with capscrews (10). Tighten capscrews (10) to a outlined in this section. Refer to Section 300-0070,
torque of 153 Nm (113 lbf ft). SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
7. Secure bracket (15) over driveline assembly (1) with adhesives are available from your dealer.
mounting hardware previously removed.

4 SM 2178 11-02
Drivelines - Front and Rear Drivelines
Section 130-0010

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.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Capscrew 153 113
1 11 Capscrew 153 113
2 7 Capscrew 153 113
2 8 Capscrew 153 113

* * * *

SM 2178 11-02 5
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 the thru-drive differential and
Lock when moving or when the wheels are spinning. countershaft case assembly with suitable lifting
equipment. Remove bolts (50 & 74) securing
countershaft case (49) to differential housing (73) and
REMOVAL AND INSTALLATION carefully remove countershaft case (49) assembly
Numbers in parentheses refer to Fig. 1. clear of differential housing (73).

9. Support the weight of differential housing (73)


WARNING assembly with suitable lifting equipment. Remove bolts
To prevent personal injury and property (75) securing differential housing (73) to the axle
damage, be sure wheel blocks, blocking housing. Thread in three puller bolts to break the seal
materials and lifting equipment are properly between the differential and axle housing and to
secured and of adequate capacity to do the job partially pull the differential assembly out of the axle
safely. housing. Carefully remove differential housing (73)
assembly clear of axle housing. Remove shim (72).
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure the INSTALLATION
body in the partially raised position. Installation is the reversal of the 'Removal' procedure.

2. Apply the parking brake and switch off the engine. Note: Use sealing compound between the axle
housing and differential housing mounting faces.
3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in Note: Tighten all fasteners to standard torques listed
the 'Off' position. in Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container. Add gear oil of the type specified in Section 300-0020,
LUBRICATION SYSTEM, through the differential filler/
5. Remove the planetary assemblies and axle shafts level hole until the oil is level with the bottom of the
from the axle housing. Note from which side the long filler/level hole. Fill the planetary assemblies up to the
'Oil Level Check Line'.

SM 1971 Rev 1 1-03 1


Centre Axle - Differential Drive Head
Section 150-0020

SM - 250

Fig. 1 - Exploded View Of Centre Differential

2 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

LEGEND FOR FIG. 1.


1 - Drive Flange 23 - Shifter Fork Assembly 45 - Bolt 67 - Adjusting Nut
2 - Dust Cover 24 - Thrust Block 46 - Seal Ring 68 - Tapered Bearing
3 - Castle Nut 25 - Tapered Bearing 47 - Spacing Ring 69 - Bolt
4 - Differential Housing 26 - Plug 48 - Spur Gear * 70 - Differential Assembly
5 - Seal Ring 27 - Seal Ring 49 - Countershaft Case 71 - Ring Gear
6 - Shaft Seal 28 - Bolt 50 - Bolt 72 - Shim
7 - Bolt 29 - Bolt 51 - Roll Pin 73 - Differential Housing
8 - Bearing Flange 30 - Lockwasher 52 - Bolt 74 - Bolt
9 - Shim 31 - Plug 53 - Cover 75 - Bolt
10 - Ball Bearing 32 - Filter Element 54 - Nut 76 - Drive Flange Shaft
11 - Shim 33 - Limit Disc 55 - Roller Bearing 77 - Dust Shield
12 - Intermediate Flange 34 - Cover 56 - Spacing Ring 78 - Seal Retainer
13 - Bolt 35 - 'U' Section Ring 57 - Gear 79 - Shaft Seal
14 - Differential Case Half 36 - Piston 58 - Bearing Retaining Bush 80 - Snap Ring
15 - Thrust Washer 37 - Centring Ring 59 - Shim 81 - Ball Bearing
16 - Side Gear 38 - Spring 60 - Roller Bearing 82 - Shim
17 - Thrust Washer 39 - Nut 61 - Pinion Gear 83 - Circlip
18 - Pinion Gear 40 - Bolt 62 - Bearing Cap 84 - Spacing Ring
19 - Spider 41 - Contact Switch 63 - Bolt 85 - Tapered Bearing
20 - Differential Case Half 42 - Seal Ring 64 - Washer 86 - Slotted Nut
21 - Shift Collar 43 - Contact Pin 65 - Lockwire
22 - Differential Side Gear 44 - Shifter Fork Lock Pin 66 - Cotter Pin * - See Fig. 2

SM - 252

5 - Externally Splined Disc


6 - Internally Splined Disc
7 - Thrust Ring
1 - Bolt 8 - Side Gear
2 - Lockwasher 9 - Axle
3 - Cover 10 - Pinion Gear
4 - Thrust Washer 11 - Housing

Fig. 2 - Exploded View of Limited Slip Cross-axle Differential

SM 1971 Rev 1 1-03 3


Centre Axle - Differential Drive Head
Section 150-0020
DISASSEMBLY SM - 1109

Numbers in parentheses refer to Fig. 1, unless


otherwise specified.

1. If not done so previously, remove bolts (50 & 74)


which attach countershaft case (49) to differential
housing (73) and lift off the countershaft case
assembly.

2. Remove cotter pins (66) and adjusting nuts (67).


Index mark bearing caps (62) and differential housing
(73). Remove lockwire (65), bolts (63), washers (64)
and bearing caps (62). Remove the outer races of Fig. 3 - Removing Differential Assembly
tapered bearings (68) from differential assembly (70).
Remove differential assembly (70) from the differential SM - 1110
housing as shown in Fig. 3.

3. Index mark cover (3, Fig. 2) and housing (11, Fig. 2).
Remove bolts (1, Fig. 2) and lockwashers (2, Fig. 2)
and lift off cover.

4. Remove thrust washer (4, Fig. 2), two externally


splined discs (5, Fig. 2), two internally splined discs
(6, Fig. 2), thrust ring (7, Fig. 2) and side gear (8, Fig. 2).

5. Remove four pinion gears (10, Fig. 2) and axle


(9, Fig. 2) out of housing (11, Fig. 2). Fig. 4 - Removing Ring Gear Bolts

6. Remove the other side gear (8, Fig. 2), thrust ring SM - 1111
(7, Fig. 2), two internally splined discs (6, Fig. 2), two
externally splined discs (5, Fig. 2) and thrust washer
(4, Fig. 2) from housing (11, Fig. 2).

7. It is not necessary to remove ring gear (71) from


housing (11, Fig. 2) unless ring gear (71) and pinion
gear (61) are being replaced. The ring gear and pinion
gear are only sold as a matched set and cannot be
replaced separately. Remove bolts (69) as shown in
Fig. 4 and press the ring gear off the housing. If
necessary, pull the inner races of tapered bearings
(68) from the cover and housing. Fig. 5 - Removing Contact Switch

8. Screw out contact switch (41) with seal ring (42)


SM - 1112
and remove contact pin (43) from differential housing
(4) bore. Refer to Fig. 5.

9. Remove bolts (29), lockwashers (30) and cover (34)


from differential housing (4). Refer to Fig. 6.

10. Remove castle nut (3) using socket 15269943,


drive flange (1), dust cover (2) and seal ring (5) from
differential case half (14).

11. Remove bolts (7) and bearing flange (8) from


differential housing (4). Shaft seal (6) is removed with
Fig. 6 - Removing Cover
bearing flange (8). Remove shims (9 & 11) from

4 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

SM - 1113 intermediate flange (12).

12. Press the thru-drive differential case assembly


(13 thru 20) out of intermediate flange (12), as shown in
Fig. 7.

13. With a bearing puller, pull ball bearing (10) off the
bearing journal of differential case half (14).

Fig. 7 - Pressing Differential Assembly


From Intermediate Flange

SM - 1114 14. Index mark differential case halves (14 & 20).
Remove bolts (13) from differential case half (14) and
separate the differential case halves. Remove thrust
washer (15), side gear (16), thrust washers (17),
pinion gears (18) and spider (19). Refer to Fig. 8.

Fig. 8 - Separating Differential

SM - 1115 15. Remove bolts (45) from shifter fork lock pins (44).
Push down on piston (36) and remove shifter fork lock
pins (44) with seal rings (46) from differential housing
(4) as shown in Fig. 9. Remove and discard seal rings
(46).

Fig. 9 - Removing Shifter Fork Lock Pins

SM - 1116 16. Remove shifter fork (23) with thrust blocks (24),
piston (36) with centring ring (37) and spring (38) from
differential housing (4). Also remove shift collar (21).
Refer to Fig. 10.

Fig. 10 - Removing Shifter Fork And Piston

SM 1971 Rev 1 1-03 5


Centre Axle - Differential Drive Head
Section 150-0020
17. Unlock slotted nut (86) using socket 15269943 and SM - 1117
remove it from the threaded end of differential side gear
(22) as shown in Fig. 11. With a soft drift and hammer,
drive differential side gear (22) from countershaft case
(49). Remove inner race of tapered bearing (85). Inner
race of tapered bearing (25) will come out with
differential side gear (22). Remove spacing ring (47). If
necessary, pull the inner race of tapered bearing (25)
from differential side gear (22).

18. Remove inner and outer bolts (28) which fasten


differential housing (4) to countershaft case (49). Refer
to Fig. 12. Remove the differential housing. If Fig. 11 - Removing Slotted Nut
necessary, pull the outer race of tapered bearing (25)
from differential housing (4).
SM - 1118

19. Remove spur gear (48) from countershaft case


(49) as shown in Fig. 13. Pull outer race of tapered
bearing (85) from countershaft case (49) and remove
spacing ring (84).

20. Remove bolts (52) and cover (53) from


countershaft case (49) as shown in Fig. 14.

21. Unlock and remove nut (54) from pinion gear (61)
shaft. With the press set shown in Fig. 15, press pinion
gear (61) out of countershaft case (49). Remove Fig. 12 - Removing Bolts
spacing ring (56) from the shaft end of pinion gear
(61).
SM - 1119

22. Drive roller bearing (55) out of its bore in


countershaft case (49).

23. Press pinion gear (61) out of gear (57) and bearing
retaining bush (58) as shown in Fig. 16. Drive roller
bearing (60) out of the bearing retaining bush and
remove shim (59).

24. Remove circlip (83) and shim (82) from drive


flange shaft (76) and withdraw drive flange shaft from
axle housing. Remove dust shield (77) from end of
drive flange shaft (76). Fig. 13 - Removing Spur Gear

25. Remove seal retainer (78) and pull shaft seal (79)
from axle housing. Remove snap rings (80) and drive
ball bearing (81) from the axle housing.

6 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

SM - 1120 INSPECTION
The importance of careful and thorough inspection
cannot be overstressed. Thorough inspection and
necessary replacement of parts now may eliminate
costly and avoidable trouble later.

1. Clean all parts in petroleum base solvent.

2. Immediately after cleaning, dry all parts, except


bearings, with compressed air, or with a soft, clean lint
free wiping cloth. Compressed air has a corrosive
Fig. 14 - Removing Cover effect on bearings, therefore, they must be wiped dry
with a cloth.

SM - 1121 3. Coat cleaned, dried parts immediately with light oil


to prevent corrosion. If parts are not to be assembled
immediately, treat them with a good rust preventive
and wrap them with treated paper or other suitable
material designed to prevent corrosion.

4. Before installing the differential assembly to the


machine, clean the inside and outside of the axle
housing to remove any foreign material.

5. Inspect all gears, pinions, and splines for cracked or


broken teeth, excessive wear, and pitted or scored
Fig. 15 - Pressing Out Pinion Gear surfaces. Repair or replace as necessary.

SM - 1122 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. 16 - Pressing Pinion Gear Out Of Gear And Bearing

SM 1971 Rev 1 1-03 7


Centre Axle - Differential Drive Head
Section 150-0020

ASSEMBLY SM - 1133

Numbers in parentheses refer to Fig. 1 unless specified


otherwise.

Note: Tighten all fasteners without special torques


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. 17 - Measuring Dimension 'A'
1. Align the index marks on bearing caps (62) and
differential housing (73) and fasten with washers (64) SM - 1134

and bolts (63). Install the special shims and measuring


shaft into the differential bearing bores. Measure the
distance from the middle of the differential bearing
flange face. Refer to Fig. 17. This will be dimension 'A'.
e.g. 164.2 mm (6.40 in).

2. Install bearing retaining bush (58) into countershaft


case (49) until it is seated. Measure dimension 'B' from
the flange face of countershaft case (49) to the bearing
contact face using a straightedge and depth
micrometer as shown in Fig. 18. e.g. 25.75 mm (1.00 in).
Fig. 18 - Measuring Dimension 'B'
3. Measure the width of roller bearing (60) as shown in
Fig. 19. e.g. 37.05 mm (1.50 in). SM - 1135

Example:
Dimension 'A' 164.2 mm (6.40 in)
+ Dimension 'B' 25.75 mm (1.00 in)
= 189.95 mm (7.40 in)
- Bearing width 37.05 mm (1.45 in)
Dimension 'X' = 152.90 mm (5.95 in)

4. Refer to Fig. 20. Read distance dimension etched


on the face of pinion gear (61). e.g. 151.80 mm (5.92 in).

Example: Fig. 19 - Measuring Bearing Width


Dimension 'X' 152.90 mm (5.95 in)
- Pinion Dimension 151.80 mm (5.92 in)
SM - 1136
Shim Size = 1.10 mm (0.03 in)

5. Place the determined size shim (59) in bearing


retaining bush (58), then press or drive roller bearing
151.8
(60) into its bore in the retaining bush.

Fig. 20 - Pinion Gear Dimension

8 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

SM - 1137 6. Place the assembled bearing retaining bush (58) on


pinion gear (61) as shown in Fig. 21 and install gear
(57) chamfered side down.

7. Press or drive the assembled pinion gear (61) into


its bore in countershaft case (49) until it is completely
seated.

Fig. 21 - Installing Gear And Pinion Gear

SM - 1130 8. Install spacing ring (56) on the end of pinion gear


(61) shaft as shown in Fig. 22. e.g. 23.9 mm (0.93 in).
If parts are not being replaced, then use the same
spacing ring that was removed. Size of the spacing
ring is determined in Step 11.

9. Press roller bearing (55) on pinion gear (61) shaft


and into countershaft case (49).

Fig. 22 - Installing Spacing Ring

SM - 1162 10. Thread nut (54) on pinion gear (61) shaft. Tighten
nut (54) to a torque of 750 Nm (550 lbf ft). Refer to
Fig. 23.

Fig. 23 - Tightening Nut

SM - 1138 11. Install a dial indicator as shown in Fig. 24 and with


pry bars move the pinion up and down to determine
the end play. Write down the measured end play. If for
example there is an end play of 0.2 mm (0.0078 in) the
installed spacing ring (56) of 23.9 mm (0.93 in) must
be replaced by a narrower spacing ring by
0.22 - 0.24 mm (0.0086 - 0.0094 in). To do this repeat
Steps 7 through 10. With the proper thickness spacing
ring installed, bearing (55) pre-load will be 3 Nm
(18 lbf ft).

Fig. 24 - Measuring Pinion Gear End Play

SM 1971 Rev 1 1-03 9


Centre Axle - Differential Drive Head
Section 150-0020
12. Place spur gear (48) in countershaft case (49). It SM - 1131
will be necessary to mesh this gear with gear (57)
already installed. Refer to Fig. 25.

Fig. 25 - Installing Spur Gear

13. Install differential housing (4) on countershaft case SM - 1139


(49). Fasten together with bolts (28). Put Loctite 270
on the two outside bolts. Maximum torque of bolts (28)
is 160 Nm (120 lbf ft). Refer to Fig. 26.

Fig. 26 - Installing Differential Housing

14. Press outer race of tapered bearing (25) into SM - 1140


differential housing (4). Press inner race of tapered
bearing (25) on differential side gear (22). Slide
spacing ring (47) on the differential side gear and
insert differential side gear into spur gear (48). Refer to
Fig. 27.

Fig. 27 - Installing Side Gear

15. Place a spacing ring (84) of 22 mm (0.878 in) over SM - 1123


the opposite end of differential side gear (22). Press
outer race of tapered bearing (85) into its bore in
countershaft case (49). Press the inner race of tapered
bearing (85) onto differential side gear (22). Refer to
Fig. 28.

Fig. 28 - Installing Bearing And Spacer

10 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

SM - 1124 16. Thread slotted nut (86) onto the threaded end of
differential side gear (22). Tighten slotted nut (86) using
socket 15269943 to a torque of 550 Nm (400 lbf ft).
Refer to Fig. 29.

Fig. 29 - Torque Tightening Slotted Nut

SM - 1132 17. Using a dial indicator determine differential side


gear (22) end play. For example, if there is a measured
end play of 0.1 mm (0.0039 in) then spacing ring (84)
thickness must be reduced by 0.1 mm (0.0039 in). To
install a narrower spacing ring (84) repeat Steps 15 &
16. Lock slotted nut (86) to differential side gear (22).
There must be no bearing (85) end play or pre-load.
Refer to Fig. 30.

Fig. 30 - Measuring Side Gear End Play

SM - 1125 18. Mesh shift collar (21) with differential side gear
(22) splines. Refer to Fig. 31.

Fig. 31 - Installing Shift Collar

SM - 1126 19. Assemble thrust blocks (24) to shifter fork (23) and
install in differential housing (4). Thrust blocks fit into
shift collar (21) groove. Refer to Fig. 32.

Fig. 32 - Installing Shifter Fork

SM 1971 Rev 1 1-03 11


Centre Axle - Differential Drive Head
Section 150-0020
20. Place 'U' section ring (35) on piston (36) OD. Slide SM - 1127
centring ring (37) and spring (38) on the piston stem.
Insert the assembled piston into its bore in differential
housing (4). Be sure the piston stem makes contact
with shifter fork (23). Refer to Fig. 33.

Fig. 33 - Installing Piston

21. Place new seal rings (46) on the ends of shifter SM - 1128
fork lock pins (44) and insert them into differential
housing (4) bores. To facilitate assembly, push shifter
piston (36) down slightly. Bolt in place with bolts (45).
Tighten bolts (45) to a torque of 42 Nm (30 lbf ft).
Refer to Fig. 34.

Fig. 34 - Installing Shifter Fork Locks

22. If limit disc (33), filter element (32) and plug (31) SM - 1129
were removed from cover (34), reinstall them. Install
the cover on differential housing (4) and fasten with
bolts (29) and lockwashers (30). Tighten bolts (29) to a
torque of 42 Nm (30 lbf ft). Refer to Fig. 35.

Fig. 35 - Installing Cover

23. Place thrust washer (15) in differential case half SM - 1141


(14). Refer to Fig. 36.

Fig. 36 - Insert Thrust Washer

12 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

SM - 1142 24. Place side gear (16) into differential case half (14).
Refer to Fig. 37.

Fig. 37 - Insert Side Gear

SM - 1143 25. Install pinion gears (18) and thrust washers (17) on
spider (19) arms. Be sure the thrust washer notches
are properly positioned on the pinion gears. Install the
assembled spider in differential case half (14). Refer to
Fig. 38.

Fig. 38 - Installing Spider Assembly

SM - 1144 26. With a dial indicator gauge, check pinion gear (18)
backlash as shown in Fig. 39. Backlash should be
between 0.15 - 0.2 mm (0.00585 - 0.0078 in).

Fig. 39 - Checking Pinion Gear Backlash

SM - 1145 27. Align the index marks and place second differential
case half (20) on top of the assembled differential case
half (14). Bolt the two case halves together with bolts
(13). Tighten bolts (13) to a torque of 120 Nm
(90 lbf ft). Refer to Fig. 40.

Fig. 40 - Bolting Differential Case Together

SM 1971 Rev 1 1-03 13


Centre Axle - Differential Drive Head
Section 150-0020
28. Install differential assembly (13 thru 20) into the SM - 1146
bore of differential housing (4) as shown in Fig. 41. Be
sure the teeth on differential case half (20) mesh with
shift collar (21) teeth.

Fig. 41 - Installing Differential Assembly

29. Measure the distance from differential housing (4) SM - 1147


face to differential case half (14) face as shown in
Fig. 42. Record this as dimension 'A'. e.g. 9.0 mm
(0.351 in).

Fig. 42 - Measuring Dimension 'A'

30. With a straightedge and blocks measure SM - 1148


dimension 'B' from intermediate flange (12) face to the
inner race of ball bearing (10) as shown in Fig. 43. e.g.
10.5 mm (0.410 in).

Example:

Dimension 'B' 10.5 mm (0.410 in)


- Dimension 'A' 9.0 mm (0.351 in)
Difference = 1.5 mm (0.059 in)

Because of the backlash, the axial displacement of the


complete differential assembly is 0.2 mm (0.008 in). Fig. 43 - Measuring Dimension 'B'

Difference 1.5 mm (0.059 in) SM - 1149


+ 0.2 mm (0.008 in)
Shim Size = 1.7 mm (0.067 in)

31. Lift the differential assembly (13 thru 20) out of


differential housing (4). Place intermediate flange (12)
on differential case half (14) and press ball bearing
(10) on differential case half (14) as shown in Fig. 44.

Fig. 44 - Pressing Ball Bearing

14 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

SM - 1150 32. Using a seal driver, install shaft seal (6) in bearing
flange (8) with the seal lip facing down. Refer to Fig.
45.

Fig. 45 - Installing Shaft Seal

SM - 1151 33. Measure the distance ball bearing (10) is above


intermediate flange (12) face as shown in Fig. 46. This
is dimension 'A'. e.g. 5.0 mm (0.195 in).

Fig. 46 - Measuring Dimension 'A'

SM - 1152 34. Measure the distance from bearing flange (8) face
to ball bearing (10) contact face as shown in Fig. 47.
This is dimension 'B'. e.g. 6.5 mm (0.240 in).

Dimension 'B' 6.5 mm (0.240 in)


- Dimension 'A' 5.0 mm (0.195 in)
Required Shim = 1.5 mm (0.045 in)

Place the required shim (9) in bearing flange (8)


recess.

Fig. 47 - Measuring Dimension 'B'

SM - 1153 35. Coat intermediate flange (12) bolt circle with sealing
compound, install the size shim (11) determined in
Steps 29 and 30 and install bearing flange (8). Bolt the
flanges together with bolts (7). Refer to Fig. 48.

36. Install dust cover (2) and seal ring (5) on the
splined end of drive flange (1). Align the drive flange
splines with the internal splines in differential case half
(14) and install the drive flange into the differential
case assembly. Thread castle nut (3) onto the
threaded end of differential case half (14). Tighten
castle nut (3) using socket 15269943 to a torque of 1
Fig. 48 - Installing Bearing Flange 200 Nm (885 lbf ft).

SM 1971 Rev 1 1-03 15


Centre Axle - Differential Drive Head
Section 150-0020
37. If removed, install differential lock nut (39) and bolt SM - 1154
(40). Coat the bolt threads with Loctite 270. Actuate the
differential lock with compressed air while threading the
bolt with lock nut in differential housing (4) until contact
is made. After contact is made, turn adjusting bolt (40)
in approximately 1/3 turn and lock in position with lock
nut (39). Refer to Fig. 49.

Fig. 49 - Adjusting Differential Lock Bolt

38. Install contact pin (43) in differential housing (4). SM - 1111


Place seal ring (42) on contact switch (41) and insert
contact switch in differential housing as shown in Fig. 50.

39. If ring gear (71) was removed from housing


(11, Fig. 2) then assemble them. Align the index marks
and press the ring gear on the housing and bolt them
together with bolts (69). Tighten bolts (69) to a torque
of 210 Nm (160 lbf ft).

40. Press the inner races of tapered bearings (68) on


cover (3, Fig. 2) and housing (11, Fig. 2).
Fig. 50 - Installing Contact Switch
41. Place one thrust washer (4, Fig. 2) with lubrication
slot facing up in housing (11, Fig. 2).
SM - 878

42. Alternately, install an externally splined disc


(5, Fig. 2) and then an internally splined disc
(6, Fig. 2) until all the discs have been installed.

43. Install thrust ring (7, Fig. 2) on top of internally


splined disc (6, Fig. 2). Install the thrust ring with the
open face up.

44. Install one side gear (8, Fig. 2) into thrust ring
(7, Fig. 2) and make sure the side gear splines into the
two internally splined discs (6, Fig. 2). Fig. 51 - Installing Shaft and Pinion Gears

45. Assemble axles (9, Fig. 2) and pinion gears


(10, Fig. 2) together and install on the installed side SM - 879

gear (8, Fig. 2). Refer to Fig. 51

46. Install other side gear (8, Fig. 2) and other thrust
ring (7, Fig. 2) flat side up. Refer to Figs. 52 & 53.

Fig. 52 - Installing Side Gear

16 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

SM - 880 47. Alternately, install an internally splined disc


(6, Fig. 2) and then an externally splined disc (5, Fig. 2)
until all the discs have been installed.

Fig. 53 - Installing Thrust Ring

SM - 881 48. Determine the end play between the discs and the
housing as shown in Figs. 54 & 55.

Step 1 - Determine the dimension between the


housing face and internally splined disc (6, Fig. 2). e.g.
The measurement is 6.00 mm (90.236 in).

Step 2 - Determine the dimension between housing


(11, Fig. 2) and cover (3, Fig. 2). For example the
measurement is 5.80 mm (0.228 in).

Step 1 Dimension 6.00 mm (0.236 in)


Fig. 54 - Determining End Play - Step 2 Dimension 5.80 mm (0.228 in)
Difference = 0.20 mm (0.008 in)
SM - 882
The correct end play between the housing cover and
both plate packs should be between 0.20 - 0.80 mm
(0.008 - 0.031 in). The end play should be as close to
0.20 mm (0.008 in) as possible. The end play is
controlled by installing different thicknesses of
internally splined plates. Refer to the parts book for
different thicknesses of plates available.

Fig. 55 - Determining End Play

SM - 883 49. Place thrust washer (4, Fig. 2) on side gear


(8, Fig. 2) as shown in Fig. 56.

Fig. 56 - Installing Thrust Washer

SM 1971 Rev 1 1-03 17


Centre Axle - Differential Drive Head
Section 150-0020
50. Place cover (3, Fig. 2) on housing (11, Fig. 2), SM - 884
cover threads of bolts (1, Fig. 2) with Loctite 270 and
fasten cover and housing together as shown in
Fig. 57. Tighten bolts (1, Fig. 2) to a torque of 110 Nm
(82 lbf ft).

Fig. 57 - Fastening Cover and Housing

51. Temporarily install countershaft case (49) SM - 1159


assembly on differential housing (73). Bolt together
with bolts (50 & 74). Refer to Fig. 58.

Fig. 58 - Installing Countershaft Case

52. Place the two outer races of tapered bearings (68) SM - 1160
on the inner races and install the differential assembly
into differential housing (73). Install bearing cap (62),
washers (64) and bolts (63). Tighten bolts (63) to a
torque of 245 Nm (180 lbf ft). Thread in adjusting nuts
(67) and displace the differential to obtain a backlash
of 0.25 - 0.35 mm (0.010 - 0.014 in). Refer to Fig. 59.

Bearing adjusting nuts (67) have two basic functions:


Pre-loading the bearings, and positioning ring gear
(71) to obtain the correct backlash between the ring
gear and the pinion gear.
Fig. 59 - Installing Differential And Bearing Caps
53. To check the backlash between ring gear (71) and
pinion gear (61), mount a dial indicator gauge at a right
SM - 1161
angle on the ring gear outer diameter as shown in
Fig. 60. Rock the ring gear back and forth being
careful not to move the pinion.

Note: Backlash can be adjusted without changing the


bearing pre-load by loosening one bearing adjusting
nut a certain number of notches and tightening the
opposite nut the same number of notches.

54. Tighten adjusting nut (67) opposite ring gear (71) two
notches in order to obtain the bearing pre-load of
3 - 4 Nm (115 - 155 lbf ft), then recheck the backlash.
Fig. 60 - Checking Backlash

18 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020
55. Ring gear runout is measured by mounting a dial SM - 893
indicator gauge on the backside of the ring gear.
Carefully rotate the ring gear and read the dial indicator
gauge. Maximum allowable run out is
0.08 mm (0.003 in).

56. To check ring gear (71) tooth pattern, coat about


twelve ring gear teeth with prussian blue, oiled red
lead or some other easily removed paint 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.

Gear tooth patterns are covered under 'Gleason Gear


Tooth System'.

57. After all adjustments are made and the gear tooth
pattern is correct, lock adjusting nuts (67) with cotter Fig. 61 - Coast Side (Concave)
pins (66). Lock bearing cap bolts (63) in place with
lockwire (65). SM - 894

58. Coat cover (53) bolt flange with sealing compound


and install on countershaft case (49). Fasten the cover to
the countershaft case with bolts (52). Tighten bolts (52)
to a torque of 49 Nm (35 lbf ft).

59. Press ball bearing (81) into bore in the axle


housing and retain with snap rings (80). Install shaft
seal (79) in axle housing and retain with seal
retainer (78).

60. Insert dust shield (77) over drive flange shaft (76)
and insert drive flange shaft through axle housing,
shaft seal (79) and ball bearing (81). Install shim (82)
over drive flange shaft (76) and retain with circlip (83).

Fig. 62 - Drive Side (Convex)


GLEASON GEAR TOOTH SYSTEM
Ideal tooth-contact patterns are shown in Figs. 61 & 62 SM - 895
indicating the pinion distance is correct.

If the patterns obtained are the same as that shown in


Figs. 63 & 64 then decrease the pinion distance. Refer
to Fig. 65.

If the patterns obtained are the same as that shown in


Figs. 66 & 67 then increase the pinion distance. Refer
to Fig. 68.

Fig. 63 - Coast Side (Concave)

SM 1971 Rev 1 1-03 19


Centre Axle - Differential Drive Head
Section 150-0020

SM - 896 SM - 899

Fig. 64 - Drive Side (Convex) Fig. 67 - Drive Side (Convex)

SM - 897 SM - 900

Fig. 65 - Pinion Distance Must Be Decreased Fig. 68 - Pinion Distance Must Be Increased

SM - 898

Fig. 66 - Coast Side (Concave)

20 SM 1971 Rev 1 1-03


Centre Axle - Differential Drive Head
Section 150-0020

MAINTENANCE SPECIAL TOOLS


Proper lubrication of the differential assembly is The special tools referenced in this section are
essential if the differentials are to deliver the service available from your dealer. Refer to Section 300-0070,
intended. Section 300-0020, LUBRICATION SYSTEM SERVICE TOOLS, for part numbers of general service
gives full information on the proper lubrication intervals tools and sealants required.
and the lubricant which should be used.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
1 3 Castle Nut 1 200 885
1 13 Bolt 120 90
1 28 Bolt 160 120
1 29 Bolt 42 30
1 45 Bolt 42 30
1 52 Bolt 49 35
1 54 Nut 750 550
1 63 Bolt 245 180
1 69 Bolt 210 160
1 86 Slotted Nut 550 400
2 1 Bolt 110 82

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
CONDITION REASON REMEDY
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust

SM 1971 Rev 1 1-03 21


Centre Axle - Differential Drive Head
Section 150-0020

DIAGNOSIS CHART (CONTINUED)


CONDITION REASON REMEDY
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

* * * *

22 SM 1971 Rev 1 1-03


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), externally splined discs (3), internally splined
discs (4), thrust ring (5), side gears (6), pinion gears (7),
The differential is mounted to the axle housing. The differential axle (8) and cover (9).

SM 1969 4-00 1
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 850

1- Housing
2- Thrust Washers 5 - Thrust Ring 8 - Differential Axle
3- Externally Splined Discs 6 - Side Gears 9 - Cover
4- Internally Splined Discs 7 - Pinion Gears 10 - Bolts

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 (7, 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 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020

REMOVAL 8. Index mark differential housing (14) and the axle


Numbers in parentheses refer to Fig. 3. housing to ensure that differential housing (14) is
installed in the same position.

WARNING 9. Loosen and remove bolts (13) from the differential


To prevent personal injury and property and axle housings. Thread in three puller bolts to break
damage, be sure wheel blocks, blocking the seal between the differential and axle housings and
materials and lifting equipment are properly to partially pull the differential assembly out of the axle
secured and of adequate capacity to do the job housing.
safely.
10. Using suitable lifting equipment, support the weight
1. Before attempting to remove the road wheels, drive of the differential assembly.
the vehicle onto a level, solid concrete floor, preferably
after a short run to warm the oil. Note: When removing the rear differential, weld a loop
to the bottom side of the body above the differential
Note: If the rear differential is being removed, raise the and attach the lifting device.
body and prop it up with the body prop.
11. Pull out the differential assembly until it clears the
2. Apply the parking brake and switch off the engine. axle housing, then carefully lower it to the floor. Slide
the differential assembly out from beneath the vehicle.
3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in
the 'Off' position. INSTALLATION
Installation is the reversal of the 'Removal' procedure.
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container. Note: Use sealing compound between the axle
housing and differential housing mounting faces.
5. Remove the planetary assemblies and axle shafts
from the axle housing. If necessary, note from which Note: Tighten all fasteners to standard torques listed in
side the long and short axle shafts are removed. Refer Section 300-0080, AXLE BOLT AND NUT TORQUE
to Section 160-0030, AXLE GROUP (HUB). SPECIFICATIONS.

6. Identify the relationship of the driveline flange and Add gear oil of the type specified in Section 300-0020,
differential pinion flange with punch marks. LUBRICATION SYSTEM, through the differential filler/
level hole until the oil is level with the bottom of the
7. Disconnect the driveline from the differential drive filler/level hole. Fill the planetary assemblies up to the
flange. The driveline can be removed if it is convenient 'Oil Level Check Line'.
to do so.

SM 1969 4-00 3
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 851

1 - Cotter Pin 10 - Adjusting Nut 19 - Washer


2 - Slotted Nut 11 - Roller Bearing 20 - Bolt 28 - Externally Splined Plate
3 - Washer 12 - Roller Bearing 21 - Lockwire 29 - Internally Splined Plate
4 - Drive Flange 13 - Bolt 22 - Bearing Cap 30 - Side Gear
5 - Bolt 14 - Differential Housing 23 - Bolt 31 - Pinion Gear
6 - Dust Shield 15 - Spacing Washer (shim) 24 - Lock Plate 32 - Axle
7 - Pinion Shaft Seal 16 - Roller Bearing 25 - Bolt 33 - Housing
8 - Bearing 17 - Pinion Gear 26 - Cover 34 - Bolt
9 - Spacing Washer (Shim) 18 - Ring Gear 27 - Thrust Washer 35 - Thrust Ring

Fig. 3 - Exploded View of Front and Rear Differential

4 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 852 DISASSEMBLY
Numbers in parentheses refer to Fig. 3.

Note: The following removal procedure assumes the


complete axle assembly was removed from the
vehicle.

1. Punch mark the mounting position of differential


housing (14) to the axle housing as shown by arrows
in Fig. 4. Remove mounting bolts (13).

Fig. 4 - Removing Mounting Bolts

SM - 853 2. Remove both planetary assemblies and axle shafts


by following the procedure in Section 160-0030, AXLE
GROUP (HUB). Use three puller bolts to pull the
differential assembly away from the axle housing and
then lift it out of the axle housing as shown in Fig. 5.

Fig. 5 - Removing Differential Assembly

SM - 854 3. Remove lockwire (21) from bolts (20 & 23) as


shown by the arrows in Fig. 6.

Fig. 6 - Removing Lockwire

SM - 855 4. Remove bolts (23) and lock plate (24) from bearing
caps (22) as shown in Fig. 7.

Fig. 7 - Removing Lockplates

SM 1969 4-00 5
Rear Axle Group - Differential Drive Head
Section 160-0020
5. Punch mark bearing caps (22) and differential SM - 856
housing (14) as shown in Fig. 8. Loosen adjusting nuts
(10). Remove bolts (20), washers (19) and bearing
caps (22).

Fig. 8 - Removing Bearing Caps

6. Remove both adjusting nuts (10) as shown in Fig. 9. SM - 857

Fig. 9 - Removing Adjusting Nuts

7. Lift the differential assembly out of differential SM - 858


housing (14) with the special tool as shown in Fig. 10.

Fig. 10 - Removing Differential

8. Remove outer races of tapered roller bearings SM - 859


(11 & 12). Pull the inner race of the bearings with a
puller from cover (26) and housing (33) with the puller
shown in Fig. 11.

Fig. 11 - Removing Bearing Inner Race

6 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 860 9. Remove bolts (25) from cover (26) as shown in


Fig. 12.

Fig. 12 - Removing Cover Bolts

SM - 861 10. Punch mark cover (26) and housing (33) as shown
by the arrows in Fig. 13, then lift off the cover.

11. Remove thrust washer (27), two externally splined


plates (28), two internally splined plates (29), thrust
ring (35) and side gear (30).

12. Remove four pinion gears (31) and axle (32) out of
housing (33).

13. Remove other side gear (30), thrust ring (35), two
internally splined plates (29), two externally splined
Fig. 13 - Removing Cover plates (28) and thrust washer (27) from housing (33).

SM - 862 14. If necessary, pull the inner race of tapered roller


bearing (11) off housing (33). If ring gear (18) is being
removed from housing (33), punch mark them so they
can be assembled in the same position. Remove
bolts (34) as shown in Fig. 14 and press ring gear (18)
off housing (33).

15. Remove cotter pin (1), slotted nut (2), washer (3)
and drive flange (4) from pinion gear (17).

Fig. 14 - Removing Ring Gear Bolts

SM - 863 16. Remove and discard pinion shaft seal (7) from
differential housing (14) as shown in Fig. 15.

Fig. 15 - Removing Pinion Shaft Seal

SM 1969 4-00 7
Rear Axle Group - Differential Drive Head
Section 160-0020
17. Press pinion gear (17) out of differential housing SM - 864
(14) as shown in Fig. 16. Remove spacing washer (15).

Fig. 16 - Pressing Out Pinion Shaft

18. With the special tool shown in Fig. 17 pull the inner SM - 865
race of the bearing off the pinion drive end.

Fig. 17 - Pulling Inner Race of Bearing

INSPECTION 5. Check for pitted, scored or worn thrust surfaces of


1. Clean all parts with a suitable solvent. Dry all parts, differential case halves.
except bearings, with compressed air or with soft,
clean lint free cloths. DO NOT spin bearings with 6. During assembly and installation, make sure that
compressed air. Place bearings on a clean surface, mated, punch marked or otherwise identified parts are
cover with lint free cloths and allow to dry. returned to their original positions, if still serviceable.

2. Coat cleaned, dried parts immediately with light oil


to prevent corrosion. If parts are not to be assembled ASSEMBLY
immediately, treat them with a good quality rust Numbers in parentheses refer to Fig. 3.
preventive and wrap them with treated paper or
suitable material designed to prevent corrosion. Note: Tighten all fasteners without special torques
specified to standard torques listed in
3. Before installing the differential assembly into the Section 300-0080, AXLE BOLT AND NUT TORQUE
axle housing, clean the inside and outside of the axle SPECIFICATIONS.
housing to remove any debris or dirt.
The first step in the assembly procedure is to
4. Inspect all gears, pinions and splines for cracked or determine the thickness of the spacing washer or shim
broken teeth, excessive wear, and pitted or scored (15). Fig. 18 illustrates the special tools needed to
surfaces. Repair or replace as necessary. determine the shim size.
Dimensions A + B + C = X which is the shim size.
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.

8 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 866

1 Measuring Piston 15269936


2 Thrust Washer 15269935
3 Adaptor Pieces 15269937
4 Measuring Shaft 15269934

Fig. 18 - Determining Shim Thickness

SM - 867 1. Using a feeler gauge, determine the gap between


the measuring piston and measuring shaft as shown in
Fig. 19. For example:

Dimension 'A' + 'B' = 191.8 mm (7.551 in)


+ Dimension 'C' = 15.0 mm (0.591 in)
(half the diameter of the measuring shaft).

Dimension 'X' = 206.8 mm (8.142 in)

Fig. 19 - Determining Pinion and Shaft Gap

SM - 868 2. Next, determine the thickness of tapered roller


bearing (16) as shown in Fig. 20. For example:

(Straight edge +
gauge blocks) = 90.0 mm (3.543 in)
- Measured Value = 43.9 mm (1.728 in)

Bearing Thickness = 46.1 mm (1.815 in)

Fig. 20 - Determining Bearing Thickness

SM 1969 4-00 9
Rear Axle Group - Differential Drive Head
Section 160-0020
3. The arrow in Fig. 21 is pointing to a dimension SM - 869
etched on the face of pinion gear (17). For example
159.90 mm (6.295 in).

Dimension 'XI' = 46.10 mm (1.815 in)


(Bearing Thickness)
+ 159.90 mm (6.295 in)
= 206.00 mm (8.110 in)
Example:
Dimension 'X' = 206.80 mm (8.142 in)
- Dimension 'XI' = 206.00 mm (8.110 in)

Shim Thickness = 0.80 mm (0.032 in) Fig. 21 - Dimension on Drive Pinion Face

4. Place shim (15), of the correct thickness as SM - 870


determined in Steps 1, 2 and 3 into differential housing
(14) as shown in Fig. 22.

Fig. 22 - Placing Shim in Housing

5. Using a special driving tool, drive the outer race of SM - 871


tapered roller bearing (16) into differential housing (14)
as shown in Fig. 23.

Fig. 23 - Installing Outer Race of Bearing

6. Turn differential housing (14) over and install outer SM - 872


race of tapered bearing (8) into its bore as shown in
Fig. 24.

Fig. 24 - Installing Outer Race of Bearing

10 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 873 7. Heat the inner race of tapered roller bearing (16) to


approximately 90 C (190 F) and install it on the shaft
of pinion gear (17). Be sure it is seated against the
shaft shoulder as shown in Fig. 25.

Fig. 25 - Installing Inner Race of Bearing

SM - 874 8. The following steps are required to determine the


thickness of spacing washer (9). Place the special
measuring ring on the shoulder of pinion gear (17) as
shown by the arrows in Fig. 26.

Fig. 26 - Determining Thickness of Spacer

SM - 875 9. Place the pre-assembled pinion gear (17) on a


suitable spacing tube. Lift up differential housing (14)
and carefully place it over the pinion. Heat the inner
race of bearing (8) to approximately 90 C (190 F)
and install it on the shaft of pinion gear (17). Drive the
inner bearing race until it is seated against the outer
race as shown in Fig. 27.

Fig. 27 - Installing Pinion into Housing

SM - 876 10. If dust shield (6) was removed from drive flange (4),
press it back on the drive flange. Spline drive flange
(4) to pinion (17). Install slotted nut (2) and tighten to a
torque of 600 Nm (443 lbf ft). Check the rolling
resistance as shown in Fig. 28. Rolling resistance
should be 1.1 - 2.3 Nm (0.81 -1.70 lbf ft).

Note: Correct rolling resistance is obtained by


loosening or tightening the slotted nut. Record the
torque figure because it will be required later.

Fig. 28 - Checking Rolling Resistance

SM 1969 4-00 11
Rear Axle Group - Differential Drive Head
Section 160-0020
11. Remove slotted nut (2), pull off drive flange (4) and SM - 877
remove pinion gear (17) from differential housing (14).
Remove and measure the measuring ring with a
micrometer. The thickness of the compressed
measuring ring will be the thickness of spacing washer
(9).

Place spacing washer (9) on the shoulder of the pinion


shaft. Then install the assembled pinion gear into
differential housing (14).

12. Coat the outer diameter of pinion shaft seal (7)


with sealing compound. With the seal lip facing inward Fig. 29 - Installing Shaft Seal
and using the seal driver shown in Fig. 29, drive seal
(7) into differential housing (14).
SM - 878

13. Slide drive flange (4) on the shaft of pinion gear


(17). Place washer (3) on the pinion shaft and thread
on slotted nut (2). Torque slotted nut (2) to the setting
determined in Step 10. Lock slotted nut (2) in place
with cotter pin (1).

14. If ring gear (18) was removed from housing (33),


make sure the ring gear and housing surfaces are
clean and free from grease. Install two line-up studs,
line up index marks and press the ring gear back on.
Install bolts (34) and, with a dial indicator gauge, check Fig. 30 - Installing Shaft and Pinion Gears
ring gear run-out. Maximum allowable run-out is 0.08
mm (0.003 in).
SM - 879

15. Heat inner roller bearing (12) race to 90 C (190 F)


and press it on to the hub of housing (33) until it is
firmly seated.

16. Place one thrust washer (27) with the lubrication


slot facing up.

17. Alternately, install an externally splined plate (28)


and then an internally splined plate (29) until all plates
have been installed.
Fig. 31 - Installing Side Gear
18. Install thrust ring (35) on top of the internally splined
plate (29). Install thrust ring (35) with open face up.
SM - 880
19. Install one side gear (30) into thrust ring (35).
Make sure the side gear splines into the two internally
splined plates (29).

20. Assemble axles (32) and pinion gears (31)


together and install on the installed side gear (30), as
shown in Fig. 30.

21. Install the other side gear (30) and the other thrust
ring (35), flat side up, as shown in Figs. 31 and 32.

Fig. 32 - Installing Thrust Ring

12 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 881 22. Alternately install an internally splined plate (29)


and externally splined plate (28) until all plates are
installed.

23. Determine the end play between the plates and the
housing as shown in Figs. 33 and 34.

Step 1 - Determine the dimension between the


housing face and the internally splined plate (29). For
example - the measurement is 6.00 mm (0.236 in).

Step 2 - Determine the dimension between housing


Fig. 33 - Determining End Play (33) and cover face (26). For example - the
measurement is 5.80 mm (0.228 in).
SM - 882
Step 1 Dimension ........... 6.00 mm (0.236 in)
Step 2 Dimension ........... 5.80 mm (0.228 in)

Difference ....................... 0.20 mm (0.008 in)

The correct end play between the housing cover and


both plate packs should be between 0.20 - 0.80 mm
(0.008 - 0.031 in). The end play should be as close to
0.20 mm (0.008 in) as possible. The end play is
controlled by installing different thicknesses of
internally splined plates. Refer to the parts book for
Fig. 34 - Determining End Play different thicknesses of plates available.

SM - 883 24. Place thrust washer (27) on side gear (30), as


shown in Fig. 35.

25. Heat inner race of roller bearing (11) to


approximately 90 C (190 F) and press it on to the
hub of cover (26) until it is firmly seated against the
cover.

Fig. 35 - Installing Thrust Washer

SM - 884 26. Place cover (26) on housing (33), cover threads of


necked-down bolts (25) with Loctite 270 and fasten
cover and housing together as shown in Fig. 36. Use
only new necked-down bolts. Tighten bolts (25) to a
torque of 110 Nm (82 lbf ft).

Fig. 36 - Fastening Cover and Housing

SM 1969 4-00 13
Rear Axle Group - Differential Drive Head
Section 160-0020
27. Place outer races of roller bearings (11 & 12) on SM - 885
both differential ends. Using the special lifting tool
install ring gear (18) assembly into differential
housing (14), as shown in Fig. 37.

Fig. 37 - Installing Ring Gear Assembly

28. Coat the threads of adjusting nuts (10) with SM - 886


Molykote and loosely thread into lower bearing cups,
as shown in Fig. 38.

Fig. 38 - Installing Adjusting Nuts

29. Align the index marks and install bearing caps (22) SM - 887
with washer (19) and bolts (20), as shown in Fig. 39.
Tighten bolts (20) to a torque of 295 Nm (218 lbf ft).

Fig. 39 - Installing Bearing Caps

30. Thread both adjusting nuts (10) into bearing caps SM - 888
(22) as shown, until the yoke width is between
340 - 340.30 mm (13.386 - 13.400 in) diagonally
across the bearing cap lock pads, as shown in Fig. 40.

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. 40 - Measuring Yoke Width

14 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 889 31. To check the backlash between ring gear (18) and
pinion gear (17), mount a dial indicator gauge at right
angles to the outer diameter of the ring gear tooth flank
as shown in Fig. 41. Rock the ring gear back and forth
being careful not to move the pinion gear. Backlash
should be 0.30 mm (0.012 in).

Note: Backlash can be adjusted without changing the


bearing preload by loosening one bearing adjuster nut
a certain number of notches and tightening the
opposite adjuster nut the same number of notches.

Fig. 41 - Measuring Backlash

SM - 890 32. The ring gear run-out is measured by mounting a


dial indicator gauge on the backside of ring gear (18)
as shown in Fig. 42. Carefully rotate ring gear (18) and
read the dial indicator. Maximum allowable
run-out is 0.08 mm (0.003 in).

Fig. 42 - Measuring Ring Gear Runout

SM - 891 33. To check the tooth pattern of ring gear (18), coat
about twelve ring gear teeth with prussian blue, oiled
red lead or some other easily removed print or dye.
When the pinion is rotated, the paint is squeezed away
by the contact of the teeth, leaving bare areas the
exact size, shape and location of the contacts as
shown in Fig. 43.

Gear tooth patterns for the Gleason Gear Tooth


system are on the following pages.

Fig. 43 - Checking Contact Pattern

SM - 892 34. After all adjustments and gear patterns are correct,
secure adjusting nut lock plates (24) in place with bolts
(23) and lockwire (21), as shown in Fig. 44.

Fig. 44 - Locking Adjusting Nuts

SM 1969 4-00 15
Rear Axle Group - Differential Drive Head
Section 160-0020

GLEASON GEAR TOOTH SYSTEM SM - 895

Ideal tooth-contact pattern shown in Figs. 45 and 46


indicating the pinion distance is correct.

If the patterns obtained are the same as that shown in


Figs. 47 and 48 then decrease the pinion distance
(Fig. 49).

If the patterns obtained are the same as that shown in


Figs. 50 and 51 then increase the pinion distance
(Fig. 52).

Fig. 47 - Coast Side (Concave)

SM - 893 SM - 896

Fig. 45 - Coast Side (Concave) Fig. 48 - Drive Side (Convex)

SM - 894 SM - 897

Fig. 46 - Drive Side (Convex) Fig. 49 - Pinion Distance must be Decreased

16 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020

SM - 898

Fig. 50 - Coast Side (Concave)

SM - 899

Fig. 51 - Drive Side (Convex)

SM - 900

Fig. 52 - Pinion Distance must be Increased

SM 1969 4-00 17
Rear Axle Group - Differential Drive Head
Section 160-0020

MAINTENANCE should be investigated before the differential is taken


Proper lubrication of the differential assembly is apart.
essential if the differentials are to deliver the service
intended. Section 300-0020, LUBRICATION SYSTEM Whenever noises such as a grating or rattle are heard
gives full information on the proper lubrication intervals coming from the differential, stop the unit immediately.
and the lubricant which should be used. One tooth from a gear can cause damage to all gears
and bearings. When the differential is definitely at fault,
remove the axle shafts and disconnect the driveline
SPECIAL TOOLS before moving the vehicle.
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service WARNINGS
tools and sealants required. To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
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
transmitted and may be erroneously attributed to the Removing the axle shafts or drivelines
differential. Therefore, all possible sources of noise will make the parking brake ineffective.

DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth Replace damaged gear
Excessive run-out of pinion or flanged case Disassemble, correct or replace faulty
part
Continual noise Bearing worn Replace worn parts
Gears damaged or worn Replace gears
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Loose ring and pinion gear adjustment Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
3 2 Slotted Nut 600 443
3 20 Bolt 295 218
3 25 Bolt 110 82

* * * *
18 SM 1969 4-00
REAR AXLE GROUP - Axle Group (Hub)
Section 160-0030

SM - 1781

30

10
31 7 8

5 33
32

35
34

13 12

6
9 11
22
28
2,3
1 4
38
21 37
17
15
14

24
23
27 25
29 26
18
36

20 19
16
1 - Hub Carrier 29 - Slotted Nut
2 - Capscrew 11 - Wheel Bolt 20 - Retainer Ring 30 - Axle Housing
3 - Capscrew 12 - Wheel Nut 21 - Thrust Washer 31 - Brake Disc
4 - Washer 13 - Lockwasher 22 - Bolt 32 - Capscrew
5 -Nut 14 - Locking Plate 23 - 'O' Ring 33 - Washer
6 - Roller Bearing 15 - Lock Screw 24 - Plug Screw 34 - Split Pin
7 - Bearing Inner Race 16 - Ring Gear 25 - Driver 35 - Split Pin
8 - Bearing Outer Race 17 - Sun Gear Shaft 26 - Thrust Washer 36 - Shim
9 - Shaft Seal 18 - Planet Carrier 27 - Grooved Pin 37 - 'O' Ring
10 - Hub 19 - Planet Gear 28 - Axle Shaft 38 - Plug

Fig. 1 - Exploded View of Planetary and Wheel

OPERATION meshed with sun gear shaft (17) rotate anticlockwise.


Numbers and letters in parentheses refer to Fig. 1. Ring gear (16) is splined to hub carrier (1) and does
not rotate but causes planet gears (19), which are
Power from the differential is transmitted through a meshed with ring gear (16), to move around it in a
fully floating axle shaft connected to sun gear shaft (17) clockwise direction. As planet carrier (18) is bolted to
by driver (25). As sun gear shaft (17) rotates in a wheel hub (10) the wheel then rotates in a clockwise
clockwise direction, the four planet gears (19) direction.

SM 2194 Rev 1 6-03 1


Rear Axle Group - Axle Group (Hub)
Section 160-0030

REMOVAL AND DISASSEMBLY SM - 1026

Numbers in parentheses refer to Fig. 1.

Note: On dismantling, clean all parts in paraffin or


other suitable cleaning agent and place on a clean
work surface.

WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Fig. 2 - Jacking Planet Carrier Out Of Hub
secured and of adequate capacity to do the job
safely.
SM - 1027

To prevent personal injury and property


damage, the procedure for removing tyre and
rim assembly described in Section 160-0050,
WHEEL, RIM AND TYRE, must be strictly
followed.

When necessary to drive out components


during disassembly, be sure to use a soft drift
to prevent property damage and personal
injury.
Fig. 3 - Removing Planet Carrier Assembly
1. Before attempting to remove the road wheels, drive
the vehicle onto a level, solid concrete floor,
preferably after a short run to warm the oil. lowest points. Remove plug screws (24) and
'O' rings (23) and drain oil from hubs.
2. Apply the parking brake and switch off the engine.
9. Index mark planet carrier (18) and hub (10) to aid
3. Block the appropriate road wheels, place the in installation.
steering lock bar in the 'Locked' position and the
battery master switch in the 'Off' position. 10. Remove bolts (22) then prise planet carrier (18)
from hub (10) and place on the floor with planet gears
4. Whilst road wheels are still on the ground, loosen (19) facing upwards. If necessary, use jacking bolts
wheel nuts (12). in tapped holes provided, as shown in Fig. 2.

5. Jack up the axle and support with suitably placed 11. Remove bearing inner race (7) from hub carrier (1).
stands or timbers.
12. Lift out sun gear shaft (17) from planet carrier
6. Support tyre and rim assembly with a suitable sling (18) assembly. Remove retainer rings (20) and pull
and lifting device. Remove wheel nuts (12) and planet gears (19) from planet carrier (18). Remove
remove tyre and rim assembly from the machine. thrust washer (21).
Remove opposite road wheel in the same way.
13. Remove driver (25) from axle shaft (28). Remove
7. Place suitable containers under the differential and thrust washer (26) from grooved pins (27) on hub
both hubs (10). Remove differential drain plug and carrier (1). Pull axle shaft (28) from axle housing
drain oil from the differential. (30).

8. Rotate hubs (10) until plug screws (24) are at their 14. Remove the brake calliper. Refer to Section
165-0010, BRAKE PARTS - REAR.

2 SM 2194 Rev 1 6-03


Rear Axle Group - Axle Group (Hub)
Section 160-0030

SM - 1028 18. Remove shaft seal (9), roller bearing (6) and
bearing outer race (8) from hub (10) as shown in Fig. 5.

19. If it is necessary to remove hub carrier (1) from


axle housing (30), index mark hub carrier and axle
housing to aid in installation. Support hub carrier (1)
with suitable lifting equipment and remove capscrews
(2 & 3), washers (4), nuts (5) and slot pins (34 & 35).
If necessary, tap hub carrier (1) loose from axle
housing (30).

20. If necessary, drive or press wheel bolts (11) from


Fig. 4 - Removing Slotted Nut
hub (10).

SM - 1029
INSPECTION
Numbers in parentheses refer to Fig. 1.

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 washers (21 & 26) to make sure they
are free of burrs and are absolutely flat. Replace all
'O' rings.

Fig. 5 - Removing Bearing Outer Race


ASSEMBLY AND INSTALLATION
Numbers in parentheses refer to Fig. 1.

SM - 1030 Note: Tighten all fasteners without special torques


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

WARNING
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely.
Fig. 6 - Installing Wheel Bolts
1. Cover the mounting flange of axle housing (30)
with Loctite 574 sealing compound and line up the
15. Remove two lock screws (15) and locking plate (14) index mark on hub carrier (1) with the mark on axle
from ring gear (16). Remove slotted nut (29) from hub housing (30). Secure hub carrier (1) to axle housing
carrier (1) with the special tool (15269943, socket) as (30) with capscrews (2 & 3), washers (4), nuts (5)
shown in Fig. 4. Remove shims (36) from hub carrier and slot pins (34 & 35). Tighten capscrews (2 & 3) to
(1). a torque of 460 Nm (340 lbf ft).

16. Using suitable lifting equipment, remove ring gear 2. If removed, install new wheel bolts (11) on hub
(16), then hub (10) assembly from hub carrier (1). (10) using the special tool shown in Fig. 6.

17. If necessary, remove capscrews (32), washers 3. Place brake disc (31) on hub (10) and secure with
(33) and brake disc (31) from hub (10). capscrews (32) and washers (33). Tighten
capscrews (32) to a torque of 295 Nm (220 lbf ft).

SM 2194 Rev 1 6-03 3


Rear Axle Group - Axle Group (Hub)
Section 160-0030
4. Install roller bearing (6) in inner bore of hub (10) SM - 1031
using special tool (15275085, driver). Coat outer
diameter of shaft seal (9) with Loctite 574 sealing
compound and, with the seal lip facing down, press
shaft seal (9) into the bore of hub (10) with the special
tool (15275086, driver) as shown in Fig. 7. Turn the hub
over and press bearing outer race (8) into the hub bore
using special tool (15269896, driver). Note: Driver
handle (15269898) also required.

5. With a suitable lifting device, pick up hub (10)


assembly, then, being careful to prevent damaging
Fig. 7 - Installing Shaft Seal
the lip of shaft seal (9), slide hub (10) assembly onto
hub carrier (1). Be sure hub (10) assembly is firmly
seated against the shoulder of hub carrier (1). SM - 1032

6. Install bearing inner race (7) on the splined end of


hub carrier (1) as shown in Fig. 8. Be sure the inner
race is firmly seated.

7. Slide ring gear (16) over the splines of hub carrier


(1). Be sure it is pushed all the way in.

8. Select shim (36) and install over the splines of hub


carrier (1) so that front edge of ring gear (16) is
protruding by 0.03 - 0.30 mm (0.001 - 0.012 in).
Fig. 8 - Installing Bearing Inner Race
9. Install slotted nut (29) on hub carrier (1) threads
and, using special tool (15269943, socket) shown in
SM - 1033
Fig. 9, tighten slotted nut (29) to a torque of 1 000 Nm
(738 lbf ft).

Note: During tightening the wheel hub must be


spinning.

10. Check the rolling resistance of hub (10) by wrapping


a length of string around hub (10) and pulling with a
suitable scale as shown in Fig. 10. The rolling resistance
(T) should be 12 - 18 Nm (9 - 13 lbf ft) for new bearings,
or 6 - 9 Nm (4.5 - 6.5 lbf ft) for run-in bearings.
Fig. 9 - Tightening Slotted Nut
Formula to calculate F.
F = T/R
SM - 1034

Where:
F
F = Pull in N (lbf)
T = Rolling resistance Nm (lbf ft)
R = Radius of hub m (ft)

Adjust shim (36) thickness to achieve the correct


rolling resistance. If rolling torque not reached, select
a thinner shim (36). If rolling torque is exceeded,
select a thicker shim (36).

11. When rolling resistance is correct, remove slotted


Fig. 10 - Checking Hub Rolling Resistance
nut (29).

4 SM 2194 Rev 1 6-03


Rear Axle Group - Axle Group (Hub)
Section 160-0030

SM - 1035 (4.5 - 6.5 lbf ft) for run-in bearings.

15. Carefully slide axle shaft (28) through the bore of


hub carrier (1) until the axle shaft splines into the
differential side gears. Place thrust washer (26) onto
grooved pins (27) on hub carrier (1). Slide driver (25)
onto axle shaft (28).

16. Press planet gear assemblies (19) onto the pins


of planet carrier (18) as shown in Fig. 11. Secure
planet gears by installing retainer rings (20).
Fig. 11 - Installing Planet gear Assemblies 17. Position thrust washer (21) into the recess in
planet carrier (18). Before positioning sun gear shaft (17)
SM - 2830
it is necessary at this stage to determine the end play
of sun gear shaft (17) before installing the planetary
assembly into the hub. The required end play should
Y be 0.3 - 0.5 mm (0.012 - 0.020 in) and can be
A achieved by installing different thicknesses of thrust
X
washer (21).

Note: Thrust washers are available in thicknesses of


6.5 mm (0.256 in), 6.3 mm (0.248 in), 6.0 mm (0.236 in),
PLANET CARRIER
5.0 mm (0.197 in), 3.5 mm (0.138 in), 3.3 mm (0.130 in),
3.1 mm (0.122 in), 2.9 mm (0.114 in) and 2.7 mm
(0.106 in).
Fig. 12 - Measuring Dimension 'A'
Determine end play of sun gear shaft (17) as follows:

SM - 2831
a. Position the assembled planet carrier (18) as
shown in Fig. 12. Place a straight edge along top of
HUB planetary gears and measure the dimensions to carrier
mounting face (dimension 'X') and thrust washer (21)
(dimension 'Y'). Note the difference and record this as
dimension 'A'.

Example:
Dimension 'X' = 100.00 mm (3.937 in)
B Dimension 'Y' = 85.40 mm (3.362 in)
SUN GEAR SHAFT
Dimension 'A' = 14.60 mm (0.575 in)
Fig. 13 - Measuring Dimension 'B'
b. Slide sun gear shaft (17) fully into driver (25).
Place a straight edge across the mounting surface of
12. Using Loctite 243, coat the threads of hub carrier hub (10) and measure the distance from the mounting
(1) and slotted nut (29). Thread slotted nut (29) on hub surface of hub (10) to the end of sun gear shaft (17) as
carrier (1) threads and, using the special tool shown in shown in Fig. 13. Record this as dimension 'B'.
Fig. 9, tighten slotted nut (29) to a torque of
1 000 Nm (738 lbf ft). Example:
Dimension 'B' = 14.90 mm (0.587 in)
13. Install locking plate (14) and secure with lock
screws (15). Tighten lock screws (15) to a torque of Example:
79 Nm (58 lbf ft). Dimension 'A' = 14.60 mm (0.575 in)
Dimension 'B' = 14.90 mm (0.587 in)
14. Re-check the rolling resistance of hub (10). The Difference (End play) = 0.30 mm (0.012 in)
rolling resistance (T) should be 12 - 18 Nm
(9 - 13 lbf ft) for new bearings, or 6 - 9 Nm

SM 2194 Rev 1 6-03 5


Rear Axle Group - Axle Group (Hub)
Section 160-0030
18. Remove sun gear shaft (17) from driver (25) and MAINTENANCE
position in planet carrier (18) in mesh with planet gears
Proper lubrication of the axle group is essential if axles
(19).
are to deliver the service intended. Section
300-0020, LUBRICATION SYSTEM gives full
19. Coat the face of planet carrier (18) with Loctite
information on the proper lubrication intervals and the
574 sealing compound. Install planet carrier (18)
lubricant which should be used.
assembly into hub (10) and secure with bolts (22).
Tighten bolts (22) to a torque of 190 Nm (140 lbf ft).
SPECIAL TOOLS
20. Place a new 'O' ring (23) on plug screw (24) and
The special tools referenced throughout this section
thread assembled plug screw into the outer face of
are available from your dealer. Refer to Section
planetary carrier (18). Tighten plug screw (24) to a
300-0070, SERVICE TOOLS, for part numbers of
torque of 80 Nm (60 lbf ft).
general service tools and sealants required.
21. Install brake calliper. Refer to Section 165-0010,
BRAKE PARTS - REAR. AXLE DIAGNOSIS
Noises originating in the tyres, transmission, brakes
22. Install differential drain plug. Add gear oil of the
or drivelines might be attributed by mistake to the
type specified in Section 300-0020, LUBRICATION
axle components, therefore, all possible sources of
SYSTEM, through the differential filler/level hole until
noise should be investigated before deciding the axle
the oil is level with the bottom of the filler/level hole.
is at fault.
23. Fill the planetary assemblies up to the 'Oil Level
Check Line' with gear oil of the type specified in WARNING
Section 300-0020, LUBRICATION SYSTEM. To prevent personal injury and property
damage, be sure wheel blocks, blocking
24. Refit road wheels, securing with wheel nuts (12). materials and lifting equipment are properly
Remove stands or timber supports and lower the secured and of adequate capacity to do the job
machine to the ground. Fully tighten wheel nuts to a safely.
torque of 590 Nm (435 lbf ft). Remove blocks from
the wheels. True axle noises may be located by lifting or jacking
the machine up until all tyres are clear of the floor or
Note: Wheel nuts should be checked and tightened if ground. Securely block the machine in this position.
necessary, after the first 10 hours of operation. Run power train at moderate speed. Be certain all
Check torque every 50 hours (weekly) thereafter. tyres are off the ground to prevent damage to the
differential and make sure that there is no brake drag.

AXLE DIAGNOSIS CHART


CONDITION REASON REMEDY
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

6 SM 2194 Rev 1 6-03


Rear Axle Group - Axle Group (Hub)
Section 160-0030

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 2 Capscrew 460 340
1 3 Capscrew 460 340
1 12 Wheel Nut 590 435
1 15 Lock Screw 79 58
1 22 Bolt 190 140
1 24 Plug Screw 80 60
1 32 Capscrew 295 220

* * * *

SM 2194 Rev 1 6-03 7


REAR AXLE GROUP - Wheel Rim and Tyre
Section 160-0050

SM - 1038

1 - Flanges
2 - 'O' Ring 5 - Wheel Rim 8 - Driver (if used)
3 - Bead Seat Band 6 - Valve Assembly 9 - Lock Washer
4 - Lock Ring 7 - Valve Cap 10 - Wheel Nut

Fig. 1 - Cutaway View of Wheel Rim

DESCRIPTION AND OPERATION One of the following pieces of hoisting equipment


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

SM 2179 Rev2 08-05 1


Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

REMOVING TYRE AND RIM ASSEMBLY SM - 1039

FROM MACHINE
Numbers in parentheses refer to Fig. 1.

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
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.

1. Position the vehicle in a level work area, apply the


parking brake and shutdown the engine.

2. Block all road wheels, except the one to be raised,


and place the battery master switch in the 'Off'
position.
1 - Outer Flange 4 - Lock Ring
3. Break wheel nuts (10) loose with tyre still on the 2 - Driver (if used) 5 - Wheel Rim
ground, but do not remove from wheel studs. 3 - Bead Seat Band 6 - Inner Flange

Fig. 2 - Typical Rim Assembly


4. Jack up the axle to the height required to allow
removal of the tyre and rim assembly.
SM - 205

5. Place safety blocks under the axle.

6. Support tyre and rim assembly with a suitable sling


and attach a suitable lifting device.

7. Remove wheel nuts (10) and lock washers (9)


securing wheel rim (5) to the wheel. Fig. 3 - Pry Bar

8. With lifting device, remove tyre and rim assembly SM - 206


from the wheel and lift clear of the vehicle.

DISMOUNTING TYRE FROM RIM


Numbers in parentheses refer to Fig. 2, unless
otherwise specified.

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 2179 Rev2 08-05


Rear Axle Group - Wheel Rim and Tyre
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 the rim, be sure the
equipment is of sufficient capacity and properly 15. If necessary, remove inner flange (6).
secured to do the job safely.
Note: If tyre rim is on the vehicle, and no tyre lifting
1. Remove valve cap (7, Fig. 1) and valve core and equipment is available, 'walk' the tyre off the rim as
leave valve open to prevent trapping of air in tyre. Tape follows:
valve threads for protection.
Force bottom of tyre outward as far as possible; lower
2. If used, remove driver (2) from bead seat band (3) jack enough to allow weight of tyre to rest on ground;
and wheel rim (5). force top of tyre out as far as possible; raise jack to
original height and repeat the above until the tyre is off
3. Break outer tyre bead loose with pry bar shown in the rim.
Fig. 3.

4. Insert flat hooked end of pry bar into breaking slots INSPECTION
between bead seat band (3) and outer flange (1). See
Tyre
Fig. 4. A pipe over the straight end of the pry bar will
increase leverage. Check the interior surface of the tyre to determine its
condition. Inspect for cuts or fabric breaks that have
5. Twist pry bar toward tyre to break bead. penetrated the tyre body. The casing should be
inspected closely for any sharp , pointed object that
6. A second pry bar may be inserted in the space may have penetrated the tyre body but is invisible from
between bead seat band (3) and outer flange (1). Twist the outside. All dust, dirt, water or other foreign matter
the second pry bar to maintain the space gained by the should be cleaned from the inside of tyre.
first pry bar.
Rim Assembly
7. Move the first pry bar around wheel rim (5), twisting
and following with the second pry bar, until the outer Overloading, improper tyre inflation, rough terrain, high
tyre bead is loose. speed, accidents, dirt accumulation, and corrosion all
tend to reduce the service life of rims and rim
8. Pry bead seat band (3) away from lock ring (4) by components. It is recommended that rims be
placing hooked end of pry bar in the groove of wheel inspected, as below, not less often than at every tyre
rim (5), between ends of lock ring (4), and prying up change and that, as the warranty limit approaches,
with the pry bar. Using two pry bars, as in Step 7, work consideration be given to periodic replacement.
completely around wheel rim (5).
The rim and its components are designed with built-in
9. Pry lock ring (4) out in the same manner by starting safety factors, to prevent the components from flying
at prying notch in wheel rim (5) assembly, and work all off with killing force during inflation. Check
the way around wheel rim (5) with two pry bars. components for cracks, bends, distortion, or other
damage. If damage is found, the component must be
10. Remove and discard 'O' ring (2, Fig. 1). replaced.

11. Remove lock ring (4) then pry out and remove bead
seat band (3). WARNING
Never mix components of one manufacturer's
12. Breaking slots are provided inside the rims. The rims with those of another. Using the rim base
inner bead may be broken as described in Steps 4 of one manufacturer with the lock ring of
through 8. If the tyre and rim assembly is on the another or vice versa is dangerous. The lock
vehicle, the following procedure may be used for ring of one may not fully engage with the lock
breaking the inner bead. ring groove of the other. Always consult the
rim manufacturer for proper matching and
13. Place jack between inner flange (6) and vehicle assembly instructions.
frame. Extend jack until tyre bead is broken. Continue
around the rim until tyre bead is broken at all points.
SM 2179 Rev2 08-05 3
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 207

WARNING (cont.)
Also, use and servicing of damaged, worn out,
or improperly assembled rim assemblies is a
very dangerous practice. Failure to comply
with the above warnings could result in
explosions from tyre pressure causing serious
personal injury and property damage.

Clean all rust and dirt from the rim parts and wheel
and apply a coat of good grade primer paint. Allow the
paint to dry thoroughly before remounting tyre.

The rim parts used with tubeless tyres form an


important part of the air chamber. Therefore, they
1 - Lock Ring 2 - Drive Lug
should be carefully checked for distortion or mutilation
that would prevent an effective air seal when the tyre Fig. 5 - Installing Typical Lock Ring
and rim are reassembled.
5. Install outer flange (1) on wheel rim (5).
Rubber 'O' rings are air seals for tubeless tyre and rim
assemblies and therefore should be carefully handled 6. Align lock ring driver notch in bead seat band (3)
to provide an airtight seal when the tyre is remounted with notch in wheel rim (5), and install bead seat band
on the rim. Always use new 'O' rings when mounting a on rim.
tubeless tyre.
7. On vehicles which use a driver (2), align driver slot
Note: Handle 'O' rings carefully, as damage will of bead seat band (3) with driver pocket of wheel rim
prevent an airtight seal for tyre inflation. (5) and install bead seat band (3) on wheel rim (5).

8. Install lock ring (4) in groove of wheel rim (5) so that


MOUNTING TYRE ON RIM lock ring lug engages both notches. Notches and lock
Numbers in parentheses refer to Fig. 2, unless ring lug must line up correctly. If necessary, use only a
otherwise specified. soft hammer to rotate the lug. Use pry bar for installing
lock ring (4), as shown in Fig. 5.
For mounting a tyre with rim on or off machine, the
procedure is basically the same. 9. Force bead seat band (3) past 'O' ring groove in
wheel rim (5) by prying, or with lift truck forks. Use
blocking between the forks and tyre to prevent
WARNING damage. Insert a new 'O' ring (2, Fig. 1) in groove of
When lifting tyre onto the rim, be sure the the rim behind lock ring (4). Lubricate area of front
equipment is of sufficient capacity and taper of bead seat band (3) adjacent to 'O' ring (2, Fig. 1),
properly secured to do the job safely. with a thin solution of soap and water or another
approved lubricant which is not harmful to rubber.
1. For off-machine installation, lay wheel rim (5) on Avoid using an excessive amount of lubricant.
blocks or mounting stand with 'O' ring groove up.
Wheel rim (5) should be off the floor enough to allow 10. If used, install driver (2). Make sure all rim
tyre to rest on rim and not the floor. Blocks are not to components are correctly assembled.
extend more than 13 mm (0.50 in) beyond rim base.
11. Lift the tyre upwards to effect a seal between bead
2. If removed, install inner flange (6) over wheel rim (5). seat band (3) and 'O' ring (2, Fig. 1). In some cases
the tyre will automatically spring out, making this step
3. Lubricate tyre beads and 'O' ring, with a thin solution unnecessary.
of vegetable base soap and water.
12. Refer to heading, 'Tyre Inflation' in this section for
4. Using suitable lifting equipment, lower tyre onto the proper procedure for inflating the tyre.
wheel rim (5). Seat tyre firmly against inner flange (6).

4 SM 2179 Rev2 08-05


Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

MOUNTING TYRE AND RIM ASSEMBLY


A.
ON MACHINE Use an air compressor and reservoir located
Numbers in parentheses refer to Fig. 1. inside a heated building, when available, so
that alcohol, methanol, or other flammable
antifreeze liquids are not needed in the air
WARNING tanks to prevent moisture freezing in the tank
To prevent personal injury and property and lines in subfreezing outside
damage, be sure blocking materials and lifting temperatures.
equipment are properly secured and of
adequate capacity to do the job safely. B.
Make sure that paints, lacquers, paint
1. Support tyre and rim assembly with a suitable thinners, or similar materials that produce
chain, or rope sling. Attach sling to overhead lifting volatile, flammable vapours are not used or
device. Slide assembly onto wheel of the vehicle, with stored near the air intake of the compressor
lock ring (4) and bead seat band (3) facing outward. that supplies the air for inflating tyres. The
compressor should be isolated from all such
2. Install lock washers (9) and wheel nuts (10) on sources of flammable vapours.
wheel studs. Gradually tighten wheel nuts opposite
each other until all wheel nuts are snug. Tighten wheel C.
nuts (10) to a torque of 590 Nm (435 lbf ft). Tighten Be sure to thoroughly flush and blow off all
wheel nuts (10) again, after 10 hours of operation. flammable solvents used for cleaning the air
compressor inlet screen before using the
compressor for tyre inflation, or any other
TYRE INFLATION purpose.

D.
WARNING Do not charge batteries, either in or out of a
To prevent personal injury and property machine, near the air inlet of a compressor
damage, the tyre and rim assembly should be used for inflating tyres. Charging batteries
placed in a safety cage before inflating. If no produces highly explosive hydrogen gas
safety cage is available or tyre is on the which can be readily drawn into a nearby
machine, the tyre and rim assembly should be compressor inlet and pumped into the tyre.
wrapped with safety chains or with lash cables
before inflating. E.
Never exceed the specified concentration of
Even with these precautions remember that alcohol when adjusting the alcohol vaporizer,
air-blast is a potential hazard. Tyre inflation or adding alcohol to the auxiliary air tank,
should be carried out away from busy working used on machine air systems to prevent
areas. freezing or moisture condensate in below-
freezing temperatures. Excessive alcohol,
WARNING added to the machines air tanks in this
To avoid personal injury and property damage, manner can produce flammable vapours that
never stand or sit in front of a mounted tyre will be pumped into a tyre when this air
during tyre inflation. Use a clip-on air chuck supply is used for tyre inflation if the tyre
with a long hose and stand to one side while inflation kit is not equipped with a moisture
the tyre is being inflated. filter. Alcohol added to machine air systems
in recommended concentration to prevent
WARNING condensate freezing are below hazardous
To prevent personal injury and property levels for tyre inflation.
damage, always prevent flammable vapours
that could produce tyre explosions, from being F.
pumped into tyres during inflation, by Another source of hazardous flammable
observing the following precautions: vapours in tyres is the tyre bead lubricant.
Always use bead lubricants that do not
introduce flammable vapours into the tyre.

SM 2179 Rev2 08-05 5


Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 208 All machines whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on the body
or frame.

Nitrogen gas improves tyre pressure retention,


increases tyre life by reducing carcass oxidation from
within, minimizes rim rust and has no detrimental
effects on the tyre. It also reduces the potential of a
tyre explosion because it is an inert gas and will not
support combustion inside the tyre.

The same tyre inflation pressure used for air inflation


should be used for nitrogen inflation. Tyre valves
formerly used with air inflation are entirely satisfactory
for use with nitrogen gas.

Nitrogen Tyre Inflation Kit

WARNINGS
Fig. 6 - Typical Safety Cage DO NOT USE charging assembly, Part No.
9359489, for tyre inflation because this
assembly does not include a pressure
Inflation regulator, safety relief valve, and adequate
Note: Always use tyre inflation equipment with an air pressure gauging which is mandatory for tyre
filter that removes moisture from the air supply, when inflation purposes. Tyre volume is as much as
available, to prevent moisture corrosion of internal rim 90 times greater than the average accumulator
parts. volume and hence it takes very much longer to
inflate a tyre - up to 40 minutes or more for
1. Inflate tyre to 1 bar (15 lbf/in) initially to seat very large tyres.
components and tap lock ring lightly to ensure correct
seating. Visually check that all components are in Nitrogen gas cylinders used to inflate
place, then continue inflation observing all safety tyres are generally charged to approximately
precautions. (See Step 2). 152 bar (2 200 lbf/in2). A tyre blowout and/or
rim failure could occur if inflation equipment is
2. If the tyre is off the machine, place it in a safety not properly used. Proper nitrogen charging
cage after initially inflating to 1 bar (15 lbf/in) to seat equipment and personnel training for its use is
components. See Fig. 6. a must to avoid over inflation.

3. Inflate tyres to 5.2 bar (75 lbf/in) to seat beads and 1. A nitrogen tyre inflation kit is available from your
seal the 'O' ring, then adjust to the recommended dealer and consists of the following. Refer to Fig. 7.
inflation pressure.
a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with
4. For recommended operating air pressure, refer to two dual pressure gauges.
the 'Tyre Inflation Pressures' table.
b. Safety relief valve, 8.6 bar (125 lbf/in), that will
assure an upper limit to the pressure available for tyre
NITROGEN TYRE INFLATION inflation.
Note: All Warnings and procedures under 'Tyre
Inflation' will apply, except for differences covered by c. A 15.2 m (50 ft) length of flexible hose with
this passage. interconnecting fittings. On the tyre end of the hose is
a large bore quick connect/disconnect clip-on chuck.
In certain environments it is recommended that tyres
be inflated with dry nitrogen gas, and that the resulting 2. The pressure regulator is connected to a nitrogen
oxygen content of the inflation does not exceed 5%. compressed gas cylinder available from local suppliers.

6 SM 2179 Rev2 08-05


Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 1040 Re-inflation of a Mounted Tyre


To re-inflate a tyre with dry nitrogen gas which is now
inflated with air, proceed as follows:

1. Exhaust the tyre until only air at atmospheric


pressure remains in the tyre.

2. Re-inflate the tyre using only dry nitrogen gas to


4.15 bar (60 lbf/in) gauge as a minimum, or to bead-
seating pressure as a maximum.

3. Adjust to the service inflation pressure required:

a. If the required service inflation pressure is LESS


than 4.1 bar (60 lbf/in), remove the clip-on chuck and
adjust the pressure with the tyre gauge in the usual
manner.

b. If the required service inflation pressure is greater


than 4.1 bar (60 lbf/in), further inflate, with dry
nitrogen gas only, to the pressure level required. Then
remove the clip-on chuck and adjust the pressure with
the tyre gauge in the usual manner.

New Tyre Mounts and Remounts


Fig. 7 - Nitrogen Tyre Inflation Kit
To newly mount or remount a tyre to its rim, use only
dry nitrogen gas; this includes the pressure required to
3. The usual procedure for using this type of seat the beads. After seating the tyre beads, remove
equipment is as follows: the clip-on chuck and adjust the pressure with the tyre
gauge in the usual manner.
a. Connect nitrogen tyre inflation kit to nitrogen
compressed gas supply. DO NOT connect clip-on Note: Although a little more nitrogen gas is used to
chuck to the tyre valve at this time. seat beads than that used for re-inflation of a mounted
tyre, refer to 'Re-inflation of a Mounted Tyre', its cost is
b. Open valve on nitrogen supply. generally negligible in comparison to the time and
labour saving and, longer tyre life achievable with the
c. With flexible hose and clip-on chuck connected to reduced oxygen content which results.
nitrogen tyre inflation kit assembly but not connected
to the tyre, adjust pressure regulator so that its output
pressure is not more than 1.4 bar (20 lbf/in) higher TYRE EXPLOSION HAZARD
than the desired tyre inflation pressure.

d. Connect clip-on chuck to the tyre valve. The tyre will WARNING
now inflate. Tyre pressure can be monitored by Whenever a machines tyre(s) is (are) exposed
observing the gauge at the pressure regulator. STAY to excessive heat such as a machine fire or
AWAY FROM THE TYRE. extremely hot brakes the hazard of a
subsequent violent tyre explosion must be
e. When desired inflation pressure has been achieved, recognized. All persons must avoid
back off the regulator or close the valve on the approaching the machine so as not to be
compressed gas cylinder. physically endangered in the event of an
explosion of the tyre and rim parts.
f. Remove the clip-on chuck and adjust the tyre
pressure with the tyre gauge in the usual manner.

SM 2179 Rev2 08-05 7


Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 1041

WARNING (cont.)
The machine should be moved to a remote AT LEAST AT LEAST
15 m (50 ft) 460 m (1 500 lbf ft)
area, but only when this can be done with
complete safety to the operator operating or
towing the machine. All other persons should
stay clear of the machine. The fire or
overheated brakes, wheel, etc. should be
extinguished or cooled from a safe distance.
Do not attempt to extinguish the fire or cool
the machine by use of hand-held fire
extinguishers.

If it is absolutely necessary to approach a


machine with a suspect tyre, approach only
from the front or the back. Stay at least 15 m
(50 ft) from the tread area. Keep observers out
of the area and at least 460 m (1 500 ft) from
the tyre sidewall. Refer to Fig. 8. The tyre(s)
should be allowed at least eight (8) hours
cooling time after the machine is shut down or
the fire extinguished before approaching
closer.
Fig. 8 - APPROACH AREA.
Do Not Approach Tyre in Shaded Area
There is always a possibility of a tyre
explosion whenever the smell of burning
rubber or excessively hot brakes is detected. TYRE AND WHEEL RIM MAINTENANCE
The danger is also present when a fire on the
machine reaches the tyre and wheel area. Tyre Repairs
Under such conditions, all personnel must Prompt repair of tyre injuries will prevent small injuries
avoid approaching the machine in a manner from enlarging and causing tyre failure. Use the best
that could result in injury should an explosion tyre facilities available. If good repair facilities are not
actually occur. Move the machine to a remote available, have the nearest dealer make the necessary
area only if it can be done without endangering repairs.
the operator or other personnel in the area.
Minor cuts, snags, or punctures should be repaired
upon discovery. Skive with a sharp pointed knife
WARNING around any cut in the tyre tread area that is of
DO NOT WELD ON OR HEAT RIM sufficient depth or shape to hold pebbles or dirt. The
COMPONENTS. For several years the company angle of the skive should be no more than sufficient to
and tyre and rim manufacturers have warned expel all foreign material and should extend no deeper
users never to weld rim components with the than the breaker. The skive should go to the bottom of
tyre mounted on the rim. The gases that build the hole. Tyres with shallow cuts, if treated promptly,
up inside the tyre during arc welding or may be allowed to continue in service. If the cut
heating on rim components can ignite, extends deeper into the tyre carcass, the tyre should
resulting in one of these explosive-like failures be removed for repair.
of the tyre and rim. This warning also applies
to nitrogen inflated tyres. Ignition will not The tyre must be removed from the rim to repair larger
occur in the nitrogen atmosphere, but the punctures or cuts. Irregular shaped punctures or cuts
pressure buildup from the heat of welding may less than 13 mm (0.50 in) in size can be repaired with
be sufficient to cause a blowout severe enough a plug and hot patch. Insert a repair plug into the hole
to injure or kill. It is recommended to scrap the to keep out moisture and to back up the hot patch.
part if heat is necessary to repair any rim Trim the plug off flush with the inside of the casing,
component. buff, and apply the hot patch according to the
instructions supplied with the hot patch equipment.

8 SM 2179 Rev2 08-05


Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

Punctures 13 mm (0.50 in) or larger, large cuts, or Inspect Tyres Regularly


bruise breaks require sectional or reinforced vulcanized A systematic plan for tyre inspection will more than
repair. Cover the repair patch with a layer of cushion pay for itself in lowered tyre costs per hour of
gum after application to the tubeless tyre to ensure an operation. All tyres should be checked regularly for
airtight repair. Any cords of the inside ply that are cuts, bruises, ply material breaks, excessive or
exposed in buffing and are not covered with repair uneven wear, embedded foreign matter, and any other
patch must be coated with cushion gum to prevent air damage which can be repaired. A considerable
leakage into the carcass plies on tubeless tyres. increase in tyre service can be realized if tyre injuries
are repaired before they have progressed to the
irreparable stage.
Recapping and Retreading
There are two general methods employed in restoring The rim mounting nuts should also be checked
the tread surface of off-the-highway tyres: recapping periodically and tightened to the torque specified.
and retreading.

A recapped tyre has a new tread cured right over the Prevent Overloading
old tread surface. Off-highway machines are designed to carry a
maximum allowable payload. Excessive loading will
A retreaded tyre has the old tread removed entirely and overstress both the machine and tyres and shorten the
a new tread cured directly onto the body of the tyre. A life of both.
tyre can be recapped or retreaded if the cord body is
free of cuts, bruises and separation, and is thoroughly
sound, including previous repairs. Prevent Contact with Oil
Prevent tyre contact with petroleum products. Rubber
that is exposed to oil, gasoline, or grease becomes
TYRE CARE soft and spongy and deteriorates rapidly. Always avoid
To obtain maximum service from off-highway tyres, the driving machine through a puddle of gasoline, fuel oil,
following common-sense precautions should be lubricating oil, or grease. Never let a tyre stand in an
followed. oil or grease spot overnight.

Maintain Correct Inflation Store Tyres Properly


The most common cause of tyre damage is improper The best of care given to tyres in service by operators
inflation. Both over-inflation and under-inflation are and maintenance personnel can be completely
detrimental to tyre life. Tyre pressure should be nullified by careless storage. Time is not the only
checked daily, preferably before the machine is placed contributing factor to the deterioration of rubber
in operation. Refer to 'Tyre Inflation Pressures' table. products. Therefore, tyres that are to be stored must
be protected from light, heat, oils, dirt, moisture, and
The valve cores should be checked for leaks. Keep in ozone. Stored tyres should be carefully covered with a
mind that valve cores are delicate mechanisms that tarpaulin or some other suitable material, such as
wear out in service; therefore, they should be replaced opaque plastic sheeting, to prevent contact with the
with new ones when they become worn. Each tyre contaminants listed above.
should be equipped with a valve cap to prevent dirt
from damaging the valve core and causing air leakage.
Proper Handling of Tyres and Wheel Rim
Parts
Maintain Good Haul Roads Tyres should be stored vertically. Horizontal stacking
Because haul roads are considered temporary roads may compress the tyre walls, making inflation difficult. If
they are frequently neglected. The better the haul road, tyres are stored in racks, the lower supporting members
the longer the tyre and machine life of off-highway should provide as broad a surface as possible to the tyre
machines. tread to avoid a concentration of load.

Although it takes time and effort to maintain good haul The beads of tubeless tyres must be protected from
roads, the delay and cost of tyres and machine damage or a faulty air seal will result. Do not use
breakdowns caused by poor haul roads is many times hooks, cables, or chains in contact with the tyre beads
greater.
SM 2179 Rev2 08-05 9
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
when lifting these tyres. If forklift trucks are used for 'O' rings are seals and should be carefully stored in a
handling, they should be equipped with broad, well- cool, dry place where they will not be injured or
rounded arms to distribute the load and prevent damaged.
damage to the tyre bead. When handling tyres with the
fork truck do not scrape the fork across the bead. Valve cores should also be stored in a cool, dry and
clean place.
Tubeless tyre rims perform an important function as
part of the assembly air seal. Proper care, therefore,
must be taken not to distort or mutilate the rim parts MAINTENANCE
because they must mate properly to form part of the Check tyre pressures daily, preferably before the
basic air chamber. Since the rim base and bead seat machine is placed in operation. Refer to 'Tyre Inflation
band are mating surfaces, distortion may prevent easy Pressures' table.
assembly as well as possibly resulting in no seal.
Every 50 hours of operation (weekly), torque tighten
Never drop, tumble, or roll rim parts. wheel rim nuts to 590 Nm (435 lbf ft).

If rim parts are stored outdoors, they should be given a Check tyres regularly and replace or repair if required.
protective coat of a good commercial primer.

Similar parts should be stacked neatly to prevent distortion. SERVICE TOOLS


The nitrogen tyre inflation kit shown in Fig. 7 is
Babbit or lead hammers, not sledge hammers, should available from your dealer. Refer to Section 300-0070,
be used in assembling rim parts. SERVICE TOOLS for part numbers of general service
tools required.

TYRE INFLATION PRESSURES (BRIDGESTONE)


FRONT CENTRE AND REAR
2
MODEL TYRE SIZE bar lbf/in bar lbf/in2
TA30 23.5 R 25** 4.75 69 4.75 69
750/65 R 25 3.25 47 3.25 47

TYRE INFLATION PRESSURES (MICHELIN)


FRONT CENTRE AND REAR
2
MODEL TYRE SIZE bar lbf/in bar lbf/in2
TA30 23.5 R 25** 4 58 4 58
750/65 R 25 3.0 44 3.0 44

TYRE INFLATION PRESSURES (PIRELLI)


FRONT CENTRE AND REAR
2
MODEL TYRE SIZE bar lbf/in bar lbf/in2
TA30 23.5 R 25** 4.8 70 4.8 70

TYRE INFLATION PRESSURES (CONTINENTAL)


FRONT CENTRE AND REAR
2
MODEL TYRE SIZE bar lbf/in bar lbf/in2
TA30 23.5 R 25** 5.0 73 5.0 73

10 SM 2179 Rev2 08-05


Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

TYRE INFLATION PRESSURES (MARANGONI)


FRONT CENTRE AND REAR
2
MODEL TYRE SIZE bar lbf/in bar lbf/in2
TA30 750/65 R 25** 3.0 43 3.0 43

TUBELESS TYRE LEAK DIAGNOSIS


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.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Wheel Nut 590 435

* * * *

SM 2179 Rev2 08-05 11


BRAKE PARTS - Brake Parts - Rear
Section 165-0010

SM - 2477

1,5

4,5

4,5

1,5

1 - Capscrew 3 - Brake Heads


2 - Brake Disc 4 - Bolt 5 - Washer

Fig. 1 - Cutaway View of Typical Brake Head and Disc Mounting

are two brake heads and one brake disc at each wheel.
WARNINGS
Use only hydraulic oils meeting specifications Each calliper brake head assembly consists of a
outlined in Section 300-0020, LUBRICATION torque plate, two brake pads (one on each side of the
SYSTEM. Do Not use Brake Fluid (J1703). Use brake disc) and four brake pistons, two on each side of
of improper fluids is destructive to rubber the brake disc. The piston bores on each side of the
components of brakes resulting in loss of torque plate are interconnected by internal passages
braking and possible catastrophic failure.
When the brake is actuated, hydraulic oil enters brake
Exercise extreme caution while working head and forces pistons against brake pads which are,
on the braking system. in turn, forced against each side of the brake disc,
slowing or stopping the disc and wheel rotation.

DESCRIPTION AND OPERATION


GENERAL INSPECTION
The service brakes are of the calliper disc-type. The
calliper brake head is designed for use with hydraulic 1. Inspect brake pads for wear. If the brake pad friction
oil as specified in Section 300-0020, LUBRICATION material is worn down to 3 mm (0.12 in) thickness, the
SYSTEM. Do Not use Brake Fluid (J1703). pads must be replaced.

The head is bolted to a mounting plate on


the axle housing. The disc is bolted to the wheel. There

SM 2180 11-02 1
Brake Parts - Brake Parts - Rear
Section 165-0010

SM - 049

1 - Bleeder Valve 5 - Torque Pin 9 - Piston Plug 13 - Packing


2 - Screw 6 - Bolt 10 - Seal 14 - Backup Ring
3 - Torque Pin 7 - Washer 11 - Piston 15 - Dust Cap
4 - Brake Pads 8 - Cover Plate 12 - Boot 16 - Torque Plate

Fig. 2 - Exploded View of Typical Brake Head

3. Inspect brake piston and torque plate for wear.


WARNING
Failure to replace pads when worn to limits will
result in loss of braking and possible BRAKE PAD REMOVAL AND
catastrophic failure. INSTALLATION
Numbers in parentheses refer to Fig. 2.
2. Inspect brake disc as follows:

a. Measure original thickness of disc at outside WARNINGS


diameter (this area is not contacted by brake pad To prevent personal injury and property
friction material). damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
b. Measure thickness of disc at three points on the secured and of adequate capacity to do the job
brake pad friction material contact circumference and safely.
determine the average disc thickness.
To prevent personal injury and property
c. Subtract 'b' from 'a'. If difference is 3 mm (0.12 in) damage, the procedure for removing tyre and
or greater, the disc must be replaced. rim assembly described in Section 160-0050,
WHEEL RIM AND TYRE, must be strictly
Note: Refer to Section 160-0030, AXLE GROUP followed.
(HUB), for brake disc replacement instructions.

2 SM 2180 11-02
Brake Parts - Brake Parts - Rear
Section 165-0010
1. Position the vehicle in a level work area, apply the Note: Make sure torque pins (3 & 5) do not touch brake
parking brake and switch off the engine. Operate disc (2, Fig. 1). If they do, loosen bolts (2) and adjust
steering right and left several times to relieve any torque pins to clear disc by 1.5 - 3.2 mm
pressure in the steering system. (0.06 - 0.125 in). Check to make sure that bolts (2) fully
engage in torque pin grooves and retighten bolts.

WARNINGS 11. Pump brake pedal until brake pads (4) contact
Hydraulic fluid pressure will remain within the brake disc (2, Fig. 1).
braking system after engine shutdown. Operate
the brake pedal continuously until the pressure 12. When new brake pads are installed on a machine,
has dissipated before carrying out any work on the brake pad friction material should be burnished in
the braking system or serious injury could accordance with the following procedure to achieve
result. maximum braking performance:

To prevent possible personal injury, keep a. Drive vehicle at 8 - 30 km/h (5 - 20 mile/h) with
hands and fingers etc. clear of the area between brakes applied at just enough pressure to produce a
the disc and the brake head pistons. noticeable drag. Heavy smoke and foul odour from the
brake pad friction material is normal during this
2. Block all road wheels, except the wheel to be procedure.
removed, and place the battery master switch in the
'Off' position. Note: An infrared thermometer pointed at the disc after
stopping, can safely and easily determine brake disc
3. Remove wheel from the machine following temperature. Refer to 'Special Tools'.
instructions in Section 160-0050, WHEEL RIM AND
TYRE. b. Continue cycle until the brake disc achieves a
temperature of 315 - 370 C (600 - 700 F).
4. Loosen bolts (2) securing large torque pins (3) at the
end of torque plate (16). It is not necessary to loosen or c. Permit disc to cool to less than 95 C (200 F).
remove the two smaller torque pins (5) at opposite end.
d. Repeat Steps a and b.
5. Move the two unlocked torque pins (3) away from
brake disc (2, Fig. 1). e. Allow brake to cool to within 10 C (50 F) of ambient
temperature, while driving the vehicle with the brakes
6. Remove dust cap (15) from bleeder valve (1) and released.
attach a bleeder hose to bleeder valve. Open bleeder
valve (1). Use a screwdriver or pry bar inserted between f. Repeat Steps a and b until full braking performance
brake disc (2, Fig. 1) and brake pads (4) to press (per applicable government regulations) is achieved.
pistons (11) back as far as possible, into the piston
bores of torque plate (16). Close bleeder valve.
BRAKE REMOVAL AND DISASSEMBLY
7. Rotate brake pads (4) out of the opened end of Numbers in parentheses refer to Fig. 2, unless
torque plate (16). Inspect boots (12) for deterioration. otherwise specified.

8. Install new brake pads (4) by placing friction


material next to the disc and rotating into position in WARNINGS
torque plate (16). To prevent personal injury and property
damage, be sure wheel blocks, blocking
9. Push the two unlocked pins (3) towards the disc. materials and lifting equipment are properly
secured and of adequate capacity to do the job
10. Coat threads with locking compound and install two safely.
loosened bolts (2) until bolts seat in grooves of torque
pins (3). This can be checked by limited axial To prevent personal injury and property
movement of pins as the bolts are being seated. damage, the procedure for removing tyre and
Tighten bolts (2) to a torque of 43 - 51 Nm (32 - 38 lbf rim assembly described in Section 160-0050,
ft). WHEEL RIM AND TYRE, must be strictly
followed.

SM 2180 11-02 3
Brake Parts - Brake Parts - Rear
Section 165-0010
1. Position the vehicle in a level work area, apply the 9. Clean torque plate (16) making sure no solvent
parking brake and switch off the engine. Operate remains in fluid passages or grooves. Inspect boot (12)
steering right and left several times to relieve any and seal (10) grooves, and land areas between grooves
pressure in the steering system. for damage or cracks. Minor nicks and scratches may
be blended with crocus cloth. Replace torque plate (16)
if corrosion is excessive or boot (12) and seal (10)
WARNINGS grooves are damaged, prohibiting proper rebuild of the
Hydraulic fluid pressure will remain within the brake head.
braking system after engine shutdown. Operate
the brake pedal continuously until the pressure 10. Inspect pistons (11) for minor scratches and nicks
has dissipated before carrying out any work on and blend with crocus cloth. If piston (11) is badly
the braking system or serious injury could nicked or scratched, or if the chrome plate is worn
result. off, replace piston (11).

To prevent possible personal injury, keep 11. Torque pins (3 & 5) that are deeply grooved should
hands and fingers etc. clear of the area between be replaced.
the disc and the brake head pistons.

2. Block all road wheels, except the wheel to be ASSEMBLY


removed, and place the battery master switch in the Numbers in parentheses refer to Fig. 2, unless
'Off' position. otherwise specified.

3. Remove wheel from the machine following 1. Lubricate seals (10), packings (13) and pistons
instructions in Section 160-0050, WHEEL RIM AND (11) with petroleum base oil or vaseline.
TYRE.

4. Remove fasteners securing wheel guards to axle WARNING


housing, and remove guards. Do not use brake fluid (SAE J1703).

5. Remove hydraulic fluid inlet line at brake head 2. Install backup rings (14), packings (13) and boots
assembly. Plug line and brake head to prevent ingress (12) in torque plate (16) piston bores. Lubricate per
of dirt. Step 1.

6. Remove bolts (4, Fig. 1) and washers (5, Fig. 1) 3. Install pistons (11) in torque plate (16) as follows:
from mounting at axle housing and remove brake head Position lubricated piston (11) into boot (12) and piston
assembly to a clean working area. bore, holding piston at a slight angle. Insert forefinger
between piston (11) and boot (12) and rotate forefinger
around outside diameter of piston (11), lifting inside
WARNING diameter of boot (12) over outside diameter of piston (11).
Hydraulic fluid may cause irritation. Avoid skin Make sure outside diameter lip of boot (12) remains in the
and eye contact with fluid. groove in piston (11) bore.

7. Disassemble brake head assembly in sequence of 4. After piston (11) is through boot (12), centre piston
index numbers in Fig. 2. Items (1, 2 & 3) may be left in by feel over packing (13). Apply by hand, a turning
torque plate (16) when servicing packings (13), seals (10), thrusting pressure, working piston (11) into and through
backup rings (14), and boots (12) if desired. packing (13).

Note: Repair kits are available which include new 5. When assured pistons (11) are through packings
boots (12), backup rings (14), packings (13) and (13), pressure other than hand pressure may be used
seals (10), in quantities sufficient to rebuild a brake to press pistons the remainder of the way into the
head assembly. Refer to vehicle parts book for repair piston bores. Snap open end of boot (12) into groove
kit part number. All parts included in a repair kit should of piston (11).
be replaced each time a brake head is rebuilt.
6. Lubricate seals (10) and install seals and piston
8. Inspect brake pads (4) per Step 1 in 'General plugs (9) in open end of piston bores of torque plate (16).
Inspection' procedure.

4 SM 2180 11-02
Brake Parts - Brake Parts - Rear
Section 165-0010
7. Attach cover plate (8) to torque plate (16) and housing.
secure with bolts (6) and washers (7). Tighten bolts (6)
to a torque of 505 - 515 Nm (370 - 380 lbf ft). 5. Install wheel on the vehicle following instructions in
Section 160-0050, WHEEL RIM AND TYRE.
8. When installing torque pins (3 & 5) and bolts (2)
make sure the groove in the pin is directly under the
bolt so the bolt can perform its locking and retaining BLEEDING THE BRAKING SYSTEM
function. Numbers in parentheses refer to Fig. 2.

Note: Lubricate torque pins (3 & 5) with a corrosion In order to obtain satisfactory braking, the system
resistant lubricant prior to installation to facilitate next should be bled as follows to eliminate any air in the
pin removal. hydraulic brake lines.

9. Inspect brake disc (2, Fig. 1), if worn, per 1. Fill the hydraulic tank with oil specified in Section
instructions under 'General Inspection' in this section. 300-0020, LUBRICATION SYSTEM. Start the engine
Refer to Section 160-0030, AXLE GROUP (HUB) for and allow systems to reach normal operating
brake disc replacement instructions. conditions.

2. Check oil level and add oil if low. Oil should be


INSTALLATION halfway up the sight gauge on the hydraulic tank.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
WARNING
To prevent personal injury and property
WARNINGS damage, be sure wheel blocks, blocking
To prevent personal injury and property materials and lifting equipment are properly
damage, be sure wheel blocks, blocking secured and of adequate capacity to do the job
materials and lifting equipment are properly safely.
secured and of adequate capacity to do the job
safely. 3. Ensure gear shift selector is in neutral, block all road
wheels, place the steering lock bar in the 'Locked'
To prevent personal injury and property position and release the parking brake.
damage, the procedure for installing tyre and
rim assembly described in Section 160-0050, 4. Remove dust cap (15) and install a clear length of
WHEEL RIM AND TYRE, must be strictly followed. tubing over bleeder valve (1) on one of the brake
heads. Submerge the opposite end of the tubing in a
1. Install washers (5) on bolts (4). Use Loctite 262 on suitable container filled with hydraulic oil, specified in
bolts (4). Section 300-0020, LUBRICATION SYSTEM.

2. Position brake head (3) over brake disc (2) on brake 5. Crack open the bleeder valve (1) and gently operate
mounting plate, aligning bolt holes. Install assembled treadle valve several times to bleed air in the brake
bolts (4) and washers (5) through mounting plate and lines.
into torque plate, and tighten bolts (4) to a torque of
515 Nm (380 lbf ft). 6. When the oil from the brake head is clear (not cloudy
or creamy) close bleeder valve (1) and remove tubing.
Note: Make sure torque pins (3 & 5, Fig. 2) do not
touch brake disc (2). If they do, loosen bolts (2, Fig. 2)
and adjust pins to clear disc by 1.5 - 3.2 mm WARNING
(0.06 - 0.125 in). Check to make sure that bolt (2, Fig. 2) Do not operate the vehicle until all air is bled
fully engages in pin groove and tighten bolt (2, Fig. 2) from the braking system.
to a torque of 43 - 51 Nm (32 - 38 lbf ft).
7. Perform steps 4 through 6 for the remaining 11 brake
3. Attach hydraulic fluid inlet line at brake head head assemblies.
assembly.

4. Install fasteners and secure wheel guards to axle

SM 2180 11-02 5
Brake Parts - Brake Parts - Rear
Section 165-0010

MAINTENANCE Note: This service interval applies to normal driving.


Check the pads more frequently under more severe
Numbers in parentheses refer to Fig. 2.
conditions. Thickness of pad friction material should
never be allowed to wear below 3 mm (0.12 in).
Every 10 Hours (Daily)
Inspect brake assemblies to ensure that all bolts are
Note: Repair kits are available which include new boots
tight and there are no leaks. Inspect boots for
(12), backup rings (14), packings (13) and seals (10), in
deterioration.
quantities sufficient to rebuild a brake head assembly.
Refer to vehicle parts book for repair kit part number.
Check oil level and add oil if low. Fill hydraulic tank
All parts included in a repair kit should be replaced
with oil specified in Section 300-0020, LUBRICATION
each time a brake head is rebuilt.
SYSTEM. Oil should be halfway up the sight gauge on
the hydraulic tank.
SERVICE TOOLS
Every 250 Hours (Monthly)
Refer to Section 300-0070, SERVICE TOOLS, for part
Check brake pads and discs for wear and adjust or
numbers of the non-contact infrared thermometer and
replace where necessary. Test for proper function.
general service tools and adhesives required. These
tools are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 4 Bolt 515 380
2 2 Bolt 43 - 51 32 - 38
2 6 Bolt 505 - 515 370 - 380

* * * *

6 SM 2180 11-02
PARKING BRAKE - Parking Brake and Mounting
Section 170-0010

SM - 2801

11 13

10
14 3 2

7,8

4,5 16
1 1

6 12 6

15

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 2181 11-02 1
Parking Brake - Parking Brake and Mounting
Section 170-0010

REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 2.
otherwise specified.
1. Remove calliper head assembly as described under
removal.
WARNINGS
To prevent personal injury and property 2. Remove snap ring (13) from power screw shaft (18),
damage, be sure wheel blocks, blocking and remove fasteners securing control strap (27) to
materials and lifting equipment are properly slack adjuster (14).
secured and of adequate capacity to do the job
safely. 3. Slide slack adjuster (14) from power screw shaft (18).

Hydraulic fluid pressure will remain 4. Remove and discard washer (16), wave spring
within the braking system after engine shut washer (15) and packing (17) from power screw
down. Operate the treadle pedal continuously shaft (18).
until the pressure has dissipated before
carrying out any work on the braking system or 5. Remove bolts (2) and washers (3) securing cap
serious injury could result. assembly (21) to calliper (6).

1. Position the vehicle on a level surface, apply the 6. Remove as a unit, power screw shaft (18),
parking brake, block all road wheels and place the piston (5) and cap assembly (19 through 22) from
steering lock bar in the 'Locked' position. calliper (6).

2. Raise the body and install body safety prop to 7. Slide power screw shaft (18) and piston (5) from cap
secure in partially raised position. assembly (21).

3. Pull out push control to release the parking brake. 8. Unscrew piston (5) from power screw shaft (18).

4. Release spring tension on slack adjuster clevis pin 9. Remove and discard thrust bearing (19) from power
(7) by unscrewing tensioning bolt on slack adjuster (3) screw shaft (18) and gasket (20) from cap
until clevis pin (7) feels loose. Remove cotter pin (8) assembly (21).
and clevis pin (7) from actuator (9).
10. Remove and discard piston seal (4) from calliper (6).
Note: On engine shutdown the parking brake will
automatically apply. Ensure there is sufficient
clearance for actuator rod travel. INSPECTION
Numbers in parentheses refer to Fig. 2.
5. Switch off the engine and place the battery master
switch in the 'Off' position. 1. Thoroughly clean all parts. Inspect journal bearing
(22) in cap assembly (21) for wear. Journal bearing (22)
6. Disconnect and plug hydraulic line from actuator (9). ID should not exceed 38.35 mm (1.51 in). Replace if
Cap actuator (9) to prevent ingress of dirt. necessary.

7. Remove nuts (10) and washers (11) securing 2. Replace cap assembly (21) if excessively worn.
actuator (9) to cap assembly (13). Remove actuator (9)
from cap assembly (13). 3. Inspect all brake parts for cracks, excessive wear or
scoring. Replace brake parts as required.
8. Support calliper head assembly (2) and remove bolts
(4 & 16), washers (5) and nuts (6) securing mounting
plates (1) to mounting bracket on the frame. ASSEMBLY
Numbers in parentheses refer to Fig. 2.
9. Remove mounting plates (1) and calliper head
assembly (2) from the vehicle. 1. Install new piston seal (4) into seal groove in calliper
(6).

2. Apply grease (Lubriplate Aero or equivalent) to flat

2 SM 2181 11-02
Parking Brake - Parking Brake and Mounting
Section 170-0010
SM - 2802

18

19 20

21

6 3
2

12

'A'

11
22 26
24 25
17
10 15
14
16 7
1

'A'
27
4
8
23 5
9 13
AT POSITION 'A'

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 2181 11-02 3
Parking Brake - Parking Brake and Mounting
Section 170-0010
10. With adjusting screw facing towards actuator (12) 6. Align actuator (9) to slack adjuster (3) and tighten
slide slack adjuster (14) on power screw shaft (18) nuts (10).
aligning slack adjuster (14) arm with clevis (7).
7. Loosen bolt (15) at the control arm of slack adjuster
11. Install snap ring (13) on power screw shaft (18). (3) and control strap (12).

12. Remove nuts (10), lockwashers (25) and washers 8. Position control arm of slack adjuster (3) in fully
(11) securing actuator (12) to cap assembly (21). released position (forcing it in a direction away from
Remove actuator (12) from cap assembly (21) to aid in actuator (9)) by turning adjustment screw (14) on the
installation. slack adjuster (3), until it comes to a positive stop
inside the control strap (12).

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).
otherwise specified.
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 2181 11-02
Parking Brake - Parking Brake and Mounting
Section 170-0010

SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 6 Nut 75 55

* * * *

SM 2181 11-02 5
SUSPENSION SYSTEM - Front Suspension
Section 180-0020

SM - 2803

18

18
4

5 30
29
12
13
14 15
8 2
27 9,10,11 31 16 31 16

6
16 7
2
7 9,10,11
8
15
19
20 12,13,14
20 19
21
17 16 6

17
22
1
26 25 3 29
23 27
28
24

1 - Suspension Frame 11 - Shim 21 - Link Assy


2 - Spherilastic Bush 12 - Bolt 22 - Spacer
3 - Nut 13 - Bolt 23 - Chain & Shackle
4 - Axle Plate 14 - Bolt 24 - Bolt
5 - Axle Plate 15 - Washer 25 - Lockwasher
6 - Locknut 16 - Hardened Washer 26 - Nut
7 - Inner Bush 17 - Bolt 27 - Shock Absorber
8 - Outer Bush 18 - Rubber Mounts 28 - Bolt
9 - Shim 19 - Stop Screw 29 - Hardened Washer
10 - Shim 20 - Locknut 30 - Nut
31 - Bolt
Fig. 1 - Exploded View of Front Suspension

DESCRIPTION (4 & 5) and front frame. In addition, there are are four
Numbers in parentheses refer to Fig. 1. heavy duty double acting shock absorbers (27) (two off
each side) to smooth out the ride. Two chain and
The front axle assembly is mounted on the leading shackle assemblies (23) provide extra retention on
arms of suspension frame (1) which pivots on the front rebound.
frame.

Suspension is provided by two heavy duty rubber REMOVAL


suspension mounts (18) mounted between axle plates Numbers in parentheses refer to Fig. 1.

SM 2182 11-02 1
Suspension System - Front Suspension
Section 180-0020

WARNINGS 11. Using jack, lower suspension frame (1) onto a


To prevent personal injury and property suitable trolley until rubber suspension mounts (18) are
damage, be sure wheel blocks, blocking free of compression.
materials and lifting equipment are properly
secured and of adequate capacity to do the job 12. Remove thread caps and mounting hardware
safely. securing shock absorbers (27) to front frame. Remove
shock absorbers (27), and remove rubber suspension
mounts (18).
Hydraulic fluid pressure will remain
within the braking system after engine shut 13. Support the rear end of suspension frame (1) using
down. Operate the treadle pedal continuously suitable equipment. Loosen and remove locknuts (20)
until the pressure has dissipated before securing stop screw (19) in front frame. Remove stop
carrying out any work on the braking system or screw (19) from front frame.
serious injury could result.
14. Using torque multiplier (see Special Tools), loosen
1. Position the vehicle in a level work area, ensure the nuts (6) securing suspension frame (1) to front frame.
body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel several 15. Remove nuts (6), hardened washers (16) and bolts
times to relieve any pressure in the steering system. (31) securing suspension frame (1) to front frame.

2. Block rear road wheels, place the steering lock bar 16. Remove bolts (12 - 14) and washers (15) securing
in the 'Locked' position and place the battery master outer bushes (8) to front frame. Remove inner bushes
switch in the 'Off' position. (7), outer bushes (8) and shims (9 - 11).

3. Whilst the front road wheels are still on the ground, 17. Carefully lower suspension frame (1) assembly
loosen the wheel nuts. onto the trolley and remove from under the vehicle.

4. Using suitable lifting equipment, raise the machine DISASSEMBLY


until both front tyres are off the ground. Support the
vehicle with suitable stands and blocking at the front Numbers in parentheses refer to Fig. 1.
frame and articulation pivot area.

5. Support one tyre and rim assembly with suitable WARNING


lifting equipment and remove wheel nuts securing the To prevent personal injury and property
rim to the axle. Remove tyre and rim assembly. damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
6. Repeat step 5 for the opposite tyre and rim safely.
assembly.
1. Remove nuts (30), hardened washers (29) and bolts
7. Disconnect hydraulic brake line at tee on front axle (28) securing front axle assembly and axle plates (4 &
assembly. Disconnect differential breather line. Cap 5) to suspension frame (1). Using suitable lifting
lines and fittings to prevent ingress of dirt. equipment, remove front axle assembly from
suspension frame (1).
8. Jack up suspension frame (1) and remove nuts (26),
lockwashers (25) and bolts (24) securing chain and 2. If required, press spherilastic bushes (2) from
shackle assemblies (23) to suspension frame (1) and suspension frame (1) using press tool and power press
link assembly (21). (See Special Tools).

9. Support driveline and remove bolts securing driveline 3. If required, remove bolts (17), spacer (22), washers
to front axle. Refer to Section 130-0010, FRONT AND and nuts (3) securing link assembly (21) to front frame.
REAR DRIVELINES.
ASSEMBLY
10. Remove thread caps and mounting hardware
securing shock absorbers (27) to suspension frame (1). Numbers in parentheses refer to Fig. 1.

2 SM 2182 11-02
Suspension System - Front Suspension
Section 180-0020
Note: Tighten all fasteners without special torques SM - 2804

specified to standard torques listed in Section FRONT


300-0080, STANDARD BOLT AND NUT TORQUE GAP 'A'
1
FRAME
2
SPECIFICATIONS. 9,10,11
8
7
12,13,14,15
16
WARNING 33,34

To prevent personal injury and property


5
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely. 20
6
19
1. If spherilastic bushes (2) were removed during 16

disassembly, install new spherilastic bushes as


follows:
0.75 -
a. Coat bores in suspension frame (1) with a water 1.25 mm

based lubricant.
1 - Suspension Frame 12 - Bolt
2 - Spherilastic Bush 13 - Bolt
b. Using press tool and power press (See Special
5 - Bolt 14 - Bolt
Tools), install spherilastic bushes (2) in suspension 6 - Locknut 15 - Washer
frame (1). 7 - Inner Bush 16 - Hardened Washer
8 - Outer Bush 19 - Stop Screw
9 - Shim 20 - Locknut
2. Using suitable lifting equipment, position front axle 10 - Shim 33 - Loctite Primer T
assembly on suspension frame (1). Position axle 11 - Shim 34 - Loctite 648
plates (4 & 5) and secure with bolts (28), hardened
washers (29) and locknuts (30). Tighten locknuts (30) Fig. 2 - Sectional View of Suspension Pivot
to a torque of 680 Nm (501 lbf ft).
4. Position suspension frame (1) completely to one
3. If removed, install link assembly (21) to front frame side and take a measurement of the gap between boss
using bolts (17), spacer (22), washers and nuts (3). on front frame and inside face of outer bush (8). Half
this size to obtain the thickness of shim (9 - 11) pack
INSTALLATION required for Gap 'A' (Fig. 2) at both sides.
Numbers in parentheses refer to Figs. 1 & 2. Note: Do not overshim, it is important to leave some
clearance.
WARNING 5. Remove outer bushes (8) and shim Gap 'A' at both
To prevent personal injury and property sides with shims (9 - 11) calculated at Step 4.
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job 6. Reinstall outer bushes (8), bolts (12 - 14) and
safely. washers (15). Hand tighten bolts at this stage.
1. Position suspension frame (1) assembly and trolley 7. Install rubber suspension mounts (18) between axle
under the front frame with spherilastic bushes (2) to the plates (4 & 5) and front frame.
rear.
8. Mount two hydraulic jacks (see Special Tools) below
2. Using suitable lifting equipment, lift suspension suspension frame. Using hydraulic pump to operate
frame (1) assembly and locate inner bushes (7) and hydraulic jacks, compress rubber suspension mounts
outer bushes (8) in front frame. (18) to 300mm (11.8").
3. Install bolts (31), hardened washers (16) and nuts (6) 9. Using torque multiplier (see Special Tools), tighten
through spherilastic bearings (2). Hand tighten nuts (6) nuts (6) to a torque of 1 835 Nm (1 325 lbf ft).
at this stage.
10. Remove bolts (12 - 14) and washers (15). Apply

SM 2182 11-02 3
Suspension System - Front Suspension
Section 180-0020
Loctite Primer T (33) and Loctite 648 (34) to threads of 18. Reconnect hydraulic brake line at tee on front axle
bolts and reinstall bolts (12 - 14) and washers (15). assembly. Reconnect differential breather line. Cap
Tighten bolts (12 - 14) to a torque of 170 Nm (125 lbf lines and fittings to prevent ingress of dirt.
ft).
19. Using suitable lifting equipment, position one tyre
11. Connect chain and shackle assemblies (23) and rim assembly on a front wheel and secure with
between link assembly (21) and suspension frame (1) wheel nuts. Tighten locknuts to a torque of 590 Nm
and secure with bolts (24), lockwashers (25) and nuts (435 lbf ft).
(26).
20. Using suitable lifting equipment, position opposite
12. Install shock absorbers (27) to the front frame and tyre and rim assembly on the opposite front wheel and
secure with locknuts. Tighten upper locknuts to a secure with wheel nuts.
torque of 103 Nm (74 lbf ft). Refit thread caps.
21. Using suitable lifting equipment, raise front frame
13. Align bottom of shock absorbers (27) with mounting sufficiently to remove stands and blocking from the
holes on suspension frame (1) and secure with front frame and articulation pivot. Lower vehicle to the
locknuts. Tighten lower locknuts to a torque of 103 Nm ground and remove lifting equipment. Tighten all wheel
(74 lbf ft). Refit thread caps. nuts to a torque of 590 Nm (435 lbf ft).

14. Install and adjust stop screw (19) to achieve 0.75 - 22. Remove wheel blocks from rear road wheels and
1.25 mm clearance (Fig. 2) between suspension frame place the steering lock bar in the 'Stowed' position.
(1) and stop screw (19).
23. Bleed all air from hydraulic brake lines. Refer to
15. Once clearance is obtained, install and tighten Section 165-0010, BRAKE PARTS - REAR.
locknut (20).

16. Remove trolley from underneath tractor frame. SPECIAL TOOLS


Refer to Section 300-0070, SERVICE TOOLS, for part
17. Install driveline between axle and transmission and numbers of torque multiplier, hydraulic jack, power
secure with bolts removed previously. Refer to Section press, press tool and general service tools and
130-0010, FRONT AND REAR DRIVELINES. sealants required. These tools and sealants are
available from your dealer.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 6 Nut 1835 1325
1 12 - 14 Bolt 170 125
1 30 Locknut 680 501
1 27 Shock Absorber Nut (Upper) 103 74
1 27 Shock Absorber Nut (Lower) 103 74
- - Wheel Nut 590 435

* * * *

4 SM 2182 11-02
SUSPENSION SYSTEM - Rear Suspension
Section 180-0040

SM - 2805

33
26 31 24

25 30 11
34 9
27 27
28 28
7 6
23 8
23 B
19
FR
ON 18
T 2 30 24

16,17 25
A
A 3,4
22 A C

23 26

1 27
6 16,17 16,17
5 A 28

30 8
7
26 24 29
A DETAIL B
25 A
25
27 16,17 A
9 21
28 11

13 32
1 10 23
A 12 C 5 19
15 22
14 A 30 3,4
A B
23
16,17 30
20 31 26
20
B 2
27 27
23
16,17 A 28 23
29 28 A
DETAIL A 19 DETAIL C

1 - Suspension Link Brkt 13 - Lube Fitting 24 - Bolt


2 - Suspension Link Brkt 14 - Bolt 25 - Lockwasher
3 - Control Link 15 - Lockwasher 26 - Bolt
4 - Bushing 16 - Control Link 27 - Hardened Washer
5 - Suspension Link Brkt 17 - Bushing 28 - Nut
6 - Equaliser Beam 18 - Bolt 29 - Locknut
7 - Bushing 19 - Locknut 30 - Interleaf Mount
8 - 'V' Seal 20 - Bolt 31 - Bolt
9 - Retainer 21 - Bolt 32 - Bolt
10 - Lockwasher 22 - Bolt 33 - Brake Pipe Guard RH
11 - End Cap 23 - Hardened Washer 34 - Brake Pipe Guard LH
12 - Bolt

Fig. 1 - Exploded View of Rear Suspension

DESCRIPTION The rear suspension system is effectively maintenance


free due to the use of rubber bushings (4 & 17) being
Numbers in parentheses refer to Fig. 1.
used in control links (3 & 16). Lubrication of bushings
(7) in equaliser beams (6) is through lube fittings (13).
Each axle is coupled to the chassis by three rubber
bushed control links (16) which provide longitudinal
location and control torque reactions. Lateral location REMOVAL
is by means of two control links (3). The centre and
Numbers in parentheses refer to Fig. 1.
rear axles are linked by longitudinal equaliser beams
(6) which pivot on either side of the chassis.
WARNING
Loads acting on the axles are balanced by equaliser
To prevent personal injury and property
beams (6), with bonded rubber/metal laminated
damage, be sure wheel blocks, blocking
interleaf mounts (30) between the axles and beam ends
materials and lifting equipment are properly
providing the cushioning medium.
secured and of adequate capacity to do the job
safely.

SM 2183 11-02 1
Suspension System - Rear Suspension
Section 180-0040
12. Remove bolts (24) and lockwashers (25) securing
WARNING interleaf mounts (30) to suspension link brackets (1 &
Hydraulic fluid pressure will remain 2) mounted on the centre and rear axles. Remove
within the braking system after engine shut interleaf mounts (16).
down. Operate the treadle pedal continuously
until the pressure has dissipated before 13. Remove bolts (14) and lockwashers (15) securing
carrying out any work on the braking system or end cap (11) to equaliser beam (6). Remove end
serious injury could result. cap (11).

1. Position the vehicle in a level work area, raise the 14. Remove bolts (12) and lockwashers (10) securing
body and install the body safety prop to secure the retainer (9) to spindle on the frame. Remove retainer (9).
body in the partially raised position.
15. Using suitable lifting equipment, support equaliser
2. Apply the parking brake and switch off the engine. beam (6) and withdraw from spindle on the frame.
Turn steering wheel several times to relieve any
pressure in the steering system. 16. Remove and discard 'V' seal (8) from bushing (7). If
required, remove bushing (7) from spindle on the frame.
3. Block the front road wheels, place the steering lock
bar and oscillation lock pin in the 'Locked' position and 17. Repeat steps 13 through 16 to remove the opposite
the battery master switch in the 'Off' position. equaliser beam (6).

4. Using suitable blocking equipment, block equaliser 18. Remove locknuts (19), hardened washers (23) and
beams (6) to prevent movement when raising the bolts (18) securing centre control links (16) to cross
trailer frame. shaft mounting brackets.

5. Whilst the rear road wheels are still on the ground, 19. Remove locknuts (29), hardened washers (23) and
loosen the wheel nuts. bolts (20) securing centre control links (16) to
suspension link brackets (5). Remove centre control
6. Using suitable lifting equipment, raise the trailer links (17).
frame until the rear wheels are off the ground. Support
the vehicle with suitable stands and blocking 20. Remove locknuts (29), hardened washers (23) and
equipment at the trailer frame, articulation pivot area bolts (20) securing control link (16) to bracket
and centre and rear axles. assembly (2) on the rear axle and the LH frame
mounting bracket. Remove control link (16).
7. Support one tyre and rim assembly with suitable
lifting equipment and remove wheel nuts and 21. Remove locknuts (29), hardened washers (23) and
lockwashers securing the rim to the axle. Remove tyre bolts (20) securing control link (16) to bracket
and rim assembly. assembly (1) on the centre axle and the LH frame
mounting bracket. Remove control link (16).
8. Repeat step 7 for the remaining rear tyre and rim
assemblies. 22. Remove locknuts (29), hardened washers (23) and
bolts (20) securing control link (16) to bracket
9. With a suitable container in position, disconnect assembly (1) on the rear axle and the RH frame
hydraulic brake lines from the tee pieces at the centre mounting bracket. Remove control link (16).
and rear axle assemblies. Cap lines and fittings to
prevent entry of dirt. 23. Remove locknuts (29), hardened washers (23) and
bolts (20) securing control link (16) to bracket
10. Remove mounting hardware connecting brake line assembly (2) on the centre axle and the RH frame
guards (33 & 34) to axles and remove brake line mounting bracket. Remove control link (16).
guards.
24. Remove locknuts (28), hardened washers (27) and
11. Remove blocking materials from equaliser bolts (26 & 31) securing suspension link bracket (2) on
beams (6). Remove locknuts (29), lockwashers (25) the rear axle. Remove suspension link bracket (2).
and bolts (21) securing interleaf mounts (30) to
equaliser beams (6). 25. Remove locknuts (28), hardened washers (27) and
bolts (26) securing suspension link bracket (1) on the

2 SM 2183 11-02
Suspension System - Rear Suspension
Section 180-0040
rear axle. Remove suspension link bracket (1). suspension link bracket (1) to centre axle with bolts
(26), hardened washers (27) and locknuts (28). Tighten
26. Remove bolts (22) and hardened washers (23) bolts (26) to a torque of 671 Nm (495 lbf ft).
securing suspension link bracket (5) on the rear axle.
Remove suspension link bracket (5). 5. Apply Loctite 243 to bolts (24) and secure interleaf
mounts (30) to centre axle with bolts (24) and
27. Remove locknuts (28), hardened washers (27) and lockwashers (25). Tighten bolts (24) to a torque of 165
bolts (26) securing suspension link bracket (1) on the Nm (122 lbf ft).
centre axle. Remove suspension link bracket (1).
6. Install suspension link bracket (5) on rear axle.
28. Remove locknuts (28), hardened washers (27) and Apply Loctite 270 to bolts (22) and secure suspension
bolts (26 & 31) securing suspension link bracket (2) on link bracket (5) to rear axle with bolts (22) and washers
the centre axle. Remove suspension link bracket (2). (23). Tighten bolts (22) to a torque of 324 Nm (239 lbf
ft).
29. Remove bolts (22) and hardened washers (23)
securing suspension link bracket (5) on the centre axle. 7. Install suspension link bracket (2) on LH side of the
Remove suspension link bracket (5). rear axle. Apply Loctite 243 to bolts (26 & 31) and
secure suspension link bracket (2) to rear axle with
30. If either axle assembly requires to be removed from bolts (26 & 31), hardened washers (27) and locknuts
under the vehicle; raise axle assembly with suitable (28). Tighten bolts (26 & 31) to a torque of 671 Nm (495
lifting equipment, remove blocking from under the axle lbf ft).
assembly and lower axle assembly onto a suitable
trolley. Slide the axle assembly from under the vehicle 8. Install suspension link bracket (1) on RH side of the
to a suitable work area. rear axle. Apply Loctite 243 to bolts (26) and secure
suspension link bracket (1) to rear axle with bolts (26),
hardened washers (27) and locknuts (28). Tighten bolts
INSTALLATION (26) to a torque of 671 Nm (495 lbf ft).
Numbers in parentheses refer to Figs. 1, 2 & 3.
9. Apply Loctite 243 to bolts (24) and secure interleaf

WARNING SM - 1425
To prevent personal injury and property
damage, be sure wheel blocks, blocking 9 7
materials and lifting equipment are properly 12,10
secured and of adequate capacity to do the job
safely.

1. Ensure centre and rear axle assemblies are 11


correctly positioned and securely blocked below the
frame.

2. Install suspension link bracket (5) on centre axle.


Apply Loctite 270 to bolts (22) and secure suspension
link bracket (5) to centre axle with bolts (22) and 13
washers (23). Tighten bolts (22) to a torque of 324 Nm
(239 lbf ft).

3. Install suspension link bracket (2) on RH side of the 14,15


centre axle. Apply Loctite 243 to bolts (26 & 31) and 6 8
secure suspension link bracket (2) to centre axle with
bolts (26 & 31), hardened washers (27) and locknuts 6 - Equaliser Beam 11 - End Cap
7 - Bushing 12 - Bolt
(28). Tighten bolts (26 & 31) to a torque of 671 Nm (495 8 - 'V' Seal 13 - Lube Fitting
lbf ft). 9 - Retainer 14 - Bolt
10 - Lockwasher 15 - Lockwasher
4. Install suspension link bracket (1) on LH side of the
Fig. 2 - Sectional View of Equaliser Beam Installation
centre axle. Apply Loctite 243 to bolts (26) and secure

SM 2183 11-02 3
Suspension System - Rear Suspension
Section 180-0040
mounts (30) to rear axle with bolts (24) and SM - 2806
lockwashers (25). Tighten bolts (24) to a torque of 165
Nm (122 lbf ft).

10. If bushings (7) were removed from spindle on the 16

frame, thoroughly clean spindles with Loctite activator


'N' and allow to dry. Apply Loctite 648 retaining
compound all over bushing (7) contact area of the
spindles and install bushings (7) on the spindles.
Ensure paint dot on bushing (7) is at TDC, and that one
of the grease channels lines up with channel on spindle
end face (both grease channels should be at bottom).
Once installed, end face of spindle should protrude by
20 23 19
3mm.

Note: A curing time of fifteen minutes is required for


acceptable handling strength.
16 - Control Link 20 - Bolt
19 - Locknut 23 - Hardened Washer
11. Install new 'V' seals (8) over bushings (7) with the
lip to the outside, as shown in Fig. 2. Fig. 3 - Sectional View of Typical Control Link Mounting

12. Clean bores on equalising beams (6) and, using washers (23) and locknuts (29). Tighten bolts (20) to a
suitable lifting equipment, install beams onto bushings torque of 556 Nm (410 lbf ft).
(7). Apply Loctite 243 to bolts (12) and secure retainers
(9) to spindles with bolts (12) and lockwashers (10). 19. Install control link (3) between suspension link
Tighten bolts (12) to a torque of 150 Nm (110 lbf ft). bracket (2) and RH frame mounting bracket and secure
at suspension link bracket (2) with bolts (32), hardened
13. Apply Loctite 243 to bolts (14) and Loctite 574 washers (23) and locknuts (19). Tighten bolts (32) to a
gasket eliminator to mounting face of end caps (11). torque of 556 Nm (410 lbf ft).
Secure end caps (11) to equalising beams (6) with
bolts (14) and lockwashers (15). Tighten bolts (14) to a 20. Secure control link (3) at RH frame mounting
torque of 75 Nm (55 lbf ft). bracket with bolts (20), hardened washers (23) and
locknuts (19). Tighten bolts (20) to a torque of 556 Nm
14. If removed, install lube fittings (13) in end caps (11). (410 lbf ft).
Lubricate with grease specified in Section 300-0020,
LUBRICATION SYSTEM, until excess lube is seen. 21. Install control link (3) between suspension link
bracket (2) and LH frame mounting bracket and secure
15. Apply Loctite 243 to bolts (21) and secure interleaf at suspension link bracket (2) with bolts (32), hardened
mounts (30) to equaliser beams (6) with bolts (21), washers (23) and locknuts (19). Tighten bolts (32) to a
lockwashers (25) and locknuts (29). Tighten bolts (21) torque of 556 Nm (410 lbf ft).
to a torque of 165 Nm (122 lbf ft).
22. Secure control link (3) at LH frame mounting
16. Install centre control links (17) between suspension bracket with bolts (20), hardened washers (23) and
link brackets (5) and cross shaft mounting brackets. locknuts (19). Tighten bolts (20) to a torque of 556 Nm
Secure at cross shaft mounting brackets with bolts (410 lbf ft).
(18), hardened washers (23) and locknuts (19). Tighten
bolts (18) to a torque of 556 Nm (410 lbf ft). 23. Remove caps and connect hydraulic brake lines to
the tee pieces at the centre and rear axle assemblies.
17. Secure centre control links (17) at suspension link Clip brake lines with clips removed during removal.
brackets (5) with bolts (20), hardened washers (23) and
locknuts (29). Tighten bolts (20) to a torque of 556 Nm 24. Connect brake line guards (33 & 34) to axles and
(410 lbf ft). secure with mounting hardware removed during
removal.
18. Install control links (17) between rear and centre
axle suspension link brackets (1 & 2) and frame 25. Using suitable blocking equipment, block equaliser
mounting brackets and secure with bolts (20), hardened beams (6) to prevent movement when installing the

4 SM 2183 11-02
Suspension System - Rear Suspension
Section 180-0040
rear tyre and rim assemblies. 31. Remove wheel blocks from the front road wheels
and place the steering lock bar and oscillation lock pin
26. Using suitable lifting equipment, position one tyre in the 'Stowed' position.
and rim assembly on one rear wheel and secure with
wheel nuts and lockwashers.
MAINTENANCE
27. Repeat step 26 for remaining tyre and rim Numbers in parentheses refer to Fig. 1.
assemblies.
Pre-Starting Inspection: Visually check condition and
28. Using suitable lifting equipment, raise the trailer mounting of equaliser beams (6), interleaf mounts (30)
frame sufficiently to remove stands and blocking and control links (3 & 16).
equipment from the centre and rear axles, articulation
pivot area and trailer frame. Lower vehicle to the Every 250 Hours: Lubricate bushings (7) in equaliser
ground and remove the lifting equipment. beams (6) through lube fittings (13), with grease
specified in Section 300-0020, LUBRICATION
29. With the vehicle lowered to the ground, tighten all SYSTEM, until excess lube is seen.
wheel nuts to a torque of 590 Nm (435 lbf ft).

30. Place the battery master switch in the 'On' position, SERVICE TOOLS
start the engine and check hydraulic brake lines for There are no special tools required for the procedures
leaks. Bleed all air from the hydraulic brake lines as outlined in this section. Refer to Section 300-0070,
described in Section 165-0020, HYDRAULIC BRAKING SERVICE TOOLS, for part numbers of general service
SYSTEM SCHEMATIC. tools and adhesives required during the removal and
installation of the rear suspension. These tools and
adhesives are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 12 Bolt 150 110
1 14 Bolt 75 55
1 18 Bolt 556 410
1 20 Bolt 556 410
1 22 Bolt 324 239
1 24 Bolt 1 085 800
1 26 Bolt 671 495
1 31 Bolt 671 495
1 32 Bolt 556 410
- - Wheel Nut 590 435

* * * *

SM 2183 11-02 5
SUSPENSION SYSTEM - Rear Suspension
Section 180-0040

SM - 3308

33 26 31 24

34 R.H.S. 25 30 11
27 9
27
28 28 46
L.H.S. 45 43 44
7 6 47 38
23 8 48
FR 23
ON 19 DETAIL C
T B
18
2
32
17 30
3,4 24
A 32
22
16 A 25
23 A C
26
1
17 32
3,4 27
5
A 28
6 3,4
8
7
24 2
30 A
25 29 A 35 40
25 A 41

5 3,4 37
9 21 32 39 35
26 11 37
C 22 35 42,49
27 1 13
10 32 23
28 A 12 39
15 46 37
14 A 30 16 17 45
A 47
B 32
3,4 17 36 36
32
31 26 35
44 35
29 38
B 2 48
23 27
27 43 2
20 3,4 A
28 A 28
DETAIL A DETAIL B DETAIL D

1 - Suspension Link Brkt 17 - Spherical Bearing 33 - Brake Pipe Guard RH


2 - Suspension Link Brkt 18 - Bolt 34 - Brake Pipe Guard LH
3 - Control Link 19 - Locknut 35 - elbow
4 - Bushing 20 - Bolt 36 - Hose assembly
5 - Suspension Link Brkt 21 - Bolt 37 - P-Clip
6 - Equaliser Beam 22 - Bolt 38 - Lockwasher
7 - Bushing 23 - Hardened Washer 39 - Bolt
8 - 'V' Seal 24 - Bolt 40 - Manifold Bracket
9 - Retainer 25 - Lockwasher 41 - Lube Fitting
10 - Lockwasher 26 - Bolt 42 - Bolt
11 - End Cap 27 - Hardened Washer 43 - Pin
12 - Bolt 28 - Nut 44 - Washer
13 - Lube Fitting 29 - Locknut 45 - Spacer
14 - Bolt 30 - Interleaf Mount 46 - V-Ring Seal
15 - Lockwasher 31 - Bolt 47 - V-Ring Seal
16 - Panhard Rod 32 - Retainer 48 - Bolt
49 - Washer
Fig. 1 - Exploded View of Rear Suspension

DESCRIPTION
Numbers in parentheses refer to Fig. 1. laminated interleaf mounts (30) located between the
axles and beam ends providing the cushioning
Each axle is coupled to the chassis by three rubber medium.
bushed control links (3) which provide longitudinal
location and control torque reactions. Lateral location is The rear suspension system requires minimal
by means of two Panhard rod links (16). The centre maintenance due to the use of rubber bushings (4)
and rear axles are linked by longitudinal equaliser being used in control links (3). Lubrication of Spherical
beams (6) which pivot on either side of the chassis. bearings (17) in Panhard rods (16) is through lube
fittings (41), similarly lubrication of bushings (7) in
Loads which act on the axles are balanced by equaliser beams (6) is through lube fittings (13).
equaliser beams (6), with bonded rubber/metal

SM 2183 Rev1 10-04 1


Suspension System - Rear Suspension
Section 180-0040
and rear axle assemblies. Cap lines and fittings to
REMOVAL prevent entry of dirt.
Numbers in parentheses refer to Fig. 1.
10. Remove mounting hardware connecting brake line
guards (33 & 34) to axles and remove brake line
WARNING guards.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 11. Remove blocking materials from equaliser
materials and lifting equipment are properly beams (6). Remove locknuts (29), washers (25) and
secured and of adequate capacity to do the job bolts (21) securing interleaf mounts (30) to equaliser
safely. beams (6).

12. Remove bolts (24) and lockwashers (25) securing


WARNING interleaf mounts (30) to suspension link brackets (1 &
Hydraulic fluid pressure will remain 2) mounted on the centre and rear axles. Remove
within the braking system after engine shut interleaf mounts (30).
down. Operate the treadle pedal continuously
until the pressure has dissipated before 13. Remove bolts (14) and lockwashers (15) securing
carrying out any work on the braking system or end cap (11) to equaliser beam (6). Remove end
serious injury could result. cap (11).

1. Position the vehicle in a level work area, raise the 14. Remove bolts (12) and lockwashers (10) securing
body and install the body safety prop to secure the retainer (9) to spindle on the frame. Remove retainer (9).
body in the partially raised position.
15. Using suitable lifting equipment, support equaliser
2. Apply the parking brake and switch off the engine. beam (6) and withdraw from spindle on the frame.
Turn steering wheel several times to relieve any
pressure in the steering system. 16. Remove and discard 'V' seal (8) from bushing (7). If
required, remove bushing (7) from spindle on the frame.
3. Block the front road wheels, place the steering lock
bar and oscillation lock pin in the 'Locked' position and 17. Repeat steps 13 through 16 to remove the opposite
the battery master switch in the 'Off' position. equaliser beam (6).

4. Using suitable blocking equipment, block equaliser 18. Remove locknuts (19), hardened washers (23) and
beams (6) to prevent movement when raising the trailer bolts (18) securing centre control links (3) to cross
frame. shaft mounting brackets.

5. Whilst the rear road wheels are still on the ground, 19. Remove locknuts (29), hardened washers (23) and
loosen the wheel nuts. bolts (20) securing centre control links (3) to
suspension link brackets (5). Remove centre control
6. Using suitable lifting equipment, raise the trailer links (3).
frame until the rear wheels are off the ground. Support
the vehicle with suitable stands and blocking 20. Remove locknuts (29), hardened washers (23) and
equipment at the trailer frame, articulation pivot area bolts (20) securing control link (3) to bracket assembly
and centre and rear axles. (2) on the rear axle and the LH frame mounting bracket.
Remove control link (3).
7. Support one tyre and rim assembly with suitable
lifting equipment and remove wheel nuts and 21. Remove locknuts (29), hardened washers (23) and
lockwashers securing the rim to the axle. Remove tyre bolts (20) securing control link (3) to bracket assembly
and rim assembly. (1) on the centre axle and the LH frame mounting
bracket. Remove control link (3).
8. Repeat step 7 for the remaining rear tyre and rim
assemblies. 22. Remove locknuts (29), hardened washers (23) and
bolts (20) securing control link (3) to bracket assembly
9. With a suitable container in position, disconnect (1) on the rear axle and the RH frame mounting
hydraulic brake lines from the tee pieces at the centre bracket. Remove control link (3).

2 SM 2183 Rev1 10-04


Suspension System - Rear Suspension
Section 180-0040
23. Remove locknuts (29), hardened washers (23) and trolley. Slide the axle assembly from under the vehicle
bolts (20) securing control link (3) to bracket assembly to a suitable work area.
(2) on the centre axle and the RH frame mounting
bracket. Remove control link (3). INSTALLATION
Numbers in parentheses refer to Figs. 1, 2 & 3.
24. Refer to detail D: Remove hose assemblies (36)
and elbows (35) from panhard rods (16).
WARNING
25. Remove hose assemblies and elbows (35 &36) To prevent personal injury and property
from manifold bracket (41). Remove remote lube damage, be sure wheel blocks, blocking
fittings (41) if necessary. materials and lifting equipment are properly
secured and of adequate capacity to do the job
26. Remove bolts (39) securing p-clips (37) and hoses safely.
(36) in place. Carefully remove hose assemblies and
elbow (35 & 36) from panhard rods (16). 1. Ensure centre and rear axle assemblies are correctly
positioned and securely blocked below the frame.
27. If necessary remove manifold bracket (41) from
frame, by removing bolts (42) and washers (49). 2. Install suspension link bracket (5) on centre axle.
Apply Loctite 270 to bolts (22) and secure suspension
28. Refer to details B & C: Remove bolts (48), washers link bracket (5) to centre axle with bolts (22) and
(44) and Lockwashers (38) from suspension link washers (23). Tighten bolts (22) to a torque of 324 Nm
brackets (2) and frame assembly. Remove pins (43). (239 lbf ft).

29. Remove V-ring seals (46 & 47), Spacers (45) and 3. Install suspension link bracket (2) on RH side of the
Panhard rods (16) from suspension link brackets (2) centre axle. Apply Loctite 243 to bolts (26 & 31) and
and frame assembly. secure suspension link bracket (2) to centre axle with
bolts (26 & 31), hardened washers (27) and locknuts
30. Remove locknuts (28), hardened washers (27) and (28). Tighten bolts (26 & 31) to a torque of 671 Nm (495
bolts (26 & 31) securing suspension link bracket (2) on lbf ft).
the rear axle. Remove suspension link bracket (2).
4. Install suspension link bracket (1) on LH side of the
31. Remove locknuts (28), hardened washers (27) and centre axle. Apply Loctite 243 to bolts (26) and secure
bolts (26) securing suspension link bracket (1) on the suspension link bracket (1) to centre axle with bolts
rear axle. Remove suspension link bracket (1). SM - 1425
9 7
32. Remove bolts (22) and hardened washers (23) 12,10
securing suspension link bracket (5) on the rear axle.
Remove suspension link bracket (5).
11
33. Remove locknuts (28), hardened washers (27) and
bolts (26) securing suspension link bracket (1) on the
centre axle. Remove suspension link bracket (1).

34. Remove locknuts (28), hardened washers (27) and 13


bolts (26 & 31) securing suspension link bracket (2) on
the centre axle. Remove suspension link bracket (2).
14,15
35. Remove bolts (22) and hardened washers (23) 6 8
securing suspension link bracket (5) on the centre axle.
Remove suspension link bracket (5).
6 - Equaliser Beam 11 - End Cap
7 - Bushing 12 - Bolt
36. If either axle assembly requires to be removed from 8 - 'V' Seal 13 - Lube Fitting
under the vehicle; raise axle assembly with suitable 9 - Retainer 14 - Bolt
lifting equipment, remove blocking from under the axle 10 - Lockwasher 15 - Lockwasher
assembly and lower axle assembly onto a suitable Fig. 2 - Sectional View of Equaliser Beam Installation

SM 2183 Rev1 10-04 3


Suspension System - Rear Suspension
Section 180-0040
(26), hardened washers (27) and locknuts (28). Tighten SM - 3298
bolts (26) to a torque of 671 Nm (495 lbf ft).
5. Apply Loctite 243 to bolts (24) and secure interleaf
mounts (30) to centre axle with bolts (24) and
lockwashers (25). Tighten bolts (24) to a torque of 165
Nm (122 lbf ft). 3

6. Install suspension link bracket (5) on rear axle.


Apply Loctite 270 to bolts (22) and secure suspension
link bracket (5) to rear axle with bolts (22) and washers
(23). Tighten bolts (22) to a torque of 324 Nm (239 lbf
ft).

7. Install suspension link bracket (2) on LH side of the 20 23 19


rear axle. Apply Loctite 243 to bolts (26 & 31) and
secure suspension link bracket (2) to rear axle with
bolts (26 & 31), hardened washers (27) and locknuts 3 - Control Link 20 - Bolt
19 - Locknut 23 - Hardened Washer
(28). Tighten bolts (26 & 31) to a torque of 671 Nm (495
lbf ft).
Fig. 3 - Sectional View of Typical Control Link Mounting
8. Install suspension link bracket (1) on RH side of the
rear axle. Apply Loctite 243 to bolts (26) and secure Secure end caps (11) to equalising beams (6) with
suspension link bracket (1) to rear axle with bolts (26), bolts (14) and lockwashers (15).
hardened washers (27) and locknuts (28). Tighten bolts Tighten bolts (14) to a torque of 75 Nm (55 lbf ft).
(26) to a torque of 671 Nm (495 lbf ft).
14. If removed, install lube fittings (13) in end caps (11).
9. Apply Loctite 243 to bolts (24) and secure interleaf Lubricate with grease specified in Section 300-0020,
mounts (30) to rear axle with bolts (24) and LUBRICATION SYSTEM, until excess lube is seen.
lockwashers (25). Tighten bolts (24) to a torque of 165
Nm (122 lbf ft). 15. Apply Loctite 243 to bolts (21) and secure interleaf
mounts (30) to equaliser beams (6) with bolts (21),
10. If bushings (7) were removed from spindle on the lockwashers (25) and locknuts (29). Tighten bolts (21)
frame, thoroughly clean spindles with Loctite activator to a torque of 165 Nm (122 lbf ft).
'N' and allow to dry. Apply Loctite 648 retaining
compound all over bushing (7) contact area of the 16. Install centre control links (3) between suspension
spindles and install bushings (7) on the spindles. link brackets (5) and cross shaft mounting brackets.
Ensure paint dot on bushing (7) is at TDC, and that one Secure at cross shaft mounting brackets with bolts
of the grease channels lines up with channel on spindle (18), hardened washers (23) and locknuts (19). Tighten
end face (both grease channels should be at bottom). bolts (18) to a torque of 556 Nm (410 lbf ft).
Once installed, end face of spindle should protrude by
3mm. 17. Secure centre control links (3) at suspension link
brackets (5) with bolts (20), hardened washers (23) and
Note: A curing time of fifteen minutes is required for locknuts (29). Tighten bolts (20) to a torque of 556 Nm
acceptable handling strength. (410 lbf ft).

11. Install new 'V' seals (8) over bushings (7) with the 18. Install control links (3) between rear and centre axle
lip to the outside, as shown in Fig. 2. suspension link brackets (1 & 2) and frame mounting
brackets and secure with bolts (20), hardened washers
12. Clean bores on equalising beams (6) and, using (23) and locknuts (29). Tighten bolts (20) to a torque of
suitable lifting equipment, install beams onto bushings 556 Nm (410 lbf ft).
(7). Apply Loctite 243 to bolts (12) and secure retainers
(9) to spindles with bolts (12) and lockwashers (10). 19. Pre-assemble Panhard rods (16), spherical
Tighten bolts (12) to a torque of 150 Nm (110 lbf ft). bearings (17) and retainers (32).

13. Apply Loctite 243 to bolts (14) and Loctite 574 20. Refer to Details B: Install both LH and RH Panhard
gasket eliminator to mounting face of end caps (11). rod assemblies (16) between suspension link brackets

4 SM 2183 Rev1 10-04


Suspension System - Rear Suspension
Section 180-0040
(2) and the frame by taking Panhard rods (16) and 31. Using suitable lifting equipment, raise the trailer
locating into mating slot of the suspension link bracket frame sufficiently to remove stands and blocking
(2), between spacers (45) and v-ring seals (46 & 47). equipment from the centre and rear axles, articulation
Secure in place by locating Pin (43) and securing in pivot area and trailer frame. Lower vehicle to the
place with washers (44), lockwasher (38) and bolt (48). ground and remove the lifting equipment.
Tighten bolts (48) to a torque of 75 Nm (55 Ibf ft).
32. With the vehicle lowered to the ground, tighten all
21. Refer to detail C: Perform the same procedure wheel nuts to a torque of 590 Nm (435 lbf ft).
stated in step 20. for securing panhard rods (16) in
place to axle. 33. Place the battery master switch in the 'On' position,
start the engine and check hydraulic brake lines for
22. Refer to detail D: Install manifold bracket (40) onto leaks. Bleed all air from the hydraulic brake lines as
frame and secure in place using washers (49) and bolts described in Section 165-0020, HYDRAULIC BRAKING
(42). SYSTEM SCHEMATIC.

23. Fit elbows (35) and grease nipples (41) to manifold 34. Remove wheel blocks from the front road wheels
bracket (40), now fit elbows (35) to panhard rods (16). and place the steering lock bar and oscillation lock pin
in the 'Stowed' position.
24. Fit hose assemblies (36) to elbows (35) and run
hoses using p-clips (37)and bolts (39) to secure in
place. MAINTENANCE
Numbers in parentheses refer to Fig. 1.
25. If removed install lube fittings (41) in bracket (40).
Lubricate with grease specified in Section 300-0020, Pre-Starting Inspection: Visually check condition and
LUBRICATION SYSTEM, until excess lube is seen. mounting of equaliser beams (6), interleaf mounts (30)
and control links (3 & 16).
26. Remove caps and connect hydraulic brake lines to
the tee pieces at the centre and rear axle assemblies. Every 50 Hours: Lubricate spherical bearings (17) in
Clip brake lines with clips removed during removal. panhard rods (16) through remote lube fittings (41), with
grease specified in Section 300-0020, LUBRICATION
27. Connect brake line guards (33 & 34) to axles and SYSTEM, until excess lube is seen.
secure with mounting hardware removed during
removal. Every 250 Hours: Lubricate bushings (7) in equaliser
beams (6) through lube fittings (13), with grease
28. Using suitable blocking equipment, block equaliser specified in Section 300-0020, LUBRICATION
beams (6) to prevent movement when installing the SYSTEM, until excess lube is seen.
rear tyre and rim assemblies.

29. Using suitable lifting equipment, position one tyre SERVICE TOOLS
and rim assembly on one rear wheel and secure with There are no special tools required for the procedures
wheel nuts and lockwashers. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
30. Repeat step 26 for remaining tyre and rim tools and adhesives required during the removal and
assemblies. installation of the rear suspension. These tools and
adhesives are available from your dealer.

SM 2183 Rev1 10-04 5


Suspension System - Rear Suspension
Section 180-0040

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 12 Bolt 150 110
1 14 Bolt 75 55
1 18 Bolt 556 410
1 20 Bolt 556 410
1 22 Bolt 324 239
1 24 Bolt 1 085 800
1 26 Bolt 671 495
1 31 Bolt 671 495
1 48 Bolt 75 55
- - Wheel Nut 590 435

* * * *

6 SM 2183 Rev1 10-04


ELECTRICAL SYSTEM - Circuit Diagrams
Section 190-0000

COMPONENT DESIGNATIONS
A4 - 12V Radio/Cassette K14 - Start Interlock Relay S1 - Battery Master Switch
A5 - Radio/Cassette Speaker K15 - Headlamp Relay S2 - Starter Keyswitch
K17 - Reverse Relay S7 - Emerg/Park Brake Switch
B2 - Coolant Temp Sender K21 - Trans Shift Clutch S9 - Washer Switch, F
B7 - Coolant Level Sensor K22 - Lockup Clutch S10 - Wiper Switch, F
B8 - Fuel Level Sender K23 - Ignition Sensed Relay S11 - Rear Wash/Wipe Switch
B13 - Rotational Speed Sensor K27 - Difflock Relay S13 - Horn Button
B19 - Throttle Position Sensor K33 - Radiator Fan Relay S14 - Hazard w/l Switch
B21 - Trans Oil Temp Sender K34 - Horn Relay S15 - Direction Ind Switch
B32 - Trans Oil Ret Temp Sender K40 - Radiator Fan Clutch S18 - Lights Switch
B35 - Trans Oil Cooler Fan Temp K47 - Intermittent Wipe Relay S19 - Dipswitch
Sender K50 - Brake Lights Control Relay S20 - Headlamp Flash Switch
B36 - Brake Pedal Potentiometer K51 - Brake Pedal Ret Control S22 - Body Proximity Switch
Relay S31 - Park Brake w/l Switch
E3 - Interior Light K52 - Body Proximity Switch Relay S37 - Axle Difflock Swt (Unused)
E5 - Reverse Light K57 - Sound Power Relay No. 1 S41 - Auxiliary Lights Switch
E6 - Flashing Amber Reverse K58 - Sound Power Relay No. 2 S48 - Acc Press Switch (Tractor)
Light S49 - Acc Press Switch (Trailer)
E7 - Instrument Panel Lights L3 - Reverse Alarm S57 - Steering Press Switch
E11 - Side Marker Light, L L5 - Electric Horn S60 - Difflock Request Switch
E12 - Taillight, L L6 - Reverse Camera S68 - Eng Diag/Request Switch
E13 - Side Marker Light, R L7 - Reverse Camera Monitor S69 - Accel Idle Validation Switch
E14 - Taillight, R S74 - Kickdown Switch
E15 - High/Low Beam H'lamp, L M1 - Starter Motor S78 - Body Lower Emergency
E16 - High/Low Beam H'lamp, R M4 - Washer Motor, F Switch
E19 - Rear Fog Lamp M5 - Wiper Motor, F S79 - Heated Mirror Switch
E21 - Rotating Beacon M6 - Wiper Motor, B S81 - Ret/Eng Brake 1st Stage
E23 - Work Light M7 - Washer Motor, B Retardation Request Swt
E26 - High Beam H'lamp, L M13 - Air Seat Compressor S82 - Eng Brake 2nd Stage
E27 - High Beam H'lamp, R Retardation Request Swt
E35 - Heated Mirror N3 - Voltage Convertor 24V/12V S90 - Trans Filter Restriction Swt
N4 - Speedo Frequency Divider
G1 - Generator/Alternator N5 - Brake Pedal Interface X1 - Handlamp Socket
G2 - Battery Module
Y3 - Retarder Valve
H6 - Direction Indicator; F, L P1 - Speedometer/Odometer Y4 - Emerg/Park Brake Solenoid
H7 - Direction Indicator; B, L P2 - Tachometer Y7 - Difflock Solenoid (Trans/
H8 - Direction Indicator; F, R P3 - Coolant Temp Gauge mid-axle)
H9 - Direction Indicator; B, R P4 - Fuel Gauge Y26 - Body Raise Solenoid
H10 - Brake Light, L P12 - Hourmeter Y27 - Body Lower Solenoid
H11 - Brake Light, R P15 - Trans Temp Gauge Y32 - Trans oil cooler fan solenoid
H29 - Cigar Lighter Illumination Y33 - System Hyd Unloader Valve
R7 - Cigar Lighter Y34 - System Hyd Float Valve
K1 - Starter Relay R10 - Rkr Switch 'Locating' LED Y36 - Trans oil cooler fan isolation
K4 - Dir Ind Flasher Unit R11 - Rkr Switch 'Function' LED solenoid
K5 - A/C Comp Clutch/Relay
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 Wire Colours
O - Orange
B - Black
L - LEFT, R - RIGHT, F - FRONT, B - BACK Y - Yellow
N - Brown
P - Purple
U - Blue
DIODE RESISTOR FUSE PLUG W - White
R - Red
S - Slate
TRAILER G - Green
K - Pink
CONNECTION L - Light Green

SM 2184 Rev 2 03-05 1


Electrical System - Circuit Diagrams
Section 190-0000

FUSES
Location Fuse No. Circuit Current Rating
1 Ignition Sensed Relay Contacts (Heater) 30A
2 Keyswitch 15A
4 Rear Wash/Wipe 10A
5 Horn Relay Coil, Front Wash/Wipe 10A
Main Fuse Box - 6 Air Seat Compressor 10A
Column A 7 Lights Supply 10A
8 Main Beam/Flash 10A
9 Wiper Park Front and Rear 7.5A
10 Hazards 7.5A
11 Transmission System Ignition Supply 7.5A
12 Reverse System 7.5A
13 Brake Lights 5A
14 Interior Light, Handlamp 5A
15 Direction Indicators/Rocker Switch LEDs 5A
16 Emergency/Park Brake 3A
Main Fuse Box - 17 Warning Light Module 3A
Column B 18 Heated Mirrors 15A
19 Gauges/Ignition Sensed Relay Coils 3A
21 Neutral Start 3A
22 Washers, Front 3A
23 Washers, Rear 3A
24 Horn 10A
25 Ignition Sensed Relay Contacts (Air Conditioning) 30A
26 Air Cond/Heater/Ventilation System 15A
28 Front Working Lights 15A
Main Fuse Box - 29 Rear Working Lights 15A
Column C 30 Rotating Beacon 5A
31 Auxiliary Fused Supply (Cab Manufacturers Harness) 3A
35 Brake Pedal Interface Module 15A
36 Cigar Lighter 10A
38 Reverse Camera Monitor Supply 10A
Main Fuse Box - 39 Reverse Camera Supply 10A
Column D 40 Body Proximity Switch 10A
47 Sound Power Legislation Relay No. 1 Supply 3A
48 TOC8 Hydraulics Electronic Control Module Supply 30A
49 QSM ECM Battery Supply 7.5A
50 QSM ECM Battery Supply 7.5A
51 QSM ECM Ignition Sensed Supply 5A
55 Radio/Cassette Voltage Convertor Supply 10A
Battery Box 56 Body Hydraulics Auxiliary/Emergency Dump Switch 10A
Fuse Box 58 Spare Battery Supply 10A
59 Transmission Battery System Supply 7.5A
61 Alternator Charge Cable (Power Fuse) 100A
62 Cab Busbar Supply Cable (Power Fuse) 100A

2 SM 2184 Rev 2 03-05


Electrical System - Circuit Diagrams
Section 190-0000

RELAYS
Location Relay Circuit
K23 Ignition Sensed Relay - Air Con
Main Fuse Box - K23 Ignition Sensed Relay - Wipers
Column E K34 Horn
K15 Headlamps
K17 Reverse Alarm/Lights
Main Fuse Box - K14 Neutral Start
Column F K5 Air Conditioner Compressor
K51 Brake Pedal Retarder Control
K50 Brake Lights Control
Main Fuse Box - K23 Ignition Sensed Relay - Engine Ignition
Column G K33 Radiator Fan
K4 Indicator Flasher Unit
Main Fuse Box - K52 Body Proximity Switch
Column H K27 Diff-lock
K23 Ignition Sensed Relay - Radio/Cassette
Below Right K47 Intermittent Wipe
Hand Console K57 Sound Power Legislation Relay No. 1
K58 Sound Power Legislation Relay No. 2

SM - 2807

Column A B C D E F G H

F12 F24 F36 F48


F11 F23 F35 F47 K23 K17 K50 K32
F10 F22 F34 F46
F9 F21 F33 F45
F8 F20 F32 F44 K23 K14 K23 K52
F7 F19 F31 F43
F6 F18 F30 F42
F5 F17 F29 F41 K34 K5 K33 K27
F4 F16 F28 F40
F3 F15 F27 F39
F2 F14 F26 F38 K15 K51 K4 K23
F1 F13 F25 F37

Fig. 1 - Main Fuse Box - Fuse/Relay Location

SM - 2808 SM - 3395

F54 F60

F53 F59

F58
K47
F52

F51 F57

F50 F56 K57

F49 F55 K58

Fig. 2 - Battery Box Fuse Box - Fuse Location Fig. 3 - Relays Below Right Hand Console

SM 2184 Rev 2 03-05 3


Electrical System - Circuit Diagrams
Section 190-0000
SM - 2917A

4 SM 2184 Rev 2 03-05


Electrical System - Circuit Diagrams
SM - 2917B Section 190-0000

SM 2184 Rev 2 03-05 5


Electrical System - Circuit Diagrams
Section 190-0000
SM - 2917C

6 SM 2184 Rev 2 03-05


Electrical System - Circuit Diagrams
SM - 2917D Section 190-0000

SM 2184 Rev 2 03-05 7


Electrical System - Circuit Diagrams
Section 190-0000
SM - 2917E

8 SM 2184 Rev 2 03-05


Electrical System - Circuit Diagrams
SM - 2917F Section 190-0000

SM 2184 Rev 2 03-05 9


Electrical System - Circuit Diagrams
Section 190-0000
SM - 2917G

10 SM 2184 Rev 2 03-05


Electrical System - Circuit Diagrams
SM - 2917H Section 190-0000

SM 2184 Rev 2 03-05 11


Electrical System - Circuit Diagrams
Section 190-0000
SM - 2917I

12 SM 2184 Rev 2 03-05


Electrical System - Circuit Diagrams
SM - 2917J Section 190-0000

SM 2184 Rev 2 03-05 13


Electrical System - Circuit Diagrams
Section 190-0000
SM - 2917K

14 SM 2184 Rev 2 03-05


SM - 2917L Section 190-0000

SM 2184 Rev 2 03-05 15


Electrical System - Circuit Diagrams
Section 190-0000
SM - 2917M

16 SM 2184 Rev 2 03-05


SM - 2917N Section 190-0000

SM 2184 Rev 2 03-05 17


ELECTRICAL SYSTEM - Hydraulic System ECU
Section 190-0085

SM - 2858

Fig. 1 - IQAN TOC8 Electronic Control Unit

SM - 2861
DESCRIPTION
The hydraulic electronic control unit (ECU) (Fig. 1) is a
A
stand alone control which controls the machines
hydraulic systems, including body hoist and B
transmission oil cooler fan drive. The IQAN-TOC8
ECU communicates with a variety of input and output
devices. It utilises analog/digital inputs, proportional
current outputs and digital outputs.

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 A - Green LED, Power On
B - Yellow/Red LED, Status
the cab, on the support below the right hand console
(see Fig. 2). Fig. 2 - Hydraulic ECU Location

WARNING
ECU Inputs
Before any welding is done on a machine Refer to Figs. 3 & 4 and Section 190-0000, CIRCUIT
equipped with an IQAN-TOC8 hydraulic DIAGRAMS.
system, disconnect the following in this order:
Battery earth cable, battery supply cable, Ignition Switch - connected to the starter keyswitch,
alternator earth cables, alternator supply rendering the circuit energised or de-energised.
cables and electrical connections at the engine
ECM, transmission ECU, body control lever, Starter Motor Relay - when starter motor relay is
hydraulics ECU and cab bulkhead to avoid activated, a digital signal is fed to the ECU.
damage to electrical components. Turn off
battery master switch to isolate the batteries Body Control Lever - three position lever sends
before disconnecting any components. analog signals to ECU.

After welding connect all of the above in the Transmission Cooler Fan Drive Temperature
reverse order. Sensor - sensor at transmission sends analog signal
to ECU.

SM 2200 2-03 1
Electrical System - Hydraulic System ECU
Section 190-0085

SM - 2859

BODY-UP WARNING LIGHT + IGNITION SWITCH

STARTER MOTOR RELAY

BODY LOWER TRANSMISSION OIL TRANSMISSION OIL


EMERGENCY COOLER FAN DRIVE COOLER FAN DRIVE
SWITCH ISOLATION SOLENOID PROPORTIONAL SOLENOID

1 5
PROPORTIONAL
3 4
2 CONTROL VALVE
(RAISE) 33
8 9
6 7

13
10 11 FLOAT
12 44
SOLENOID
30
16
14 COLD START
IQAN-TOC8 SOLENOID
17
45
18
ECU 32

31 31
15

19 21 22
46
20
25
BODY CONTROL
24
LEVER 23
26

PROPORTIONAL
27
CONTROL VALVE 29
(LOWER)

BODY-UP
+ PROXIMITY
SWITCH ON
2nd GEAR RESTRICTION CHASSIS
TRANSMISSION
COOLER FAN DRIVE
OUTPUT INPUT
TEMPERATURE SENSOR

Fig. 3 - Layout Of Hydraulic ECU System

Body Up Proximity Switch - sends a digital signal to Transmission Oil Cooler Fan Drive Proportional
ECU depending on position of body. Solenoid - the transmission cooler fan drive
temperature sensor feeds back to the ECU, which
Body Lower Emergency Switch - located in the cab, outputs a signal to the fan drive proportional solenoid
the switch sends a digital signal to ECU when (typically 150 - 210 mA measured across pins 19 and
pressed. This is used to lower the body in the event of 20, resulting in a delivery between 38 - 83 bar (551 -
system failure. 1204 lbf/in2)). This causes the fan speed to increase
proportionally. Refer to Section 215-0050, MAIN
HYDRAULIC VALVE ASSEMBLY.
ECU Outputs
Cold Start Solenoid - when ECU receives input from Transmission Oil Cooler Fan Drive Isolation
starter motor relay, the ECU sends an ouput signal to Solenoid - the transmission cooler fan drive
activate cold start solenoid. This prevents the engine temperature sensor feeds back to the ECU, which
starting under hydraulic load. outputs a signal to the fan drive isolation solenoid.
Refer to Section 210-0060, TRANSMISSION OIL
Body Raise/Lower - when ECU receives signals from COOLER.
body control lever, ECU sends output signals to the
raise and lower proportional control valves to shift the Body-Up Warning Light - the body-up proximity
main control valve spool accordingly. Typical output switch sends a signal to the ECU, and depending on
from ECU is 250 - 800 mA, providing a delivery the body position, the ECU sends a signal to
pressure between 4 - 25 bar (58 - 363 lbf/in2) at main illuminate the warning light in the cab.
control valve spool. For raise proportional control
valve, measure current output across pins 17 and 18 Body Float Solenoid - the body lower emergency
on ECU. For lower proportional control valve, measure switch sends a signal to the ECU, which outputs a
across pins 31 and 32. signal to energise body float solenoid. This ensures

2 SM 2200 2-03
Electrical System - Hydraulic System ECU
Section 190-0085

SM - 2860

Voltage In Alarm Out


Temp Sensor [Mv] C1:3 A
A C1:37 A - Body Raise Solenoid
C1:6 B
C1:9 C B - Body Lower Solenoid
Body Control Lever Lower [%] C1:12 D Current Out
C1:5 E Raise/Lower
Analog Inputs A C1:17/31 17 31
C1:7 F Solenoid [%] A B
Body Control Lever Raise [%] C1:8 G +RET C1:18 18 32
C1:10 H -RET C1:32
Current
C1:27 I Trans. Cooler Fan Drive 19
B C1:19/33 Outputs
C1:41 J Proportional Solenoid [%]
+RET C1:20 20
Body Raised - Closed Digital In -RET C1:34
Body Lowered - Open C1:3 A
Body-Up Proximity Switch C1:6 B Digital Out
Energises Cold Starter Motor Signal C1:9 C
A C1:21
Body-Up Warning
Start Solenoid C1:12 D Light
Ignition Switch C1:5 E
B C1:22 Cold Start Solenoid
C1:7 F
Energises or De-energises C1:8 G Body Control Lever
Feed to Solenoids C C1:35
C1:10 H Detente Solenoid
Digital Outputs
C1:27 I
D C1:36 2nd Gear Restriction
C1:41 J
E C1:23 Body Float Solenoid
Frequency In
C1:3 A F C1:24 Trans. Cooler Fan Drive
C1:6 B Isolation Solenoid
C1:9 C
C1:12 D PWM Out

A C1:21/22

Power
B C1:35/36
C1.15 -BAT
C1:28 +BAT
C C1:23/24
C1:4 -VREF-A
Power In C1:2 +VREF-A
C1:13 -VREF-B
C1:11 +VREF-B
C1:29 -BAT2
C1:42 +BAT2

RS-232
C1:25 RX
C1:26 TX
Communication Port C1:39 DSR
C1:40 RES
C1:38 GND

42 29
28 15
14 1

Fig. 4 - IQAN TOC8 ECU (C1) Pin Connections

that the hoist side of the body cylinders are vented to damaged, especially when body is laden.
tank, allowing body to lower onto chassis under it's
own weight. Check the body float solenoid across pin 23 on ECU
and vehicle ground. Solenoid is rated at 15 W, 0.6 A,
The body float solenoid is always energised when the 42 ohms.
body-up proximity switch is made. This prevents the
body being powered down onto the chassis. Also Body Control Lever Detent - when the body control
prevents pressure being trapped in the hoist side of lever is pushed fully forward to power down the body,
cylinders when travelling, ensuring body is resting on the ECU energises a detent solenoid within the lever
the chassis. If body is not resting on the chassis when to hold the lever fully forward. This continues until the
travelling, hinge points and cylinders may be body-up proximity switch is made, when the ECU de-

SM 2200 2-03 3
Electrical System - Hydraulic System ECU
Section 190-0085

SM - 2862

Status Flash (yellow light)

Normal (no errors)

Error Error Flash (red light)


code
1 Output errors

2 Input errors

3 VREF error

4 Supply voltage
error
5 Temp critical or
checksum error
6 Fatal software
error

Fig. 5 - LED Indicator Showing Different Modes

energises the detent solenoid so that the lever returns signal verification. If any software error is detected,
to the neutral position, and the body float solenoid is appropriate precautions will be taken.
energised (see Body Float Solenoid).

2nd Gear Restriction - when the body-up proximity System Diagnosis


switch is broken, the ECU sends a signal to the Refer to Figs. 2 & 5.
transmission ECU to restrict the transmission to The two LEDs on the ECU are used to diagnose basic
second forward gear. When the body-up proximity system errors. The ECU indicates error status through
switch is made i.e. body is lowered, full gear range is the red blinking LED as shown in Fig. 5, giving an
available. immediate diagnosis as to the nature of the error that
has occurred.

System Safety If there are no errors, the bottom LED flashes yellow
Input/Output Protection - all inputs to the ECU are to indicate normal status. Some errors will cause the
designed to withstand the maximum specified supply ECU to stop operating or at least shut down the
voltage. The outputs are protected against short outputs to increase safety. The green LED indicates
circuit. Additionally, an error on one input/output will power on.
not influence other inputs/outputs. External fuse (10A),
located in the battery box, will blow if supply exceeds
35 V. WARNING
Do not use the machine if an error code is
Current Check - for the current outputs, a current present. Shutdown the machine until the
check is performed. The ECU compares the return problem is resolved.
current with the output's set-value. If current deviation
occurs, the user will be notified through an appropriate Refer to table of error codes for corrective action. The
error code on the unit's LED. ECU has a RS232 interface below the right hand
console which plugs directly into a laptop. This allows
If the ECU detects a short circuit to battery supply, the communication with the ECU using IQANdevelop
unit will shut off the outputs in order to increase safety. software, and gain more information about the ECU's
status.
Memory Test - the ECU will perform a self test during
operation to verify the software. The test includes a
processor and memory verification, and an internal

4 SM 2200 2-03
Section 190-0085

Error Codes, Messages and Actions


Situation Error Code Action ECU Remarks
ERROR: OUTPUT HIGH
COUT: Error 1 Active output shuts off Check wiring and loads
Current return low or high
COUT: Error 1 Active output shuts off Check application
Both directions
commanded
DOUT: Error 1 Active output shuts off Check load
Overload
PWMOUT: Error 1 Active output shuts off Check application
Both directions
commanded
COUT/DOUT: Error 6 Active output shuts off Replace ECU
Internal driver
failure
ERROR: INPUT
VIN: Error 2 Active input goes to Check wiring and sensors
> specified max or error value
< specified min
ERROR: VREF
VREF_< 4.9 V Error 3 - Check voltage, replace ECU
VREF_> 5.1 V Error 3 - Check voltage, replace ECU
LOW/HIGH SUPPLY VOLTAGE
+BAT < 8.5 V Error 4 - Check voltage supply
+BAT > 34 V Error 4 - Check voltage supply
HIGH TEMPERATURE
Internal temperature Error 5 - Check ambient temperature,
> max temp allow ECU to cool
Internal temperature Error 6 - Replace ECU
sensor error
ERROR: PARAMETER
Parameter error Error 5 No calibration of signals Replace ECU
ERROR: SOFTWARE
Software error Error 6 Unit stops operating Replace ECU

SM 2200 2-03 5
Electrical System - Hydraulic System ECU
Section 190-0085

REMOVAL 3. Disconnect the battery ground cable first, then the


battery supply cable, before disconnecting harness
from IQAN-TOC8 ECU inside cab.
WARNINGS
To prevent personal injury and property 4. Remove bolts securing ECU to support below the
damage, be sure wheel blocks, blocking right hand console, and remove ECU.
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely. INSTALLATION
1. Secure ECU to support below the right hand
console using bolts removed previously.
High electrical current can cause sparks
and personal injury from burns. Turn battery 2. Firstly connect harness to ECU, then connect
master switch to the 'Off' position before battery supply cable and battery ground cable in that
removing any components. Remove battery order.
ground cable first, and reconnect last, to avoid
damaging electrical components. 3. Turn master switch on, start engine and ensure that
the top LED is green which indicates voltage is being
1. Position the vehicle in a level work area, ensure the supplied, and that the bottom LED flashes yellow,
body is fully lowered, apply the parking brake and indicating normal status.
switch off the engine. Turn steering wheel several
times to relieve any pressure in the steering circuit. 4. Remove wheel blocks from all road wheels.
2. Operate the treadle valve continuously to discharge
the accumulators, block all road wheels, place the SPECIAL TOOLS
steering lock bar in the 'Locked' position and the
There are no special tools required for procedures
battery master switch in the 'Off' position.
outlined in this section. To obtain IQANdevelop
diagnostic software, contact your dealer.

* * * *

6 SM 2200 2-03
ELECTRICAL SYSTEM - Switches and Sensors
Section 190-0270

SM - 2810

11
FUEL
12
P1S
TANK 3 PBS
2
HYD. ACC2S 9
VALVE
10

1 HEADER TANK ACC1S

7
13

8
REAR FRAME RAIL

TRANS RETARDER
HOUSING RHS

4 14
IN
25
20
15
10
5
7

FRONT FRAME RAIL ON AIR CLEANER HYDRAULIC TANK

1 - Engine Coolant Temperature Sender 6 - Transmission Oil Temp Sender 10 - Front Brake Pressure Switch
2 - Engine Coolant Level Sensor 7 - Trans Oil Cooler Fan Temp Sensor 11 - Park Brake Pressure Switch
3 - Fuel Level Sender 8 - Retarder Oil Temperature Sensor 12 - Steering System Pressure Switch
4 - Starter Relay 9 - Rear Brake Pressure Switch 13 - Body Up Proximity Switch
5 - Air Cleaner Restriction Gauge 14 - Hydraulic Filter Restriction Gauge

Fig. 1 - Layout View of Switches and Sensors

DESCRIPTION (17, Fig. 2) on the dash panel to alert the operator of a


fault in the engine circuit. Refer to Section 110-0030,
Numbers in parentheses refer to Fig. 1, unless
ENGINE AND MOUNTING.
otherwise specified.
Engine Coolant Temperature Sender (1) - Located
This section describes the location and function of
in the right hand side of the engine. Sends a signal
various switches and sensors fitted to the vehicle to
indicating engine coolant temperature to engine
monitor all major components and systems. Gauges
coolant temperature gauge (3, Fig. 2).
and warning lights located in the dash panel, relay this
information to the operator.
Engine Coolant Level Sensor (2) - Located in the
radiator header tank, the sensor sends a signal to
Note: Always make sure all gauges, warning lights
engine coolant level warning light (26, Fig. 2)
and controls are working properly before operating the
indicating that engine coolant level is low.
vehicle.
Engine Coolant Temperature Gauge (3, Fig. 2) -
Engine Indicates the engine coolant temperature. The gauge
should read between 70o C and 100o C after the engine
The Quantum engine management system monitors
has warmed. If the gauge reads above this, stop
the engine at all times and sends a signal to the
engine and investigate the cause.
engine check light (16, Fig. 2) and engine stop light

SM 2185 Rev 1 5-03 1


Electrical System - Switches and Sensors
Section 190-0270

SM - 2811
1 2 3 4 5 6

C
C 100 120
80 100
60 250
40 175 210 120 50 210 150
175
105 F 250 120 F 300
50 10
1
4

4
0 4

40 ENGINE HOURS 20
000000
20 30 30 15
20 10 min-1 20
x100
20 20
10 40
5 25
20
Mph
0 50 0 30
MPH

7 8 9 10 11 12 13 14 15 16 17

STOP
STOP

1 2 P

18 19 20 21 22 23 24 25 26 27 28

1 - Speedometer 11 - Blank 20 - Rear Brake Accumulator Pressure W/L


2 - Hourmeter 12 - Direction Indicators Ind/L 21 - Unused
3 - Engine Coolant Temperature Gauge 13 - Blank 22 - Emergency Steering W/L
4 - Transmission Oil Temperature Gauge 14 - Blank 23 - Blank
5 - Fuel Level Gauge 15 - Transmission Stop W/L 24 - Unused
6 - Tachometer 16 - Engine Check W/L 25 - Engine Coolant Temperature W/L
7 - Alternator Charging W/L 17 - Engine Stop W/L 26 - Engine Coolant Level W/L
8 - Headlight Main Beam Ind/L 18 - Blank 27 - Maintenance W/L
9 - Body Up W/L 19 - Front Brake Accumulator Pressure W/L 28 - Parking Brake Ind/L
10 - Differential Lock Ind/L

Fig. 2 - Layout View of Instruments and Indicator/Warning Lights

Tachometer (6, Fig. 2) - Driven from the engine ECU, SM - 2812


the tachometer indicates the number of engine
crankshaft revolutions per minute. The needle shows
the variations in engine operating speed. Never 3 1 2
accelerate the engine to speeds indicated by the red
OFF
zone on the dial face.
ON

Tachometer Calibration
1. Ensure all three encoding switches at the back of
the tachometer are OFF.

2. To verify calibration, a stroboscope can be used to


compare engine speed with tachometer reading. If
necessary, the tachometer can be fine-tuned using
adjustment screw (see Fig. 3).

Hourmeter (2, Fig. 2) - Driven from the engine


alternator, the hourmeter records the total number of
engine hours.

Starter Relay (4) - Mounted on the tractor frame rail,


the starter relay powers up the starter motor when the
keyswitch is turned.
Fig. 3 - Tachometer Calibration

2 SM 2185 Rev 1 5-03


Electrical System - Switches and Sensors
Section 190-0270

Speedometer Calibration Table - number is displayed then release the button for a few
seconds until the next digit flashes.
All units with standard tyres
Unit Transmission Pulses 4. Repeat step 3 to obtain the desired impulses/
TA25 6 WG 210 333650 revolution. The speedometer is now calibrated.
TA27 6 WG 260 232100
TA30 6 WG 310 232100 Transmission Oil Temperature Sender (6) - The
sender, located on the elbow at the retarder housing,
sends a signal to indicate transmission oil temperature
SM - 2813
on the transmission oil gauge in the cab (4, Fig. 2).

Transmission Oil Cooler Fan Temperature Sensor


(7) - Located in the retarder housing, the sensor sends
a signal to the hydraulics ECU to operate the
transmission oil cooler fan drive at a speed
proportional to transmission oil temperature.

Retarder Oil Temperature Sensor (8) - The


temperature sensor is located at the retarder housing
and records both the retarder and converter oil
temperature, which is supplied to the transmission
ECU.

Braking System
Rear Brake Pressure Switch (9) - The normally
closed (NC) pressure switch, 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
warning light (20, Fig. 2) when pressure drops to 122
Fig. 4 - Speedometer Calibration bar (1769 lbf/in2). An audible buzzer also sounds.

Front Brake Pressure Switch (10) - The normally


Transmission closed (NC) pressure switch, located in port ACC1S of
Refer to Section 120-0010, TRANSMISSION AND the main hydraulic valve, senses the pressure in the
MOUNTING, for further information on switches and front brake circuit. The pressure switch sends a signal
sensors fitted to the transmission. to illuminate 'Red' front brake accumulator pressure
warning light (19, Fig. 2) when pressure drops to 122
Speedometer/Hourmeter (1, Fig. 2) - Driven by a bar (1769 lbf/in2). An audible buzzer also sounds.
signal from the transmission ECU, the speedometer
indicates travel speed in kilometres per hour and miles Parking Brake Pressure Switch (11) - The normally
per hour. A digital hourmeter is incorporated in the closed (NC) pressure switch, located in port PBS of
speedometer to record total hours of engine operation. the main hydraulic valve, senses pressure in the
parking brake circuit. The pressure switch closes at a
Speedometer Calibration pressure of 5 bar (70 lbf/in2) and sends a signal to
1. Determine the impulse setting required. Reference illuminate 'Green' parking brake indicator light (28, Fig.
speedometer calibration table. 2), indicating that the parking brake is applied.

2. Depress and hold calibration button at the back of


the speedometer (see Fig. 4) with a suitable Steering System
screwdriver and turn the ignition keyswitch to position Steering System Pressure Switch (12) - The
'1'. Release button when PULSE is displayed. normally closed (NC) pressure switch is located in port
P1S of the main hydraulic valve. The pressure switch
3. After a few seconds, the digits will flash in closes and sends a signal to illuminate 'Red'
sequence. Depress the button until the desired emergency steering warning light (22, Fig. 2) when

SM 2185 Rev 1 5-03 3


Electrical System - Switches and Sensors
Section 190-0270
steering pressure drops to 5 bar (70 lbf/in2) or lower. Fuel Tank
An audible buzzer also sounds.
Fuel Level Sender (3) - Located at the rear of the fuel
tank, the fuel level sender sends a signal to fuel level
Hydraulic System gauge (5, Fig. 2) to indicate the amount of fuel left in
the tank.
Hydraulic Filter Restriction Gauge (14) - The
hydraulic filter restriction gauge is located on top of
hydraulic tank. After 1 000 hours or when the needle Body
moves into the red zone, whichever comes first, the
Body Up Proximity Switch (13) - Mounted off the
hydraulic filter should be changed.
inside of the trailer left hand frame rail. When the body
is raised off the trailer frame, the switch sends a signal
Air Cleaner to illuminate body up warning light (9, Fig. 2).
Air Cleaner Restriction Gauge (5) - Mounted on the
Note: Never move the vehicle until body up warning
air cleaner, the restriction gauge indicates the degree
light (9, Fig. 2) goes out, indicating that the body is
of air cleaner element restriction as the red panel rises
fully lowered onto the trailer frame.
in the gauge window. The filter element(s) should be
replaced if the red band locks in place when the
Note: The proximity switch prevents the body being
engine is shut down. Reset the gauge by pressing the
fully powered down onto the frame. When the
button on the gauge with the engine running.
proximity switch makes contact, the body control lever
detent is de-energised and float solenoid at main
hydraulic valve is energised.

* * * *

4 SM 2185 Rev 1 5-03


FUEL SYSTEM - Fuel System
Section 200-0040

SM - 2814

18
17 8
15
97 6
16 7
14
19
1

10
5 3 13
4

3
2 11
12

1 - Fuel Tank 7 - Washer 13 - Fuel Line


2 - Bolt 8 - Shims 14 - ECM Cooling Plate
3 - Washer 9 - Nut 15 - Electronic Unit Injector
4 - Shims 10 - Fuel Line 16 - Strainer
5 - Nut 11 - Fuel Line 17 - Filler Cap
6 - Bolt 12 - Fuel Filter/Water Separator 18 - Padlock
19 - Fuel Pump
Fig. 1 - Fuel Lines and Components

DESCRIPTION
Numbers in parentheses refer to Fig. 1. The electronic unit injector (15) is a lightweight,
compact unit that injects diesel fuel directly into the
The fuel system consists of the Quantum Celect Plus combustion chamber. The amount of fuel injected and
electronic fuel system controls, fuel filter (12), fuel the beginning of injection timing is determined by the
pump (19), ECM cooling plate (14), electronic unit electronic control module (ECM). The ECM sends a
injectors (15), fuel tank (1) and the necessary command pulse which activates the injector solenoid.
connecting fuel lines.
The EUI (15) performs four functions:
The fuel filter (12) is mounted inside the battery box,
alongside the oil filter. a - Creates the high fuel pressure required for efficient
injection.
Fuel pump (19) is attached to a drive assembly b - Meters and injects the exact amount of fuel required
mounted on the rear side of the gear case at the front to handle the load.
LH side of the engine and transfers fuel from fuel tank c - Atomizes the fuel for mixing with the air in the
(1), via fuel filter (12), to the electronic unit injectors combustion chamber.
(15). d - Permits continuous fuel flow for component cooling.

SM 2186 12-02 1
Fuel System - Fuel System
Section 200-0040
SM - 2815
11
12

10 19,20,21,22,23

14 17
13 16 18
17
2,3
4

19,20,21,22,23

17
18 15
17
5

9
8
6

1 - Fuel Tank 7 - Bolt 13 - Padlock 19 - Shim


2 - Filler Cap 8 - Bolt 14 - Key 20 - Shim
3 - Filter Assembly 9 - Washer 15 - Bolt 21 - Shim
4 - Strainer 10 - Fuel Sender Guard 16 - Bolt 22 - Shim
5 - Step Plate 11 - Bolt 17 - Hardened Washer 23 - Shim
6 - Step Assy 12 - Washer 18 - Nut

Fig. 2 - Fuel Tank and Mounting

Electronic unit injectors are self compensating and tightening.


virtually eliminate engine tune-ups.
A fuel tank breather/filter assembly is incorporated into
Note: Never apply 12 V directly to terminals on the the fuel filler cap (17), allowing fuel tank (1) to vent to
injector as it will burn out. Before removing injectors, atmosphere, preventing pressure from building up
the fuel passages must be blown out to prevent fuel within fuel tank (1) assembly.
flow from entering the cylinder head.

ECM cooling plate (14) is mounted behind the ECM on OPERATION


the LH side of the engine and absorbs heat generated Numbers in parentheses refer to Fig. 1.
by the ECM. Fuel from fuel pump (19) outlet line flows
through ECM cooling plate (14) to absorb this heat. Fuel is drawn from fuel tank (1) through fuel filter (12)
and enters fuel pump (19). Leaving fuel pump (19)
Flexible fuel lines (10, 11 & 13) are used to facilitate under pressure, the fuel flows through ECM cooling
connection of lines leading to and from fuel tank (1), plate (14) to the engine cylinder head. The fuel flows to
and to minimize the effects of any vibration in the electronic unit injectors (15) in the cylinder head
installation. through passages integral with the cylinder head.
Surplus fuel exits the cylinder head and back to fuel
When installing fuel lines, it is recommended that tank (1) through fuel line (10).
connections be tightened only sufficiently to prevent
leakage of fuel; thus flared ends of the fuel lines will
not become twisted or fractured because of excessive

2 SM 2186 12-02
Fuel System - Fuel System
Section 200-0040

REMOVAL 13. Remove nuts (18), bolts (15), hardened washers


(17) and shims (19 - 23) securing fuel tank (1)
Numbers in parentheses refer to Fig. 2, unless
assembly to the front frame bumper. Using a suitable
otherwise stated.
lifting device, remove fuel tank (1) assembly from the
vehicle.
WARNING
To prevent personal injury and property DISASSEMBLY
damage, be sure wheel blocks, blocking
Numbers in parentheses refer to Fig. 2, unless
materials and lifting equipment are properly
otherwise stated.
secured and of adequate capacity to do the job
safely.
1. Remove bolts (7) securing step plate (5) to fuel tank
(1).
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
2. Remove bolts (8) and washers (9) securing step
assembly (6) to fuel tank (1).
2. Block all road wheels and place the battery master
switch in the 'Off' position.
3. Remove grab handles from fuel tank (1).
3. Pull on handle to release hood catch mechanism
3. Remove screws and washers securing fuel sender to
and raise hood.
fuel tank (1). Remove fuel sender.
4. Remove transmission oil cooler from vehicle. Refer
to Section 210-0060, TRANSMISSION OIL COOLER. ASSEMBLY
Numbers in parentheses refer to Fig. 2, unless
5. Remove padlock (13) and remove filler cap (2) from
otherwise stated.
fuel tank (1).
1. Install fuel sender to tank (1) using screws and
6. Remove fuel strainer (4) from fuel tank (1) and clean
washers.
with clean diesel fuel.
2. Install grab handles to fuel tank ().
7. With a suitable container in position, remove
drain plug from fuel tank (1) and drain fuel from fuel
3. Install step assembly (6) to fuel tank (1) and secure
tank (1). Reinstall drain plug and tighten securely when
using bolts (8) and washers (9).
fuel tank (1) is completely drained.
4. Install step plate (5) to fuel tank (1) and secure using
8. Identify and tag fuel lines (10, 11 & 13, Fig. 1) and,
bolts (7).
with a suitable container available to catch leakage,
disconnect fuel lines (10, 11 & 13, Fig. 1). Cap open
line ends and adaptors to prevent entry of dirt. INSTALLATION
Numbers in parentheses refer to Fig. 2, unless
9. Remove hose clamp mounting plate from inside face
otherwise stated.
of fuel tank (1) assembly.

10. Remove bolts (11) and washers (12) securing fuel


WARNING
sender guard (10) to fuel tank (1). Remove fuel sender
To prevent personal injury and property
guard (10). Disconnect electrical harness from fuel
damage, be sure wheel blocks, blocking
sender.
materials and lifting equipment are properly
secured and of adequate capacity to do the job
11. Using suitable lifting equipment, support fuel tank
safely.
(1) assembly. Ensure fender is adequately supported.
Remove fasteners securing fender to fuel tank (1)
Note: Tighten all fasteners to standard torques
assembly.
specified in Section 300-0080, STANDARD BOLT AND
NUT TORQUE SPECIFICATIONS.
12. Remove nuts (18), bolts (16), hardened washers
(17) and shims (19 - 23) securing fuel tank (1)
1. Using suitable lifting equipment, position fuel tank
assembly to the front frame rail.
SM 2186 12-02 3
Fuel System - Fuel System
Section 200-0040
(1) assembly to the front frame.
WARNINGS
2. Secure the front of fuel tank (1) assembly to the To prevent personal injury and property
front frame bumper with bolts (15), hardened washers damage, be sure wheel blocks and blocking
(17), shims (19 - 23) and nuts (18). Use shims (19 - 23) materials are properly secured and of adequate
as necessary to improve transverse alignment of fuel capacity to do the job safely.
tank (1) assembly.

3. Secure the inside of fuel tank (1) assembly to the To prevent personal injury or even death,
front frame rail with bolts (16), hardened washers (17), welding of the fuel tank is strictly prohibited at
shims (19 - 23) and nuts (18). Use shims (19 - 23) as all times, due to the hazardous flammable
necessary to improve longitudinal alignment of fuel liquids and vapours present inside the tank,
tank (1) assembly. even when empty.

4. Secure fender to fuel tank (1) assembly using


fasteners previously removed. General
Refill fuel tank (1) at the end of each day's operation to
5. Reconnect electrical harness to fuel sender. Fit fuel prevent condensation from contaminating the fuel.
sender guard (10) using bolts (11) and washers (12). When filling fuel tank (1), check that there is no buildup
of dirt and sludge at fuel strainer (4, Fig. 2) and filler
6. Refit hose clamp mounting plate to inside face of cap (2, Fig. 2). Remove and clean fuel strainer and
fuel tank (1) assembly. filler cap as required.

7. Remove blanking caps and secure fuel lines (10, 11


& 13, Fig. 1) to adaptors, as identified at removal. Every 10 Hours/Daily:
Make a visual check for fuel leaks at all engine
8. Install fuel strainer (4) in fuel tank (1). mounted fuel lines, connections and at the fuel tank
suction and return lines. Examine lines for leaks and
9. Fill fuel tank (1) assembly with clean diesel fuel check all fittings, clamps and ties carefully.
specified in Section 300-0020, LUBRICATION
SYSTEM. Make sure that fuel lines are not resting on or touching
rotating components, heated surfaces including
10. Install filler cap (2) assembly on fuel tank filler exhaust manifolds or sharp edges. If fittings have
neck. Tighten filler cap (2) securely and secure in place loosened or cracked, or if lines have ruptured or worn
with padlock (13). through, take corrective action immediately.

11. Install transmission oil cooler to vehicle. Refer to From time to time, remove fuel sender guard and
Section 210-0060, TRANSMISSION OIL COOLER. check condition of electrical connections at fuel level
sender.
12. Place the battery master switch in the 'On' position,
start the engine and run for a few minutes to ensure Fuel Filter/Water Separator (12) - Drain the water and
fuel is being supplied to the engine. Check for leaks at sediment from the separator daily.
fuel lines (10, 11 & 13, Fig. 1) and tighten if required.
Position the vehicle on a level work area, apply the
13. Remove wheel blocks from all road wheels. parking brake, shut off the engine and, with a suitable
container below the drain valve to catch spillage, open
the drain valve by hand. Turn the valve anticlockwise
MAINTENANCE approximately 1.5 to 2 turns until draining occurs. Drain
Numbers in parentheses refer to Fig. 1. the filter sump until clear fuel is visible. Turn the valve
clockwise to close the drain valve.

Note: Do not overtighten the drain valve as


overtightening can damage the threads.

4 SM 2186 12-02
Fuel System - Fuel System
Section 200-0040

Every 500 Hours: TROUBLESHOOTING


Check condition of filler cap (2, Fig. 2) and clean fuel
strainer (4, Fig. 2) and filler cap with clean fuel. Locating Air Leaks in Fuel Lines
Air drawn into the fuel system may result in uneven
running of the engine, black or white smoking and
Every 1 000 Hours: stalling when idling, or a loss of power. Poor operation
Fuel Filter/Water Separator (12) - Clean the area is particularly noticeable at lower engine speeds. If air
around the filter head and replace the fuel filter/water is found in the fuel, the source will normally be
separator. between the fuel tank and the fuel pump.

Position the vehicle on a level work area, apply the Check for loose, faulty or improper fuel line
parking brake and switch off the engine. Using a strap connectors. Presence of an air leak may be detected
type filter wrench, remove the fuel filter/water separator by following the procedures under 'Checking Fuel Flow'.
and discard the thread adaptor sealing ring. Clean the
gasket surface of the filter head.
Checking Fuel Flow
Install the new thread adaptor sealing ring (supplied 1. Disconnect the fuel return line from the fitting at the
with new filter) and apply a film of clean engine oil to fuel tank and hold the open end in a suitable container.
lubricate the filter seal. Fill the new fuel filter/water
separator with clean fuel specified in Section 2. Start and run the engine at maximum rev/min and
300-0020, LUBRICATION SYSTEM. immerse the end of the fuel return line in the fuel. Air
bubbles rising to the surface of the fuel will indicate air
Install new fuel filter/water separator on the filter head being drawn into the fuel system on the suction side of
and tighten by hand until the gasket contacts the filter the pump. If air is present, tighten all fuel lines
head surface. Tighten fuel filter/water separator per connections between the fuel tank and fuel pump.
filter manufacturer's instructions.
3. If the fuel flow is insufficient for satisfactory engine
Note: Mechanical tightening of the filter is not performance then proceed as follows:
recommended and may result in seal and/or cartridge
damage. Tighten filter by hand only. a. Replace the fuel filter/water separator, as described
under 'Maintenance'. Start the engine and run it at
Fuel Filler Cap maximum rev/min and recheck for the presence of air.
Remove filler cap (2, Fig. 2) from filler neck. With the If fuel flow is still unsatisfactory, perform step 'b'.
handle in the up and rotated position, remove the two
screws securing the filter assembly (3, Fig. 2) to the b. Check the fuel lines for restrictions due to pinching,
cap. Discard 'O' rings. Clean top of filler cap and valve kinking or other damage. If no problem is found,
cavity. Install new filter assembly to filler cap using substitute another fuel pump that is known to be
new screws and 'O' rings (supplied with new filter). operating correctly and recheck the fuel flow. When
Tighten screws to 10 - 13 in lbs. changing the fuel pump, inspect the fuel pump drive.
Clean all fuel lines with compressed air and be sure all
fuel connections are tight.
Diesel Fuel Oil
The sulphur content of diesel fuel oil should be as low c. Disconnect the fuel lines from the ECM cooling
as possible to avoid premature wear of piston rings plate and, using a suitable connector, connect the two
and line, excessive deposit formation, and minimise fuel lines, bypassing the cooling plate. Run the engine
sulphur dioxide exhausted into the atmosphere. at maximum rev/min and recheck the fuel flow. If the
Limited amounts can be tolerated, but the amount of fuel flow with the cooling plate bypassed is normal, the
sulphur in the fuel and engine operating conditions can cooling plate should be replaced.
influence corrosion and deposit formation tendencies.
The use of diesel fuel oil with a MAXIMUM sulphur
content of 0.5% is recommended for use. Refer to
Section 300-0020, LUBRICATION SYSTEM.

SM 2186 12-02 5
Fuel System - Fuel System
Section 200-0040

SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.

* * * *

6 SM 2186 12-02
FUEL SYSTEM - Electronic Foot Pedal
Section 200-0051

SM - 2816

6 5

3,4

1 - Harness 4 - Switch & Detent


2 - Pedal 5 - Bolt
3 - Potentiometer 6 - Washer

Fig. 1 - Electronic Foot Pedal

DESCRIPTION AND MOUNTING.


Numbers in parentheses refer to Fig. 1.
REMOVAL
The electronic foot pedal assembly provides an
electrical signal to the engine's fuel control system in Numbers in parentheses refer to Fig. 1.
proportion to the degree of pedal actuation. Maximum
and minimum stops are built into the pedal assembly
during manufacture. The pedal assembly comes WARNING
preset and therefore no adjustment is necessary. To prevent personal injury and property
damage, be sure wheel blocks are properly
The pedal incorporates an idle validation switch which secured and of adequate capacity to do the job
informs the engine ECM that the pedal is in the idle safely.
position. Kickdown switch, which can be used when
automatic range is selected, allows for the possibility 1. Position the vehicle in a level work area, ensure the
of selecting a lower gear by pressing down fully on body is fully lowered, apply the parking brake and
pedal (2) and holding (see Fig. 2). This can be used to switch off the engine.
provide a downshift on demand provided that the
vehicle speed is within the range allowable. That is, the 2. Block all road wheels and place the battery master
vehicle is not travelling at a speed that would result in switch in the 'Off' position.
the engine overspeeding in the lower gear. To
disengage the transmission kickdown, release the 3. Disconnect electrical harness (1) from dash harness.
pedal (2) and allow it to return to a light throttle
position. Refer to Section 120-0010, TRANSMISSION 4. Remove bolts (5) and washers (6) securing pedal
assembly to cab wall. Remove pedal assembly.

SM 2187 Rev1 10-04 1


Fuel System - Electronic Foot Pedal
Section 200-0051

SM - 2798 Note: With the pedal at idle position, the diagnostic


reader should show 0%.

3. Press pedal fully to full throttle position (before


kickdown, ref. Fig. 2) and release three times.

Note: The diagnostic reader should show 100% at full


throttle position.

4. If these figures are achieved, the pedal is correctly


IDLE calibrated. Turn keyswitch off and remove diagnostic
reader.
FULL THROTTLE

KICKDOWN 5. If figures are not realised, the pedal will have to be


Fig. 2 - Accelerator Load Ranges and Kickdown Position re-calibrated. Turn the keyswitch to position '1' and
disconnect the accelerator harness. Wait a few
INSTALLATION seconds then re-connect. this will cancel the original
calibration and allow a re-calibration procedure to be
Numbers in parentheses refer to Fig. 1.
executed; see previous steps 1-4.
Note: Tighten all fasteners to standard torques listed in TROUBLESHOOTING
Section 300-0080, STANDARD BOLT AND NUT
The pedal can be checked by measuring the voltage
TORQUE SPECIFICATIONS.
signal across the pedal harness.
1. Position pedal assembly on cab wall and secure with
Voltage Ref: Measure voltage across red
bolts (5) and washers (6). Ensure that pedal assembly
and black wires - reading
(1) is free to operate.
should be 5V.
2. Connect electrical harness (1) to dash harness.
Pedal at Idle: Measure voltage across
Pedal must be calibrated before the machine is
white and black wires -
operated. See 'Pedal Calibration'.
reading should be less than
0.8V.
3. Place the battery master switch in the 'On' position,
remove wheel blocks and start the engine. Ensure that
Pedal at Full Throttle: Measure voltage across
pedal (2) assembly operates correctly.
white and black wires -
reading should be greater
Note: The engine should be started with the foot 'OFF' than 3.1V.
pedal (2) assembly.

MAINTENANCE
PEDAL CALIBRATION
Limited repair of the electronic foot pedal assembly is
The pedal calibration must be checked if the harness is by replacement of parts only. Refer to vehicle Parts
disconnected or the pedal replaced. Using Cummins Book for part numbers.
INSITE diagnostic reader, the pedal can be checked as
follows:
SPECIAL TOOLS
1. With engine off, turn keyswitch to position '1', and Refer to Section 300-0070, SERVICE TOOLS, for part
connect diagnostic reader. numbers of Cummins engine INSITE diagnostic tools
which can be used to check pedal calibration. These
tools are available from your dealer.

* * * *

2 SM 2187 Rev1 10-04


COOLING SYSTEM - Cooling System
Section 210-0000

SM - 2817

15 2

1 4
13
14

12 7 11 5

8 3
6
10
9

1 - Header Tank 5 - Charge Air Inlet Pipe 9 - Radiator Outlet Pipe 13 - Filter Inlet Line
2 - Radiator Assembly 6 - Engine Oil Cooler 10 - Radiator Inlet Pipe 14 - Filter Outlet Line
3 - Engine Water Pump 7 - Thermostat Housing 11 - Deaeration Line 15 - Charge Air Outlet Pipe
4 - Coolant Filter 8 - Make-up Line 12 - Deaeration Line

Fig. 1 - Cooling Lines and Flow

DESCRIPTION charge cooler mounted on top of a radiator, with an air


Numbers in parentheses refer to Fig. 1. conditioning condenser and a hydraulic oil cooler
mounted on the front.
A radiator and fan cooling system is used on the
Quantum engines installed in these vehicles. This
system has a centrifugal type water pump (3) to OPERATION
circulate coolant throughout the system. A full blocking Numbers in parentheses refer to Fig. 1, unless
type thermostat located in thermostat housing (7), otherwise specified.
attached to the right hand side of the cylinder head,
controls the flow of coolant. Upon starting a cold engine or when the coolant is
below operating temperature, the coolant is restricted
The main components of the cooling system are; at thermostat housing (7) and bypass line provides
header tank (1), radiator assembly (2), engine water water circulation within the engine during the warm-up
pump (3), coolant filter (4), engine oil cooler (6) and period.
thermostat housing (7).
Note: Engine coolant thermostats start to open at
The radiator assembly (2) consists of an air-to-air 82 C (180 F) and are fully open at 93 C (199 F).

SM 2188 Rev 1 6-03 1


Cooling System - Cooling System
Section 210-0000
Engine water pump (3) draws coolant from the radiator SM - 2818
through radiator outlet pipe (9). Engine water pump (3)
then pumps coolant through engine oil cooler (6) and 3
engine block and passes up through the cylinder head 1
to thermostat housing (7).

When the coolant reaches operating temperature, the


thermostats open allowing coolant to flow into the
radiator through radiator inlet pipe (10). The coolant
passes through a series of tubes in radiator assembly
(2) core, where the coolant temperature is lowered by
the air stream created by the revolving fan, and into the 4
radiator outlet pipe (9) to be re-circulated back through
the system.

Aerated coolant is drawn off to header tank (1) from the


radiator and engine through deaeration lines (11 & 12). 2
Excess coolant at header tank (1) is discharged
through an overflow line from the filler neck.

The use of antifreeze is mandatory with the cooling 1 - Air-to-Air Charge Cooler 3 - Outlet Pipe
2 - Inlet Pipe 4 - Inlet Pipe
system. Refer to 'Recommended Coolants'. The lack of
coolant flow through the radiator with the thermostats
closed allows the coolant in radiator assembly (2) to Fig. 2 - Air-to-Air Charge Cooler Lines and Flow
freeze under low ambient temperature conditions.
enters air-to-air charge cooler (1). The hot air travels
Coolant Filter through a series of tubes in air-to-air charge cooler (1)
core, where the air temperature is lowered. From here
The cooling system is protected by a replaceable spin-
the air flows through outlet pipe (3) and into the engine
on type coolant filter (4) mounted on the left hand side
intake manifold through inlet pipe (4). From the engine
of the engine. The filter provides mechanical filtration
intake manifold the air travels into the cylinders where
by means of a closely packed element through which
it mixes with atomized fuel from the injectors. This
the coolant passes. Any impurities such as sand and
cooler air aids combustion, thereby increasing fuel
rust particles suspended in the cooling system will be
economy.
removed by the straining action of the element. The
removal of these impurities will contribute to longer
engine water pump (3) life and proper operation of the PREVENTIVE MAINTENANCE
thermostats.
To ensure the continued efficient functioning of the
cooling system, certain checks and operations should
Coolant flows from the engine block (3) through filter
be performed at regular intervals.
inlet line (13) and into coolant filter (4). Coolant flows
through the filter element and exits through filter outlet
line (14) and back into the engine block. Shut-off cocks
WARNING
on both filter lines allow coolant filter (4) to be replaced
Do not remove the pressure control cap from
with the minimum loss of coolant.
the radiator header tank or attempt to drain the
coolant until the engine has cooled. Once the
Air-To-Air Charge Cooling engine has cooled, use extreme caution when
removing the cap. Remove cap slowly as the
Numbers in parentheses refer to Fig. 2.
sudden release of pressure from a heated
cooling system can result in a loss of coolant
In the air system used on the Quantum engines,
and possible personal injury (scalding) from
outside air is drawn into the engine through the air
the hot liquid.
cleaner, passes through the air filter element and is
pulled into the turbocharger where it is compressed. It
then exits the turbocharger through inlet pipe (2) and

2 SM 2188 Rev 1 6-03


Cooling System - Cooling System
Section 210-0000

Every 10 Hours (Daily)


Check coolant level and add recommended coolant if WARNING
low. Fill the radiator header tank with coolant until Do not remove the pressure cap from a hot
coolant reaches the bottom of the filler neck and holds engine. Wait until the coolant temperature is
at that level. below 50 C (120 F) before removing the
pressure cap. Heated coolant spray or steam
Note: Any time a significant amount of coolant is can cause personal injury.
added, the coolant concentration MUST be checked.
Failure to use recommended coolant and to maintain 1. Remove the cooling system pressure cap from
mixture at sufficient concentration levels can result in header tank.
damage to the cooling system and its related
components. Always maintain concentrations at 2. Close shut off valves at coolant filter inlet and outlet
recommended levels. Refer to 'Recommended lines and, using filter wrench, remove and discard
Coolants'. coolant filter from engine.

Check cooling fan for cracks and damage. Check fan


mounting and tighten if required. Replace cooling fan if WARNING
damaged. A small amount of coolant can leak when
servicing the coolant filter with the shut off
Check coolant lines, pipes and components for leaks valves in the closed position. To avoid personal
and wear. Check drive belts for damage. injury, avoid contact with hot coolant.

3. Clean the filter adaptor with a clean, lint free cloth.


Every 250 Hours
Inspect the radiator and air-to-air charge cooler fins 4. Lightly coat new coolant filter seal with clean engine
and, if necessary, clean with a quality grease solvent oil as specified in Section 300-0020, LUBRICATION
such as mineral spirits and dry with compressed air. SYSTEM.

Note: Fuel oil, kerosene or gasoline should not be used 5. Start coolant filter on the filter adaptor and tighten it
to clean fins. by hand until the seal touches the adaptor filter head.
Tighten an additional 1/2 to 3/4 of a turn after contact,
Note: It may be necessary to clean radiator and or as specified by the filter manufacturer.
air-to-air charge cooler fins more frequently if the
vehicle is being operated in extremely dusty or dirty Note: Mechanical tightening of coolant filter is not
areas. necessary and will distort or crack the adaptor. Tighten
coolant filter by hand only.

WARNING 6. Open shut off valves at coolant filter inlet and outlet
To prevent possible injury when using lines, and install pressure cap on header tank.
compressed air, wear adequate eye protection
and do not exceed 2.75 bar (40 lbf/in). 7. Start the engine and check for leaks. If any leaks are
noted, have them corrected. Add recommended coolant
as required.
Every 1 000 Hours
Coolant Filter - Replace coolant filter as follows: Note: Any time a significant amount of coolant is added,
the coolant concentration MUST be checked.
Note: There is a shut off valve at the coolant inlet and
outlet lines of coolant filter. Closing these valves will
enable coolant filter to be replaced without an Every 7 500 Hours
excessive loss of coolant. Check the coolant concentration using Terex Pro-Cool
Test Strips (see special tools). Add Terex Pro-Cool
Booster if necessary.

SM 2188 Rev 1 6-03 3


Cooling System - Cooling System
Section 210-0000

Cleaning The Cooling System 7. Shut off the engine and drain the cooling system.

Note: If the water being drained is still dirty, the


WARNING system must be flushed again until the water is clean.
Do not remove the pressure control cap from
the radiator header tank or attempt to drain the 8. Refill the cooling system with the proper mix of
coolant until the engine has cooled. Once the coolant and water and install new coolant filter. Refer to
engine has cooled, use extreme caution when instructions under 'Recommended Coolants'.
removing the cap. Remove cap slowly as the
sudden release of pressure from a heated 9. Install filler cap on the radiator header tank, operate
cooling system can result in a loss of coolant the engine and check for coolant leaks.
and possible personal injury (scalding) from
the hot liquid. RECOMMENDED COOLANTS
Note: It is recommended to use a cleaner such as
Fleetguard RESTORE, or equivalent, when cleaning WARNING
the cooling system. Hazardous substance. To prevent personal
injury, wear appropriate personal protective
1. Drain the cooling system. Do not allow the cooling equipment when there is a risk of contact or
system to dry out or remove the coolant filter. inhalation of fumes. Always work in a well
ventilated area.
2. Add 3.8 litres (1 US gal) of cleaner for each
38 - 57 litres (10 - 15 US gal) of cooling system
capacity, and fill the system with clean water. WARNING
If substance gets into your eyes, immediately
Note: Fleetguard RESTORE contains no antifreeze and flush eyes gently with water for at least 15
the cooling system should not be allowed to freeze minutes. Seek immediate medical attention.
during the cleaning operation. If substance contacts skin, immediately flush
with water for at least 15 minutes. Remove
3. Slide the heater temperature control to high to allow contaminated clothing. Wash affected area with
maximum coolant flow through the heater core. The soap and water and seek immediate medical
blower switch does not have to be on. attention.
If substance is swallowed or inhaled, seek
4. Operate the engine at normal operating temperature, immediate medical attention.
at least 85 C (185 F) for 1 - 1.5 hours.
Heavy duty diesel engines installed in these vehicles
require a heavy duty coolant for optimum performance.
WARNING Terex Pro-Cool extended life antifreeze coolant is an
Do not remove the filler cap from the radiator ethylene glycol based formulation specifically designed
header tank or attempt to drain the coolant until to meet Cummins and other heavy duty diesel engines
the engine has cooled to below 50 C (120 F). requirements.

5. Shut off the engine and drain the cooling system. Terex Pro-Cool extended life antifreeze coolant meets
the performance of ASTM D4985 specification for
6. Fill the cooling system with clean water and operate heavy duty engines.
the engine at high idle for 5 minutes with the coolant
temperature above 85 C (185 F). The following table provides mixing information. Clean
tap water or demineralized water is recommended for
dilution. A 40% to 70% concentration range is
WARNING suggested for optimum corrosion protection, however a
Do not remove the filler cap from the radiator Terex Pro-Cool solution is recommended and is used
header tank or attempt to drain the coolant until as a factory fill. Concentrations over 70% are not
the engine has cooled to below 50 C (120 F). recommended because of poor heat transfer capability,
adverse freeze protection and possible silicate dropout.
Concentrations below 30% offer little freeze, boil over
or corrosion protection.

4 SM 2188 Rev 1 6-03


Cooling System - Cooling System
Section 210-0000
Note: TEREX Pro-Cool obtained from recognised Terex 1. Compare FREEZEPOINT (end pad) to colour chart
Distributors is 50/50 pre-mixed. No dilution with water on reverse side of the card and record result
is required.
2. Next compare MOLYBDATE (middle pad) to colour
Terex Pro-Cool Extended Life Antifreeze/Coolant chart on reverse side of the card and record result.
Freeze/Boil Protection
3. Finally compare NITRITE test to colour chart on
% Coolant Freezing Point,C/F Boiling Point,C/F
reverse side of the card and record result.
33 -17 / 0 123 / 256
e. All three readings must be completed no later than
40 -24 / -12 126 / 260
75 SECONDS after dipping strip. It is okay to estimate
50 -36 / -34 128 / 265 a value a between colour blocks, but if uncertain about
70 -67 / -90 135 / 277 the colour match, pick the LOWER numbered block
(e.g if nitrite colour is not F, use column E).

f. Determine where the MOLYBDATE level intersects


Test Kit Procedures the NITRITE level on the chart. For best results follow
Coolant Test Strips should be used to measure nitrite test times carefully. Use a stopwatch or clock with a
and glycol concentrations (See Special Tools). sweep second hand. Comparing the test strips to the
Cavitation/corrosion protection is indicated on the strip colour chart too soon or too late may result in incorrect
by the level of nitrite concentration. Freeze/boil over readings and improper treatment and could result in
protection is determined by glycol concentration. Use liner pitting and engine damage.
the test strips as follows:
Note: Failure to properly maintain coolant with SCA
a. Collect coolant sample from the radiator draincock, can result in damage to the cooling system and its
sample not to be taken from header tank. Coolant must related components. Conversely, over-concentration of
be between 10 - 60C (50 - 140F) when checking. SCA inhibitor can result in poor heat transfer, leading to
engine damage. Always maintain concentrations at
b. Remove one strip from packet, DO NOT TOUCH the recommended levels.
pads on the end of the strip. DISCARD STRIP IF
NITRITE TEST PAD HAS TURNED BROWN.
SPECIAL TOOLS
c. Dip strip in coolant sample for one second remove, Refer to Section 300-0070, SERVICE TOOLS, for part
and shake strip briskly to remove excess liquid. numbers of the coolant test strips and general service
tools required. These strips and tools are available
d. 45 seconds after dipping strip compare and record from your dealer.
results in the following order :

SM 2188 Rev 1 6-03 5


Cooling System - Cooling System
Section 210-0000

COOLING SYSTEM DIAGNOSIS CHART


Engine coolant temperature Low coolant level Fill coolant system to correct fill level
too high Check for leaks and repair
Faulty radiator pressure cap Check pressure cap, replace if required
Air in cooling system Purge air from cooling system
Front of radiator obstructed Remove obstruction and clean radiator
preventing free flow of air fins
Fan drive belt broken or Adjust or replace fan belt
slipping
Thermostats not opening Replace thermostats
Restricted cooling system Flush cooling system
passages
Faulty engine water pump Repair or replace engine water pump
Engine coolant temperature Thermostats remain open or Replace thermostats
too low open at too low a temperature
Leakage around thermostat Replace thermostat seals
seals
Extremely cold weather Cover radiator or install radiator shutters

* * * *

6 SM 2188 Rev 1 6-03


COOLING SYSTEM - Radiator and Mounting
Section 210-0040

SM - 2819

1
2 8
3

7
4
5
6
34 33
32 31 29
27
30

14 9
28 15 23
24 22 21
25 15 14
38 26 20
37 27 14 19
35 14

37 12
36 17 13 10
14 11
15
18 14
17 16

1 - Bolt 11 - Bolt 21 - Connector 30 - Deaeration Line


2 - Washer 12 - Connector 22 - Shut-Off Valve 31 - Make-up Line
3 - Nut 13 - Elbow 23 - Plug 32 - Header Tank
4 - Bolt 14 - Clamp 24 - Elbow 33 - Filler Cap
5 - Snubbing Washer 15 - Hose 25 - Reducer 34 - Overflow Line
6 - Rubber Mounting 16 - Coolant Outlet Pipe 26 - Connector 35 - Elbow
7 - Nut 17 - Clamp 27 - Clamp 36 - Bolt
8 - Support Bracket 18 - Hose 28 - Deaeration Line 37 - Washer
9 - Connector 19 - Coolant Inlet Pipe 29 - Elbow 38 - Nut
10 - Washer 20 - Hose Assy

Fig. 1 - Exploded View of Radiator Mounting and Hoses

DESCRIPTION Fan plate assembly (10, Fig. 2) improves the engine


cooling fan efficiency, provides a more uniform
Numbers in parentheses refer to Fig. 1, unless
distribution of air over charge air cooler core (1, Fig. 2)
otherwise specified.
and radiator core (2, Fig. 2) and helps restrict
recirculation of air within the engine compartment.
Radiator assembly is mounted in front of the engine
cooling fan at the front end of the vehicle. It is fed from
Recirculation baffles incorporated in the hood assembly
header tank (32) located in front of the operators
prevent hot air from the engine cooling fan being
compartment and mounted to the goalpost
reintroduced into the cooling air circuit.
arrangement.

The radiator assembly consists of an air-to-air charge REMOVAL


cooler mounted on top of a radiator, with an air
Numbers in parentheses refer to Fig. 1, unless
conditioning condenser and a hydraulic oil cooler
otherwise specified.
mounted on the front. Refer to Section 210-0000,
COOLING SYSTEM.

SM 2189 1-03 1
Cooling System - Radiator and Mounting
Section 210-0040

SM - 2820

5
3

11 1

10 6

4
9
7
4 - Bottom Column 8 - LH Fan Guard
1 - Charge Air Cooler Core 5 - LH Column 9 - RH Fan Guard
2 - Radiator Core 6 - RH Column 10 - Fan Plate Assy
3 - Top Column 7 - Mount 11 - Fan Cowl Assy

Fig. 2 - Exploded View of Radiator Assembly

WARNING 1. Position the vehicle in a level work area, apply the


Do not remove the pressure control cap from parking brake and switch off the engine.
the radiator header tank or attempt to drain the
coolant until the engine has cooled. Once the 2. Block all road wheels and place the battery master
engine has cooled, use extreme caution when switch in the 'Off' position.
removing the cap. Remove cap slowly as the
sudden release of pressure from a heated 3. Pull on handle to release hood catch mechanism
cooling system can result in a loss of coolant and raise hood.
and possible personal injury (scalding) from
the hot liquid. 4. Remove hood assembly from the vehicle. Refer to
Section 100-0040, HOOD AND MOUNTING.

WARNING 5. Disconnect electrical harness from horns, and


To prevent personal injury and property remove horns and mounting from front of radiator.
damage, be sure wheel blocks, blocking Disconnect electrical harness from engine cooling fan.
materials and lifting equipment are properly
secured and of adequate capacity to do the job 6. Remove filler cap (33) carefully from header tank
safely. (32).

2 SM 2189 1-03
Cooling System - Radiator and Mounting
Section 210-0040
7. Remove plug (23) and open shut-off valve (22) at the SM - 2818
bottom of radiator assembly and drain coolant into a
3
suitable container. Close shut-off valve (22) when
coolant is completely drained and refit plug (23). 1

8. Remove bolt (4), snubbing washer (5) and nut (7)


securing support bracket (8) to the engine bracket.

9. Remove bolts (1), washers (2) and nuts (3) securing


support bracket (8) to mounting brackets on radiator
assembly. Remove support bracket (8).
4
10. Ensure air conditioning lines from condenser
mounted on front of charge air cooler (1, Fig. 2), and
from receiver drier mounted at rear left hand side of
radiator assembly are identified for ease of installation.
Disconnect air conditioning lines. Fit blanking caps to 2
open lines and ports.

Note: Refer to Section 260-0130, AIR CONDITIONING 1 - Charge Air Cooler 3 - Outlet Pipe
before disturbing the air conditioning circuit. 2 - Inlet Pipe 4 - Inlet Pipe
Fig. 3 - Air-To-Air Charge Cooler Piping
11. Ensure hydraulic lines connected to hydraulic oil
cooler mounted on front of radiator (2, Fig. 2) are
identified for ease of installation and with suitable 18. Slacken clamps (14) and remove coolant inlet pipe
containers available to catch leakage, disconnect (19), hoses (15) and clamps (14) from radiator
hydraulic lines. Fit blanking caps to open lines and assembly and engine thermostat housing.
ports.
19. Slacken clamps (14 & 17) and remove coolant
12. Disconnect deaeration line (28) from connector (9) outlet pipe (16), hoses (15 & 18) and clamps (14 & 17)
in radiator and deaeration line (30) from elbow (29) in from bottom of radiator assembly and engine water
engine. Identify lines for ease of installation and cap pump inlet.
open lines and elbows.
20. Install two eye bolts in lifting bosses on side of
13. Disconnect all clips and clamps securing air radiator assembly. Using suitable lifting equipment
conditioning lines, hydraulic lines and deaeration lines support radiator assembly.
to radiator assembly. Move all lines away from radiator
assembly to prevent fouling on removal of radiator 21. Remove bolts (11) and washers (10) securing
assembly. radiator assembly to the frame.

14. Remove bolts, washers and nuts securing fan 22. Remove radiator assembly from the vehicle to a
guards (8 & 9, Fig. 2) to radiator assembly. Remove clean area for disassembly. Support radiator standing
fan guards (8 & 9, Fig. 2) from radiator assembly. upright to allow access to front and rear of radiator.

15. Slacken clamps securing cooler hoses to air inlet Note: If Header Tank (32) requires to be removed,
pipe (2, Fig. 3) and remove air inlet pipe from charge air follow steps 23 through 28.
cooler (1, Fig. 3) and engine turbocharger.
23. Disconnect electrical harness from coolant level
16. Remove nut, washers and clamp securing air outlet sensor at bottom of header tank (32).
pipe (3, Fig. 3).
24. With a suitable container available to catch
17. Slacken clamps securing cooler hoses to air outlet leakage, remove drain plug from radiator header tank
pipe (3, Fig. 3) and remove air outlet pipe (3, Fig. 3) (32) and drain coolant. Apply Loctite 225 to drain plug
from charge air cooler (1, Fig. 3) and inlet pipe (4, Fig. and reinstall in header tank.
3).
25. Ensure all cooling lines connected to header tank

SM 2189 1-03 3
Cooling System - Radiator and Mounting
Section 210-0040
are identified for ease of installation and with suitable INSPECTION
containers available to catch leakage, disconnect
Numbers in parentheses refer to Fig. 2.
deaeration lines (28 & 30) and overflow line (34). Fit
blanking caps to all open lines.
1. Steam clean all parts thoroughly with a suitable
solvent.
26. Slacken clamp (27) and disconnect make-up line
(31) from header tank (32). Blank off open line end.
2. Examine charge air cooler core (1), radiator core (2),
condenser core and hydraulic oil cooler core carefully
27. Following removal instructions in Section
for possible damage. Repair any damage discovered if
100-0040, HOOD AND MOUNTING, remove goalpost
equipped to do so, or, have repairs made at a reputable
and header tank (32) as an assembly from the vehicle.
radiator repair shop.
28. Remove bolts (36), nuts (38) and washers (37)
securing header tank (32) to goalpost. Remove header ASSEMBLY
tank (32) from goalpost. Numbers in parentheses refer to Fig. 2, unless
otherwise specified.
DISASSEMBLY
Note: Tighten all fasteners to standard torques listed in
Numbers in parentheses refer to Fig. 2, unless
Section 300-0080, STANDARD BOLT AND NUT
otherwise specified.
TORQUE SPECIFICATION.
Note: Take care not to damage charge air cooler core
1. Fit RH column (6) and LH column (5) to charge air
(1), radiator core (2), condenser core and hydraulic oil
cooler core (1) and radiator core (2) using fasteners
cooler core during disassembly.
removed during 'Disassembly'.
1. Remove drain cock assembly (12, 13 & 20 - 23, Fig.
2. Secure mounts (7) to bottom column (4) with bolts
1) from bottom of radiator core (2). Remove connector
removed during 'Disassembly'.
(9, Fig. 1) from radiator core (2).
3. Fit top column (3) and bottom column (4) to radiator
2. Remove receiver drier and mounting from rear of
assembly using fasteners removed during
radiator assembly.
'Disassembly'.
3. Remove mounting hardware securing hydraulic oil
4. Position fan cowl assembly (11) to radiator
cooler to radiator assembly. Remove hydraulic oil
assembly and secure with fasteners removed during
cooler from radiator assembly.
'Disassembly'.
4. Remove mounting hardware securing air conditioning
5. Position fan plate assembly (10) to radiator
condenser to radiator assembly. Remove condenser
assembly and secure with fasteners removed during
from radiator assembly.
'Disassembly'.
5. Remove bolts, washers and nuts securing fan plate
Note: When installing radiator, ensure clearance around
assembly (10) to radiator assembly. Remove fan plate
cooling fan tips to plate assembly is of equal
assembly (10) from radiator assembly.
dimension all round.
6. Remove bolts and washers securing fan cowl
6. Install air conditioning condenser and hydraulic oil
assembly (11) to radiator assembly. Remove fan cowl
cooler to radiator assembly picking up mounting
assembly (11) from radiator assembly.
locations and hardware as identified at 'Disassembly'.
7. Remove bolts securing mounts (7) to bottom of
7. Fit connector (9, Fig. 1) to radiator core (2). Fit drain
radiator, and remove mounts (7).
cock assembly (12, 13 & 20 - 23, Fig. 1) to bottom of
radiator core (2).
8. Remove remaining bolts and washers securing top
column (3), LH column (5), RH column (6) and bottom
8. Install receiver drier to rear of radiator assembly
column (4) to charge air cooler core (1) and radiator
picking up mounting locations and hardware as
core (2).
identified at 'Disassembly'.

4 SM 2189 1-03
Cooling System - Radiator and Mounting
Section 210-0040

INSTALLATION radiator assembly with bolts, washers and nuts


removed during 'Removal'.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
12. Remove blanking caps from deaeration lines
(28 & 30) and connect deaeration line (28) to connector
Note: Tighten all fasteners without special torques
(9) in radiator assembly and deaeration line (30) to
specified to standard torques listed in Section
elbow (29) in engine. Do not clip lines at this point.
300-0020, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
13. Remove blanking caps from hydraulic oil cooler
lines and fittings. Connect all hydraulic lines to
WARNING hydraulic oil cooler as identified at removal.
To prevent personal injury and property
damage, be sure lifting equipment is properly 14. Remove blanking caps from air conditioning lines
secured and of adequate capacity to do the job and fittings. Connect air conditioning lines to condenser
safely. and receiver drier. Refer to Section 260-0130, AIR
CONDITIONING for procedure on charging the system.
1. Using suitable lifting equipment, position radiator
assembly on the frame and secure with bolts (11) and 15. Secure all lines with clips and clamps as removed
washers (10). during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
evident.
2. Position support bracket (8) on mounting brackets at
top of radiator assembly and secure in place with bolts
(1), washers (2) and nuts (3). 16. Ensure fittings, lines and pipes are securely
tightened to prevent leaks at initial fill and start up.
3. Secure support bracket (8) to engine bracket with
bolt (4), snubbing washer (5), rubber mounts (6) and nut Note: If Header Tank (32) was removed and has not
(7). yet been installed, proceed from step 17, however, if
header tank (32) was not removed or has been
reinstalled, proceed from step 24.
4. Install coolant outlet pipe (16) between radiator outlet
port and engine water pump inlet, and secure with
hoses (15 & 18) and clamps (14 & 17). 17. Fit header tank (32) to goalpost and secure using
bolts (36), nuts (38) and washers (37).
5. Install coolant inlet pipe (19) between radiator inlet
port and engine thermostat housing, and secure with 18. Following installation instructions in Section
hoses (15) and clamps (14). 100-0040, HOOD AND MOUNTING, install header tank
(32) and goalpost assembly on the vehicle.
6. Install air outlet pipe (3, Fig. 3) between engine inlet
pipe (4, Fig. 3) and charge air cooler (1, Fig. 3) and 19. Remove blanking from make-up line (31) and
secure with hoses and clamps. connect to header tank (32). Secure with clamp (27).

7. Secure air outlet pipe (3, Fig. 3) with clamp, nut and 20. Remove blanking caps from deaeration lines
washers removed during 'Removal'. (28 & 30) and connect to appropriate fittings on header
tank (32), as noted on removal.
8. Install air inlet pipe (2, Fig. 3) between engine
turbocharger and charge air cooler (1, Fig. 3) and 21. Connect overflow line (34) to header tank (32).
secure with hoses and clamps.
22. Secure all lines with clips and tie clips as removed
9. Feed electrical harness from engine cooling fan during removal. Ensure no lines are chaffing on sharp
through hole in fan plate assembly (10, Fig. 2). Fit edges or resting against areas where heat will be
grommet if previously removed. evident.

10. Connect engine cooling fan electrical harness to 23. Connect electrical harness to coolant level sensor
main electrical harness. at bottom of header tank (32).

11. Install LH and RH fan guards (8 & 9, Fig. 2) to 24. Refer to Section 210-0000, COOLING SYSTEM for
correct selection of coolant. Fill the cooling system

SM 2189 1-03 5
Cooling System - Radiator and Mounting
Section 210-0040
through filler in header tank (32) with coolant until External Cleaning
coolant level stabilizes at the bottom of filler neck.
Note: If a build up of dirt is apparent during routine
inspection, the following cleaning procedure should be
25. Check all line and pipe connections for leaks prior
adopted.
to starting the vehicle. Tighten as required.

26. Switch the battery master switch to the 'On'


WARNING
position, start up the engine and check for leaks.
To prevent possible injury when using
Tighten lines and fittings and top up coolant level as
compressed air or steam jet, wear adequate eye
required.
protection and do not exceed pressure values
stated.
27. Install filler cap (33) on header tank (32) after the
coolant level has stabilized at the bottom of filler neck.
1. Direct a steam jet at 100 - 300 kN/m, or
compressed air at 500 - 700 kN/m on to the faces of
28. Following installation instructions in Section the radiator core.
100-0040, HOOD AND MOUNTING, install hood
assembly on the vehicle.
2. Liberally brush a liquid detergent on to those
surfaces which were not satisfactorily cleaned at
29. Remove wheel blocks from road wheels.
step 1. Leave to soak for at least 1 hour.

CLEANING 3. Apply a high pressure steam jet at 100 - 300 kN/m, or


compressed air at 500 - 700 kN/m on to the treated
Internal Cleaning - Water Tubes surfaces, forcing the fouling material out from the radiator
core.
If scale deposits are present inside the water tubes of
the radiator, it is necessary to use a suitable scale
4. Leave radiator core to dry before reinstalling the
remover such as 'Powdered Scale Solvent', or
cooling equipment.
equivalent. This material is a free-flowing powder,
inhibited to prevent attack on the cooling system
Note: In the case of grossly fouled surfaces which are
materials.
not cleaned adequately in steps 1 through 4, the
following procedure may be used.
WARNING
5. Ensure that the radiator core is dry.
Take care to avoid contact of skin or eyes with
the solvent. If contact is made it should be
6. Liberally brush on to both sides of the radiator core
washed off immediately with clean water and
an emulsifying cleaner such as 'Gunk', or equivalent,
medical advice should be taken.
and leave to soak for at least 1 hour.
For general cleaning use it is recommended to use a
7. Apply a high pressure steam jet at 100 -300 kN/m,
concentration of 50 - 100 kg/m of water at a
or compressed air at 500 - 700 kN/m on to the treated
temperature of up to 60 C. Rapid circulation or
surfaces, from several different angles, forcing the
agitation with compressed air will reduce the time for
fouling material out from the radiator core.
cleaning.
8. For surfaces with stubborn deposits, it may be
Note: If scale deposits within the radiator are
necessary to repeat steps 5 through 7, brushing the
exceptionally heavy, concentrations up to 200 kg/m
surfaces between stages using a stiff bristle brush.
may be used.
The most convenient method of use is to prepare a
9. Leave radiator core to dry before reinstalling the
concentrated solution by mixing the powder in hot
cooling equipment.
water in a tank and then adding the concentrated
solution to water contained in the radiator.

Note: The solvent must always be added carefully to


water, not water to solvent.

6 SM 2189 1-03
Cooling System - Radiator and Mounting
Section 210-0040

MAINTENANCE
Refer to Section 210-0000, COOLING SYSTEM for
recommended preventive maintenance procedures,
service intervals and coolant selection procedures.

SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
adhesives are available from your dealer.

* * * *

SM 2189 1-03 7
COOLING SYSTEM - Transmission Oil Cooler
Section 210-0060

SM - 2821

12,
13,14
6

16
TRANS. RETARDER 21
HOUSING 5
7
19

12,
13,14

16
8,9,10,11 3 TRANSMISSION
OIL COOLER
15
2 8,9,10,11

15 20
1 17
18
TO HYDRAULIC TO HYDRAULIC
TANK OIL COOLER
TRANSMISSION OIL
TEMP. SENDER
FROM MAIN
HYDRAULIC
VALVE

1 - Elbow 6 - Bracket 11 - Bolt 16 - Elbow


2 - Elbow 7 - Bracket 12 - Clamp 17 - Hose
3 - Hose 8 - Clamp 13 - Plate 18 - Hose
4 - Tube Assy 9 - Bushing 14 - Screw 19 - Hose
5 - Tube Assy 10 - Stacking Nut 15 - 'O' Ring 20 - Hose
21 - Motor
Fig. 1 - Transmission Oil Cooler Lines

DESCRIPTION AND OPERATION The fan motor (21) is proportionally controlled by the
Numbers in parentheses refer to Fig. 1, unless hydraulic ECU. The higher the transmission
otherwise stated. temperature, the more hydraulic oil is supplied to the
fan motor (21) through hose (18). Refer to Section 215-
The transmission oil cooler (1, Fig. 2) is mounted on 0050, MAIN HYDRAULIC VALVE. Hydraulic oil leaving
the right hand side of the tractor, on top of the fuel the fan motor (21) returns through hose (20) to the
tank. The transmission oil cooler is an air blast cooler, hydraulic tank via the hydraulic oil cooler.
using hydraulic oil from the main hydraulic circuit to
supply the fan motor (21). An isolation solenoid valve also controls flow to the fan
motor (21), preventing hydraulic oil being supplied to
Transmission oil to be cooled exits from the bottom the motor (21) until the transmission oil temperature
port of transmission retarder housing and flows through increases to 90 C (194 F). This prevents the
hose (17) and tube assembly (5) into bottom of cooler transmission oil being overcooled. Refer to Section
(1, Fig. 2). Transmission oil flows through the crossflow 215-0050, MAIN HYDRAULIC VALVE.
core and is cooled by air flow produced by the rotation
of fan (4, Fig. 2), which is driven by motor (21). Cooled The isolation solenoid valve, mounted on the right hand
transmission oil then exits the top of cooler (1, Fig. 2) fender, is failsafe i.e. if the solenoid fails, the valve will
and flows through tube assembly (4) and hose (3) and default to an open position, allowing hydraulic oil to the
into the top port of transmission retarder housing. motor (21). The solenoid valve is controlled by the
hydraulic ECU (refer to Section 190-0085, HYDRAULIC
SYSTEM ECU).

SM 2190 Rev1 12-04 1


Cooling System - Transmission Oil Cooler
Section 210-0060

SM - 3374

24
23

25 1
21
9 8
10
13

11 26 14
20 12 15
19 16
18

4
20 6
18 19
29
9 5
8
17

3
25

24
3
2 22
7
23
25

20
19
18

1 - Cooler 8 - Bolt 14 - Washer 20 - Washer


2 - Fan Ring Assy 9 - Washer 15 - Lockwasher 21 - Bracket
3 - Motor 10 - Nut 16 - Nut 22 - Bracket
4 - Fan 11 - Toothed Washer 17 - Fan Guard 23 - Bolt
5 - Adaptor 12 - Washer 18 - Bolt 24 - Washer
6 - Mounting 13 - Nut 19 - Lockwasher 25 - Seal
7 - Elbow 26 - Beading

Fig. 2 - Exploded View of Transmission Oil Cooler Assembly

REMOVAL switch in the 'Off' position.


Numbers in parentheses refer to Fig. 4, unless
otherwise specified. 3. Pull on handle to release hood catch and raise hood.

4. Remove hood assembly from the vehicle. Refer to


WARNING Section 100-0040, HOOD AND MOUNTING.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 5. Open drain valve (14) at the bottom of the cooler
materials and lifting equipment are properly assembly and drain transmission oil into a suitable
secured and of adequate capacity to do the job container. Close drain valve when oil is completely
safely. drained.

1. Position the vehicle in a level work area, apply the 6. Remove bracket from rear of cooler. It may be
parking brake and switch off the engine. Turn steering possible to remove bracket without disturbing hoses.
wheel several times to relieve any pressure in the
steering circuit. Operate brake pedal continuously to 7. With a suitable container available to catch leakage,
relieve pressure in the braking system. disconnect supply hose (18, Fig. 1), case drain hose
(19, Fig. 1) and return hose (20, Fig. 1) from fan motor
2. Block all road wheels and place the battery master (21, Fig. 1) and secure clear of transmission oil cooler.

2 SM 2190 Rev1 12-04


Cooling System - Transmission Oil Cooler
Section 210-0060

SM - 2823

4
7 10

1
9
6
3 2
8
11

5 12

1 - Cooler Core 5 - Bottom Channel 9 - Baffle


2 - Side Column 6 - Cowl Assy 10 - Baffle
3 - Side Column 7 - End Column 11 - Baffle
4 - Top Channel 8 - End Column 12 - Adaptor

Fig. 3 - Exploded View of Transmission Oil Cooler

Fit blanking caps to open lines and ports. DISASSEMBLY


Numbers in parentheses refer to Fig. 2, unless
8. With a suitable container available to catch leakage, otherwise stated.
disconnect transmission hoses (3 & 17, Fig. 1) from
tube assemblies (4 & 5, Fig. 1). Fit blanking caps to Note: Take care not to damage cooler core during
open lines and ports. disassembly.

9. Support transmission oil cooler assembly with 1. Remove clamp (6, Fig. 1) and mounting hardware
suitable lifting equipment. (12 - 14, Fig. 1) securing tube assembly (4, Fig. 1) to
cooler (1).
10. Remove nuts (11), bolts (1), hardened washers (8 &
9), isolators (5) and washers (10) from cooler brackets 2. Disconnect tube assembly (4, Fig. 1) from elbow
(2) and support plate (6). (16, Fig. 1) and remove. Remove elbow (16, Fig. 1)
from cooler (1), noting orientation.
11. Using suitable lifting equipment, remove
transmission oil cooler from machine to a clean area 3. Remove clamp (7, Fig. 1) and mounting hardware
for disassembly. (12 - 14, Fig. 1) securing tube assembly (5, Fig. 1) to
cooler (1).

SM 2190 Rev1 12-04 3


Cooling System - Transmission Oil Cooler
Section 210-0060

SM - 2824

1
8
16

13
9
4 1

6
8
5
4 1
12 10
11
9

5 8

7 10
9
3 11 15
5
14
2

10 7
11 3

1 - Bolt 5 - Isolator 9 - Hardened Washer 13 - Bolt


2 - Cooler Bracket 6 - Support Plate 10 - Washer 14 - Drain Valve
3 - Washer 7 - Bolt 11 - Locknut 15 - Seal
4 - Washer 8 - Hardened Washer 12 - Nut 16 - Plug

Fig. 4 - Transmission Oil Cooler Mounting

4. Disconnect tube assembly (5, Fig. 1) from elbow 9. Remove bolts (8) and washers (9) securing motor (3)
(16, Fig. 1) and remove. Remove elbow (16, Fig. 1) to mounting (6), and remove motor (3).
from cooler (1), noting orientation.
10. Remove nuts (16), lockwashers (15) and washers
5. Remove bolts (18), lockwashers (19) and washers (14) securing fan ring assembly (2) to cooler (1).
(20) securing fan guard (17) to fan ring assembly (2), Remove fan ring assembly (2) from cooler (1).
and remove fan guard (17).
11. Remove bolts (23) and washers (24) securing
6. Remove bolts (18), lockwashers (19) and washers brackets (21 & 22) to cooler (1).
(20) securing mounting (6) to cooler (1). Remove
mounting (6) complete with motor (3), fan (4) and 12. Remove mounting hardware securing cowl
adaptor (5). assembly (6, Fig. 3) to cooler (1), and remove cowl
assembly (6, Fig. 3).
7. Remove nut (13), toothed washer (11) and washer
(12) securing fan (4) and adaptor (5) to motor (3) shaft. 13. Remove mounting hardware securing end columns
Pull fan (4) and adaptor (5) from motor (3) shaft. (7 & 8, Fig. 3) to top and bottom channels (4 & 5, Fig.
3).
8. Remove bolts (8), washers (9) and nuts (10)
securing fan (4) to adaptor (5). 14. Remove remaining mounting hardware to allow end

4 SM 2190 Rev1 12-04


Cooling System - Transmission Oil Cooler
Section 210-0060
columns (7 & 8, Fig. 3), side columns (2 & 3, Fig. 3) 12. Fit elbows (16, Fig. 1) to cooler (1) in correct
and baffles (9 - 11, Fig. 3) to be removed. orientation.

15. Remove mounting hardware securing top and 13. Fit bracket (6, Fig. 1) to cooler. Fit tube assembly
bottom channels (4 & 5, Fig. 3) to cooler core (1, Fig. (4, Fig. 1) to top elbow (16, Fig.1) and secure with
3), and remove channels (4 & 5, Fig. 3). clamp (12, Fig. 1), plate (13, Fig. 1) and screws (14,
Fig. 1).

ASSEMBLY 14. Fit bracket (7, Fig. 1) to cooler. Fit tube assembly
Numbers in parentheses refer to Fig. 2, unless (5, Fig. 1) to bottom elbow (16, Fig.1) and secure with
otherwise stated. clamp (12, Fig. 1), plate (13, Fig. 1) and screws (14,
Fig. 1).
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. INSTALLATION
Numbers in parentheses refer to Fig. 4, unless
1. Secure top and bottom channels (4 & 5, Fig. 3) to otherwise specified.
cooler core (1, Fig. 3) using mounting hardware
removed previously. Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
2. Fit end columns (7 & 8, Fig. 3), side columns (2 & 3, TORQUE SPECIFICATIONS.
Fig. 3) and baffles (9 - 11, Fig. 3) to cooler core (1,
Fig. 3) and secure using mounting hardware removed
previously. WARNING
To prevent personal injury and property
3. Secure cowl assembly (6, Fig. 3) to cooler (1) using damage, be sure lifting equipment is properly
mounting hardware removed previously. secured and of adequate capacity to do the job
safely.
4. Secure brackets (21 & 22) to cooler (1) using bolts
(23) and washers (24). 1. Using suitable lifting equipment, position
transmission oil cooler assembly on machine and
5. Secure fan ring assembly (2) to cooler (1) using nuts secure to cooler brackets (2) and support plate (6) with
(16), lockwashers (15) and washers (14). nuts (11), bolts (1), hardened washers (8 & 9), isolators
(5) and washers (10).
6. Fit motor (3) to mounting (6) using bolts (8) and
washers (9). 2. Connect transmission hoses (3 & 17, Fig. 1) to tube
assemblies (4 & 5, Fig. 1).
7. Assemble fan (4) to adaptor (5) using bolts (8),
washers (9) and nuts (10). 3. Fit bracket to rear of cooler, using fasteners
removed previously.
8. Press fan (4) and adaptor (5) onto motor (3) shaft,
ensuring key is fitted. 4. Connect supply hose (18, Fig. 1), case drain hose
(19, Fig. 1) and return hose (20, Fig. 1) to fan motor
9. Secure fan (4) and adaptor (5) using washer (12), (21, Fig. 1).
toothed washer (11) and nut (13).
5. Following installation instructions in Section
10. Install mounting (6) complete with motor (3), fan (4) 100-0040, HOOD AND MOUNTING, install hood
and adaptor (5) to cooler (1). assembly on the vehicle.

Note: When installing mounting, ensure clearance 6. Fill transmission oil cooler with transmission oil
around fan (4) tips to fan ring assembly (2) is of equal specified in Section 300-0020, LUBRICATION
dimension all round. SYSTEM. Refer to Section 120-0010,
TRANSMISSION AND MOUNTING, for filling
11. Secure fan guard (17) to fan ring assembly (2) procedure and level check.
using bolts (18), lockwashers (19) and washers (20).
7. Top up hydraulic tank as necessary with hydraulic

SM 2190 Rev1 12-04 5


Cooling System - Transmission Oil Cooler
Section 210-0060
oil specified in Section 300-0020, LUBRICATION Every 250 Hours
SYSTEM. Inspect the transmission oil cooler fins and, if
necessary, clean with a quality detergent (see
8. Check all line and pipe connections for noticeable Cleaning).
leaks prior to starting the vehicle.
Note: Fuel oil, kerosene or gasoline should not be used
9. Switch the battery master switch to the 'On' to clean fins.
position, start up the engine and check for leaks.
Tighten lines and fittings and top up systems as Note: It may be necessary to clean cooler fins more
required. frequently if the machine is being operated in extremely
dusty or dirty areas.
10. Lower hood assembly and remove wheel blocks.

CLEANING
MAINTENANCE
External Cleaning
Motor Overhaul
Numbers in parentheses refer to Fig. 2.
Internal parts of the motor are lubricated by the
operating fluid itself; therefore preventive maintenance Note: If a build up of dirt is apparent during routine
is limited to keeping the fluid in the system clean. Dirt inspection, the following cleaning procedure should be
should not be allowed to accumulate on the motor or adopted.
around the shaft seal. Check frequently that all fittings
and bolts are tight.
WARNING
Every 10 Hours To prevent possible injury when using
compressed air or steam jet, wear adequate eye
Check cooling fan for cracks and damage. Check fan
protection and do not exceed pressure values
mounting and tighten if required. Replace cooling fan if
stated.
damaged.
1. Direct a steam jet at 100 - 300 kN/m, or
Check lines and components for leaks and damage.
compressed air at 500 - 700 kN/m on to the faces of
the cooler core (1).
Check the fan and motor for debris or damage. Clean
or replace as required.
2. Liberally brush a liquid detergent on to those
surfaces which were not satisfactorily cleaned at
Note: The fan is a non-serviceable component. step 1. Leave to soak for at least 1 hour.
However, the following instructions must be strictly
adhered to:
3. Apply a high pressure steam jet at 100 - 300 kN/m,
or compressed air at 500 - 700 kN/m on to the treated
1. DO NOT clean around fan drive with steam or high surfaces, forcing the fouling material out from the
pressure jet. cooler core (1).
2. DO NOT add any fluids or lubricants to the drive.
Note: In the case of grossly fouled surfaces which are
not cleaned adequately in steps 1 through 3, the
3. DO NOT restrict fan rotation during engine operation following procedure may be used.
for ANY reason.
4. Ensure that the cooler core (1) is dry.
4. DO NOT operate a machine with a damaged fan
assembly. Replace a damaged fan as soon as the 5. Liberally brush on to both sides of the cooler core (1)
fault is noted. an emulsifying cleaner such as 'Gunk', or equivalent,
and leave to soak for at least 1 hour.
5. IMMEDIATELY investigate and correct ANY
operator complaint involving drive or cooling
6. Apply a high pressure steam jet at 100 - 300 kN/m,
performance.
or compressed air at 500 - 700 kN/m on to the treated
surfaces, from several different angles, forcing the

6 SM 2190 Rev1 12-04


Section 210-0060
fouling material out from the core. 2. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through cooler (1). Solution should
7. For surfaces with stubborn deposits, it may be be circulated through cooler (1), in the reverse direction
necessary to repeat steps 4 through 6, brushing the to normal flow, for approximately 15 minutes, after
surfaces between stages using a stiff bristle brush. soaking for 10 minutes. The duration of circulation
depends on how badly clogged the cooler is. Flush
thoroughly with clean hot water.
Internal Cleaning - Tubes
In the event of a major mechanical failure, the
transmission oil cooler assembly should be cleaned SERVICE TOOLS
thoroughly or replaced. There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
1. Clean transmission oil cooler before sludge hardens. SERVICE TOOLS, for part numbers of general service
After transmission oil cooler is completely drained, tools and adhesives required. These tools are available
circulate a solution of Agmasol PS40 through the from your dealer.
cooler core (1) to remove sludge.

* * * *

SM 2190 Rev1 12-04 7


COOLING SYSTEM - Hydraulic Oil Cooler
Section 210-0100

SM - 2826

17

15 7
11 3
4
10 6

16

16
6
5 1
TO TANK RETURN
4 5
TUBE ASSY.
OUT 4
8
18
14
9
13
2
19
12
IN
8

7 9
4
10

11
FROM TEE AT CHECK
VALVE ON RH FENDER

1 - Hydraulic Oil Cooler 8 - Adaptor 14 - Bolt


2 - Bracket Assembly 9 - Elbow 15 - Adaptor
3 - Bracket Assembly 10 - Hose 16 - Tee
4 - Bolt 11 - Hose 17 - Elbow
5 - Washer 12 - Bracket 18 - Hose
6 - Locknut 13 - Clamp 19 - Hose
7 - Washer
Fig. 1 - Exploded View of Hydraulic Oil Cooler and Mounting

DESCRIPTION AND OPERATION


Numbers and letters in parentheses refer to Fig. 1. WARNING
To prevent personal injury and property
The air cooled hydraulic oil cooler is mounted on the damage, be sure wheel blocks and lifting
front of the radiator assembly, with the purpose of equipment are properly secured and of
cooling hydraulic oil circulating through the hydraulic adequate capacity to do the job safely.
tank.
1. Position the vehicle in a level work area, apply the
Hydraulic oil from the transmission oil cooler motor parking brake and switch off the engine. Turn steering
enters hydraulic oil cooler (1) through inlet line (10). wheel several times to relieve any pressure in the
steering circuit. Operate brake pedal continuously to
The hydraulic oil is cooled by the air flow through the relieve pressure in the braking system.
fins and exits through outlet line (11) and flows back to
the hydraulic tank. 2. Block all road wheels and place the battery master
switch in the 'Off' position.

REMOVAL 3. Remove drain plug from hydraulic tank remote drain


Numbers in parentheses refer to Fig. 1. fitting. Drain oil in the hydraulic tank into a suitable
container and re-install drain plug.

4. Remove mounting hardware securing front grille on


the hood assembly. Remove front grille from the hood.

SM 2191 1-03 1
Cooling System - Hydraulic Oil Cooler
Section 210-0100
5. Remove inlet line (10) from elbow (9) and connector
(8) in hydraulic oil cooler (1). Drain oil from inlet line WARNING
(10) into a suitable container. Plug inlet line and cap To prevent personal injury and property
port to prevent ingress of dirt. damage, be sure wheel blocks and lifting
equipment are properly secured and of
6. Remove outlet line (11) from elbow (9) and connector adequate capacity to do the job safely.
(8) in hydraulic oil cooler (1). Drain oil from outlet line
(11) into a suitable container. Plug outlet line and cap 1. If removed, secure bracket assemblies (2 & 3) to
port to prevent ingress of dirt. the radiator assembly with bolts (4) and hardened
washers (5), and install horns.
7. Remove mounting hardware securing hydraulic oil
cooler (1) to bracket assemblies (2 & 3). Remove 2. Secure hydraulic oil cooler (1) to bracket
hydraulic oil cooler (1) from its mounting. assemblies (2 & 3) with mounting hardware, as
removed at 'Removal'.
8. If required, remove horns along with bolts (4) and
washers (7) securing bracket assemblies (2 & 3) to the 3. Install inlet line (10) and outlet line (11) in their
radiator assembly. respective ports, as removed at 'Removal'.

CLEANING AND INSPECTION 4. Fill hydraulic tank with oil. Refer to Section
230-0040, HYDRAULIC TANK, for correct fill level and
1. Inspect fins on hydraulic oil cooler carefully, for Section 300-0020, LUBRICATION SYSTEM for
trapped debris and damage. If hydraulic oil cooler fins specifications of oil to be used.
show signs of leakage or are excessively damaged, it
must be replaced as an assembly. 5. Place the battery master switch in the 'On' position,
start engine and operate the body hydraulics several
2. Check connectors in hydraulic oil cooler ports for times to circulate the oil. Check hydraulic oil cooler (1)
damaged threads. Replace if required. and lines for leaks. Tighten fittings as required.
3. After hydraulic oil cooler is completely drained, 6. Install front grille assembly to the hood with
circulate a solution of Agmasol PS40 through the mounting hardware, as removed at 'Removal'.
cooler tubes.
7. Remove wheel blocks from all road wheels.
4. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through the hydraulic oil cooler, in
the reverse direction to normal flow, for approximately MAINTENANCE
15 minutes. The duration of circulation depends on Check and clean hydraulic oil cooler every 4 000
how badly clogged the cooler tubes are. Flush hours, or more frequently, if required. Debris in the
thoroughly with clean hot water. cooling fins can restrict the flow of air through the
cooler which significantly reduces the cooling effect.
INSTALLATION
Note: In the event of a hydraulic failure, hydraulic oil
Numbers in parentheses refer to Fig. 1. cooler should be removed and cleaned to prevent
clogging.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. SERVICE TOOLS
There are no special tools required for procedures
Note: Tighten all hydraulic lines fitted with ORFS outlined in this section. Refer to Section 300-0070,
connections, as described in Section 220-0000, SERVICE TOOLS, for part numbers of general service
STEERING SYSTEM SCHEMATIC. Renew all tools and adhesives required. These tools are available
'O' rings where used. from your dealer.

* * * *

2 SM 2191 1-03
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
SM - 2828 closed. As the main pump starts rotating it builds up
residual pressure and the priority valve opens, feeding
the main pump pressure through to the fan drive (17 &
18) & body tipping (5 & 29) 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 (15) 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 (21 &
25) and therefore enable the main pump to meet the
Fig. 1 - Main Hydraulic Valve Assembly charging or steering pressure requirements. At the
same time the higher load sense pressure assists the
DESCRIPTION spring in the priority valve (15), the priority valve will
Numbers in parentheses refer to Fig. 2 then close to reduce the flow to the fan or body tipping
circuit and therefore making sure the brake charging &
The Main Hydraulic Valve Assembly is mounted on the steering always has priority over the other functions.
left hand side of the tractor frame next to the
transmission.
Steering Function
The Main Hydraulic Valve Assembly controls the Refer to Section 220-0000, STEERING SYSTEM
following functions;
Steering actuation pressure is controlled by steering
(a) System relief protection for main pump. load sense orifice (20).The steering load sense orifice
(b) Priority function (20) controls main pump pressure in the steering load
(c) Steering function. sense line. As pressure increases through steering
(d) Brake charging function. load sense orifice (20), main pump pressure increases
(e) Park/emergency function. lifting steering check valve (24) allowing steering
(f) Body control function. actuation pressure to access the steering orbitrol
(g) Transmission cooler fan drive. control valve.
(h) Cold start function.

Valves that control all the above functions are Emergency Steering
integrated into the Main Hydraulic Valve Assembly and Refer to Section 220-0000, STEERING SYSTEM.
are identified in Figs. 2 through 7.
The emergency valve (19) 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 (14) protects the main mounted on the transmission.
hydraulic valve assembly components against
pressure spikes. This system relief valve is pre-set at
265 bar (3850 lbf/in2 )and is non-adjustable. Brake Charging Function
Refer to Section 250-0000, BRAKE SYSTEM.

Priority Function Brake charge valve (8) and brake pressure reducer
This function automatically ensures that the steering valve (7) are integral valves that form part of the brake
and brake charging circuits are given preference over charging function. Brake charge valve (8) ensures that
the fan and body tipping functions. there is sufficient load sense pressure to the main
pump to allow the charge pressure to be generated.
When the pump is not running, the priority valve (15) is Brake pressure reducer valve (7) maintains a safe

SM 2192 Rev 2 5-04 1


2
1 5

3 4
2
Section 215-0050

47
8 9 33

6 7

13
10 11

12 44 30

16
14
17
45
15 18 32

31 31

19 21 22
46
20
25

24
23
26

29
27

1 - Orifice 10 - Check Valve 19 - Emergency Steer Valve 29 - Proportional Pressure Control Valve
2 - Bleed Down Sequence Valve 11 - Orifice 20 - Orifice 44 - Orifice
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly

3 - Check Valve 12 - Orifice 21 - Shuttle Valve 45 - Orifice


4 - Check Valve 13 - Float Solenoid 22 - Shuttle Valve 47 - Relief Valve
5 - Proportional Pressure Control Valve 14 - Relief Valve 23 - Check Valve
6 - Park/Emergency Brake Solenoid 15 - Priority Valve 24 - Check Valve
7 - Pressure Reducing Valve 16 - Cold Start Solenoid 25 - Shuttle Valve
8 - Brake Charge Valve 17 - Hydraulic Proportional Control Valve 26 - Body System Relief Valve
9 - Pressure Reducing Valve 18 - Pressure Compensating Valve 27 - Emergency Steer Relief Valve
SM2918

Fig. 2 Main Hydraulic Valve Assembly Schematic - Based on Engine Shutdown

SM 2192 Rev 2 5-04


MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
operating pressure within the front and rear brake transmission oil temperature reaches 90C (195F).
accumulators.
The hydraulic ECU receives an electrical signal from
the transmission cooler fan drive temperature switch,
Park/Emergency Brake Function mounted on the transmission retarder housing. Once
Refer to Section 250-0000, BRAKE SYSTEM. an electrical signal reflecting a transmission oil
temperature of 90C (195F) has been received, the
Park/Emergency brake solenoid (6) is the integral valve hydraulic ECU sends a signal to de-energise the fan
that controls hydraulic pressure to the park and drive solenoid valve, allowing actuation pressure to
emergency brake function of the truck. access the fan drive circuit. This fan drive solenoid
valve is a fail safe system. If power or connection is
lost the fan drive solenoid valve will de-fault to the
Body Control Function open (de-energised) condition.
Refer to Section 230-0000, BODY SYSTEM
The hydraulic ECU (Refer to Section 190-0085) sends
Proportional pressure control valve (5) is the integral an electrical signal from Pin C1:24 to the fan drive
valve that controls the body tipping function. This valve solenoid valve. This signal de-energises the fan drive
is operated via the body control lever located in the solenoid, opening the transmission cooler fan drive
operators cab. The body control lever sends an circuit.
electrical signal to the hydraulic ECU. (Refer to Section
190-0085). The hydraulic ECU processes this signal The transmission cooler fan speed pressure is
and delivers an actuating electrical signal to the controlled by the Electro-Hydraulic Proportional Control
proportional pressure control valve (5). The proportional Valve (17). A varying current input into this valve of
pressure control valve (5) converts this electrical signal between 150 to 210 mA controls the pressure between
into a pilot pressure, that then is allowed to stroke the 34 bar (490 psi) and 87 bar (1260 psi). This pressure
body control spool to the lift position. then acts upon the Shuttle Valve (22) and onto the
main pump load sense connection via Shuttle Valve
Proportional pressure control valve (29) is the integral (25). This pressure acts upon the spring chamber of
valve that controls the body lower function. This valve the Logic Valve (18) that controls the pressure at the
is operated via the body control lever located in the fan.
operators cab. The body control lever sends an SM2829
1
electrical signal to the hydraulic ECU (Refer to Section
190-0085). The hydraulic ECU processes this signal
and delivers an actuating electrical signal to the
proportional pressure control valve (29). The
proportional pressure control valve (29) converts this
electrical signal into a pilot pressure, that then is
allowed to stroke the body control spool to the lower 2
position.

Body relief valve (47) is located on the raise side of the


circuit and prevents pressure spikes at maximum
extension of the cylinders when the body is raised at
maximum engine speed. Relief valve (47) is set at 230
bar (3 335 lbf/in2 ).

3
Transmission Cooler Fan Drive
The transmission cooler fan speed is modulated by
proportionally controlling the pressure at the fan motor.
Fan speed is a function of the pressure at the fan RHS
motor. 1 - Transmission Oil Temp. Sender
2 - Trans. Cooler Fan Drive Temp. Switch
On a cold start, the transmission cooler fan will not 3 - Retarder Oil Temperature Switch
rotate. A fan drive solenoid valve, mounted on the right
hand fender next to the transmission cooler, will remain Fig. 3 - Trans. Cooler Fan Drive Temperature Switch
closed, blocking actuating pressure until the
SM 2192 Rev 2 5-04 3
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050

Trans. Cooler Fan Drive Temperature Switch - Typical Analog Outputs (Mv) Vs' Oil Temperature (C)

Temp.(C) 20 25 35 50 70 90 95 120 140 150

Mv. 900 780 760 330 170 95 80 40 35 0

The hydraulic ECU receives an analog input from the Cold start solenoid (16) energises when starter motor
Transmission Cooler Fan Drive Temperature Switch at signal is high, this dumps all load sense pressure from
Pin C1:3. The temperature sensor output is calibrated the main hydraulic pump, rendering the pump off-load.
against actual temperature within the hydraulic ECU. This reduces parasitic losses during engine cranking
The hydraulic ECU converts the analog signal into a procedure.
varying current output. This varying current output,
from Pin C1:19, controls Electro-Hydraulic Proportional There is about a 2 second delay before de-energising
Control Valve (17) increasing and decreasing pressure cold start solenoid (16) (starter motor signal low). This
at the fan motor. The fan speed increases and de- function prevents brake charging during engine start
creases proportionally between transmission oil up, which is particularly important in cold climates.
temperatures of 90 to 140C (195 to 285F).
A starter motor high signal is received by the hydraulic
The Fan Drive Solenoid will remain de-energised until ECU at Pin C1:9. The hydraulic ECU converts this high
the transmission oil temperature falls to 87C (188F). signal into digital output signal at Pin C1:22, energising
At this point the oil flow to the transmission cooling fan the cold start solenoid (16). The signal to energise the
will stop. cold start solenoid (16) will remain on until a starter
motor low signal is received by the hydraulic E.C.U. at
Refer to troubleshooting charts. Pin C1:9, this will negate the digital output signal from
Pin C1:22.
(Refer to section 190-0085 for full Hydraulic E.C.U.
Cold Start Function detail.)
Cold Start Solenoid (16) is the integral valve that
controls the cold start function of the Main hydraulic
valve assembly
SM2833

16

16 - Cold Start Solenoid


17 - Hydraulic Proportional Control Valve
18 - Pressure Compensating Valve
22 - Shuttle Valve
44 - Orifice
45 - Orifice

Valve (16) Coil Rating


Ohms Amps Watts
42 0.6 15
44
Voltage: 24V
45 Valve (17) Coil Rating
Ohms Amps Watts
22
25 0.9 21
17 Voltage: 24V

18

Fig. 4 - Main Hydraulic Valve Assembly - Transmission Cooler Fan Valves/Cold Start Solenoid

4 SM 2192 Rev 2 5-04


MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
SM2834

25

15 15 - Priority Valve
21 - Shuttle Valve
25 - Shuttle Valve

21

Fig. 5 - Main Hydraulic Valve Assembly - Transmission Cooler Fan Valves

Transmission Cooler Fan Drive Trouble Shooting


Symptom Possible Cause Remedy
Fan will not rotate once transmission Hydraulic E.C.U. no receiving Replace transmission cooler fan
oil temperature is >90C (195F). appropriate signal from transmission drive temperature switch. (Ref. Fig.
cooler fan drive temperature switch, 3)
when transmission oil is >90C
(195F).

Fan drive solenoid, located on right (a) Check signal from hydraulic
hand fender remains closed. E.C.U. - Pin C1:24. Should be
low signal.
(b) Check electrical connections.
(c) Replace fan drive solenoid.

Check for output fault at hydraulic Ref. Output from Pin C1:19. Ref.
E.C.U. Section 190-0085 Hydraulic E.C.U.

Fan control logic valve (18) sticking in Replace fan control logic valve (18).
the open position.

Contamination in load sense orifices Disconnect fan at main hydraulic


(44 &45) and/or shuttle valves (22 & valve assembly and plug port DF.
25). Raise and lower the body several
times to flush out system. If this is
unsuccessful, replace main
hydraulic valve assembly.

SM 2192 Rev 2 5-04 5


MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050

Transmission Cooler Fan Drive Trouble Shooting


Symptom Possible Cause Remedy
Fan will not modulate its speed over Residual current at hydraulic Check current at valve (17).
the desired temperature range. proportional valve (17).

No voltage at hydraulic proportional (a) Check electric connections at


valve (17). valve (17).
(b) Check annalog signal from
Trans. Cooler Fan Drive
Temperature Switch.
(c) Check output signal from
Hydraulic E.C.U. Pin C1:19.

Fan Proportional Solenoid Valve(17) Replace Valve(17).


Faulty.

Contamination or Air in Load Sense Disconnect the fan and plug port
Drillings or Shuttle Valves (22 & 25) DF. Raise and lower the body
several times to flush out the
system. If this does not work
change the whole manifold block.

Fan Pressure Modulating Valve(18) Replace valve(18).


Faulty

Contamination in Orifices(44 & 45) Clean Orifices (44 & 45).


Fan Speed too low. Fan Proportional Solenoid(17) Faulty. Replace Valve(17).

Faulty Fan Motor. Replace Fan Motor. Ref. Section


210-0060 Transmission Oil Cooler

Fan unstable over the speed range Orifices(44 or 45) Blocked. Clean Orifices
when another function is selected.
Fan Proportional Pressure Solenoid Replace Valve(17)
(17) Faulty.

Fan Pressure Modulating Logic Replace Valve(18)


Valve(18) Faulty.
Check Main Pump setting. Ref.
Section 230-0050 Main Hydraulic
Pump

6 SM 2192 Rev 2 5-04


MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050

REMOVAL 7. Disconnect mounting hardware securing main


hydraulic valve assembly to vehicle.
WARNING
To prevent personal injury and property DISASSEMBLY
damage, be sure wheel blocks, blocking
All integral valves on the main hydraulic valve
materials and lifting equipment are properly
assembly can easily be removed. On removal of all
secured and of adequate capacity to do the job
integral valve assemblies, clean and examine for wear
safely.
or damage.
1. Position the vehicle in a level work area, apply the
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.

WARNING ASSEMBLY
Accumulators are charged with Nitrogen. The
All integral valves must be re-installed into correct
service pressure is 95 bar (1380 lbf/in) at 20 C
locations on the main hydraulic valve assembly. All
(68o F). To prevent personal injury and property
integral valves must be torqued to correct value.
damage do not attempt to remove any valves or
fittings until all nitrogen pressure is completely
1. Re-install O.R.F.S. connectors into correct ports.
relieved.
Replace o-rings and seals. Ref. Fig. 6
SM - 1335
2. Block all road wheels and place battery master
switch in the 'Off' position. FITTING NUT
TUBE
3. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose on
remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
hose and reinstall blanking cap.

4. Main hydraulic valve assembly is accessed by


SLEEVE
raising the operator cab. (Refer to Section 260-0010, 'O' RING 'O' RING
CAB AND MOUNTING.)
Fig. 6 - Assembly of Typical ORFS Connector
WARNING 2. Install M10 eye bolt into clamp mounting hole at port
Never work under or near an unsupported 'T' located on top of main hydraulic valve assembly.
raised operator cab assembly. Always ensure Support main hydraulic valve assembly with suitable
cab safety prop is in correct position. lifting equipment, using eye bolt.

5. Clean outer area of the main hydraulic valve 3. Manoeuvre main hydraulic valve assembly into
assembly with a suitable cleaning solvent. Ensure all position and secure to vehicle with mounting hardware.
hydraulic lines connected to the main hydraulic valve
assembly are identified for ease of installation. With 4. Remove blanking caps from all hydraulic lines and
suitable containers catch any oil leakage when fittings. Re-connect hydraulic lines to correct fittings
disconnecting hydraulic lines. Install blanking caps to astagged at removal.
all open lines and fittings.
5. Lower operator cab and secure. Ref. Section 260-
6. Install M10 eye bolt into clamp mounting hole at port 0010, CAB AND MOUNTING.
'T' located on top of main hydraulic valve assembly.
Support main hydraulic valve assembly with suitable 6. Fill hydraulic tank with hydraulic oil as described in
lifting equipment, using eye bolt. Section 300-0020, LUBRICATION SYSTEM. Ensure

SM 2192 Rev 2 5-04 7


MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
arear around fill area is clean. Install filler cap on 9. Bleed brake system after main hydraulic valve
hydraulic tank. 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.

8. Check hydraulic tank oil level and replenish if


required.
Main Hydraulic Valve Assembly - Integral Valve Tightening Torques

Valve No. Description Qty. Tighten Torque Nm

2 Directional Control Bleed Down Valve 1 50

3 Check Valve 1 30

4 Check Valve 1 30

5 Body Raise Solenoid Valve 1 3

6 Park Brake Valve 1 30

24 Volt Coil 1 3.5

Coil Nut 1 3.5

7 Brake Accumulator Pressure Valve 1 60

8 Brake Pressure Low Setting 1 60

9 Servo Pressure Reducing Valve 1 60

10 Check Valve 1 30

11 M6 Orifice Screw 1 3

12 M6 Orifice Screw 1 3

13 Float Solenoid Valve 1 30

24 Volt Coil 1 3

Coil Nut 1 3

14 Shock Relief Valve (265 Bar) 1 60

15 System Press. Generating Logic Valve 1 40

16 Cold Start Solenoid Valve 1 30

24 Volt Coil 1 3

Coil Nut 1 3

8 SM 2192 Rev 2 5-04


MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
Main Hydraulic Valve Assembly - Integral Valve Tightening Torques

Valve No. Description Qty. Tighten Torque Nm

17 Fan Proportional Press. Control Valve 1 60

CoilNut 1 3.5

18 Fan Control Logic Valve 1 115

19 Emergency Steering Valve 1 100

20 Steering Pressure LS Orifice 1 115

21 Shuttle Valve 1 10

22 Shuttle Valve 1 10

23 Check Valve 1 100

24 Check Valve 1 100

25 Shuttle Valve 1 10

26 Body Raise LS Relief Valve 1 10

27 Emergency Steering Relief Valve 1 60

29 Body Lower Solenoid Valve 1 3

31 Plug G1/8 3 15

32 Plug G1/4 1 30

33 Plug G3/8 3 45

34 Plug 9/16 UNF 1 30

35 Plug G1/4 1 30

40 Nut M12 3 80

44 M6 Orifice Screw 1 3

45 M6 Orifice Screw 1 3

46 M6 Orifice Screw 1 3

47 Relief Valve 1 80

SM 2192 Rev 2 5-04 9


MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050

SM2919
1 - Orifice 4 32 26 7
9
2 - Bleed Down Sequence Valve
3 - Check Valve 24
4 - Check Valve 3
5 - Proportional Pressure Control Valve 11
6 - Park/Emergency Brake Solenoid
7 - Pressure Reducing Valve
8 - Brake Charge Valve
9 - Pressure Reducing Valve
10 - Check Valve
11 - Orifice 16
12 - Orifice 13 10/12
13 - Float Solenoid
14 - Relief Valve 2
15 - Priority Valve
16 - Cold Start Solenoid 34
17 - Hydraulic Proportional Control Valve 20
18 - Pressure Compensating Valve
19 - Emergency Steer Valve
20 - Orifice 6
21 - Shuttle Valve
22 - Shuttle Valve
23 - Check Valve
24 - Check Valve 29
44
25 - Shuttle Valve
26 - Body System Relief Valve
27 - Emergency Steer Relief Valve
45
29 - Proportional Pressure Control Valve
5 22/46
44 - Orifice
45 - Orifice
47 - Relief Valve 17
18

31 8
19 27
33
23

35 14

25

15

21

47

Fig. 7 - Main Hydraulic Valve Assembly - Integral Valve Positions

10 SM 2192 Rev 2 5-04


STEERING SYSTEM - Steering System Schematic
Section 220-0000
SM - 2842

1 - Steering Orbitrol Valve


2 - Steering Cylinders
2 2 3 - Emergency Steering Pump
4 - Main Hydraulic Pump

L R Integral Valves to Main Hydraulic Valve Assembly


1 14 - Relief Valve
15 - Priority Valve
19 - Emergency Steer Valve
20 - Steering Load Sense Orifice
23 - Check Valve
24 - Check Valve
25 - Shuttle Valve
27 - Emergency Steering Relief Valve

T LS P

14

15

19 21

20
25

24
23

27

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 (1) 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 2197 2-03 1
STEERING SYSTEM - Steering System Schematic
Section 220-0000

Steering Cylinders (2) 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 transmission cooler fan and tipping
rod can have oil applied to either side, extending or functions.
retracting the piston rod.
When the main pump (4) is not running, the priority
Cylinder mounting is by pins, spacers, seals and, valve (15) is closed. As the main pump (4) starts
spherical bearings secured with circlips. Spherical rotating it builds up residual pressure entering the main
bearings permit a limited amount of cylinder hydraulic valve assembly at port P1. The pressure
misalignment when travelling over rough terrain. opens priority valve (15), feeding the main pump
pressure through to the transmission cooler fan drive &
lift valve.
Emergency Steering Pump (3)
The emergency steering ground driven pump, mounted During the tipping operations and whilst the
on the transmission, provides flow to the steering transmission cooler fan is running, if the demand
circuit in the event that the Main Pump (4) can no pressure at the brake charging or the steering circuit is
longer function effectively. less than these functions, the priority valve (15)
remains open, but the oil takes the path of the least
resistance and the requirements of the brake charging
Main Hydraulic Pump (4) or steering circuits are met.
Refer to Section 230-0050, MAIN HYDRAULIC PUMP.
If the demand pressure for brake charging or steering
Mounted off the transmission power takeoff, the main circuit is higher than that demanded by the
hydraulic pump supplies hydraulic oil for operating the transmission cooler fan drive or tipping function, this
steering, body, brakes and transmission cooler fan higher pressure will be fed to the main pump load
drive circuits. sense line via the shuttle valves (21 & 25) and
therefore enable the main pump (4) to meet the brake
The main hydraulic pump is an axial piston, variable charging or steering circuit pressure requirements. At
displacement type, with load sense and pressure the same time the higher load sense pressure assists
regulator. the spring in the priority valve (15). The priority valve
(15) will then close to reduce the flow to the
transmission cooler fan or tipping circuit and therefore
Valves 14, 15, 19, 20, 23, 24, 25 & 27 making sure the brake charging & steering circuit
These valves for part of the steering and emergency always has priority over the other vehicle functions.
steering circuit and are an integral part of the main
hydraulic valve assembly, mounted on the left hand
side of the tractor frame. Refer to Section 215-0050, PRIORITY FLOW CONTROL TO
MAIN HYDRAULIC VALVE ASSEMBLY. STEERING

This function ensures that the flow from the steering


Diagnostic Test Point
valve (1) is maintained at all times regardless of the
Steering and load sense pressures can be checked at other pressure demand within the system.
the diagnostic check points located inside the battery
box. Refer to Fig. 2. To achieve this function the pressure at the steering
valve (1) has to be at a level equal to that demanded
Steering system pressure is set at 240 bar (3500 lbf/ by the steering plus the differential control pressure set
in2) by the steering valve.

Load Sense (LS) pressure is set 25 bar (360 lbf/in2) The pressure demanded by the steering is fed back to
below steering system pressure, i.e. at maximum the main pump (4) & the priority valve (15) via shuttle
setting LS pressure will be 215 bar (3120 lbf/in2).

2 SM 2197 2-03
STEERING SYSTEM - Steering System Schematic
Section 220-0000
valve (21). The priority valve (15) will close & the main Check valve (24) prevents the emergency steer flow
pump will increase its displacement to make sure there going towards the main pump (4), which may already
is enough flow & pressure available to meet that have failed.
demanded by the steering.

The steering load sense orifice (20) feeds oil from the STEERING PRESSURE SETTING
main pump supply, to boost the load sense pressure
back to the main pump during the steering operation. WARNING
This is to make sure an adequate flow is always Machine has to fully articulate to set steering
available from the main pump (4) to meet that pressure, therefore steering lock bar cannot be
demanded by the steering. This is commonly known as 'Locked'. To prevent personal injury and
a dynamic load sense system. property damage, exercise extreme caution
while working around articulation and
Note: The maximum steer pressure is set by the oscillation pivot area.
pressure cut off (compensator) on the main hydraulic
pump (240 bar (3500 lbf/in2)). Refer to Section 230- The maximum steer pressure is set by the pressure
0050 MAIN HYDRAULIC PUMP. cut off (compensator) on the main pump (240 bar (3500
lbf/in2)). Refer to Section 230-0050, MAIN HYDRAULIC
PUMP.
EMERGENCY STEERING
The emergency steering ground driven pump (3) Steering pressure can be checked at the diagnostic
provides flow to the steering circuit in the event that check point located inside the battery box (refer to Fig.
the main pump (4) can no longer function effectively. 2). Install pressure gauge capable of reading at least
240 bar (3500 lbf/in2) to correct diagnostic check point.
Engine failure, transmission failure or internal failure of
the main pump (4) could cause ineffective Steer truck over relief (against steering stops) to
performance. observe maximum cut-off pressure of 240 bar (3500
lbf/in2). Adjust pressure cut-off screw on main pump (4)
The emergency steering pump (3) will also assist with if necessary. Refer to Section 230-0050, MAIN
flow from the main pump to articulate the vehicle if the HYDRAULIC PUMP.
main pump cannot deliver the flow required by the SM - 2849
steering circuit. This can happen at low engine speed
when the vehicle is moving and the operator attempts
to articulate the vehicle rapidly.

To protect the ground driven emergency steering pump


(3) the maximum pressure at the pump is set by the
relief valve (27) to 179 bar (2600 lbf/in2). 1
2
P
The emergency steering valve (19) is sensing the main FB 3
pump (4) pressure and the load sense pressure at the RB 4
spring end of the valve (19). During normal operation
5
the differential pressure between the main pump (4)
6
outlet and the load sense line will be approximately 25
bar (360 lbf/in2) and the emergency steering valve (19) 7

will stroke against its spring dumping the emergency 8


steer pump (3) flow to tank. 9

In the event of the main pump (4) not been able to


supply sufficient flow for the steering, the differential
pressure between the main pump (4) outlet and the 1 - Pump LS Pressure 7 - Trans. Converter Press.
load sense line will be reduced. As soon as the 2 - Front Brake Pressure 8 - Body System Press.
differential pressure drops below 8.5 bar (125 lbf/in2) 3 - Rear Brake Pressure 9 - Trans. System Pressure
4 - Park Brake Pressure P - Primary Accumulator
the emergency steering valve (19) will close and the 5 - Steering Pressure FB - Front Brake Accumulator
ground driven pump (3) flow will be diverted across 6 - Trans. Retarder Press. RB - Rear Brake Accumulator
check valve (23) and supply the steering system. Fig. 2 - Diagnostic Pressure Check Points (Battery Box)

SM 2197 2-03 3
STEERING SYSTEM - Steering System Schematic
Section 220-0000

24

20

19 27

23

14

25

15

14 - Relief Valve
15 - Priority Valve 21
19 - Emergency Steer Valve
20 - Steering Load Sense Orifice
23 - Check Valve
24 - Check Valve
25 - Shuttle Valve
27 - Emergency Steering Relief Valve

Fig. 3 - Steering System Valves Integral to Main Hydraulic Valve Assembly

4 SM 2197 2-03
STEERING SYSTEM - Steering System Schematic
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.
allowed to adopt a natural position.
Hydraulic Oil
d. Where a tube is fitted, ensure that the connection is
aligned correctly. The steering system should be kept filled with
hydraulic oil as listed in Section 300-0020,
e. Tighten the nut a further 1/4 to 1/2 a turn using the LUBRICATION SYSTEM.
correct size spanner (wrench).
MAINTENANCE
f. Check that a satisfactory hose or tube routing has
been achieved. Maintenance instructions, intervals and warnings, in
the individual steering and body hydraulic component
SM - 1335 sections of this manual, should be adhered to at all
times.
FITTING NUT
TUBE
SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, SERVICE
SLEEVE TOOLS, for part numbers of these tools.
'O' RING 'O' RING

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/in.
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.
Non-contact Infrared Thermometer
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 2197 2-03 5
STEERING SYSTEM - Steering System Schematic
Section 220-0000
simply aim, pull the trigger, and read the temperature. O' Ring Face Seals (ORFS) - Seal Kit
Since there is no need to touch what you are
The steering system utilizes 'O' Ring Face Seal
measuring, temperatures of hard-to-reach or moving
(ORFS) connectors. An ORFS kit, 15271082, is
components can be taken without getting burned or
available. This kit contains a minimum stock
shocked.
requirement of all sizes of ORFS type seal.

Steering System Trouble Shooting


Symptom Possible Cause Remedy
System does not reach the maximum Fault with main pump or pressure cut- Refer to Section 230-0050, MAIN
operating pressure off incorrectly set HYDRAULIC PUMP

Faulty relief valve (14) Replace valve (14)

Priority valve (15) sticking open or Replace valve (15)


wrong spring setting

Fault in LS orifice (20) Replace/clean orifice (20)

Heavy steering due to not enough Fault with main pump or standby Refer to Section 230-0050, MAIN
flow being available at the steering pressure incorrectly set HYDRAULIC PUMP
valve but differential pressure
between the main pump outlet and Faulty steer valve Refer to Section 220-0090,
the load sense port is between 15 - STEERING VALVE
22 bar (218 - 319 lbf/in2)
Priority valve (15) - sticking open or Replace valve (15)
wrong spring setting

Fault in LS orifice (20) Replace/clean (20)

Leaking shuttle valve (21) Replace valve (21)

No steering flow available whilst the Ground driven pump faulty Replace ground driven pump at
vehicle is still travelling and engine is transmission.
switched off
Emergency steer valve (19) sticking Replace valve (19)
open

Emergency steer relief valve (27) Replace valve (27)


pressure setting too low.

With no functions operated pressure Emergency steer valve (19) spool Replace valve (19)
at ground driven pump too high. sticking closed.

6 SM 2197 2-03
STEERING SYSTEM - Steering Valve
Section 220-0090

SM - 2016

12 11 10 8 16 7 6 5 4

1
15

19

2
17

18 14

20 13 9 3

1 - Capscrew 7 - Valve Housing 13 - Bearing Race 19 - Gerotor Gear


2 - End Cap 8 - Sleeve 14 - 'O' Ring 20 - Retainer
3 - 'O' Ring 9 - Ball - Check 15 - Dust Seal 21 - 'O' Ring
4 - Gerotor Housing 10 - Pin 16 - Spool 22 - 'O' Ring
5 - Spacer Plate 11 - Centring Springs 17 - Seal 23 - Roll Pin
6 - Driveshaft 12 - Needle Bearing 18 - Backup Ring 24 - Ball valve

Fig. 1 - Sectional View of Steering Valve

DESCRIPTION the road shock, to the opposite end of the cylinders.


Numbers in parentheses refer to Fig. 1. This shock, if left unchecked, might damage steering
linkage components.
The steering valve can be identified as item 1 in Section
220-0000, STEERING SYSTEM SCHEMATIC. The main components of the steering valve are valve
housing (7), gerotor housing (4), gerotor gear (19),
The steering valve, mounted off the underside of the driveshaft (6), sleeve (8) and spool (16).
cab floor and connected to the steering column,
controls hydraulic flow in the steering system. The There are five ports on valve housing (7) as follows:
steering valve is of a closed centre design, which
means that the valve does not have any flow through it Port 'P' - Supply from main hydraulic valve
when it is in the neutral or no steering position. The Port 'T' - Return to tank
steering valve has integral cylinder relief valves which Port 'R' - Cylinder supply for right hand turn
relieve shock loads on the steering cylinders by Port 'L' - Cylinder supply for left hand turn
transferring excessive pressure applied to the oil by Port 'LS' - Load Sensing to main hydraulic valve

SM 2193 1-03 1
Steering System - Steering Valve
Section 220-0090
Turning action of the steering wheel is transmitted SM - 282
through the steering column to sleeve (8) and
POCKETS
driveshaft (6), which is fastened to the sleeve with
centring pin (10). Rotation of driveshaft (6) causes
gerotor gear (19) to rotate in gerotor housing (4).
When gerotor gear (19) rotates, oil in gerotor housing
(4) pockets (see Fig. 2) is forced out and flows through
spool (16) and sleeve (8) to the steering cylinder port.

Spool (16) contains porting matched to sleeve (8) and


rotates within sleeve (8) to provide directional control
of the oil. See Fig. 3.
GEROTOR HOUSING GEROTOR GEAR

OPERATION Fig. 2 - Gerotor Gear Set


Numbers in parentheses refer to Fig. 1.
SM - 283

When the operator turns the steering wheel a certain RIGHT LEFT
number of degrees for either a left or right hand turn, SYSTEM TURN TURN
the movement is transmitted through the steering PRESSURE FEED FEED
column to spool (16). After a minimum rotation of 2.5 METER TO
PORTS TANK
degrees, the ports in spool (16) start to align with ports
in sleeve (8). When the steering wheel is rotated to a
maximum of 10 degrees the ports are fully aligned
allowing full oil flow. After 10 degrees of travel in either
direction the spool and sleeve rotate as an assembly
through centring pin (10).

Oil from the priority valve flows into valve housing (7)
at port 'P' and is channelled through sleeve (8) and
spool (16) to gerotor housing (4). Porting in gerotor
housing (4) permits oil to flow into pockets formed by Fig. 3 - Porting of Spool and Sleeve
gerotor housing (4) and gerotor gear (19). As spool
(16) rotates, driveshaft (6) also rotates which, in turn, REMOVAL
rotates gerotor gear (19) to which it is splined. When
gerotor gear (19) rotates it progressively forces oil out Numbers in parentheses refer to Fig. 4.
of the pockets (see Fig. 2) of gerotor housing (4). The
oil is channelled through sleeve (8) and spool (16) and
exits valve housing (7) through port 'R' for a right hand WARNING
turn, or port 'L' for a left hand turn. Oil then travels To prevent personal injury and property
through steering lines to the steering cylinders. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
As the steering cylinder pistons move, oil forced out of secured and of adequate capacity to do the job
the steering cylinders returns to valve housing (7). The safely.
return oil passes through valve sleeve (8) and spool
(16) and exits through port 'T' to tank. 1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering
When the steering effort is released, centring spring wheel several times to relieve any pressure in the
(11) which was put under tension by the rotation of steering circuit. Operate brake pedal continuously to
spool (16), forces sleeve (8) to rotate back to its relieve pressure in the braking system.
original position. This puts the ports out of alignment
and stops pump oil flow to the steering cylinders. The 2. Block all road wheels and place the battery master
vehicle stops turning further but will hold the present switch in the 'Off' position.
turning radius until spool (16) is rotated past the 2.5
degree minimum. 3. Remove hydraulic tank remote drain plug and drain

2 SM 2193 1-03
Steering System - Steering Valve
Section 220-0090

SM - 2827

12 22
20 21

13

14

18

19
12

7
6 9 16
5
10
4 11 17

2 8

1 15

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 6. Slide bellows (13) over steering shaft (14) to gain
plug in hydraulic tank remote drain fitting. access to bottom joint (12) and loosen bolt which
tightens joint (12) onto stub shaft (8).
4. Pull floor mat back to allow access to bolts (7).
Raise cab and secure with prop. Refer to Section 260- 7. Support steering valve (1) and remove bolts (7),
0010, CAB AND MOUNTING. locknuts (2) and washers (3 & 6) securing mounting
plate (5) to cab floor. Remove steering valve (1) and
5. Clean outer area of steering valve (1) with a suitable mounting plate (5) to a clean area for disassembly.
solvent. Ensure all hydraulic lines connected to Remove nitrile seal (9) and discard rubber mounts (4),
steering valve (1) are identified for ease of installation if damaged.
and with suitable containers available to catch
leakage, disconnect hydraulic lines. Cap all lines and
plug all ports to prevent entry of dirt.

SM 2193 1-03 3
Steering System - Steering Valve
Section 220-0090

SM - 2017

9 11 13 12 13
16 20 14 17 18 15

3 4 19 21 5
1
22

6
8
10

24
23

1 - Capscrew 7 - Valve Housing 13 - Bearing Race 19 - Gerotor Gear


2 - End Cap 8 - Sleeve 14 - 'O' Ring 20 - Retainer
3 - 'O' Ring 9 - Ball - Check 15 - Dust Seal 21 - 'O' Ring
4 - Gerotor Housing 10 - Pin 16 - Spool 22 - 'O' Ring
5 - Spacer Plate 11 - Centring Springs 17 - Seal 23 - Roll Pin
6 - Driveshaft 12 - Needle Bearing 18 - Backup Ring 24 - Ball valve

Fig. 5 - Exploded View of Steering Valve

DISASSEMBLY SM - 2018

Numbers in parentheses refer to Fig. 5, unless


otherwise specified. 19

Note: Steering valves fitted with anti-cavitation valves


must be disassembled and assembled in the vertical
postion to prevent ball valves (24) becoming trapped in
the wrong cavities within the valve housing (7).

1. Remove bolts (10, Fig. 4) and washers (11, Fig. 4)


securing mounting plate (5, Fig. 4) to steering valve (1,
Fig. 4).

2. Clamp steering valve assembly horizontally in a soft 19 - Gerotor Gear


jawed vice and break loose the seven capscrews (1).
With capscrews (1) loosened, place steering valve Fig. 6 - Gerotor Gear and Splined Drive Engaged

4 SM 2193 1-03
Steering System - Steering Valve
Section 220-0090

SM - 2019 vertically in vice, end cap (2), up.

11 Note: Hidden pin. If tension on this pin is released


19
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)


10 from valve housing (7). Remove and discard 'O' ring
10 - Pin 19 - Gerotor Gear (21) from gerotor housing (4).
11 - Centring Springs
Fig. 7 - Compressing Centering Spring 5. Remove spacer plate (5) from valve housing (7).

6. Remove and discard 'O' ring (22) from valve


SM - 2020
housing (7).

19 7.Using a cloth to protect the hand, place gerotor gear


(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
spring (11) radially CW or CCW, decreasing the coil
diameter of the centering spring (11) allowing spool
and sleeve assembly to be removed. Refer to Fig. 7.

9. With drive held stationary and centering spring (11)


19 - Gerotor Gear compressed, carefully push spool (16), sleeve (8), ball
checks (9), drive shaft (6), pin (10), bearing races (13),
Fig. 8 - Removing Spool and Sleeve Assembly retainer (20) and needle thrust bearing (12), as a complete
assembly, from valve housing (7). Refer to Fig. 8.
SM - 2021
10. Remove bearing race (13) and needle thrust
bearing (12) from spool and sleeve assembly.
6 8 11 13
20 11. Using suitable pliers, remove retainer (20) and
bearing race (13) from spool (16) and sleeve (8)
assembly. Refer to Fig. 9.

12. Remove centering spring (11) from spool (16) and


sleeve (8) assembly. Refer to Fig. 9.

13. Remove pin (10) and slide drive shaft (6) from
spool (16) and sleeve (8) assembly. Refer to Fig. 9.

9 9 10 16 14. Carefully remove spool (16) and ball checks (9)


from sleeve (8). Refer to Fig. 9.
6 - Driveshaft 11 - Centring Springs
8 - Sleeve 13 - Bearing Race 15. Use a soda straw as a guide tool to remove the roll
9 - Ball - Check 16 - Spool
10 - Pin 20 - Retainer pin (23) and ball valve (24) from the anti-cavitation
valve ports. Insert two soda straws, one in each anti-
Fig. 9 - Sectional View of Spool and Sleeve Assembly cavitation valve bore. Remove valve housing (7) from

SM 2193 1-03 5
Steering System - Steering Valve
Section 220-0090

SM - 2022 vice and tilt until roll pins (23) and ball valves (24) slide
PORT FACE through the straws and out of the valve housing (7).
Refer to Fig. 10.

16. Remove and discard 'O' ring (14), seal (17) and
backup ring (18) from valve housing (7).
PORT
FACE
17. Using a thin blade screwdriver, pry dust seal (15)
from valve housing (7). Take care not to damage dust
seal seat.
TOP
VIEW

24
INSPECTION
Anti-Cavitation Valves -
Insert Soda Straws (2), 1. Clean all metal parts in a suitable solvent and blow
one into each of these dry with compressed air. Do not wipe dry with cloth or
two threaded holes. 23 paper towel as lint or other matter may get into the
hydraulic system and cause damage.

TILT 2. Check all mating surfaces and replace any parts that
HOUSING have scratches or burrs that could cause leakage.

SODA STRAW 3. Do not use course grit or try to file any metal parts.

Note: Replace all 'O' rings and seals with new 'O' rings
23 - Roll Pin
24 - Ball Valve
and seals at 'Assembly'. Lubricate all 'O' rings and
seals with a petroleum jelly.
Fig. 10 - Removing Ball Valves

ASSEMBLY
SM - 2023
PORT FACE Numbers in parentheses refer to Fig. 5, unless
otherwise specified.
23

Note: Tighten all fasteners without special torques


specified to standard torques listed in Section
24 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.

GUIDE TOOL Note: Steering valves fitted with anti-cavitation valves


(Soda Straw)
must be disassembled and assembled in the vertical
postion to prevent ball valves (24) becoming trapped in
the wrong cavities within the valve housing (7).
Anti-Cavitation Valves
1. Use a soda straw as a guide tool to insert the roll pin
(23) and ball valve (24) into the anti-cavitation valve
ports. Insert soda straw into anti-cavitation valve bore.
Drop ball valve (24) through straw into bore. Remove
straw and drop roll pin (23) into bore. Repeat for
second anti-cavitation valve bore. Refer to Fig. 11.

2. Apply a light coating of clean hydraulic fluid to spool


(16). Slide spool (16) and ball checks (9) into sleeve
23 - Roll Pin (8). Refer to Fig. 12.
24 - Ball Valve
Fig. 11 - Installing Ball Valves

6 SM 2193 1-03
Steering System - Steering Valve
Section 220-0090
SM - 2024 SM - 2027

6 8 11 13

6 8
16

10
6 - Drive Shaft
8 - Sleeve
9 - Ball Check
10 - Pin 9 9 10 16
16 - Spool
9
Fig. 12 - Installing Spool and Ball Checks

SM - 2025

17
6 16
18
6 - Drive Shaft
20
8 - Sleeve
9 - Ball Check 12 14
8 10 10 - Pin
11 - Centring Springs 16 - Spool
12 - Needle Bearing 17 - Seal
6 - Drive Shaft 10 - Pin 13 - Bearing Race 18 - Backup Ring
8 - Sleeve 16 - Spool 14 - 'O' Ring 20 - Retainer
Fig. 13 - Installing Centring Pin and Drive Shaft Fig. 15 - Sectional View of Seals and Bearings

SM - 2026 end of spool (16). Compress centring spring (11)


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.

6. Apply a light coating of petroleum jelly to the inside


11 16 13 20 diameter of dust seal (15) and install in valve housing (7).

7. Apply a light coating of petroleum jelly to needle


11 - Centring Springs 16 - Spool thrust bearing (12), bearing race (13), 'O' ring (14),
13 - Bearing Race 20 - Retainer
seal ring (17) and backup ring (18). Install each item
Fig. 14 - Installing Bearing Race and Retainer onto spool (16), as shown in Fig. 15.

Note: Needle thrust bearing is positioned between the


3. Insert drive shaft (6) into spool (16) in sleeve (8) two bearing races (13) and must be centered around
carefully so that holes line up. Install pin (10) through retainer (20).
sleeve (8), spool (16) and drive shaft (6) assembly
until pin (10) becomes flush at both sides of sleeve (8). Note: Clamp steering valve housing (7) vertically in a
See Figs. 12 & 13. soft jawed vice.

4. Position one end of centring spring (11) into slotted

SM 2193 1-03 7
Steering System - Steering Valve
Section 220-0090

SM - 2028 SM - 2029

Fig. 16 - Compressing Centering Spring Fig. 17 - Installing Spool and Sleeve Assembly

SM - 2030

7
3 4 19 21 5
1
22

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

8. Using a cloth to protect the hand, place gerotor gear valve housing (7). Align bolt holes in spacer plate (5) with
(19) over end of drive shaft (6). Insert special tool tapped holes in valve housing (7). Refer to Fig. 18.
through valve housing (7) and engage with splined
end of spool (16) and sleeve (8) assembly. Twist tool 13. Lubricate and install new 'O' ring (21) in groove in
to compress centering spring (11) radially CW or spacer plate (5). Refer to Fig. 18.
CCW. Refer to Fig. 16.
14. Install gerotor housing (4) on valve housing (7).
9. Keep centering spring (11) compressed and Align bolt holes in gerotor housing (4) with tapped
carefully insert assembled parts into valve housing (7), holes in valve housing (7). Refer to Fig. 18.
as shown in Fig. 17.
15. Align gerotor gear (19) on driveshaft (6) and
10. Release tension on centering spring (11) and gerotor housing (4), as shown in Fig. 18.
remove special tool and gerotor gear (19).
16. Lubricate and install new 'O' ring (3) in groove in
11. Lubricate and install new 'O' ring (22) in groove in gerotor housing (4).
valve housing (7). Refer to Fig. 18.
17. Install end cap (2) on gerotor housing (4), as
12. Install spacer plate (5) with the 'O' ring groove up, on shown in Fig. 18.

8 SM 2193 1-03
Steering System - Steering Valve
Section 220-0090

SM - 313 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


260-0010, CAB AND MOUNTING.

7. Fill hydraulic tank with hydraulic oil, as specified in


Section 300-0020, LUBRICATION SYSTEM. Refer to
'Filling and Bleeding The Steering System'.
Fig. 19 - Cap Screw Tightening Sequence
8. Remove wheel blocks from all road wheels, place
18. Align cap screw (1) holes and install seven dry cap the battery master switch in the 'On' position and start
screws (1) in end cap (2). Pre-tighten cap screws (1) to the engine. Operate the steering and check hydraulic
17 Nm (12.5 lbf ft) then tighten to a torque of 34 Nm lines for leaks. Tighten lines and fittings as required.
(25 lbf ft), in the sequence shown in Fig. 19.

19. Using bolts (10, Fig. 4) and washers (11, Fig. 4)


FILLING AND BLEEDING THE STEERING
secure mounting plate (5, Fig. 4) to steering valve (1, SYSTEM
Fig. 4). 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
INSTALLATION system.
Numbers in parentheses refer to Fig. 4.
2. Start engine and let it idle. Immediately add oil to the
Note: Tighten all fasteners to standard torques listed hydraulic tank as required. When no more oil can be
in Section 300-0080, STANDARD BOLT AND NUT added and oil is clear, proceed as follows:
TORQUE SPECIFICATIONS.
a. Turn the steering wheel from lock to lock to bleed
Note: Tighten all hydraulic lines fitted with ORFS the air in the steering cylinders and lines.
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all Note: Immediately upon valve spool actuation oil must
'O' rings where used. be added to the hydraulic tank to replenish the oil
moving into the circuit.

WARNING
To prevent personal injury and property WARNING
damage, be sure wheel blocks, blocking Do not operate the vehicle until all air is bled
materials and lifting equipment are properly from the oil.
secured and of adequate capacity to do the job
safely. b. When the oil in the tank is clear (not cloudy or
creamy), the system is free of air.
1. Make certain area of installation is clean.
Note: Slight creep or drift of the steering wheel is normal.
2. Install rubber mounts (4) if removed, and secure
steering valve (1) and mounting plate (5) to cab floor c. Fill hydraulic tank with hydraulic oil specified in
with bolts (7), washers (3 & 6) and locknuts (2). Section 300-0020, LUBRICATION SYSTEM. Refer to
Section 230-0040, HYDRAULIC TANK, for correct fill
3. Install nitrile seal (9) to steering shaft (14). level. Install filler cap on tank.

4. Slide bottom joint (12) of steering shaft (14) over


stub shaft (8) and secure by tightening bolt. Slide
bellows (13) down over bottom joint (12) and stub
shaft (8).

SM 2193 1-03 9
Steering System - Steering Valve
Section 220-0090

SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for
details of the centring spring installation tool
referenced in this section. This tool is available from
your dealer.

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
5 1 Capscrew 34 25

STEERING CONTROL DIAGNOSIS


CONDITION REASON REMEDY
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 2193 1-03
STEERING SYSTEM - Steering Cylinder
Section 220-0120

SM - 3315

14
13

10 11 9
11 12
7 15,16 1 5
3 6
2 14
13

A 4
4
20 8 20
18 18
19 19

PART OF PART OF
FRAME FRAME
17 17

A
ORIENTATION OF
22 22
CUSHION SLEEVE

21
23

1 - Cylinder Body 7 - Wiper 12 - Piston Seal 17 - Pin


2 - Piston Rod 8 - Cushion Sleeve 13 - Spherical Bearing 18 - Hardened Washer
3 - End Cap 9 - Piston 14 - Circlip 19 - Lockwasher
4 - Lube Fitting 10 - Grub Screw 15 - Back Up Ring 20 - Bolt
5 - 'O' Ring 11 - Wear Ring 16 - 'O' Ring 21 - Spacer (0.001" thk)
6 - Rod Seal 22 - Spacer
23 - Spacer (0.140" thk)
Fig. 1 - Sectional View of Steering Cylinder and Mounting

DESCRIPTION (17), spacers (22) and spherical bearings (13) secured


with circlips (14). Spherical bearings (13) permit a
Numbers in parentheses refer to Fig. 1.
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
When the operator turns the steering wheel for a
There are two single stage, double acting cushioned
steering operation, movement of the piston rod
steering cylinders on the machine. The piston rod (2)
generates force required to pivot the tractor frame.
end is connected to the articulation and oscillation
pivot, and, the cylinder base end is connected to the
In the neutral position, with the steering valve
front frame. Single stage double acting means that
centralized, oil movement between the steering
piston rod (2) can have oil applied to either side,
cylinders and the steering valve is stopped. Trapped
extending or retracting the piston rod.
oil in the system locks both steering cylinders and the
angle of steering set by the operator is maintained.
Rod end cylinder mounting is by pins (17), spacers
Refer to Section 220-0090, STEERING VALVE, for
(21, 22 & 23) and spherical bearings (13) secured with
operation of the steering valve.
circlips (14). Base end cylinder mounting is by pins

SM 2349 10-04 1
Steering System - Steering Cylinder
Section 220-0120

REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.

WARNINGS WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure lifting equipment is properly
materials and lifting equipment are properly secured and of adequate capacity to do the job
secured and of adequate capacity to do the job safely.
safely.
1. Ensure clean working conditions, remove any port
Hydraulic fluid pressure will remain plugs thus allowing easy entry of air into the cylinder,
within the system after engine shutdown. preventing a vacuum when parts are withdrawn from
Operate the treadle pedal continuously until the cylinder body (1).
pressure has dissipated before carrying out any
work on the hydraulic system or serious injury 2. Remove circlips (14) from base end of cylinder body
could result. (1) and piston rod (2) end. Press out spherical
bearings (13).
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering 3. Using special tool which can be fabricated as shown
wheel several times to relieve any pressure in the in Fig. 2, unscrew end cap (3) until thread is
steering circuit. Operate brake pedal continuously to disengaged from cylinder body (1).
relieve pressure in the braking system.
4. Pull end cap (3) and piston rod (2) out of cylinder
2. Place steering lock bar in the 'Locked' position. body (1) 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 piston seal (12) and wear rings
one steering cylinder. Cap all lines and fittings to (11) from piston (9).
prevent ingress of dirt.
7. Remove grub screw (10) from wear ring groove in
4. Support steering cylinder with a suitable lifting piston (9).
device.
8. Provide an anti-torsion device through piston rod (2)
5. Remove bolt (20), lockwasher (19) and hardened eye to allow unscrewing of piston (9). Using special
washer (18) securing pin (17) at base end of the tool which can be fabricated as shown in Fig. 3,
cylinder. Remove pin (17) securing base end to the unscrew piston (9) from piston rod (2).
front frame.
9. Remove and discard 'O' ring (5) from piston (9).
6. Remove bolt (20), lockwasher (19) and hardened Remove and retain cushion sleeve (8) from piston rod
washer (18) securing pin (17) at piston rod (2) end of (2).
the cylinder. Remove pin (17) securing piston rod (2)
end to the articulation and oscillation pivot. 10. Pull end cap (3) assembly off piston rod (2).
Remove and discard back up ring (15) and 'O' ring (16)
7. Remove cylinder assembly from the machine. from end cap (3) outer grooves. Remove and discard
Spacers (21,22 & 23 ) will come free at this time. wiper (7) and rod seal (6) from end cap (3) inner
grooves.
8. Remove cylinder assembly to a clean area for
disassembly. Drain oil from cylinder assembly into a 11. If damaged, remove lube fittings (4) from cylinder
suitable container. body (1) and piston rod (2).

9. Repeat steps 3 through 8 for opposite steering


cylinder assembly.

2 SM 2349 10-04
Steering System - Steering Cylinder
Section 220-0120

INSPECTION 8. Insert piston grub screw (10), through wear ring


groove in piston (9), into groove machined in piston rod
Numbers in parentheses refer to Fig. 1
(2). Tighten grub screw (10) to a torque of 13 - 20 Nm
(10 - 15 lbf ft). Ensure the extreme of grub screw (10)
1. Clean all parts of the cylinder with a suitable solvent
is below the level of wear ring groove.
and dry with clean, lint-free cloths. Clean all grooves
carefully to remove any foreign material.
9. Insert new piston seal (12) and new wear rings (11)
in piston (9) external grooves.
2. Check cylinder body (1), end cap (3) grooves and
outer diameter of piston (9) for scratches, cracks or
10. Fully grease piston (9) OD and 'O' ring (16) in end
other signs of damage. Remove ridges, nicks and
cap (3).
scratches with a fine stone and re-clean. Replace any
components which cannot be repaired.
11. Ensure bore of cylinder is well lubricated with
hydraulic oil. Carefully insert piston rod (2) and end
3. Inspect piston rod (2) for distortion, cracks or other
cap (3) assembly into cylinder body (1).
defects. Replace piston rod (2) if defective area is
irreparable.
12. Engage end cap (3) /cylinder body (1) thread and
screw up fully. Using special tool which can be
4. Check spherical bearings (13) for wear and replace if
fabricated as shown in Fig. 2, tighten end cap (3) to a
necessary.
torque of 542 - 610 Nm (400 - 450 lbf ft).

ASSEMBLY 13. Replace lube fittings (4) if required.


Numbers in parentheses refer to Fig. 1.
INSTALLATION
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
Note: Tighten all fasteners to standard torques listed
damage, be sure lifting equipment is properly
in Section 300-0080, STANDARD BOLT AND NUT
secured and of adequate capacity to do the job
TORQUE SPECIFICATIONS.
safely.
Note: Tighten all hydraulic lines fitted with ORFS
1. Press spherical bearings (13) in base end of cylinder
connections, as described in Section 220-0000,
body (1) and piston rod (2) end. Secure spherical
STEERING SYSTEM SCHEMATIC. Renew all
bearings (13) with circlips (14).
'O' rings where used.
2. Install new rod seal (6) into bore of end cap (3) with
the lip pointing towards the internal face of end cap (3).
WARNING
Install new wiper (7) into bore of end cap (3).
To prevent personal injury and property
damage, be sure lifting equipment is properly
3. Install new back up ring (15) and 'O' ring (16) in
secured and of adequate capacity to do the job
external groove of end cap (3).
safely.
4. Guide end cap (3) assembly onto piston rod (2),
1. Install a suitable strap, or other lifting device, around
taking care not to damage rod seal (6) on the thread.
one cylinder assembly and position cylinder assembly
on the vehicle, with piston rod (2) end of cylinder ready
5. Install cushion sleeve (8) into piston rod (2) counter
for mounting.
bore. Note correct orientation, spigot face abuts
counter bore face (see Fig. 1).
2. Install spacers (22) either side of piston rod (2) end
of cylinder. Note: Install spacers (21 & 23) in correct
6. Install new 'O' ring (5) into internal groove of piston
order and side of piston rod as shown. Now insert pin
(9).
(17). Secure pin (17) to articulation and oscillation pivot
with bolt (20), lockwasher (19) and hardened washer
7. Using special tool which can be fabricated as shown
(18).
in Fig. 3, screw piston (9) on piston rod (2). Tighten
piston (9) to a torque of 746 - 813 Nm (550 - 600 lbf ft).

SM 2349 10-04 3
Steering System - Steering Cylinder
Section 220-0120
3. Install seals spacers (22) either side of base end of 8. Place the steering lock bar in the 'Stowed' position
cylinder and insert pin (17). Secure pin (17) to front and remove wheel blocks.
frame with bolt (20), lockwasher (19) and hardened
washer (18). 9. Place the battery master switch in the 'On' position,
start the engine and operate the steering, from lock to
4. Connect hydraulic lines to steering cylinder ports, as lock several times, to purge air out of the hydraulic
tagged during removal. lines. Check hydraulic lines and fittings for leaks.
Tighten lines and fittings as required.
5. Repeat steps 1 through 4 for installation of opposite
steering cylinder.
MAINTENANCE
6. Lubricate pins (17) through lube fittings (4) with Inspect steering cylinders regularly for leaks or
lubricant, as specified in Section 300-0020, damage, repair as required. Lubricate cylinder pins
LUBRICATION SYSTEM. every 250 hours, as specified in Section 300-0020,
LUBRICATION SYSTEM.
7. Check oil level in hydraulic tank and add oil if low.
Refer to Section 230-0040, HYDRAULIC TANK, for
correct fill level. Refer to Section 300-0020, SPECIAL TOOLS
LUBRICATION SYSTEM, for the type of oil used. Special tools can be fabricated as shown in Figs. 2 & 3.
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools
are available from your dealer.

SM - 407

DRILL
RAD
DEEP

RAD TYP
BURN OUT

SQUARE

SECURE ALUMINIUM DRILL AND REAM THROUGH


COLLAR WITH (3) M8 AND FIT 8 (0.315)
CAP SCREWS HARDENED DOWEL
TORQUE PINS 2 PLACES

Dimensions in mm (inches)
Fig. 2 - End Cap Torque Tool

4 SM 2349 10-04
Steering System - Steering Cylinder
Section 220-0120

SM - 633

SILVER STEEL
SQUARE

OUTER SHIELD TO BE SECURED DOM TUBE


TO INNER BODY WITH 2BA CAPSCREWS

Dimensions in mm (inches)
Fig. 3 - Piston Torque Tool

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 9 Piston 746 - 813 550 - 600
1 3 End Cap 542 - 610 400 - 450
1 10 Grub Screw 13 - 20 10 - 15

* * * *

SM 2349 10-04 5
BODY SYSTEM - Body System Schematic
Section 230-0000
SM - 2848

18

LOWER

ACC3
RAISE
1
DL

5
PPA

PP B A
1
9 33 47

T
13

30
R

15 32
P1
31 31
L
LSM
21 22
46

25

PP

26

PPB
29

T LSP T

1 - Body Cylinders 21 - Shuttle Valve 31 - Copy Spool


5 - Proportional Control Valve (Raise) 22 - Shuttle Valve 32 - Load Sense Dump Valve
9 - Pressure Reducing Valve 25 - Shuttle Valve 33 - Make Up Check Valve
13 - Float Solenoid 26 - Relief Valve 46 - Orifice
15 - Priority Valve 29 - Proportional Control Valve (Lower) 47 - Relief Valve
18 - Primary Accumulator 30 - Control Spool

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 2199 Rev 1 6-03 1
BODY SYSTEM - Body System Schematic
Section 230-0000

Body Cylinders (1) Valves 5, 9, 13, 15, 21, 22, 25, 26, 29, 30, 31,
Refer to Section 230-0130, BODY CYLINDER. 32, 33, 46 & 47
These valves form part of the brake 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, Pin C1:8. The hydraulic ECU converts this signal
retracted is obtained by a tapered spear at the base to an output current at Pin C1:17 to between 250 & 800
end of the cylinder body entering a cavity in the piston mA dependent upon how far the lever is selected. This
rod through a cushioning ring. This gradually slows the current is delivered to the Electro-Hydraulic
piston which in turn helps to control destructive shock Proportional Pressure Control Valve (5) which converts
effects when the piston bottoms. this current into a pilot pressure.

Cylinder mounting is by pins, spacers and spherical The primary accumulator (18) pressure is reduced to a
bearings secured in place by circlips. Spherical 35 bar (508 lbf/in2) pilot control pressure by pressure
bearings permit a limited amount of cylinder reducing valve (9). This pilot control pressure acts
misalignment. upon the poportional pressure control valve (5) which
reduces the pilot pressure to between 4 bar (58 lbf/in2)
and 25 bar (363 lbf/in2), depending on the current output
Accumulators (18) fom the hydraulic ECU. This pilot pressure then selects
Refer to Section 250-0060, ACCUMULATOR. the main spool (30) in the lift valve section of the main
hydraulic valve assembly to the raise position.
The primary accumulators mounted inside the battery
box located on the front left hand side of the tractor. When the main spool (30) has been stroked to the raise
The primary accumulator supports the service brake position, oil from the main pump flows through the
system and the body pilot pressure system. The control spool (30) out of port 'A' on the main hydraulic
primary accumulator is of the piston type and valve, onto the tip cylinders (1).
precharged with nitrogen to 95 bar (1 380 lbf/in). It
consists of a charging valve assembly, cylinder When oil from the main pump flows through control
assembly and piston. The charging valve is equipped spool (30), a pressure is created at the head of copy
with a locking feature which, when opened, will allow spool (31). The copy spool (31) strokes down allowing
precharge to be checked or accumulator charged. a load sense pressure to be fed back to the load sense
port of the main pump via shuttle valves (22 & 25). The
The piston acts as a separator dividing the cylinder main pump then increases its displacement and flow
assembly into two sections. The section nearest the passes to port 'A' lifting the body. Returning flow from
charging valve contains the nitrogen precharge. the tipping cylinders (1) passes to Port 'B', through the
Hydraulic oil from the accumulator charge valve flows control spool (30) back to tank.
through accumulator check valves in the brake
manifold valve and into the other section of the The load sense pressure created by copy spool (31) is
accumulator. controlled to a maximum of 195 bar (2830 lbf/in2) by
relief valve (26). This will result in a maximum main
Accumulator pressure is monitored by pressure pump delivery pressure for the body raise circuit of 220
switches in the brake lines (Ref. Section 250-0000, bar (3200 lbf/in2). This is a result of the 195 bar (2830
BRAKING SYSTEM). lbf/in2) maximum load sense pressure, plus the 25 bar

2 SM 2199 Rev 1 6-03


BODY SYSTEM - Body System Schematic
Section 230-0000

SM - 2866 this signal to an output current at Pin C1:31 between


250 and 800 mA dependent upon how far the lever is
selected. This current is seen at the Electro-Hydraulic
Proportional Pressure Control Valve (29) that converts
this current into a pilot pressure.

The pilot control pressure of 35 bar (508 lbf/in2),


created by pressure reducing valve (9) is reduced by
the proportional pressure control valve (29) to between
4 bar (58 lbf/in2) & 25 bar (363 lbf/in2), depending on the
current output from the hydraulic ECU. This pilot
pressure selects the main spool (30) in the lift valve
section of the main hydraulic valve assembly to the
Fig. 2 - Body Control Lever (Operators Cab) lower position.

SM - 2867 When the main spool (30) has been stroked to the
lower position, oil from the main pump flows through
the control spool (30) out of port 'B' on the main
hydraulic valve, onto the tip cylinders (1).

When oil from the main pump flows through control


spool (30), a pressure is created at the head of copy
spool (31). The copy spool (31) strokes down allowing
a load sense pressure to be fed back to the load sense
port of the main pump via shuttle valves (22 & 25). 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 (30) 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 hydraulic ECU pin
C1:35, 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 the hydraulic ECU pin
C1:6. When the body reaches the proximity switch the
Fig. 3 - Body Control Lever Positions 24 Volt signal is switched off, this tells the hydraulic
ECU to de-energise the electric detent allowing the
(360 lbf/in2) stand by pressure of the main pump. Refer lever to spring back to the mid position. At the same
to Section 230-0050, MAIN HYDRAULIC PUMP. time the hydraulic ECU ramps back the current to
proportional pressure control valve (29) to de-select the
Body relief valve (47) is located on the raise side of the main spool (30) and energises the coil on the float
circuit and prevents pressure spikes at maximum solenoid valve (13) allowing the body to float down to
extension of the cylinders when the body is raised at the chassis over the last few centimeters of travel.
maximum engine speed. Relief valve (47) is set at 230
bar (3 335 lbf/in2 ). To prevent damage to the body hinge points or the tip
cylinders (1) the float solenoid valve (13), which is
connected to Pin C1:23 on the hydraulic ECU is
LOWERING THE BODY 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, Pin C1:12. The hydraulic ECU converts body is sitting firmly on the chassis.

SM 2199 Rev 1 6-03 3


BODY SYSTEM - Body System Schematic
Section 230-0000

SM - 2920

5 - Proportional Control Valve (Raise)


9 - Pressure Reducing Valve - Pilot Pressure
13 - Float Solenoid
15 - Priority Valve
21 - Shuttle Valve
22 - Shuttle Valve
25 - Shuttle Valve
26 - Relief Valve - Body Raise Pressure LS
29 - Proportional Control Valve (Lower)
31 - Copy Spools 25 PORT 'DL'
32 - Load Sense Dump Valve
46 - Orifice
47 - Relief Valve

15
Valve (5 & 29) Coil Rating
Ohms Amps Watts
21 1.1 25
Voltage: 24V

Valve (13) Coil Rating 31


Ohms Amps Watts (x2 HIDDEN)
42 0.6 15
Voltage: 24V 21

PORT 'B'

PORT 'A'

26 47
9 32 PORT 'T'

LOWER PILOT PRESSURE INLET TO MAIN SPOOL

13

29

5 22/46

RAISE PILOT PRESSURE INLET TO MAIN SPOOL


REF. LIFT VALVE SECTION

Fig. 4 - Main Hydraulic Valve Assembly - Body Control Valve Locations

4 SM 2199 Rev 1 6-03


Body System - Body System Schematic
Section 230-0000

When the body meets the proximity switch on the SM - 2849

chassis the control spool is de-selected and reverts to


the neutral position. This action closes the copy spool
(31). The load sense dump valve (32) allows a
controlled load sense pressure drain back to the
hydraulic tank.

When the control spool (30) moves to the neutral 1


position, oil delivery from the main pump is blocked. 2
To compensate for this over the last few centimeters P
FB 3
of travel, make up check valve (33) opens allowing a
RB 4
controlled oil flow via port 'B' to the lower side of the tip
cylinders (1). The make up check valve (33) opening 5
safeguards the system against cavitation when the 6
main pump flow is blocked during the lowering
7
procedure of the body.
8
9

CHECKING SYSTEM PRESSURES

WARNINGS 1 - Pump LS Pressure 7 - Trans. Converter Press.


To prevent personal injury and property 2 - Front Brake Pressure 8 - Body System Press.
damage, be sure wheel blocks and blocking 3 - Rear Brake Pressure 9 - Trans. System Pressure
4 - Park Brake Pressure P - Primary Accumulator
materials are properly secured and of adequate 5 - Steering Pressure FB - Front Brake Accumulator
capacity to do the job safely. 6 - Trans. Retarder Press. RB - Rear Brake Accumulator
Fig. 5 - Diagnostic Pressure Check Points (Battery Box)
Hydraulic fluid pressure will remain
within the system after engine shut down. start the engine and allow all systems to be charged
Operate the brake treadle pedal continuously normally.
until the pressure has dissipated before
carrying out any work on the system or serious 5. Pull back body control lever. Allow body to raise
injury could result. over relief. The pressure observed on the pressure
gauge should be 220 bar (3200 lbf/in2).
CHECKING MAIN BODY SYSTEM 6. Pressure setting can be adjusted by adjusting relief
PRESSURE valve (26) on the main hydraulic valve assembly. Relief
1. Position the vehicle in a level work area, apply the valve (26) actually sets the load sense pressure for the
parking brake, switch off the engine and turn steering body circuit, controlling the load sense to a maximum
wheel in both directions several times to relieve any of 195 bar (2830 lbf/in2). This will result in a maximum
pressure in the steering circuit. main pump delivery pressure for the body raise circuit
of 220 bar (3200 lbf/in2). This is due to the 195 bar
2. Operate the brake treadle valve continuously to (2830 lbf/in2) maximum load sense pressure, plus the
relieve pressure in the accumulators. Block all road 25 bar (360 lbf/in2) stand by pressure of the main
wheels, place the steering lock bar in the 'Locked' pump. Refer to Section 230-0050, MAIN HYDRAULIC
position and the battery master switch in the 'Off' PUMP. The operator cab will require to be raised to
position. access relief valve (26). Refer to Section 260-0010,
CAB AND MOUNTING.
3. This following procedure will check that the body
raise pressure is properly set. Connect a hydraulic 7. Adjust relief valve (26) until 220 bar (3200 lbf/in2) is
gauge, capable of recording a pressure of 0 - 345 bar observed on the pressure gauge, while raising the body
(0 - 5 000 lbf/in), to body system pressure diagnostic over relief.
pressure point inside battery box (8, Fig. 5).
8. Shut off the engine and remove the pressure gauge
4. Place the battery master switch in the 'On' position, from diagnostic check point.

SM 2199 Rev 1 6-03 5


BODY SYSTEM - Body System Schematic
Section 230-0000
9. Remove wheel blocks, place the steering lock bar in SM - 1335
the 'Stowed' position, start the engine and check the
body system for proper operation. FITTING NUT
TUBE

CHECKING PILOT CONTROL PRESSURE


1. Position the vehicle in a level work area, apply the
parking brake, switch off the engine and turn steering
wheel in both directions several times to relieve any
pressure in the steering circuit.
SLEEVE
'O' RING 'O' RING
2. Operate the brake treadle valve continuously to
relieve pressure in the accumulators. Block all road
Fig. 6 - Assembly of Typical ORFS Connector
wheels, place the steering lock bar in the 'Locked'
position and the battery master switch in the 'Off' a. Ensure 'O' ring/seal is in place and that the joining
position. surfaces are clean. If necessary, retain 'O' ring/seal in
place with a light coating of grease or vaseline.
3. The operators cab has to be raised at this stage so
that port 'DL' on the main hydraulic valve can be b. Initially, the nuts should be tightened by hand.
accessed. Refer to Section 260-0010, CAB AND
MOUNTING. c. Where a hose is fitted, ensure that it is not twisted
or kinked when the nuts are tightened so that it is
4. Connect a hydraulic gauge, capable of recording a allowed to adopt a natural position.
pressure of 0 - 345 bar (0 - 5 000 lbf/in2), into port 'DL' on
the main hydraulic valve assembly. d. Where a tube is fitted, ensure that the connection is
aligned correctly.
5. Place the battery master switch in the 'On' position,
start the engine and allow all systems to be charged e. Tighten the nut a further 1/4 to 1/2 a turn using the
normally. correct size spanner (wrench).

6. A hydraulic pressure of 35 bar (500 lbf/in2) should f. Check that a satisfactory hose or tube routing has
be observed on the pressure gauge. been achieved.

7. Pressure setting can be adjusted by adjusting


pressure reducing valve (9) on the main hydraulic HYDRAULIC OIL
valve. Adjust pressure reducing valve (9) until 35 bar The braking system should be kept filled with hydraulic
(500 lbf/in2) is observed on the pressure gauge. oil as specified in Section 300-0020, LUBRICATION
SYSTEM.
8. Check body system for proper operation.
Whenever there is a hydraulic system failure, the oil
9. Shut off the engine and remove the pressure gauge should be drained, the entire system flushed, oil filters
from port 'DL'. replaced, oil screens thoroughly cleaned and clean
hydraulic oil added to eliminate all metal particles or
10. Operators cab should be lowered into travel foreign matter.
position. Check hydraulic lines for any leakage.

11. Remove wheel blocks, place the steering lock bar SERVICE TOOLS
in the 'Stowed' position, start the engine and check the It is recommended that the following service tools are
body system for proper operation. used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
'O' RING FACE SEALS (ORFS) from your dealer. Refer to Section 300-0070, SERVICE
Where hydraulic lines are fitted with ORFS TOOLS, for part numbers of these tools.
connections, the following procedure should be carried
out during 'Installation'. Refer to Fig. 6.

6 SM 2199 Rev 1 6-03


Body System - Body System Schematic
Section 230-0000

Multi-Gauge Non-contact Infrared Thermometer


The multi-gauge, 15269784, is basically four pressure The infrared thermometer, 15269785, can be used to
gauges in one. Continuous system pressure readings spot heat problems early in electrical, mechanical and
are indicated on one of three simultaneously reading hydraulic systems. Hand held and easy to use, you
gauges through a pressure range of 30 in of vacuum to simply aim, pull the trigger, and read the temperature.
5 000 lbf/in. Since there is no need to touch what you are
The following items should be added to the multi-gauge measuring, temperatures of hard-to-reach or moving
to enable the gauge to be used on the diagnostic components can be taken without getting burned or
pressure check points; shocked.
15018226 Diagnostic Coupling
00118748 Connector (2 off) O' Ring Face Seals (ORFS) - Seal Kit
15004085 Hose Assembly (-04 HP, 2130 mm long)
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 2199 Rev 1 6-03 7


BODY SYSTEM - Body System Schematic
Section 230-0000

Body System Trouble Shooting


Symptom Possible Cause Remedy
Body will not lift Pressure Level in the system not high Check pressure at the pump and re-
enough adjust Relief Valve (26). Refer to
Section 230-0050, MAIN
HYDRAULIC PUMP.
Relief valve (47) stuck open.

No electric current at the proportional Check voltage at the electric


control valve (5) connector of for Valve (5) when
pulling back on the lever in the cab.
If no voltage present refer to
Sections190-0085 HYDRAULIC
ECU and 230-0081, BODY
CONTROL LEVER

Proportional control valve (5) faulty Replace Valve (5)

Control lever in the cab faulty Check output from lever. Refer to
Sections190-0085 HYDRAULIC
ECU and 230-0081, BODY
CONTROL LEVER

Main control spool (30) in the lift Replace lift section of the main
section of the main hydraulic valve hydraulic valve assembly
assembly sticking

Copy spool (31) sticking Check condition of copy spool,


replace if necessary. Replace Main
Hydraulic Valve Assembly

Contamination in the load sense Clean orifice (46). Replace Main


drillings and the orifice (46) Hydraulic Valve Assembly

Main pump faulty Refer to Section 230-0050 MAIN


HYDRAULIC PUMP, for correct
setting procedures

Lift function too slow. Proportional control valve (5) current Check output from body control
not high enough lever. Refer to Sections190-0085
HYDRAULIC ECU and 230-0081,
BODY CONTROL LEVER

Main control spool (30) not fully Replace lift section of main
selecting. hydraulic valve assembly.

Contamination in the load sense Clean orifice (46).


drillings and the orifice (46). Replace Main Hydraulic Valve
Assembly.

Main pump faulty. Refer to Section 230-0050 MAIN


HYDRAULIC PUMP, for correct
setting procedures.

8 SM 2199 Rev 1 6-03


Body System - Body System Schematic
Section 230-0000

Body System Trouble Shooting


Symptom Possible Cause Remedy
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.

Body will not lower. Supply fuse to hydraulic ECU blown. Check that green LED on the
hydraulic ECU is illuminated.
Replace fuse F48 located inside
fuse box. Refer to Section190-0000
CIRCUIT DIAGRAMS

No electric current at proportional Check link between body control


control valve (29) lever and hydraulic ECU and
hydraulic ECU and proportional
control valve (29). Refer to
Sections 190-0085 HYDRAULIC
ECU and 230-0081 BODY
CONTROL LEVER

Proportional control valve (29) faulty. Check connections. Replace


proportional control valve (29).

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 (29) lever. Refer to Sections 190-0085
HYDRAULIC ECU and 230-0081
BODY CONTROL LEVER

Pilot pressure not high enough Re-set pilot pressure at pressure


reducing valve (9). If it cannot be
reset replace pressure reducing
valve (9).

Main control spool (30) sticking. Replace lift section of the main
hydraulic valve assembly.

Faulty main pump. Refer to Section 230-0050 MAIN


HYDRAULIC PUMP, for correct
setting procedures.

Contamination in the load sense Clean orifice (46). Replace main


drillings and the orifice(46). hydraulic valve assembly.

SM 2199 Rev 1 6-03 9


BODY SYSTEM - Body System Schematic
Section 230-0000

Body System Trouble Shooting


Symptom Possible Cause Remedy
Body will not hold Oil by-pass between control spool Replace lift section of main
(30) and valve body hydraulic valve aseembly

Oil by-pass body lift cylinders (1) Repair lift cylinders (1)

Control spool (30) not centering Check that there is zero pilot
pressure at both ends of control
spool (30). Either of proportional
control valves (5/29) could remain
active

Check body control lever. Should


be zero ouput signal from control
lever when in the neutral position

Control spool (30) damaged.


Replace control spool (30)

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 (30) sticking Replace main hydraulic valve


assembly

Faulty float solenoid valve (13) Check connections. Replace


valve(13). Refer to Section 190-
0085 HYDRAULIC ECU

Body fails too go into float and stops No voltage at the float solenoid valve Check connections at valve (13)
before it reaches the chassis (13) and hydraulic ECU. Refer to
Section 190-0085 HYDRAULIC
ECU

* * * *

10 SM 2199 Rev 1 6-03


BODY SYSTEM - Hydraulic Tank
Section 230-0040

SM - 3316

25 24 14 13 12
6

19 18
19 17
11 9
10
5

2,3,4

15

23
22

20 27
21 28
16
26
18
8
7

1 - Hydraulic Tank 9 - 'O' Ring 16 - Lockwasher 23 - Plug


2 - Filter Assembly 10 - Gasket 17 - Breather 24 - 'O'-Ring
3 - Element 11 - Cover Plate 18 - Bolt 25 - Guard
4 - 'O' Ring 12 - Cap 19 - Washer 26 - Bolt
5 - Sight Gauge 13 - 'O' Ring 20 - 'O' Ring 27 - Nut
6 - Bolt 14 - Filter Restriction Gauge 21 - Access Cover 28 - Lockwasher
7 - Drain Valve 15 - Drain Adaptor Hose 22 - 'O' Ring
8 - Seal

Fig. 1 - Exploded View of Hydraulic Tank and Mounting

DESCRIPTION cover (21). Located on top of the tank is filler cap (12),
breather (17) and filter restriction gauge (14).
Numbers in parentheses refer to Fig. 1.

The hydraulic tank (1) is the common reservoir for the OPERATION
steering, braking, body hoist and transmission oil Numbers in parentheses refer to Fig. 2.
cooler fan drive systems. It is mounted off the frame at
the rear right hand side of the tractor. Oil is added to the hydraulic tank (4) through filter
assembly (2). The hydraulic oil is drawn from hydraulic
Integral with hydraulic tank (1) assembly are filter tank (4) by main hydraulic pump (1) and pumped to the
assembly (2), oil level sight gauge (5) and access main hydraulic valve to supply the various hydraulic

SM 2350 10-04 1
Body System - Hydraulic Tank
Section 230-0040

SM - 2864
EMERGENCY
SUPPLY TO
SUPPLY TO MAIN
MAIN HYDRAULIC RETURN
HYDRAULIC
VALVE TO TANK
VALVE

1 3
2

5 5

1 - Main Hydraulic Pump


2 - Emergency Pump 3 - Hydraulic Oil Cooler 4 - Hydraulic Tank 5 - Filter Assembly

Fig. 2 - Hydraulic Schematic of Hydraulic Tank

systems. Refer to Section 215-0050, MAIN MAINTENANCE


HYDRAULIC VALVE ASSEMBLY.
Numbers in parentheses refer to Fig. 1.
Emergency steering oil is drawn from hydraulic tank (4)
Note: Tighten all fasteners without special torques
by emergency pump (2), mounted off transmission, and
specified to standard torques listed in Section
is also pumped to the main hydraulic valve. Should a
300-0080, STANDARD BOLT AND NUT TORQUE
failure occur at the main hydraulic pump (1) the
SPECIFICATIONS.
emergency pump (2) will supply the steering system
with oil to enable the vehicle to be brought to a safe
halt. Refer to Section 220-0000, STEERING SYSTEM WARNING
SCHEMATIC.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
Return oil from the hydraulic systems flows through
materials and lifting equipment are properly
hydraulic oil cooler (3) (if fitted) and filter assembly
secured and of adequate capacity to do the job
(5) before entering the tank storage area. The filter
safely.
assembly has a bypass valve which allows oil to
bypass element (3, Fig. 1) when it is cold or when the
filter element is plugged. The bypass valve opens at a Checking Oil Level
pressure differential of 1.5 bar (22 lbf/in2). Filter
1. Operate the body hoist and steering systems
restriction gauge (14, Fig. 1) shows red when element
several times to bring the oil to correct operating
(3, Fig. 1) requires to be changed.
temperature.

2. Position the vehicle in a level work area, ensure the


body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel in both
directions several times to relieve any pressure in the

2 SM 2350 10-04
Body System - Hydraulic Tank
Section 230-0040
steering circuit. Operate treadle valve continuously to directions several times to relieve any pressure in the
discharge accumulators. steering circuit. Operate treadle valve continuously to
discharge accumulators.
3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in 2. Block all road wheels, place the steering lock bar in
the 'Off' position. the 'Locked' position and the battery master switch in
the 'Off' position.
4. Check oil level and add if low. Oil should at least
reach the minimum level in the sight gauge (5). If oil is 3. Remove blanking cap from remote drain valve (7) on
required, remove filler cap (12) from hydraulic tank (1) the bottom of hydraulic tank (1). Install a hose adaptor
and fill hydraulic tank with hydraulic oil specified in (15) on remote drain fitting, open drain cock and drain
Section 300-0020, LUBRICATION SYSTEM. Install hydraulic oil into a suitable container. Close drain cock,
filler cap (12) on hydraulic tank (1) and tighten. remove hose and reinstall blanking cap on remote drain
valve (7).
Replacing Hydraulic Oil 4. Remove bolts (6 & 18) and washers (19) securing
Hydraulic oil should be changed every 2 000 hours. guard (25) and cover plate (11) to top of hydraulic tank
Refer to Section 300-0020, LUBRICATION SYSTEM, (1). Remove guard (25), cover plates (11) and gasket
for hydraulic oil used in the system. (10) from hydraulic tank (1). Discard gasket (10).

Note: When replacing the hydraulic oil due to a 5. Remove filter assembly (2) from hydraulic tank (1).
hydraulic failure, or at recommended change interval,
element (3) must be replaced and hydraulic tank (1) 6. Remove and discard element (3) from filter
cleaned thoroughly using a suitable solvent. assembly (2). Discard 'O' ring (4).

7. Remove bolts (18) and lockwashers (16) securing


Replacing Breather access cover (21) to tank (1). Remove access cover
Every 1 000 hours of operation, or sooner if the vehicle (21) and discard 'O' ring (20).
is being operated in extremely dusty conditions, the
hydraulic tank breather should be replaced.
WARNING
1. Position the vehicle in a level work area, ensure the Splashing liquid. Wear a suitable face shield
body is fully lowered, apply the parking brake and when using compressed air to dry hydraulic
switch off the engine. Turn steering wheel in both tank and components.
directions several times to relieve any pressure in the
steering circuit. Operate treadle valve continuously to 8. Clean out the inside of hydraulic tank (1) with a
discharge accumulators. suitable solvent and dry with compressed air.

2. Block all road wheels, place the steering lock bar in 9. Install new element (3) in filter assembly (2).
the 'Locked' position and the battery master switch in
the 'Off' position. 10. Install filter assembly (2) in tank (1), complete with
new 'O' ring (4).
3. Unscrew breather (17) and remove from tank (1).
Discard 'O' ring (9). 11. Place new gasket (10), cover plate (11) and guard
(25) on hydraulic tank (1). Secure with bolts (6 & 18)
4. Install new 'O' ring (9) and breather (17) to tank (1). and washers (19).

12. Install new 'O' ring (20) and secure access cover
Replacing Filter Element plate (21) on hydraulic tank (1) with bolts (18) and
Every 2 000 hours of operation or when filter restriction lockwashers (16).
gauge (14) shows red, whichever comes first, clean
filter assembly (2) and install new element (3). 13. Remove filler cap (12) from hydraulic tank (1) and
fill hydraulic tank with hydraulic oil specified in Section
1. Position the vehicle in a level work area, ensure the 300-0020, LUBRICATION SYSTEM. Install filler cap
body is fully lowered, apply the parking brake and (12) on hydraulic tank (1) and tighten.
switch off the engine. Turn steering wheel in both

SM 2350 10-04 3
Body System - Hydraulic Tank
Section 230-0040
14. Place the battery master switch in the 'On' position Inspection
and the steering lock bar in the 'Stowed' position,
Numbers in parentheses refer to Fig. 1.
remove all wheel blocks, start the engine and operate
the steering, braking and body hoist systems to
circulate the oil. WARNING
Splashing liquid. Wear a suitable face shield
15. Switch off the engine, check for leaks and check
when using compressed air to dry hydraulic
oil level as described under 'Checking Oil Level'.
tank and components.

TANK ASSEMBLY 1. Clean hydraulic tank (1) and components with a


suitable solvent and dry with compressed air.
Removal
2. Inspect hydraulic tank (1) for weld cracks and
Numbers in parentheses refer to Fig. 1.
security of internal pipes and weld fitments.

3. Inspect breather (17), filter restriction gauge (14) and


WARNING
filter assembly (2) for damage. Replace if required.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Installation
secured and of adequate capacity to do the job
Numbers in parentheses refer to Fig. 1.
safely.
Note: Tighten all fasteners without special torques
1. Position the vehicle in a level work area, ensure
specified to standard torques listed in Section
the body is fully lowered, apply the parking brake and
300-0080, STANDARD BOLT AND NUT TORQUE
switch off the engine. Turn steering wheel in both
SPECIFICATIONS.
directions several times to relieve any pressure in
the steering circuit. Operate treadle valve continuously
Note: Tighten all hydraulic lines fitted with ORFS
to discharge accumulators.
connections, as described in Section 230-0000,
BODY SYSTEM SCHEMATIC. Renew all 'O' rings
2. Block all road wheels, place the steering lock bar in
where used.
the 'Locked' position and the battery master switch in
the 'Off' position.
WARNING
3. Remove blanking cap from remote drain valve (7) on
To prevent personal injury and property
the bottom of hydraulic tank (1). Install a length of hose
damage, be sure lifting equipment is properly
on remote drain fitting, open drain cock and drain
secured and of adequate capacity to do the job
hydraulic oil into a suitable container. Close drain cock,
safely.
remove hose and reinstall blanking cap on remote drain
valve (7).
1. Using a suitable lifting device, position hydraulic
tank (1) in position on the vehicle and secure with
4. Ensure all hydraulic lines connected to hydraulic
bolts (26), lockwashers (28) and nuts (27).
tank (1) are identified for ease of installation and, with
suitable containers available to catch leakage,
2. Remove eyebolts that were installed to lift hydraulic
disconnect hydraulic lines. Fit blanking caps and
tank (1). Reinstall two bolts (18) and washers (19) on
plugs to all open lines and fittings.
top of tank (1).
5. Remove two bolts (18) and washers (19) from top of
3. Install new 'O' rings and install all hydraulic lines and
hydraulic tank (1) and install eyebolts. Attach a
fittings to hydraulic tank (1), as tagged at removal.
suitable lifting device to eyebolts and remove nuts (27),
lockwashers (28) and bolts (26) securing hydraulic tank
4. Remove filler cap (12) and fill hydraulic tank (1) with
(1) to fender and support bracket.
hydraulic oil specified in Section 300-0020,
LUBRICATION SYSTEM. Install filler cap (12) on
6. Carefully remove hydraulic tank (1) assembly from
hydraulic tank (1) and tighten.
the unit to a clean work area for inspection.

4 SM 2350 10-04
Body System - Hydraulic Tank
Section 230-0040
5. Place the battery master switch in the 'On' position SPECIAL TOOLS
and the steering lock bar in the 'Stowed' position,
There are no special tools required for the procedures
remove all wheel blocks, start the engine and operate
outlined in this section. Refer to Section 300-0070,
the steering, braking and body hoist systems to
SERVICE TOOLS, for part numbers of general service
circulate the oil.
tools required. These tools are available from your
dealer.
6. Switch off the engine, check for leaks and check oil
level as described under 'Checking Oil Level'.

* * * *

SM 2350 10-04 5
BODY SYSTEM - Main Hydraulic Pump
Section 230-0050

SM - 2837
59
70 71 69 48 66 72 61 60 58
68

72
3
75 4
76
5
51 62
50
64 1
83
82
79
81
80

54
55
78
77
84

49 47 45 44 46 52 43 41 65 2 40
53
1 - Valve Cover 47 - Shoe Plate 60 - 'O' Ring 75 - 'O' Ring
2 - Bolt 48 - Tilting Bush 61 - Servo Piston 76 - Plug
3 - Bolt 49 - Swash Plate 62 - 'O' Ring 77 - Snap Ring
4 - Nut 50 - Swash Plate Support 64 - Pin 78 - Bearing Spacer
5 - Set Screw 51 - Pump Casing 65 - Pin 79 - Roller Bearing
40 - Needle Bearing 52 - 'O' Ring 66 - Tilting Pin 80 - Driveshaft
41 - Valve Plate 53 - Plug 68 - Eye Bolt 81 - Oil Seal
43 - Cylinder Spring 54 - 'O' Ring 69 - Spring Seat 82 - 'O' Ring
44 - Spherical Bush 55 - Plug 70 - Outer Spring 83 - Seal Cover
45 - Set Plate 58 - Stopper 71 - Inner Spring 84 - Bolt
46 - Piston & Shoe 59 - Back-up Ring 72 - Plug

Fig. 1 - Sectional View Of Hydraulic Pump

DESCRIPTION The pump supplies hydraulic oil for the steering,


braking and body hoist systems, as well as the
Numbers in parentheses refer to Figs. 1 & 7.
transmission oil cooler fan drive system.
The Hydraulic Pump can be identified as item 5 in
The components of the pump can be divided into three
Section 250-0000, BRAKING SYSTEM SCHEMATIC.
sub-groupings:
The hydraulic pump is mounted off the rear of the
Rotating Group - Provides the main rotary pumping
transmission. It is an axial piston, variable
action. Consists of driveshaft (80), cylinder block (42),
displacement pump with load sense and pressure
piston and shoe (46), set plate (45), spherical bush
regulator to match the flow and pressure to the
(44) and cylinder springs (43).
demand. The pump displaces 140cc/rev, and the
pressure regulator is set to 240 bar (3 500 lbf/in2).
Swash Plate Group - Varies the pump's delivery flow

SM 2196 2-03 1
Body System - Main Hydraulic Pump
Section 230-0050

SM - 2845

A - Outlet Port
B - Outlet Kidney Slot 41 - Valve Plate 47 - Shoe Plate
C - Inlet Port 42 - Cylinder Block 80 - Driveshaft
D - Inlet Kidney Slot 46 - Piston & Shoe

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

rate. Consists of swash plate (49), shoe plate (47), block (42) being spline coupled to the shaft will also
swash plate support (50), tilting bush (48), tilting pin rotate. If the swash plate (49) has been tilted, the
(66), servo piston (61) and servo assist springs (70 & pistons and shoes (46) arranged in the cylinder block
71). (42) due to the shoes being retained on the shoe plate
(47) will both rotate with the cylinder block and
Valving Cover Group - Provides the switching of oil reciprocate once per revolution.
between suction and delivery ports. Consists of valve
cover (1), valve plate (41) and valve plate pin (65). Paying attention to one such piston, then it will move
away from the valve plate (41) for half a rotation
(suction stroke), and move towards the valve plate (41)
OPERATION for the second half of rotation (delivery stroke). The
Numbers in parentheses refer to Figs. 1, 2 & 7. Refer larger the tilt angle of the swash plate (49), the longer
to Figs. 4 - 6 for hydraulic schematics of pump. the piston (46) stroke and the higher the pump's
displacement. As the swash plate (49) tilting angle
When the pump's driveshaft (80) rotates, the cylinder approaches zero, the piston (46) does not stroke and

2 SM 2196 2-03
Body System - Main Hydraulic Pump
Section 230-0050

LS LINE FROM MAIN HYDRAULIC VALVE SM - 2844A therefore delivers minimum displacement. (Refer to
Pl
Fig. 3).

Pressure Regulator
DIFFERENTIAL
PRESSURE SPOOL
Numbers in parentheses refer to Figs. 1 & 7.
DELIVERY LINE

Pressure regulator (6) is a pilot operated differential


CUT-OFF
PRESSURE
pressure type spool regulator for load sense control.
SPOOL The load sense feedback signal from the main
hydraulic valve is fed to load sense port (PL) on top of
A
the pressure regulator (6) (see Fig. 8). This feedback
T air
signal acts on the spring chamber end of the spool
(23).
Dr B
Unregulated Condition - Refer to Fig. 4. Pump
pressure is low and the load sense signal is wide open.
Fig. 4 - Pump Schematic - Unregulated Condition The cut-off pressure spool spring (18 & 20) preload
shifts the cut-off pressure spool (24) to its extreme
LS LINE FROM MAIN HYDRAULIC VALVE SM - 2844B right position. Since the pressure drop across the main
Pl
hydraulic valve is low, both sides of the differential
pressure spool (23) see the same pressure and
therefore the spool (23) remains in the extreme right
position. This condition causes the oil at the servo
DIFFERENTIAL
PRESSURE SPOOL
piston (61) to be vented, causing spring (70 & 71) force
DELIVERY LINE to move servo piston (61) and swash plate (49) to
maximum pump displacement.
CUT-OFF
PRESSURE
SPOOL Regulated Condition - Refer to Fig. 5. Pump pressure
A
is still relatively low but the pressure drop across the
main hydraulic valve increases. The cut-off pressure
T air
spool spring (18 & 20) preload still retains the spool
(24) in its extreme right position. However, since the
Dr B pressure drop is increased, the pressure on the right
hand side of the differential pressure spool (23) (pump
delivery pressure) overcomes the combination of spring
Fig. 5 - Pump Schematic - Regulated Condition (17 & 19) preload and pressure in the load sense line in
the left hand side of the differential pressure spool (23).
LS LINE FROM MAIN HYDRAULIC VALVE SM - 2844C Therefore the spool (23) moves to the left, blocking
Pl vent line and causing pressure at large side of servo
piston (61) to increase, overcoming spring (70 & 71)
force. This reduces the swash plate (49) angle and
hence pump displacement.
DIFFERENTIAL
PRESSURE SPOOL
DELIVERY LINE This will continue until the pump flow across the main
hydraulic valve reduces the pressure drop to the value
CUT-OFF
PRESSURE
determined by the differential spool spring (17 & 19)
SPOOL preload.
A
Standby Condition - Refer to Fig. 6. When no
T air
hydraulic operations are required, the pump standby
condition is reached. The load sense line is vented to
Dr B tank. Differential pressure spool (23) shifts to the
extreme left due to pump outlet pressure. This allows
oil pressure to pass through cut-off pressure spool (24)
Fig. 6 - Pump Schematic - Standby Condition and reach the large side of servo piston (61),

SM 2196 2-03 3
Body System - Main Hydraulic Pump
Section 230-0050
overcoming spring (70 & 71) force and reducing swash 5. Support pump assembly with suitable lifting
plate (49) angle to zero. equipment. It is possible to set up a sling arrangement
using exhaust cradle. Remove bolts (56) and
The pump also has a pressure limiting function, used lockwashers (57) securing pump to transmission.
for example when steering cylinder reaches the end of Remove pump from transmission.
it's stroke. In this condition the delivery pressure will
rise, and the load sense control will try to raise delivery 6. Remove 'O' ring from pump. Wash the outside of
pressure above the now 'dead head' pressure. This pump thoroughly with a suitable solvent and move to a
causes differential pressure spool (23) to shift to the clean work area for disassembly. Discard 'O' ring.
extreme left, allowing oil pressure to pass through cut-
off pressure spool (24) and reach the large side of
servo piston (61), overcoming spring (70 & 71) force DISASSEMBLY
and reducing swash plate (49) angle to zero. Numbers in parentheses refer to Figs. 1 & 7.

Note: Discard and replace all 'O' rings and seals


REMOVAL removed during disassembly.
Numbers in parentheses refer to Figs. 1 & 7.
1. Remove drain plug (53) and drain oil from pump
casing (51).
WARNINGS
To prevent personal injury and property 2. Remove bolts (26) and then remove regulator casing
damage, be sure wheel blocks, blocking (25) from pump casing (51). Ensure 'O' ring does not
materials and lifting equipment are properly drop from the gasket surface of the regulator. Fit
secured and of adequate capacity to do the job blanking caps to all open ports.
safely.
3. Remove bolts (2 & 3) securing valve cover (1) to
Hydraulic fluid pressure will remain pump casing (51).
within the system after engine shut down.
Operate the treadle pedal continuously until the 4. Separate valve cover (1) from casing (51). Valve
pressure has dissipated before carrying out any plate (41) may detach from valve cover. Ensure
work on the braking system or serious injury contact faces of valve cover (1) and casing (51) are
could result. not damaged.

1. Position the vehicle in a level work area, apply the 5. If necessary remove needle bearing (40) and valve
parking brake, switch off the engine and turn steering plate (41) from valve cover (1). Only remove needle
wheel in both directions several times to relieve any bearing (40) if it is nearing the end of its life. Do not
pressure in the steering circuit. loosen nut (4) as this will affect delivery flow rate.

2. Operate the treadle valve continuously to relieve 6. Pull cylinder block (42) out from pump casing (51)
pressure in the braking system. Block all road wheels straight over driveshaft (80). Pull out pistons and
and place battery master switch in the 'Off' position. shoes (46), set plate (45), spherical bush (44) and
Place steering lock bar in the 'Locked' position. cylinder springs (43) at the same time. Be careful not
to damage sliding surfaces of components.
3. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose on 7. Cover splined end of shaft with plastic tape to
remote drain fitting, open drain cock and drain hydraulic prevent oil seal (81) being damaged. Remove bolts (84)
oil into a suitable container. Close drain cock, remove and seal cover (83), ensuring oil seal (81) is not
hose and reinstall blanking cap. damaged.

4. Clean pump housing and surrounding area with a 8. Hold front of driveshaft (80) and using a plastic
suitable solvent. Ensure all hydraulic lines connected hammer, tap driveshaft (80) out of pump casing (51).
to pump are identified for ease of installation and, with Do not remove roller bearing (79) unless it is
suitable containers available to catch leakage, considered to be near the end of its expected life.
disconnect hydraulic lines. Fit blanking caps to all open
lines and fittings. 9. Push down servo piston (61), and remove shoe

4 SM 2196 2-03
Body System - Main Hydraulic Pump
Section 230-0050

SM - 2836

58
59
60
69 66 61
70 63 62
71 63
68 63

72 64

73
74
75
76
51 50
79
52
78 53

77 54
80 78 55

81 56
82 57
83
84

28 30 31 33
32 34 4
26 27 29
5
72
35
21 23
17 19 37 36
13 15
12 25 38
9 3
24
8
20 22
16 18 39
7 11 14
10 6 40
8 41
42 2
1
43 65
44
45
46
48 47

49

Fig. 7 - Exploded View Of Hydraulic Pump

SM 2196 2-03 5
Body System - Main Hydraulic Pump
Section 230-0050

LEGEND FOR FIG. 7

1 - Valve Cover 22 - Spring Seat 43 - Cylinder Spring 64 - Pin


2 - Bolt 23 - Spool 44 - Spherical Bush 65 - Pin
3 - Bolt 24 - Spool 45 - Set Plate 66 - Tilting Pin
4 - Nut 25 - Casing 46 - Piston & Shoe 68 - Eye Bolt
5 - Set Screw 26 - Bolt 47 - Shoe Plate 69 - Spring Seat
6 - Pressure Regulator 27 - Plug 48 - Tilting Bush 70 - Outer Spring
7 - Set Screw 28 - Orifice 49 - Swash Plate 71 - Inner Spring
8 - Nut 29 - 'O' Ring 50 - Swash Plate Support 72 - Plug
9 - Plug 30 - Plug 51 - Pump Casing 73 - Plug
10 - Plug 31 - Plug 52 - 'O' Ring 74 - 'O' Ring
11 - 'O' Ring 32 - 'O' Ring 53 - Plug 75 - 'O' Ring
12 - 'O' Ring 33 - Plug 54 - 'O' Ring 76 - Plug
13 - Stopper 34 - Plug 55 - Plug 77 - Snap Ring
14 - Stopper 35 - Orifice 56 - Bolt 78 - Bearing Spacer
15 - 'O' Ring 36 - Plug 57 - Lockwasher 79 - Roller Bearing
16 - 'O' Ring 37 - Plug 58 - Stopper 80 - Driveshaft
17 - Spring 38 - 'O' Ring 59 - Back-up Ring 81 - Oil Seal
18 - Spring 39 - 'O' Ring 60 - 'O' Ring 82 - 'O' Ring
19 - Spring 40 - Needle Bearing 61 - Servo Piston 83 - Seal Cover
20 - Spring 41 - Valve Plate 62 - 'O' Ring 84 - Bolt
21 - Spring Seat 42 - Cylinder Block 63 - 'O' Ring

plate (47) and swash plate (49). a) Ensure that all damaged parts are fixed or replaced
before assembly.
10. Remove swash plate support (50) from pump
casing (51). b) Before assembly wash each part with clean oil and
dry with compressed air. Assemble pump in a clean
11. If necessary, remove servo piston (61), tilting pin work area to prevent contamination.
(66), outer spring (70), inner spring (71), spring seat
(69) and plug (76). Ensure servo piston (61) and tilting c) When assembling apply clean oil on the sliding
pin (66) are not damaged when being removed. surfaces and bearings.

d) When assembling parts that easily detach, like an


Pressure Regulator 'O' ring, apply clean grease to prevent them dropping
1. Remove plug (9) and then remove springs (17 & 19) out.
and spring seat (21). Be careful not to drop spool (23)
after removing plug (9). Do not remove nut (8), set 1. Install servo piston (61), tilting pin (66), outer spring
screw (7) or stopper (13) unless required. (70), inner spring (71), spring seat (69) and plug (76) in
pump casing (51). Apply adhesive on thread of servo
2. Remove plug (10) and then remove springs (18 & 20) piston (61).
and spring seat (22). Be careful not to drop spool (24)
after removing plug (10). Do not remove nut (8), set 2. Fit swash plate support (50) in pump casing (51).
screw (7) or stopper (14) unless required. Make sure that pin (64) enters into the slit of swash
plate support (50). Be careful not to install swash plate
3. Loosen plug (33) and remove spools (23 & 24). support (50) in oblique.

4. If necessary, remove plugs (27, 31, 34 & 36) and 3. Push down servo piston (61) and insert tilting pin
orifice (28 & 35). (66) into tilting bush (48) of swash plate (49). Install
swash plate (49) and shoe plate (47) into groove of
swash plate support (50) correctly.
ASSEMBLY
Numbers in parentheses refer to Figs. 1 & 7. 4. Insert driveshaft (80) into pump casing (51), tapping
driveshaft (80) lightly so that the end of roller bearing
This is largely the reverse sequence to disassembly, (79) is slightly above the surface of pump casing (51).
but note the following:- This prevents the swash plate support (50) being
displaced.

6 SM 2196 2-03
Body System - Main Hydraulic Pump
Section 230-0050
5. Cover the splined end of the driveshaft (80) with INSTALLATION
plastic tape. Apply grease on lip of oil seal (81)
Numbers in parentheses refer to Figs. 1 & 7.
installed in seal cover (83). Insert seal cover (83)
slightly into pump casing (51). Tighten bolts (84)
Note: Tighten all hydraulic lines fitted with ORFS
uniformly to locate seal cover (83), then tighten bolts to
connections, as described in Section 250-0000,
standard torque.
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
6. Sub-assemble cylinder block (42), pistons and
shoes (46), spherical bush (44), set plate (45) and
cylinder springs (43).
WARNING
To prevent personal injury and property
7. Place pump casing (51) horizontally with surface of
damage, be sure lifting equipment is properly
regulator downward. Install piston-cylinder sub-
secured and of adequate capacity to do the job
assembly into pump casing (51).
safely.
8. Install valve plate (41) on valve cover (1). When
1. Install new 'O' ring to pump.
installing valve plate (41), ensure that pin (65) enters
into the slit of valve plate (41). If stopper (58), max flow
2. Push pump inward to engage with coupling in
set screw (5) and max flow set screw lock nut (4) have
transmission. Secure pump assembly to transmission
been removed, reinstall these parts on valve plate (41)
with bolts (56) and lockwashers (57). Tighten bolts (56)
beforehand.
to a torque of 230 Nm (170 lbf ft).
9. Install valve cover (1) on pump casing (51) and
3. Remove caps and connect outlet, inlet and load
secure using bolts (2 & 3).
sense lines to pump. Before connecting case drain
line, fill pump casing through drain port with clean
10. Install regulator casing (25) to pump casing (51)
hydraulic oil as used in the hydraulic tank. Connect the
and secure with bolts (26).
case drain line to pump. Fill hydraulic tank with oil
specified in Section 300-0020, LUBRICATION
Pressure Regulator SYSTEM.
1. If removed, install plugs (27, 31, 34 & 36) and orifice
Note: It is very important that pump casing is
(28 & 35) into regulator casing (25).
completely filled with hydraulic oil. This will ensure
proper lubrication of the internal parts of pump when it
2. Install plug (33) and insert spools (23 & 24). When
is initially operated. Fill the pump casing through the
inserting spools, care should be taken not to damage
drain port. Filling only the suction line is totally
the sliding surface of the spools.
insufficient.
3. If removed, install nut (8), set screw (7) and stopper
4. Refer to 'PUMP STARTING PROCEDURE' for
(13). Insert springs (17 & 19) and spring seat (21) into
proper start-up procedure.
plug (9).

4. Install plug (9) into regulator casing (25). PUMP STARTING PROCEDURE
1. Be sure the pump case drain line is free from
5. If removed, install nut (8), set screw (7) and stopper obstructions that restrict the pump case drain flow
(14). Insert springs (18 & 20) and spring seat (22) into back to tank and cause high case drain pressure which
plug (10). can lead to an early pump failure.
6. Install plug (10) into regulator casing (25). 2. Ensure that all hydraulic controls are set to a neutral
position, the steering lock bar is in the 'Locked' position
7. Ensure 'O' rings (38) are in place and install regulator and place the battery master switch in the 'On' position.
casing (25) on pump casing (51) using bolts (26). Start the engine and allow the pump to run unloaded for
a period to ensure that all residual air within the system
is released.

3. Check for external leakage, abnormal noise and


vibrations.
SM 2196 2-03 7
Body System - Main Hydraulic Pump
Section 230-0050
4. Remove wheel blocks and place the steering lock SM - 2849
bar in the 'Stowed' position. Start the engine and check
hydraulic systems for proper operation.

PRESSURE CHECKS
To check pump delivery pressure (cut-off pressure) the
1
steering should be operated full lock against the stops.
The pump is checked against the steering system as 2
P
this is the highest pressure requirement in the hydraulic FB 3
circuit. RB 4
5
6
WARNING
7
Machine has to fully articulate to check pump
8
pressures, therefore steering lock bar cannot be
'Locked'. To prevent personal injury and 9
property damage, exercise extreme caution
while working around articulation and
oscillation pivot area.
1 - LS VAL (Load Sense Pressure)
Delivery Pressure (cut-off pressure) 5 - STR (Steering Pressure)
Install a pressure gauge capable of at least 240 bar (3
500 lbf/in2) into STR diagnostic checkpoint in battery Fig. 8 - Diagnostic Test Points
box (5, Fig. 8). When steering against stops, pressure
should be 240 bar (3 500 lbf/in2). completely filled with hydraulic oil before pump is
operated. Fill the pump casing through the drain port.
Differential Pressure (load sense pressure) Filling only the suction line is totally insufficient.
Install a pressure gauge capable of at least 240 bar (3
500 lbf/in2) into STR diagnostic checkpoint in battery
box (5, Fig. 8). Install a pressure gauge capable of at
Differential Pressure Setting
least 240 bar (3 500 lbf/in2) into LS VAL diagnostic Numbers in parentheses refer to Figs. 1 & 7, unless
checkpoint in battery box (1, Fig. 8). With steering in otherwise stated.
neutral position, pressure at STR gauge should be 25
bar (360 lbf/in2) greater than pressure at LS VAL gauge. 1. Install a pressure gauge capable of at least 240 bar
(3 500 lbf/in2) into STR diagnostic checkpoint in battery
If these pressures are not observed, then pump may box (5, Fig. 8) to measure pump delivery pressure (cut-
need to be reset (refer to Troubleshooting). off pressure) (Gauge A).

2. Install a pressure gauge capable of at least 240 bar


TROUBLESHOOTING (3 500 lbf/in2) into LS VAL diagnostic checkpoint in
If steering cannot be operated or is excessively heavy, battery box (1, Fig. 8) to measure load sense pressure
then pump delivery pressure is likely to be low and setting (Gauge B).
pump setting should be checked.
3. Ensure that all hydraulic controls are set to a neutral
If the difference (P) between delivery pressure and position, the steering lock bar is in the 'Locked' position
load sense pressure is equal to 25 bar (360 lbf/in2), and place the battery master switch in the 'On'
proceed to 'Pump Setting Procedure - Pump Delivery position. Start the engine and allow to run at low idle.
Pressure Setting'. This allows the pump to run unloaded for a period to
ensure that all residual air within the system is
However, if P is not equal to 25 bar (360 lbf/in2) carry released. Check for external leaks.
out complete 'Pump Setting Procedure'.
4. Check readings on both pressure gauges. Pump
delivery pressure (Gauge A) should always be greater
PUMP SETTING PROCEDURE than load sense pressure (Gauge B). This differential
Note: It is very important that pump casing is pressure (P) should be equal to 25 bar (360 lbf/in2). If

8 SM 2196 2-03
Body System - Main Hydraulic Pump
Section 230-0050

SM - 2846 6. Recheck readings on both pressure gauges. Pump


delivery pressure (Gauge A) should be 25 bar (360 lbf/
BACK OF PUMP
in2) greater than load sense pressure (Gauge B).

7. Once correct P is achieved, tighten nut (8) at


Load Sense differential pressure (load sense) port to 16 Nm (12 lbf
Port (PL)
ft).

8. The differential pressure (P) is now set. Switch off


Delivery the engine and relieve system pressures as described
Pressure in 'Removal'.
(Cut-off
Pressure)
9. Remove pressure gauges from diagnostic
checkpoints in battery box.

Pump Delivery Pressure Setting


Differential Numbers in parentheses refer to Figs. 1 & 7, unless
Pressure otherwise stated.
(Load Sense
Pressure)

WARNING
Machine has to fully articulate to set pump,
Fig. 9 - Pump Adjustment At Pressure Regulator therefore steering lock bar cannot be 'Locked'.
To prevent personal injury and property
the P pressure differs from 25 bar (360 lbf/in2), then damage, exercise extreme caution while
carry out steps 5 through 9. working around articulation and oscillation
pivot area.
Note: Typical readings -
STR = 34 - 38 bar (500 - 550 lbf/in2) There should be no requirement to adjust the set screw
LS Val = 11 - 13 bar (160 - 180 lbf/in2) (7) at delivery pressure (cut-off pressure) port (see Fig.
9) as this is factory set. The cut-off pressure sets the
Note: If the pump delivery pressure (Gauge A) is less pump delivery pressure. If the set screw (7) or nut (8)
than 25 bar (360 lbf/in2), disconnect transmission oil has been moved, to reset the pump delivery pressure
cooler fan solenoid, causing solenoid valve to default follow the procedure below:
to an open position, allowing hydraulic oil to the fan
motor. This will place a demand on the pump, causing 1. Install a pressure gauge capable of at least 240 bar
pump delivery pressure to increase. (3 500 lbf/in2) into STR diagnostic checkpoint in battery
box to measure pump delivery pressure (cut-off
5. At differential pressure (load sense) port (see Fig. 9), pressure).
unlock nut (8) and turn set screw (7) clockwise (looking
straight at set screw) to increase P pressure, or 2. Start the engine and run at full throttle. Steer full
counter-clockwise to decrease P pressure. lock against the stops. Observe pressure on gauge.
This cut-off pressure should be 240 bar (3 500 lbf/in2).
Note: Adjustment of P pressure = 5 bar (70 lbf/in2) If the pressure reading differs or the steering is
increase per quarter turn of set screw (7). This is a excessively heavy, then carry out steps 3 through 8.
result of an increase of 7 bar (100 lbf/in2) on the pump
delivery pressure and an increase of 2 bar (30 lbf/in2) Note: Steering has to be operated over relief (against
on the LS pressure. stops) as this is the maximum pressure the pump must
deliver. Setting pump against any other operation would
Note: Pressure should always be adjusted on the result in the pump being set at a lower maximum
increase. Hence if P pressure is too high, set screw delivery pressure.
(7) should be turned counter-clockwise approximately 2
turns, then turn set screw (7) clockwise to attain 25 bar 3. At delivery pressure (cut-off pressure) port (see Fig.
(360 lbf/in2). 9), unlock nut (8) and turn set screw (7) clockwise to
increase cut-off pressure, or counter-clockwise to

SM 2196 2-03 9
Body System - Main Hydraulic Pump
Section 230-0050
decrease cut-off pressure (adjustment 90 bar (1 305 lbf/ Note: If there are still problems with the pump
in2) per turn). pressures after completing the 'Pump Setting
Procedure', ensure set screw (5) has not been
Note: Pressure should always be adjusted on the adjusted. As a dimensional check, the distance
increase. Hence if cut-off pressure is too high, set between the end of set screw (5) to the face of nut (4)
screw (7) should be turned counter-clockwise to should be 16 mm (0.63 ").
decrease cut-off pressure below 240 bar (3 500 lbf/in2),
then turn set screw (7) clockwise to attain 240 bar (3
500 lbf/in2). LUBRICATION
Refer to Section 300-0020, LUBRICATION SYSTEM,
4. Once correct cut-off pressure has been attained, for recommended periodic oil change periods and oil
revert steering to neutral position, then steer full lock specifications.
against the stops. Observe gauge to confirm cut-off
pressure is set to 240 bar (3 500 lbf/in2). All pump parts are lubricated by the hydraulic oil
therefore the oil must be kept clean to minimize pump
Note: A change in pump tone should be heard when wear. Whenever there is a hydraulic system failure, the
cut-off pressure is reached, as pump de-strokes to oil should be drained, the entire system flushed, oil
standby condition. filter replaced and clean hydraulic oil added to
eliminate all metal particles or foreign matter.
5. If no change in pump tone is heard, cut-off pressure
is too high. Return to step 3 of procedure. If problem
persists, refer to Section 220-0000, STEERING PUMP WEAR LIMITS
SYSTEM SCHEMATIC. Before reassembling the pump after disassembly, the
Pump Wear Limits table should be consulted to
6. Tighten nut (8) at cut-off pressure port to 16 Nm (12 establish which components should be replaced.
lbf ft).

7. The differential pressure (load sense) and cut-off SPECIAL TOOLS


pressure are now set. Switch off the engine and relieve There are no special tools required for the procedures
system pressures as described in 'Removal'. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
8. Remove pressure gauge from diagnostic checkpoint tools required. These tools are available from your
in battery box. dealer.

PUMP WEAR LIMITS


INITIAL LIMIT FOR
ITEM VALUE REPLACING ACTION
Clearance between cylinder (42) 0.039 mm 0.067 mm Replace piston/cylinder
bore and piston (46)
Endplay between piston 0.1 mm 0.3 mm Replace piston-shoe assembly
and shoe (46)
Thickness of shoe 4.9 mm 4.7 mm Replace piston-shoe assembly
Free height of cylinder 39.5 mm 38.8 mm Replace cylinder spring
spring (43)
Combined height of set 23.0 mm 22.0 mm Replace set plate
plate (45) and spherical bush (44)

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 8 Nut 16 12
1 56 Bolt 230 170
* * * *
10 SM 2196 2-03
BODY SYSTEM - Body Control Lever
Section 230-0081

DESCRIPTION AND OPERATION SM - 2865

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


to rear are as follows:

Power Down - Pushing the lever forward provides


Fig. 1 - Body Control Lever
hydraulic force to power-down the body. Pushing the
lever fully forward will engage the electric detent. When
the body reaches the body proximity switch, the lever
springs back to 'NEUTRAL' and power down is ramped
back to allow the body to float down onto the chassis. WARNING
Always disconnect body control lever before
Neutral - If the body is above the body proximity welding on the machine.
switch, the lever in this position will stop and hold the
body at any desired height. If the body is below the
proximity switch, the hydraulic ECU defaults the MAINTENANCE
control spool in the main hydraulic valve to the neutral The body control lever is a non-serviceable item and
position and energises the float solenoid, allowing the should be replaced completely, if damaged, as follows:
body to float down onto the chassis. The body should
be fully lowered and in the 'NEUTRAL' position while Note: Tighten all fasteners to standard torques listed in
the machine is in motion. The lever will remain in the Section 300-0080, STANDARD BOLT AND NUT
'NEUTRAL' position when released. TORQUE SPECIFICATIONS.

Raise - Pulling the lever back and holding it in this


position directs oil to extend the body hoists and raise WARNINGS
the body. When released, the lever will spring back to To prevent personal injury and property
the 'NEUTRAL' position. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
A body lower emergency switch in the cab is secured and of adequate capacity to do the job
connected directly to the float solenoid, within the main safely.
hydraulic valve, to enable the lowering of the body in
the event of an engine, hydraulic or hydraulic ECU Hydraulic fluid pressure will remain
failure. The cause of the failure must be investigated within the system after engine shut down.
and corrected. Operate the treadle pedal continuously until the
pressure has dissipated before carrying out any
Note: The body must remain lowered with lever in the work on the hydraulic system or serious injury
'NEUTRAL' position until it is necessary to operate the could result.
body again. Failure to comply to this could result in
overheating the hydraulic oil and failure of the hydraulic 1. Position the vehicle in a level work area, apply the
system components. parking brake and switch off the engine.

SM 2202 3-03 1
Body System - Body Control Lever
Section 230-0081
2. Operate the treadle valve continuously to relieve 8. Reconnect main harness to body control lever
pressure in the hydraulic system. harness.

3. Block all road wheels, place the steering lock bar in 9. Place the battery master switch in the 'On' position,
the 'Locked' position and the battery master switch in start the engine and bring hydraulic oil to operating
the 'Off' position. temperature. Operate the body control lever to ensure
correct operation.
4. Disconnect body control lever harness from main
harness. 10. Remove wheel blocks and place the steering lock
bar in the 'Stowed' position.
5. Support body control lever and remove screws
securing body control lever on the right hand dash
panel. TROUBLESHOOTING
A faulty body control lever will cause an input error at
6. Remove body control lever from mounting location. the hydraulic ECU. Refer to Section 190-0085,
HYDRAULIC SYSTEM ECU.
7. Secure new body control lever on the right hand
dash panel with screws.
SPECIAL TOOLS
Note: Ensure harness from body control lever is at the There are no special tools required for procedures
front when lever is installed. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.

* * * *

2 SM 2202 3-03
BODY SYSTEM - Body Cylinder
Section 230-0130

SM - 2468

20 21 23 7 22,6 17,18 9 4 5 11 14 13 14 18 19 23 21 20

3 10 1 16 12 15

BODY MOUNTING FRAME MOUNTING


26
28
GROOVE 27
THIS SIDE
26
ORIENTATION OF 25
CUSHION SLEEVE
25
29
24 28 27

1 - Cylinder Body 8 - 'O' Ring 15 - Grub Screw 22 - Nylon Ring


2 - Piston Rod 9 - 'O' Ring 16 - 'O' Ring 23 - Lube Fitting
3 - End Cap 10 - Lock Ring 17 - Back Up Ring 24 - Upper Pin
4 - Cushion Sleeve 11 - Cushion Spear 18 - Cushion Sleeve 25 - Spacer
5 - Circlip 12 - Piston 19 - Circlip 26 - Bolt
6 - Rod Seal 13 - Piston Seal 20 - Spherical Bearing 27 - Lockwasher
7 - Wiper 14 - Wear Ring 21 - Circlip 28 - Washer
29 - Lower Pin
Fig. 1 - Sectional View Of Body Cylinder and Mounting

DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.

There are two single stage, double acting body hoist


cylinders, cushioned at both ends of the stroke on the WARNINGS
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 materials and lifting equipment are properly
rod (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 (24 & 29), spacers (25) Hydraulic fluid pressure will remain
and spherical bearings (20) secured in place with within the body hoist system after engine
circlips (21). Spherical bearings (20) 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 2207 9-05 1
Body System - Body Cylinder
Section 230-0130

DISASSEMBLY
WARNING Numbers in parentheses refer to Fig. 1.
Exercise extreme caution when lowering
the cylinders from the body. The cylinders will
swing out sharply as they leave their WARNING
mountings. To prevent personal injury and property
damage, be sure lifting equipment is properly
1. Position the vehicle in a level work area, ensure the secured and of adequate capacity to do the job
body is fully lowered, apply the parking brake and safely.
switch off the engine.
1. Ensure clean working conditions, remove any port
2. Press and hold down body hoist bleed down switch plugs thus allowing easy entry of air into cylinder body
and operate the body control joystick continually to (1), preventing a vacuum when parts are withdrawn
relieve pressure in the body hoist system. from cylinder body (1).

3. Block all road wheels, place the steering lock bar in 2. Remove circlips (21) 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. (20).

4. Install a suitable strap around the cylinder and 3. Remove lock ring (10) from end cap (3).
attach to a lifting device.
4. Using special tool which can be fabricated as shown
5. Position a suitable container at the base end of one in Fig. 2, unscrew end cap (3) until thread is
cylinder. Identify and remove the hydraulic lines. Cap disengaged from cylinder body (1).
hydraulic lines and cylinder ports to prevent entry of
dirt. 5. Support piston rod (2) at the rod eye and withdraw
piston rod (2) from cylinder body (1). Ensure centre
6. Remove bolt (26), lockwasher (27), washer (28) and lines of piston rod (2) and cylinder body (1) remain
upper pin (24) connecting piston rod (2) end of the coincidental during removal of piston rod (2).
cylinder to the body. If due to lack of maintenance the
upper pin can not be removed from the front, there is 6. Place piston rod (2) on supports which will not
plate on the inside of the body that can be removed to damage the piston rod diameter.
allow access to the rear of the pin to ease removal.
This plate is tack welded in place so a grinder is 7. Remove and discard piston seals (13) and wear
required to remove it. rings (14) from piston (12).

7. Lower cylinder slowly and remove spacers (25). 8. Remove grub screw (15) from wear ring (14) groove
in piston (12).
Note: Cylinder will swing out sharply as it leaves its
mounting. 9. Provide an anti-torsion device through piston rod (2)
eye to allow unscrewing of piston (12). Using special
8. Remove bolt (26), lockwasher (27), washer (28) and tool which can be fabricated as shown in Fig. 3,
lower pin (29) connecting base end of the cylinder to unscrew piston (12) from piston rod (2).
the frame.
10. Remove cushion spear (11) and 'O' rings (16) from
9. Remove spacers (25) and remove cylinder assembly piston rod (2). Discard 'O' rings (16).
to a clean area for disassembly.
11. Remove cylinder end cap (3) from piston rod (2).
10. Repeat steps 4 through 9 for opposite cylinder. Remove and discard cushion sleeve (4), circlip (5), rod
seal (6), nylon ring (22), wiper (7), 'O' rings (8 & 9) and
back up ring (17).

2 SM 2207 9-05
Body System - Body Cylinder
Section 230-0130

INSPECTION 6. Ensure cushion sleeve (18) and circlip (19) are


Numbers in parentheses refer to Fig. 1 secure in piston (12).

1. Clean all parts of the cylinder with a suitable solvent 7. Insert new piston seal (13) and new wear rings (14)
and dry with clean, lint-free cloths. Clean all grooves in piston (12).
carefully to remove any foreign material.
8. Fully grease piston (12) OD and 'O' rings (8 & 9) in
2. Check cylinder body (1) and outer diameter of piston end cap (3).
(12) for scratches, cracks or other defects. Remove
ridges, nicks and scratches with a fine stone and re- 9. Sling assembled piston rod (2) in a manner to allow
clean. Replace any components which cannot be careful leading of the assembled piston rod into
repaired. cylinder body (1). Take care not to damage piston seal
(13) on cylinder body (1) threads.
3. Inspect piston rod (2) for distortion, cracks or other
defects. Replace piston rod if defective area is 10. After piston (12) is inserted in cylinder body (1), push
irreparable. the piston rod assembly into cylinder body (1) maintaining
coincidental centre lines of piston rod and cylinder body.
4. Check spherical bearing (20) for wear and replace if
necessary. 11. Before piston rod (2) is fully home and, with slings
still taking some of piston rod (2) weight, engage end
cap (3) thread and screw home.
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 12. Push piston rod (2) to the fully retracted position and
tighten end cap (3) to a torque of 237 Nm (175 lbf ft).

WARNING 13. Re-drill end cap (3) for lock ring (10), 3 x 12 mm
To prevent personal injury and property (0.125 x 0.50 in) deep, if necessary. Insert lock ring
damage, be sure lifting equipment is properly (10) in end cap (3).
secured and of adequate capacity to do the job
safely.
INSTALLATION
1. Press spherical bearing (20) in base end of cylinder Numbers in parentheses refer to Fig. 1.
body (1) and piston rod (2) end. Secure spherical
bearings (20) with circlips (21). Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY
2. Install new cushion sleeve (4), circlip (5), rod seals (6), SYSTEM SCHEMATIC. Renew all 'O' rings where used.
nylon ring (22), 'O' rings (8 & 9) and back up (17) in end cap
(3). Load end cap (3) over piston rod (2) thread, taking care
not to damage rod seal (6) on the thread. WARNING
To prevent personal injury and property
3. Install new 'O' rings (16) on piston rod (2) and damage, be sure lifting equipment is properly
replace cushion spear (11). secured and of adequate capacity to do the job
safely.
4. Apply Loctite 243 to first two threads of piston (12).
Using special tool which can be fabricated as shown in 1. Install a suitable strap around the cylinder and
Fig. 3, screw on piston (12) and tighten to a torque of position cylinder on unit with base end of cylinder ready
1 356 Nm (1 000 lbf ft). for mounting.

5. Insert piston grub screw (15) through wear ring (14) 2. Install spacers (25) in base end of cylinder and
groove in piston (12) and into groove machined in insert lower pin (23) through mounting bores, spacers
piston rod (2). Tighten grub screw (15) to a torque of 49 (25) and cylinder. Secure lower pin (23) with washer
Nm (36 lbf ft). Ensure the extreme of grub screw (15) is (28), lockwasher (27) and bolt (26). Tighten bolt (26) to
below the level of wear ring (14) groove. a torque of 66 Nm (49 lbf ft).

SM 2207 9-05 3
Body System - Body Cylinder
Section 230-0130
3. Install spacers (25) in rod end of cylinder, align start the engine, operate the body and check cylinder lines
spherical bearing with bores in body and install upper for leaks. Tighten lines and fittings as required.
pin (24) through mounting bores, spacers (25) and
cylinder. Secure upper pin (24) with washer (28), 8. Remove wheel blocks from road wheels.
lockwasher (27) and bolt (26). Tighten bolt (26) to a
torque of 66 Nm (49 lbf ft).
MAINTENANCE
4. Connect the hydraulic oil lines to the cylinder ports Every 250 hours: Lubricate cylinder pins as described
as tagged during removal. in Section 300-0020, LUBRICATION SYSTEM. Inspect
cylinders for leaks, if leaks are found, replace seals
5. Lubricate pins at lube fittings (22) with lubricant as with seals contained in the Service Repair Kit, as
specified in Section 300-0020, LUBRICATION SYSTEM. specified in the parts book.

6. Check oil level in hydraulic tank and add if low.


Refer to Section 230-0040, HYDRAULIC TANK, for SPECIAL TOOLS
correct fill level. Refer to Section 300-0020, Special tools can be fabricated as shown in Figs. 2 & 3.
LUBRICATION SYSTEM, for the type of oil used. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools are
7. Place the battery master switch in the 'On' position, available from your dealer.

SM - 2469

50 25
160 (6.299) (1.9680) (0.984)

90 (3.54) 10
DRILL 13 (0.51) (0.394) 11
RAD X 25 (0.984) (0.433)
DEEP

10 (0.394)
RAD TYP
150 (5.90) DIA

110 (4.33) DIA


120 (4.724)

(3.154 - 0.000 )

(4.724 - 0.005 )
+0.002

120.00 - 0.13
(1.9680)
80.10 - 0.00
+0.05
94 (3.7)

+
50

19 (0.75)
SQUARE

SECURE ALUMINIUM FIT 2 OFF B&T BUSH 12 (0.472) ID


COLLAR WITH (3) M8 25 65 18 (0.708) OD AND 2 OFF 12 DIA DOWEL
CAP SCREWS (0.984) (2.560) DRIVE FIT IN BUSH
110 (4.33)
Dimensions in mm (in)
Fig. 2 - End Cap Torque Tool

4 SM 2207 9-05
Body System - Body Cylinder
Section 230-0130

SM - 2470

89 (3.5)
38.1 (1.5)

(0.375)
9.525

DIA
(0.470)
11.938
124.45 - 0.000 (4.899 - 0.000 )
+0.005

DIA
90 - 0.05 (3.543 - 0.002 )
SILVER STEEL

136 (5.35)
+
25.4 (1.0)
SQUARE

+0.13
+

(0.500)
12.7
EN3B

DIA
MILD STEEL

OUTER SHELL TO BE SECURED DOM TUBE


TO INNER BODY WITH 2BA CAP SCREWS 10.16 25.4
(0.4) (1.0)

Dimensions in mm (in)
Fig. 3 - Piston Torque Tool

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 3 End Cap 237 175
1 12 Piston 1 356 1 000
1 15 Grub Screw 49 36
1 26 Bolt 66 49

* * * *

SM 2207 9-05 5
BRAKING SYSTEM - Braking System Schematic
Section 250-0000
SM - 2848

9 TO PARKING 17 17 18
PP BRAKE

FROM
TRANSMISSION

P1
A 13 13
TO FRONT
SERVICE BRAKES T1

ACC2

ACC1

ACC1

ACC2

ACC3
PBP

PB
TS
1
P2
A
TO REAR 3 4
SERVICE BRAKES 2
T2
14
8
6 7

10 11

12

19 16

15
P1

21

25

5
LSP T

1 - Orifice 6 - Park Brake Solenoid Valve 11 - Orifice 16 - Cold Start Solenoid Valve
2 - Directional Control Valve 7 - Brake System Relief Valve 12 - Orifice 17 - Brake Accumulators
3 - Check valve 8 - Brake System Charge Valve 13 - Pressure Switch 18 - Primary Accumulator
4 - Check Valve 9 - Brake Treadle Valve 14 - Pressure Switch 19 - Pressure Switch
5 - Main Hydraulic Pump 10 - Check Valve 15 - Priority Valve 21 - Shuttle Valve
25 - Shuttle Valve
Fig. 1 - Brake System Schematic

DESCRIPTION Service Brakes


Numbers in parentheses refer to Figs. 1, 2 and 9. Refer to Section 165-0010, BRAKE PARTS.

The hydraulic braking system is of closed centre The service brakes are of the calliper disc-type. The
design wherein constant pressure is stored in calliper head is designed for use with hydraulic oil as
accumulators and is regulated as required to retard or specified in Section 300-0020, LUBRICATION
stop the machine. SYSTEM. DO NOT use BRAKE FLUID (J 1703).

A brief description of the individual components used The brake head is bolted to a mounting plate on the
in the braking system are listed below. Detailed axle housing and the brake disc is bolted to the wheel.
service and operating instructions can be found in the There are 2 brake heads and one brake disc at each of
relevant component sections of this manual. the six road wheels.

SM 2198 2-03 1
Braking System - Braking System Schematic
Section 250-0000
Each brake head assembly consists of a torque plate, Hydraulic Tank
two brake pads (one on each side of the brake disc)
Refer to Section 230-0040, HYDRAULIC TANK.
and four brake pistons (two on each side of the brake
disc). The piston bores on each side of the torque
The hydraulic tank is the common reservoir for the
plate are interconnected by internal passages.
steering, braking and body hoist systems. It is
mounted off the frame and fender bracket on the rear
When the treadle valve is actuated, hydraulic oil enters
right hand side of the tractor.
the brake head and forces the pistons against the
brake pads which are in turn forced against each side
Integral with the hydraulic tank assembly are the
of the brake disc slowing or stopping the brake disc
hydraulic oil filter, oil strainer and oil level sight gauge.
and wheel rotation.
Located on the top of the tank assembly is the filler
cap and breather.
In an emergency situation, application of the park/
emergency valve will actuate the service brakes and
the parking brake to bring the machine to a halt. In this Main Hydraulic Pump (5)
condition, a restriction in the 'PB' line will slow oil flow
Refer to Section 230-0050, MAIN HYDRAULIC PUMP.
from the parking brake allowing the service brakes to
actuate momentarily ahead of the parking brake.
Mounted off the transmission power takeoff, the main
hydraulic pump supplies hydraulic oil for operating the
Parking Brake steering, body, brakes and transmission cooler fan
drive circuits.
Refer to Section 170-0010, PARKING BRAKE AND
MOUNTING.
The main hydraulic pump is an axial piston, variable
displacement type, with load sense and pressure
The parking brake consists of a sliding calliper acting
regulator.
on a brake disc on a rear driveline and is of 'Inverted
Design' i.e. requiring pressure to hold it off.
Parking Brake Pressure Switch (14)
Operation is by a spring applied/hydraulically released
Located on the main hydraulic valve assembly it
actuator. The actuator is connected through a slack
senses pressure in the parking brake (PB) line. The
adjuster to the power screw shaft that is screwed into the
pressure switch closes at a pressure of 5 bar (70 lbf/
piston in the calliper head assembly. The calliper head
in) and sends a signal to illuminate the parking brake
assembly slides on anchor plate guides in a bracket
indicator light when the parking brake is applied.
assembly bolted to the trailer frame.

A push control on the right hand dash panel activates Brake Circuit Pressure Switches (13)
the park brake solenoid valve (6) on the main hydraulic
Front and rear brake circuit pressure switches are both
valve assembly, controlling oil pressure from the rear
located on the main hydraulic valve assembly. The
brake circuit accumulator to the actuator. Application of
pressure switches sense pressure in the front and rear
the push control releases oil from the actuator allowing
brake circuits and sends a signal to warning lights on
internal springs in the actuator to apply the parking
the dash (a buzzer also sounds) when the pressure
brake. Pulling out the push control directs oil pressure
drops below 122 bar (1 770 lbf/in). The warning lights
from the rear brake circuit accumulator to the actuator,
will remain illuminated until the pressure rises above
compressing internal springs, to release the parking
135 bar (1 960 lbf/in2).
brake.

In an emergency situation, application of the park/ Brake Accumulators (17/18)


emergency valve will actuate the service brakes and Refer to Section 250-0060, ACCUMULATOR.
the parking brake to bring the machine to a halt. In this
condition, a restriction in the 'PB' line will slow oil flow There are three accumulators mounted inside the
from the parking brake allowing the service brakes to battery box located on the front left hand side of the
actuate momentarily ahead of the parking brake. tractor; one for the front brake system and one for the
rear. The front and rear brake accumulators are
supplemented by a third (primary) accumulator (18),
also mounted inside the battery box. The primary
accumulator supports the service brake system and

2 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000
the body pilot pressure system. All three accumulators Advanced Retarder Braking
are of the piston type and are precharged with nitrogen
Mounted on the brake treadle valve is a potentiometer
to 95 bar (1 380 lbf/in). It consists of a charging valve
and brake pedal interface module.
assembly, cylinder assembly and piston. The charging
valve is equipped with a locking feature which, when
The first 5 movement of the brake pedal engages the
opened, will allow precharge to be checked or
transmission retarder, providing that the transmission
accumulator charged.
'Stop' warning light is OUT, the transmission is in
'lockup' and the oil temperature is within safe operating
The piston acts as a separator dividing the cylinder
range. Further movement of the brake pedal applies the
assembly into two sections. The bottom section
service brakes in addition to the transmission retarder.
nearest the charging valve contains the nitrogen
The transmission retarder will disengage when the
precharge. Hydraulic oil from the main hydraulic pump
brake pedal is released, or when any of the operating
flows through check valves in the main hydraulic valve
conditions become out of range.
and into the top section of the accumulators.
Accumulator pressure is monitored by pressure
switches (13) in the brake lines. Valves 1, 2, 3, 4, 6, 7, 8, 10, 11, 12, 15, 16,
21 & 25
SM - 2855
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
(F) ASSEMBLY.
13

OPERATION
13
14
(R) Numbers in parentheses refer to Figs. 1, 2 and 9.

Brake Charging
The valves integral of the main hydraulic valve
assembly automatically maintain the brake
accumulator pressures between a lower and upper
limit.

Accumulators (17) are charged from accumulator (18)


via brake system relief valve (7), to limit the pressure
in these accumulators to 155 bar (2248 lbf/in2) and then
via check valves (3 & 4) respectively.

13 - Service Brake Circuit Pressure Switches If the pressure in accumulator (18) is below the lower
14 - Park Brake Pressure Switch charge limit of 165 bar (2390 lbf/in2) the brake system
Fig. 2 - Brake System Pressure Switch Locations charge valve (8) spring closes the brake system
charge valve (8). The pressure then builds up in the
Brake Treadle Valve (9) load sense line from brake system charge valve (8) to
the shuttle valve (21) and onto the priority valve (15)
Refer to Section 250-0070, TREADLE VALVE. spring chamber where it helps this valve to close,
ensuring flow priority is to the brake charging. At the
The treadle valve controls the level of hydraulic fluid same time it also acts upon the main hydraulic pump
pressure applied to front and rear brakes and the load sense line via shuttle valve (25) to supply enough
maximum pressure available to these circuits. It is flow to charge the accumulators.
operated by a foot pedal in the operators cab and, with
the engine running, is automatically applied by the park As soon as the pressure in accumulator (18) reaches
brake solenoid valve (6) on the main hydraulic valve. the upper charge limit of 185 bar (2680 lbf/in2) the brake
system charge valve (8) opens and unloads the load
sense line to tank. This action unloads the main
hydraulic pump back to its standby pressure of 25 bar

SM 2198 2-03 3
Braking System - Braking System Schematic
Section 250-0000
(360 lbf/in2). SM - 2880

The accumulators (17 & 18) are also automatically 2


charged every time the pressure at the main hydraulic
pump rises above the pressure in accumulator (18). It
is therefore possible to achieve pressures up to the
main hydraulic pump cut off pressure of 240 bar (3 500
lbf/in2) in this accumulator (18) (eg. when steering over
relief). The brake system relief valve (7) will still limit
the pressure in accumulators (17) to 155 bar (2 248 lbf/
in2).

Orifice (12) is rated at 6 l/min and would protect all


three accumulators (17/18) against abnormally high 1
pressure spikes. However, accumulator (18) can see
system pressure if any of the main hydraulic functions
are held over relief for a period of time.

SM - 2852
12 24 36 48

K23
A K17 K50 K32
K23 K23 K52
B K14 C
K34 K5 K33 K27
K23
K15 K51 K4 D 1 - Brake Treadle Potentiometer
2 - Brake Interface Module
1 13 25 37

Fig. 3 - Fuse Box Layout (Operators Cab) Fig. 4 - Brake Treadle Potentiometer (Advanced Retarder)

Ref. Section 190-0000, Circuit Diagrams SM - 2853

1 - K50 RELAY (STOP LAMPS)


2 - K51 RELAY (RETARDER SELECT)

BRAKE LIGHT OUTPUT SIGNAL


(WHITE)

1
BRAKE LIGHT 0V
(BROWN)
SIG

RETARDER 0V (VIOLET)
BRAKE
(GREEN) PEDAL 0V PEDAL
2 INTERFACE
(BLUE)
POTENTIOMETER
RETARDER OUTPUT SIGNAL MODULE

(ORANGE) +5V
(GREY)
(+) BATTERY
(RED)

(-) BATTERY
(BLACK)

Fig. 5 - Brake Treadle Potentiometer - Interface Module Schematic (Advanced Retarder)

4 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000

Brake Apply creates an open circuit between the main hydraulic


valve assembly and port 'PP' on the brake treadle
The minimum pressure required at the brake treadle
valve. This permits a flow of oil to either energise the
valve is 105 bar (1 500 lbf/in2) and the accumulator pre-
'PP' port at the treadle valve, or, exhaust the 'PP' port
charge pressure is 90% of this at 95 bar (1380 lbf/in2).
through the main hydraulic valve assembly to tank,
dependant on operation of the park brake solenoid
The brake treadle valve controls the level of hydraulic
valve (6). The park brake solenoid valve (6) is
pressure applied to front and rear brakes and the
controlled by the park/emergency control switch inside
maximum pressure available to these circuits. It is
the operators cab.
operated by the foot pedal in the operators cab and in
an emergency with the engine running, is automatically
When the park/emergency control switch is activated
applied by the park brake solenoid valve (6) in the main
(pushed in), the electrical signal between the switch
hydraulic valve assembly (Ref. Park/Emergency Brake
and park brake solenoid valve (6) is opened. This
Function).
action de-energizes the park brake solenoid valve (6).
Oil flows through park brake solenoid valve (6) and
Mounted on the side of the brake treadle valve is a
through the directional control valve (2). The oil travels
potentiometer. This potentiometer links with the brake
pedal interface module, mounted on a dashboard SM - 2851
support, on the underside of the dashboard. The brake
pedal interface module converts voltage signals from
the potentiometer to activate transmission retarder and
A
rear brake lamps. The brake pedal interface module
energises K50, brake lamp relay and K51, transmission P(r)
P
retarder select relay. Both relays are located in T
A(r) T(r)
operator cab fuse box. When these relays are
energised an electrical circuit is complete to energise P(f)
P
appropriate lamps and solenoids. T
A(f) T(f)
A
The potentiometer works on a 0 to 5 Volt scale. K50
and K51 relays are activated when the output from the
potentiometer is greater than 1 Volt. This allows a 24 PP
Volt signal from the busbar to activate the rear brake
PP
lamps and the transmission retarder solenoid valve.
The relays are de-activated when the output from the
potentiometer is less than 1 Volt.

The first 5 movement of the brake pedal activates the


rear brake lamps and the transmission retarder,
providing that the transmission 'Stop' warning light is
OUT, the transmission is in 'lockup' and the oil
temperature is within safe operating range. Further
movement of the brake pedal applies the service
brakes in addition to the transmission retarder. The
transmission retarder will disengage when the brake
pedal is released, or when any of the operating
conditions become out of range.

Park/Emergency Brake Function


The park/emergency brake function is designed to
A(f) - Pressure to Front Brakes
electrically operate the park brake and with the engine A(r) - Pressure to Rear Brakes
running automatically actuates the service brakes also P(f) - Pressure from Front Brake Accumulator
during this operation. P(r) - Pressure from Rear Brake Accumulator
T(f) - Tank Return - Front Brakes
T(r) - Tank Return - Rear Brakes
When the engine is running, a transmission hydraulic PP - Emergency/Park Pilot Pressure
pilot pressure acts against the spring at the directional
Fig. 6 - Brake Treadle Valve Porting Arrangement
control valve (2). The directional control valve (2)
SM 2198 2-03 5
Braking System - Braking System Schematic
Section 250-0000
through the directional control valve and into the 'PP' the directional control valve (2) to move to the right
port in the treadle valve for an emergency brake under the influence of the compressed spring. This
application. movement links the 'PP' port at the brake treadle valve
with the hydraulic tank through the main hydraulic
Return oil from the parking brake circuit enters the valve assembly. This action results in a controlled
main hydraulic valve assembly. The oil flows through bleed down of the applied service brakes to hydraulic
park brake solenoid valve (6) and exits the main tank. This controlled bleed down permits a
synchronised service brake release/mechanical park
SM - 2849
brake application.

When the engine is shutdown, the park brake solenoid


valve (6) is automatically de-energised (fail safe). Park
brake hold off pressure is allowed to return to tank
through the park brake solenoid valve (6), causing park
brake to apply (spring applied). The vehicle is now held
1
with park brake only.
2
P
FB 3
RB 4 CHECKING SYSTEM PRESSURES
5 Numbers in parentheses refer to Figs. 1, 2 and 9,
6 unless otherwise stated.
7
8
WARNINGS
9
To prevent personal injury and property
damage, be sure wheel blocks and blocking
materials are properly secured and of adequate
capacity to do the job safely.

1 - Pump LS Pressure 7 - Trans. Converter Press. Hydraulic fluid pressure will remain
2 - Front Brake Pressure 8 - Body System Press.
within the system after engine shut down.
3 - Rear Brake Pressure 9 - Trans. System Pressure
4 - Park Brake Pressure P - Primary Accumulator Operate the brake treadle pedal continuously
5 - Steering Pressure FB - Front Brake Accumulator until the pressure has dissipated before
6 - Trans. Retarder Press. RB - Rear Brake Accumulator carrying out any work on the system or serious
Fig. 7 - Diagnostic Pressure Check Points (Battery Box) injury could result.
hydraulic valve assembly to the hydraulic tank. With no 1. Position the vehicle in a level work area, apply the
pressure in the parking brake circuit to hold the parking parking brake, switch off the engine and turn steering
brake off, the parking brake is applied. wheel in both directions several times to relieve any
pressure in the steering circuit.
When the emergency brake switch is deactivated
(pulled out), the electrical signal between the switch 2. Operate the brake treadle valve continuously to
and park brake solenoid valve (6) is closed, energizing relieve pressure in the braking system. Block all road
park brake solenoid valve (6). Oil flows through park wheels, place the steering lock bar in the 'Locked'
brake solenoid valve (6) and exits the main hydraulic position and the battery master switch in the 'Off'
valve assembly to the parking brake circuit to release position.
the parking brake.
3. Connect a hydraulic gauge, capable of recording a
Return oil from the 'PP' port on the brake treadle valve pressure of 0 - 345 bar (0 - 5 000 lbf/in), to park brake
flows through the directional control valve (2) through diagnostic pressure point (4, Fig. 7) inside battery box.
park brake solenoid cartridge (6) and exits the main
hydraulic valve assembly to the hydraulic tank. 4. Place the battery master switch in the 'On' position,
start the engine and release park/emergency button
When the engine is shutdown, transmission pilot (pull out), to energise the park brake line. Monitor
pressure at directional control valve (2) is lost, causing system pressure gauge. Pressure setting should be

6 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000

155 bar (2 248 lbf/in). SM - 1335

5. If necessary, pressure setting can be adjusted via FITTING NUT


brake system relief valve (7) on the main hydraulic TUBE
valve assembly. The operator cab will require to be
raised to access brake system relief valve (7). Refer to
Section 260-0010, CAB AND MOUNTING.

6. Connect a hydraulic gauge, capable of recording a


pressure of 0 - 345 bar (0 - 5 000 lbf/in), to front brake
diagnostic pressure point (2, Fig. 7) inside battery box. SLEEVE
'O' RING 'O' RING

7. Place the battery master switch in the 'On' position, Fig. 8 - Assembly of Typical ORFS Connector
start the engine and apply park/emergency brake (push
button in), to apply service brakes. Monitor system
pressure gauge. Brake actuating pressure for the front 'O' RING FACE SEALS (ORFS)
brake circuit is 105 +/- 5.1 bar (1500 +/- 75 lbf/in).
Where hydraulic lines are fitted with ORFS
8. Repeat steps 6 & 7 at rear brake diagnostic pressure connections, the following procedure should be carried
point (3, Fig. 7) inside battery box. Brake actuating out during 'Installation'. Refer to Fig. 8.
pressure for the rear brake circuit is 105 +/- 5.1 bar
(1500 +/- 75 lbf/in). a. Ensure 'O' ring/seal is in place and that the joining
surfaces are clean. If necessary, retain 'O' ring/seal in
Note: When brakes are released, a residual pressure of place with a light coating of grease or vaseline.
0.5 bar (7 lbf/in) should remain.
b. Initially, the nuts should be tightened by hand.
9. If necessary, pressure setting can be adjusted via
brake system relief valve (7) on the main hydraulic c. Where a hose is fitted, ensure that it is not twisted
valve assembly. The operator cab will require to be or kinked when the nuts are tightened so that it is
raised to access brake system relief valve (7). Refer to allowed to adopt a natural position.
Section 260-0010, CAB AND MOUNTING.
d. Where a tube is fitted, ensure that the connection is
10. Shut off the engine and remove the pressure gauge aligned correctly.
from diagnostic check point.
e. Tighten the nut a further 1/4 to 1/2 a turn using the
11. Remove wheel blocks, place the steering lock bar correct size spanner (wrench).
in the 'Stowed' position, start the engine and check the
braking system for proper operation. f. Check that a satisfactory hose or tube routing has
been achieved.

BLEEDING THE BRAKING SYSTEM


Refer to Section 165-0010, BRAKE PARTS.

SM 2198 2-03 7
Braking System - Braking System Schematic
Section 250-0000

HYDRAULIC OIL gauges through a pressure range of 30 in of vacuum to


5 000 lbf/in.
The braking system should be kept filled with hydraulic
The following items should be added to the multi-gauge
oil as specified in Section 300-0020, LUBRICATION
to enable the gauge to be used on the diagnostic
SYSTEM.
pressure check points;
15018226 Diagnostic Coupling
Whenever there is a hydraulic system failure, the oil
00118748 Connector (2 off)
should be drained, the entire system flushed, oil filters
15004085 Hose Assembly (-04 HP, 2130 mm long)
replaced, oil screens thoroughly cleaned and clean
hydraulic oil added to eliminate all metal particles or
foreign matter. Non-contact Infrared Thermometer
The infrared thermometer, 15269785, can be used to
spot heat problems early in electrical, mechanical and
SERVICE TOOLS
hydraulic systems. Hand held and easy to use, you
It is recommended that the following service tools are simply aim, pull the trigger, and read the temperature.
used when carrying out pressure and temperature Since there is no need to touch what you are
checks during maintenance procedures. These tools, measuring, temperatures of hard-to-reach or moving
along with other general service tools, are available components can be taken without getting burned or
from your dealer. Refer to Section 300-0070, SERVICE shocked.
TOOLS, for part numbers of these tools.

O' Ring Face Seals (ORFS) - Seal Kit


Multi-Gauge
The braking system utilizes 'O' Ring Face Seal (ORFS)
The multi-gauge, 15269784, is basically four pressure connectors. An ORFS kit, 15271082, is available. This
gauges in one. Continuous system pressure readings kit contains a minimum stock requirement of all sizes
are indicated on one of three simultaneously reading of ORFS type seal.

8 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000
SM - 2834/2854
4 7

3
11

10/12

25

Valve (6) Coil Rating


Ohms Amps Watts
42 0.6 15 15
Voltage: 24V

1 - Orifice
2 - Directional Control Valve
3 - Check valve
4 - Check Valve
6 - Park/Emergency Solenoid Valve
7 - Brake System Relief Valve
8 - Brake System Charge Valve
10 - Check Valve
11 - Orifice 21
12 - Orifice
15 - Priority Valve
21 - Shuttle Valve
25 - Shuttle Valve

Fig. 9 - Brake System Valves Integral to Main Hydraulic Valve Assembly

SM 2198 2-03 9
Braking System - Braking System Schematic
Section 250-0000

Braking System Trouble Shooting


Symptom Possible Cause Remedy
Front and Rear Brake Accumulators Brake System Relief Valve (7) Re-set valve (7) to the correct
(17) not reaching the correct hydraulic not set correctly or faulty setting or replace if faulty
charge pressure
Pressure at Primary Accumulator (18) Set the Charge Valve (8) to the
not high enough due to Brake System correct setting.
Charging Valve (8) not being set Replace valve (15)
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 (3) or (4) leaking Replace Check Valves (3) or (4)
(17) 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

Brake Charging System Fails to Cold Start Solenoid Valve (16) Replace Valve (16). Refer to
charge at initial engine start up remains open Section 215-0050, MAIN
HYDRAULIC VALVE ASSEMBLY

Faulty Brake System Charge Valve Replace valve (8)


(8)

Contamination in orifice(11) Replace orifice (11)

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.

Primary Accumulator (18) does not Front and Rear Brake Accumulators See previous symptoms.
hold its charge pressure. (17) are not holding their charge.

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

Leakage across the Valves (10, 9, 5 Replace each valve one at a time
or 29) is too high. (in order stated) until the fault is
found.

Accumulator Piston Seal leaking Replace the accumulator

10 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000

Braking System Trouble Shooting


Symptom Possible Cause Remedy
Ineffective Park Brake Fault with Park Brake caliper Refer to Section 170-0010,
PARKING AND MOUNTING

Park Brake Solenoid Valve (6) not Check if there is hydraulic pressure
functioning. Sticking in the selected at the Park Brake port. If there is
position pressure present, replace Valve(6).

Park Brake fails to release. No voltage at Park Brake Solenoid Check park/emergency switch in
Valve (6) when the switch is activated operators cab.
in the cab.
Check wiring between park/
emergency switch and park brake
solenoid (6).

Park Brake Solenoid Valve(6) fails to Replace valve(6).


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 'PP'. 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 (2) not Replace Valve (2)


selecting.

Fault with Park Brake System See previous trouble-shooting

Service Brakes come on when Directional Control Valve (2) sticking Replace Valve (2)
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

SM 2198 2-03 11
Braking System - Braking System Schematic
Section 250-0000

Braking System Trouble Shooting


Symptom Possible Cause Remedy
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.

* * * *

12 SM 2198 2-03
BRAKING SYSTEM - Accumulator
Section 250-0060

SM - 2873

1 - Charging Valve 1D - Locknut 6 - Backup Rings 9 - 'O' Ring


1A - Cap 1E - Body 7 - 'V' Section Ring 10 - End Cap
1B - Core 1F - 'O' Ring 8 - Wear Rings 12 - Cylinder
1C - 'O' Ring 5 - Piston

Fig. 1 - Exploded View of Accumulator

DESCRIPTION two sections. The bottom section nearest charging


Numbers in parentheses refer to Fig. 1. valve (1) contains the nitrogen precharge. Hydraulic oil
from the main hydraulic pump flows through check
The accumulators can be identified as items 17 and valves in the main hydraulic valve and into the top
18, and the pressure switches as items 13 in Section section of the accumulators.
250-0000, BRAKING SYSTEM SCHEMATIC.
Accumulator pressure is monitored by pressure
There are three accumulators mounted inside the switches located in the main hydraulic valve, which
battery box located on the front left hand side of the send a signal to illuminate warning lights in the dash
tractor; one for the front brake system and one for the panel when the pressure drops below 122 bar (1 770
rear. The front and rear brake accumulators are lbf/in). The warning lights will remain illuminated until
supplemented by a third (primary) accumulator. Refer the pressure rises above 135 bar (1 960 lbf/in).
to Fig. 2. The primary accumulator supports the
service brake system and the body pilot pressure
system. All three accumulators are of the piston type TESTING
and are precharged with nitrogen to 95 bar (1 380 lbf/
in). Each accumulator consists of a charging valve (1),
end cap (10), cylinder (12) and piston (5). Charging WARNING
valve (1) is equipped with a locking feature. Loosening To prevent personal injury and property
locknut (1D) will open the valve so that the precharge damage, be sure wheel blocks are properly
can be checked or the accumulator charged. secured and of adequate capacity to do the job
safely.

OPERATION
Numbers in parentheses refer to Fig. 1.

Piston (5) acts as a separator dividing cylinder (12) into

SM 2203 3-03 1
Braking System - Accumulator
Section 250-0060

SM - 2872 SM - 1273

P
FB
RB

1 - Line 6 - Tank Valve


2 - Valve Chuck 7 - Gland Fitting
P - Primary Accumulator 3 - Valve Extension 8 - Gland Nut
FB - Front Brake Accumulator 4 - Cylinder Valve 9 - Cylinder Adaptor
RB - Rear Brake Accumulator 5 - Pressure Gauge 10 - Bleeder Valve

Fig. 2 - Accumulator Mounting Fig. 3 - Charging Assembly Kit

3. Attempt to reseat the valve core by depressing and


WARNINGS releasing it quickly once or twice. Recheck for leakage.
Accumulators are charged with Nitrogen. If leakage continues, discharge the accumulator as
The service pressure is 95 bar (1 380 lbf/in) at described under 'Discharging Nitrogen' in this section.
20 C (68o F). To prevent personal injury and
property damage do not attempt to remove any 4. Replace valve core (1B). Tighten locknut (1D) to
valves or fittings until all nitrogen pressure is 11 Nm (100 lbf in) and replace valve cap (1A) finger
completely relieved. tight.

Testing Precharge Pressure


Hydraulic fluid pressure will remain
within the system after engine shut down. Numbers in parentheses refer to Fig. 3, unless
Operate the treadle pedal continuously until the otherwise specified.
pressure has dissipated before carrying out any
work on the braking system or serious injury Note: The nitrogen pressure in an accumulator is
could result. directly affected by changes in nitrogen temperature.
The cylinder pressure will increase or decrease
proportionally with temperature changes. An
Testing Charging Valve For Leakage accumulator pressure reading can vary about 4.3 bar
Numbers in parentheses refer to Fig. 1. (62 lbf/in) with 22 C (72 F) temperature change.
Such temperature changes could easily occur
1. Remove cover plate from bottom of battery box. between noon and midnight of the same day. Refer to
the table at the end of this section for nitrogen
2. Remove cap (1A) from charging valve (1) and loosen pressures at ambient temperatures of other than
locknut (1D). Coat open end of charging valve (1) with 20 C (68 F).
soapy water. Bubbles indicate leaky valve core (1B).
To test accumulator precharge pressure or to charge
the accumulator, a charging assembly kit can be used.
Refer to Fig. 3.

2 SM 2203 3-03
Braking System - Accumulator
Section 250-0060
1. Position the vehicle in a level work area, apply the available from a local compressed gas dealer.
parking brake, switch off the engine and turn steering
wheel in both directions several times to relieve any
pressure in the steering circuit. WARNINGS
Do not use Oxygen or any gas other than
2. Operate the treadle valve continuously to relieve Nitrogen to charge an accumulator. Oxygen
pressure in the braking system. Block all road wheels under pressure coming into contact with oil or
and place battery master switch in the 'Off' position. grease will cause a violent explosion. Always
double check to make sure you are using
3. Check accumulator mountings to be sure the Nitrogen to prevent personal injury and
accumulator is held tightly in position. property damage.

4. Remove cap (1A, Fig. 1) from accumulator charging A high pressure nitrogen pressure
valve (1, Fig. 1). Attach charging line (1) to charging regulator must be used with the charging
valve by rotating 'T' handle of valve chuck (2) assembly kit. Failure to use pressure regulator
anticlockwise until it stops then screw the swivel nut could cause property damage, personal injury
down on the valve. Loosen locknut (1D, Fig. 1) by or death.
turning anticlockwise one to two turns.
1. Attach line (1) and the swivel nut to charging valve
5. Turn 'T' handle clockwise until charging valve core (1, Fig. 1) as described in steps 1 through 4 under the
is depressed. Be sure bleeder valve (10) is tight and heading 'Testing Precharge Pressure'. Be sure valves
does not leak, and valves (4 & 6) are closed. (4 & 6) are closed.

6. To read accumulator precharge pressure, slowly 2. Attach gauging head to nitrogen bottle by screwing
open cylinder valve (4). Pressure gauge (5) will down on gland nut (8).
register precharge pressure, it should be 95 bar
(1 380 lbf/in) at 20 C (68 F) ambient temperature. 3. Open tank valve (6) slowly; pressure shown on
Refer to the table at the end of this section for nitrogen pressure gauge (5) is tank pressure.
pressures at ambient temperatures of other than 20 C
(68 F). 4. Open cylinder valve (4) slowly and charge
accumulator to 95 bar (1 380 lbf/in2) at 20 C (68 F)
7. Close cylinder valve (4) and open bleeder valve (10) ambient temperature, closing valve occasionally. Refer
to dissipate gauge pressure. Close bleeder valve (10) to the table at the end of this section for nitrogen
after pressure is relieved. If the accumulator needs pressures at ambient temperatures of other than 20 C
charged, leave line (1) and valve chuck (2) attached to (68 F).
charging valve (1, Fig. 1)). Charge the accumulator as
described under 'Charging The Accumulator'. 5. To check accumulator charge, close tank valve (6),
relieve pressure between tank and pressure gauge (5)
8. If precharge pressure is correct, rotate 'T' handle by opening bleeder valve (10) momentarily. This will
anticlockwise until it stops. Tighten locknut (1D, Fig. 1) allow gauge needle to settle, thus giving correct
on charging valve (1, Fig. 1) to 11 Nm (100 lbf in). pressure reading of accumulator charge.
Loosen the swivel nut and remove gauging head.
6. When the correct pressure for the ambient
9. Install cap (1A, Fig. 1) on charging valve (1, Fig. 1) temperature has been reached, close valves (4 & 6)
and tighten finger tight. tightly. Bleed pressure off pressure gauge (5) by
opening bleeder valve (10). Close bleeder valve when
10. Remove wheel blocks and place the battery master all pressure is bled off from the gauge and unscrew
switch in the 'On' position. gland nut (8) from the nitrogen bottle.

7. Rotate 'T' handle of valve chuck (2) anticlockwise


CHARGING THE ACCUMULATOR until it stops, tighten locknut (1D, Fig. 1) to 11 Nm (100
Numbers in parentheses refer to Fig. 3, unless lbf in), loosen the swivel nut and remove gauging head.
otherwise specified.
8. Check charging valve (1, Fig. 1) for leakage using
Note: Either oil or water pumped nitrogen can be used soapy water. Reinstall valve cap (1A, Fig. 1) and
to charge the accumulator. Both types are readily tighten finger tight.

SM 2203 3-03 3
Braking System - Accumulator
Section 250-0060
DISCHARGING NITROGEN 7. Remove accumulators to a clean area for
Numbers in parentheses refer to Fig. 1. disassembly.

Make sure charging valve (1) is closed internally by DISASSEMBLY


turning locknut (1D) clockwise. Remove cap (1A) and
Numbers in parentheses refer to Fig. 1.
core (1B) from charging valve (1). Slowly turn locknut
(1D) anticlockwise to open charging valve (1).
WARNING
Do not remove charging valve (1) until all the gas has
Accumulators are charged with Nitrogen. The
been completely evacuated.
service pressure is 95 bar (1 380 lbf/in) at 20 C
(68o F). To prevent personal injury and
property damage do not attempt to remove any
WARNING
valves or fittings until all nitrogen pressure is
Do not try to discharge the accumulator by
completely relieved.
depressing charging valve core (1B).
1. Make sure all nitrogen gas has been released
REMOVAL before starting to disassemble the accumulator. Refer
to section on 'Discharging Nitrogen'.
WARNINGS
2. Remove charging valve (1) from end cap (10).
To prevent personal injury and property
damage, be sure wheel blocks, blocking
3. With accumulator lying horizontal, hold accumulator
materials and lifting equipment are properly
cylinder (12) with a strap wrench.
secured and of adequate capacity to do the job
safely.
4. Install pins in three equally spaced holes in end cap
(10), then use a long bar working against the pins to
Accumulators are charged with Nitrogen.
remove end cap from cylinder (12). Remove and
The service pressure is 95 bar (1 380 lbf/in) at
discard 'O' ring (9).
20 C (68o F). To prevent personal injury and
property damage do not attempt to remove any
5. Grip cast web of piston (5) with pliers and, while
valves or fittings until all nitrogen pressure is
rotating, pull piston from cylinder (12). Remove and
completely relieved.
discard wear rings (8), backup rings (6) and 'V' section
ring (7).
1. Position the vehicle in a level work area, apply the
parking brake, switch off the engine and turn steering
wheel in both directions several times to relieve any INSPECTION
pressure in the steering circuit.
Numbers in parentheses refer to Fig. 1.
2. Operate the treadle valve continuously to relieve
1. Wash metal components with a suitable solvent and
pressure in the braking system. Block all road wheels
thoroughly air dry.
and place battery master switch in the 'Off' position.
2. Inspect piston (5) for cracks or burrs. Replace
3. Remove cover plate from bottom of battery box.
piston (5) if excessively scored or worn.
4. Discharge nitrogen from the accumulators as
3. Use an inspection lamp to check the bore of
described under 'Discharging Nitrogen'.
accumulator cylinder (12) for scratches or scoring. Minor
nicks, scratches or light scoring of the bore can be
5. Disconnect hydraulic lines from top of accumulators
removed by using crocus cloth. Dress the bore until all
and plug accumulators to prevent oil spillage. Cap open
apparent imperfections have been removed. Replace
lines and fittings to prevent entry of dirt.
complete accumulator assembly if the inside of cylinder
(12) is excessively scored or worn.
6. Support accumulators with an adequate sling and
lifting device. Remove bolts, nuts, washers and
4. Inspect threads in end cap (10) and threads in
clamps. Remove accumulators and drain oil from top
cylinder (12) for damage. Replace all parts worn or
section into a suitable container.
damaged beyond repair.

4 SM 2203 3-03
Braking System - Accumulator
Section 250-0060
ASSEMBLY
Numbers in parentheses refer to Fig. 1. WARNING
To prevent personal injury and property
1. Lubricate O ring (9), wear rings (8), backup rings damage, be sure lifting equipment is properly
(6), 'V' section ring (7) and inside of cylinder (12) with secured and of adequate capacity to do the job
hydraulic oil prior to assembly. safely.

2. Install new 'V' section ring (7), backup rings (6) and 1. Position accumulators in battery box with the oil inlet
wear rings (8) on piston (5). ports at the top.

3. Insert piston (5) into cylinder (12) with cupped end 2. Attach clamps securely with nuts, washers and
facing the open end of the cylinder. Do not let bolts.
'V' section ring (7) drag on cylinder threads. Use a
hammer and wood block to tap piston into place until 3. Remove caps installed at removal and install
all of piston is 50 mm (2.0 in) below beginning of hydraulic lines securely to the oil inlet ports at the top
honed bore. Keep pressure against piston while of the accumulators.
tapping 'V' section ring (7) through the bore chamfer,
otherwise piston will bounce back, damaging the 4. Charge the accumulator with Nitrogen gas as
'V' section ring. described under 'Charging the Accumulator' in this
section.
4. Install new 'O' ring (9) on end cap (10) and install
end cap (10) in cylinder (12). Tighten cap so that it is 5. Install cover to bottom of battery box.
flush with the end of cylinder (12) within 1.59 - 2.38 mm
(0.0625 - 0.0938 in) above or below. 6. Check oil level in hydraulic tank and add oil as
required. Refer to Section 230-0040, HYDRAULIC
5. Install charging valve (1). Tighten locknut (1D) TANK, for correct fill level and Section 300-0020,
clockwise to 11 Nm (100 lbf in) to close charging LUBRICATION SYSTEM, for oil specification.
valve, insert valve core (1B), replace valve cap (1A)
and tighten finger tight. 7. Place the battery master switch in the 'On' position,
start the engine and check for leaks. Tighten lines and
6. Test accumulator hydraulically for leakage or failure fittings as required. Remove wheel blocks.
at 255 - 276 bar (3 700 - 4 000 lbf/in). Discharge after
testing.
MAINTENANCE
Inspect accumulator assembly for leaks. If leaks are
INSTALLATION found, disassemble and replace all 'O' rings and seals.
Note: Tighten all fasteners without special torques Inspect hydraulic lines for wear and leaks. Replace/
specified to torques listed in Section 300-0080, tighten lines as required.
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
SPECIAL TOOLS
Note: Tighten all hydraulic lines fitted with ORFS Refer to Section 300-0070, SERVICE TOOLS, for part
connections, as described in Section 250-0000, numbers of the charging assembly kit and other
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings general service tools required. These tools are
where used. available from your dealer.

SM 2203 3-03 5
Braking System - Accumulator
Section 250-0060

SPECIAL TORQUE SPECIFICATIONS TABLE017

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft lbf in
1 1D Locknut 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.

* * * *

6 SM 2203 3-03
BRAKING SYSTEM - Treadle Valve
Section 250-0070

SM - 2874

3
4 14
5 15
11
36
6
23
7

16 24
8
25
9 26

27
17
10 28
35
18 29
19
11
20 30

12 1
21 31

13 32
22
33

34

1 - Pedal Assembly 10 - Spool 19 - Shims 28 - 'O' Ring


2 - Nut 11 - 'O' Rings 20 - Spring 29 - Backup Ring
3 - Washer 12 - Sleeve 21 - Spring 30 - Pilot Housing
4 - 'O' Ring 13 - Spool 22 - Spring 31 - Screw
5 - End Plug 14 - Cup 23 - Bearing 32 - Spring
6 - Retainer 15 - Spacer 24 - Piston 33 - Push Rod
7 - Spring 16 - Valve Housing 25 - Backup Ring 34 - Boot
8 - 'O' Ring 17 - 'O' Ring 26 - 'O' Ring 35 - Potentiometer
9 - Sleeve 18 - Retainer 27 - Piston 36 - Brake Pedal Interface Module

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 9 in
Section 250-0000, BRAKING SYSTEM SCHEMATIC. In the normal position, brake pedal assembly (1) 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 Mounted on the brake treadle valve is a potentiometer
the engine running, is automatically applied by the park (35) which links with a brake pedal interface module

SM 2208 3-03 1
Braking System - Treadle Valve
Section 250-0070

SM - 2875 SM - 2876

9 9

PP PP

SUPPLY SUPPLY
FROM FROM
P1 P1
TO FRONT A1 MAIN HYDRAULIC FROM FRONT A1 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC1 BRAKES VALVE, PORT ACC1
T1 T1

SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC2 BRAKES VALVE, PORT ACC2
T2 T2

Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release

(36) mounted on a dashboard support, underneath the assembly. Spools (10 & 13) have closed off the inlet
dashboard. The brake pedal interface module (36) ports, outlet ports and the tank ports and will remain in
converts voltage signals from the potentiometer (35) to this position as long as pedal (1) assembly is not
activate the rear brake lights and the transmission moved. If the operator further depresses pedal (1)
retarder when the treadle valve is depressed. Refer to assembly, spools (10 & 13) will move up and build
Fig. 7. more pressure in the brake until it balances the pedal
force.

OPERATION
Numbers in parentheses refer to Fig. 1. Normal Service Brake Release
Refer to Fig. 3. When the operator releases pedal (1)
Normal Service Brake Application assembly, spools (10 & 13) will become unbalanced
Refer to Fig. 2. When the operator depresses pedal and move downwards, opening outlet ports 'A1' and
assembly (1), push rod (33) is moved up and pushes 'A2' to tank. At this point, oil in the 'A1' and 'A2' lines is
on pistons (24 & 27) which in turn, pushes spools (10 released to tank through tank ports 'T1' and 'T2',
& 13) up. As spools (10 & 13) move up, the metering releasing the brakes.
notches move out of the tank cavity and close outlet
ports 'A1' and 'A2' off to tank ports 'T1' and 'T2'. Spools
(10 & 13) continue to move upwards until the metering
Emergency Stop Brake Application/
notches become exposed to the inlet pressure ports. Release
This movement opens inlet ports 'P1' and 'P2' to outlet Refer to Fig. 4. Pushing in the park/emergency control
ports 'A1' and 'A2' respectively. As hydraulic pressure results in the de-energization of the park brake
builds in the brake, oil flows through the small orifice in solenoid valve within the main hydraulic valve. This
spools (10 & 13) and into the cavities above the allows full pressure to enter the 'PP' port in the treadle
spools. As pressure rises in the brake it also rises in valve simulating a full and immediate depression of
the cavities above the spools forcing spools (10 & 13) pedal (1) assembly, i.e. pushing spools (10 & 13)
downwards closing outlet ports 'A1' and 'A2'. Spools upwards and thereby applying maximum braking
(10 & 13) are now balanced between the brake action.
pressure and the pressure of springs (20 - 22)
generated by the operators force on pedal (1) Refer to Fig. 5. Pulling out the park/emergency control

2 SM 2208 3-03
Braking System - Treadle Valve
Section 250-0070

SM - 2877 SM - 2878

9 9
SUPPLY
FROM TO TANK VIA
PP PP MAIN HYDRAULIC
MAIN HYDRAULIC
VALVE, PORT PBP VALVE, PORT PBP

SUPPLY
SUPPLY FROM
P1 P1
TO FRONT A1 FROM FROM FRONT A1 MAIN HYDRAULIC
BRAKES MAIN HYDRAULIC BRAKES VALVE, PORT ACC1
T1 VALVE, PORT ACC1 T1

SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC2 BRAKES VALVE, PORT ACC2
T2 T2

Fig. 4 - Park/Emergency Brake Application Fig. 5 - Park/Emergency Brake Release

will energize the park brake solenoid valve within the 'Stop' warning light is OUT, the transmission is in
main hydraulic valve, allowing the pressure in the 'PP' 'lockup' and the oil temperature is within safe operating
line to fall via the return to tank port opened within the range. Further movement of the pedal (1) applies the
park brake solenoid valve. Outlet ports 'A1' and 'A2' are service brakes in addition to the transmission retarder.
opened to tank ports 'T1' and 'T2' allowing oil in the 'A1' The transmission retarder will disengage when the
and 'A2' lines to return to tank, releasing the brakes. pedal (1) is released, or when any of the operating
conditions become out of range.

Advanced Retarder Braking


Refer to Figs. 1 & 7. The brake pedal interface module REBUILD CRITERIA
(36) converts voltage signals from the potentiometer Inspect the valve regularly for any signs of leakage or
(35) to activate transmission retarder and rear brake damage and replace components if necessary.
lamps. The brake pedal interface module (36)
energises brake lamp relay K50, and transmission The treadle valve should be rebuilt if one or more of the
retarder select relay K51. Both relays are located in following conditions exist:
operator cab fuse box. Refer to Section 190-0000,
CIRCUIT DIAGRAMS. When these relays are 1. Any sign of external leakage.
energised, electrical circuit is completed to energise
appropriate lamps and solenoids. Note: Check all hydraulic lines and fittings to ensure
leakage is not coming from there.
The potentiometer (35) works on a 0 to 5 Volt scale.
Initial pedal rotation starts to increase voltage from the 2. Failure of the pedal to return to full upright position.
potentiometer (35) to the brake pedal interface module
(36). K50 and K51 relays are activated when the output 3. Treadle valve holds pressure when in the neutral
from the potentiometer (35) is greater than 1 Volt. This position.
allows a 24 Volt signal from the busbar to activate the
rear brake lamps and the transmission retarder 4. Varying output pressure with the pedal fully
solenoid valve. The relays are de-activated when the depressed.
output from the potentiometer is less than 1 Volt.
5. Output pressure does not remain constant between
The first 5 movement of the pedal (1) engages the circuits.
transmission retarder, providing that the transmission

SM 2208 3-03 3
Braking System - Treadle Valve
Section 250-0070

REMOVAL SM - 2879

A
WARNINGS P2
P
To prevent personal injury and property
A2
T T2
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job P1
P
safely.
T T1
A1
Hydraulic oil pressure will remain A
within the system after engine shut down.
Operate the treadle pedal continuously until the PP
pressure has dissipated before carrying out any
work on the braking system or serious injury PP
could result.

1. Position the vehicle in a level work area, apply the


parking brake, switch off the engine and turn steering
wheel in both directions several times to relieve any
pressure in the steering circuit.

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


bottom of the hydraulic tank. Install a length of hose on
remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
hose and reinstall blanking cap. P1 - Pressure from main hydraulic valve, port ACC1
P2 - Pressure from main hydraulic valve, port ACC2
A1 - Pressure to front brakes
5. If necessary remove engine air intake tube to gain A2 - Pressure to rear brakes
access to treadle valve on front of cab. Alternatively, T1 - Tank return, front brakes
tilt the cab to gain access. Refer to Section 260-0010, T2 - Tank return, rear brakes
CAB AND MOUNTING. Fig. 6 - Treadle Valve Porting

6. Clean treadle valve assembly and surrounding area DISASSEMBLY


with a suitable solvent. Ensure all hydraulic lines
connected to the treadle valve are identified for ease of Numbers in parentheses refer to Fig. 1.
installation and, with suitable containers available to
catch leakage, disconnect hydraulic lines. Fit blanking 1. Remove blanking caps from treadle valve ports and
caps to all open lines and treadle valve ports. drain all oil from valve body ports by rotating the valve
over a suitable container.
7. Disconnect electrical connection from the brake
pedal potentiometer (35). 2. Remove treadle valve from mounting plate and
secure the valve assembly upright in a table vice.
8. Remove four bolts securing treadle valve and
mounting plate to cab. Remove treadle valve and 3. Remove circlips to allow cam assembly to be
mounting plate as an assembly from the front of cab to disassembled.
a clean area for 'Disassembly'.
4. Remove boot (34) from push rod (33), then remove
push rod (33) and spring (32) from pilot housing (30)
bore.

4 SM 2208 3-03
Braking System - Treadle Valve
Section 250-0070

SM - 2853

1 - K50 RELAY (STOP LAMPS)


2 - K51 RELAY (RETARDER SELECT)

BRAKE LIGHT OUTPUT SIGNAL


(WHITE)

1
BRAKE LIGHT 0V
(BROWN)
SIG

RETARDER 0V (VIOLET)
BRAKE
(GREEN) PEDAL 0V PEDAL
2 INTERFACE
(BLUE)
POTENTIOMETER
RETARDER OUTPUT SIGNAL MODULE

(ORANGE) +5V
(GREY)
(+) BATTERY
(RED)

(-) BATTERY
(BLACK)

Fig. 7 - Brake Treadle Potentiometer - Interface Module Schematic (Advanced Retarder)

5. Separate pilot housing (30) and valve housing (16) (16). Note: Be careful not to scratch housing bore.
by removing screws (31). Remove 'O' ring (17) from
valve housing (16). 13. Separate spacer (15) and spools (10 & 13) from
sleeves (9 & 12). Note: Excessive wear on either
6. Remove piston (27) from pilot housing (30). Note: Be spools (10 & 13) or sleeves (9 & 12) may require
careful not to scratch housing bore. replacement. Spool (10)/sleeve (9) and spool (13)/
sleeve (12) are matched sets and MUST be replaced
7. Remove 'O' rings (26 & 28) and back-up rings (25 & as matched sets - DO NOT intermix.
29) from piston (27), being careful not to damage 'O'
ring and piston grooves. 14. Remove 'O' ring (11) and cup (14) from spacer (15).
Remove other 'O' rings (11) from sleeve (12) and 'O'
8. Remove piston (24), springs (20, 21 & 22) and shims rings from sleeve (8). Note: Be careful not to damage
(19) from valve housing bore. cup and 'O' ring grooves and bores.

9. Bearing (23) should not be removed from housing


bore. Note: Excessive wear in both bearing (23) and ASSEMBLY
piston (24) may require replacement. Numbers in parentheses refer to Fig. 1.

10. Remove retainer assembly (18) from housing bore. Lubricate all new rubber components with clean
Note: Ball is pressed into retainer. hydraulic oil used in the braking system. Refer to
Section 300-0020, LUBRICATION SYSTEM.
11. Loosen nut (2) and remove end plug (5) from
housing. Remove spring (7), retainer (6), nut (2), 1. Clean all parts thoroughly before assembly.
washer (3) and 'O' ring (4) from end plug (5).
2. Install new cup (14) in spacer (15) and one new 'O'
12. Remove spacer (15), sleeves (9 & 12) and spools ring (11) on spacer (15). Note direction of cup.
(10 & 13) assembly from housing bore. This assembly
must be removed through end plug (5) end of housing 3. Install other new 'O' rings (11) on sleeve (12) and

SM 2208 3-03 5
Braking System - Treadle Valve
Section 250-0070
new 'O' rings (8) on sleeve (9). 17. Install new boot (34) on push rod (33).

4. Lubricate spool (13) with clean hydraulic oil and 18. Assemble cam assembly and secure with circlips.
carefully insert into sleeve (12). Note direction of spool.
19. Install mounting plate to treadle valve.
5. Insert spacer (15) into housing bore through end plug
(5) end. Note direction of spacer.
INSTALLATION
6. Lubricate sleeve (12) and spool (13) assembly with Numbers in parentheses refer to Fig. 1.
clean hydraulic oil and carefully insert into housing bore
using a wooden dowel. Note direction of assembly. Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
7. Carefully insert sleeve (9) into housing until it rests TORQUE SPECIFICATIONS.
against sleeve (12). Lubricate spool (10) with clean
hydraulic oil and carefully insert into sleeve (9). Note Note: Tighten all hydraulic lines fitted with ORFS
direction of spools and sleeves. connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
8. Install spring (7) and retainer (6) into housing bore. where used.

9. Install end plug (5) and torque to 11 - 20 Nm (96 - 1. Secure treadle valve and mounting plate assembly
180 lbf in) to seat sleeves. Then turn back end plug 1/4 to front of cab using four bolts removed previously.
turn and torque to 1 - 7 Nm (10 - 60 lbf in). Install new
'O' ring (4), washer (3) and nut (2). Hold end plug and 2. Connect electrical connection to the brake pedal
torque nut to 68 - 81 Nm (50 - 60 lbf ft). potentiometer (35).

10. Install new 'O' ring (17) on valve housing (16). 3. Remove blanking caps and connect hydraulic lines
to the treadle valve assembly as noted at 'Removal'.
11. Install retainer assembly (18) in housing. Note:
Depress retainer (18) until it bottoms on spacer (15). 4. If previously removed install engine air intake tube,
Spools (10 & 13) and retainer (18) should return when or if applicable, lower the cab. Refer to Section 260-
released. If the spools and retainer do not return when 0010, CAB AND MOUNTING.
released, the bore of sleeves (9 & 12) were possibly
damaged when installed. 5. Fill hydraulic tank with oil specified in Section
300-0020, LUBRICATION SYSTEM.
12. Install shims (18), springs (20, 21 & 22) and piston
(24) in valve housing bore. Note: For proper brake 6. Place the battery master switch in the 'On' position,
pressure setting, install the same number of shims and start the engine and bring hydraulic oil to operating
spacer that were removed during disassembly. If temperature.
spools (10 & 13), sleeves (9 & 12), or spring (22) were
replaced, shim adjustment may be required. 7. Apply the brakes and check for oil leaks. Tighten
line connections and fittings as necessary.
13. Install new 'O' rings (26 & 28) and new back-up
rings (25 & 29) on piston (27). Note order of back-up Note: When performing Step 8, make sure that parking
rings and 'O' rings. brake applies and releases appropriately.

14. Lubricate piston (27) with clean hydraulic oil and 8. Check brake operations by actuating pedal and park/
insert into pilot housing (30) through valve housing (16) emergency control. Ensure that the pedal assembly is
end. Be sure to install piston (27) as far as it will go free to operate.
into pilot housing bore.
9. Shut off engine and check hydraulic tank oil level.
15. Carefully attach pilot housing (30) to valve housing Replenish as necessary.
(16) using screws (31). Torque screws to 24 - 30 Nm
(18 - 22 lbf ft).

16. Install spring (32) and push rod (33) into pilot
housing (30) bore.

6 SM 2208 3-03
Braking System - Treadle Valve
Section 250-0070

CHECKING SYSTEM PRESSURES MAINTENANCE


General
WARNINGS Check all hydraulic brake lines and fittings at treadle
To prevent personal injury and property valve for leaks and damage. Tighten/replace as
damage, be sure wheel blocks and blocking required.
materials are properly secured and of adequate
capacity to do the job safely.
Every 1 000 Hours
Hydraulic fluid pressure will remain Check front and rear brake pressures at remote
within the system after engine shut down. diagnostic test points. If the pressures are outwith the
Operate the brake treadle pedal continuously specified pressure range, refer to Troubleshooting table
until the pressure has dissipated before for treadle valve and Section 250-0000, BRAKING
carrying out any work on the system or serious SYSTEM SCHEMATIC.
injury could result.

1. Position the vehicle in a level work area, apply the SPECIAL TOOLS
parking brake, switch off the engine and turn steering There are no special tools required for the procedures
wheel in both directions several times to relieve any outlined in this section. Refer to Section 300-0070,
pressure in the steering circuit. SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
2. Operate the treadle valve continuously to relieve adhesives are available from your dealer.
pressure in the braking system. Block all road wheels,
place the steering lock bar in the 'Locked' position and
the battery master switch in the 'Off' position.

3. Connect a hydraulic gauge, capable of recording a


pressure of 0 - 345 bar (0 - 5 000 lbf/in), to front brake
diagnostic pressure point (FR BRK) inside battery box.

4. Place the battery master switch in the 'On' position,


start the engine and apply park/emergency brake (push
button in), to apply service brakes. Monitor system
pressure gauge. Brake actuating pressure for the front
brake circuit is 105 +/- 5.1 bar (1500 +/- 75 lbf/in).

Note: When brakes are released, a residual pressure of


0.5 bar (7 lbf/in) should remain.

5. Repeat steps 1 through 4 at rear brake diagnostic


pressure point (RR BRK) inside battery box.

Note: Actuating pressure for the front and rear brake


circuits is 105 +/- 5.1 bar (1500 +/- 75 lbf/in), however,
system pressure is 240 bar (3 500 lbf/in) and can be
checked at the steering diagnostic pressure point
(STR) inside the battery box. 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 2208 3-03 7
Braking System - Treadle Valve
Section 250-0070

TREADLE VALVE TROUBLESHOOTING


SYMPTOM POSSIBLE CAUSE REMEDY

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
Inoperative brakes Check brakes. Refer to Section 165-0010,
BRAKE PARTS
Inoperative treadle valve. Replace treadle valve
Binding spools (10 & 13),
damaged sleeves (9 & 12),
piston (24) binding
Insufficient brakes Low hydraulic oil level Top up hydraulic oil
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
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.
pre-charge pressure Refer to Section 250-0060,
ACCUMULATOR
Inoperative brakes Check brakes. Refer to Section 165-0010,
BRAKE PARTS
Inoperative treadle valve. Replace treadle valve
Broken spring (21). Boot (34)
cut, allowing dirt under piston
(24) flange.
Excessive braking Inoperative brakes Check brakes. Refer to Section 165-0010,
BRAKE PARTS
Inoperative treadle valve. Replace treadle valve
Excessive shims (19) fitted

8 SM 2208 3-03
Braking System - Treadle Valve
Section 250-0070

TREADLE VALVE TROUBLESHOOTING


SYMPTOM POSSIBLE CAUSE REMEDY

Brakes will not release Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
completely BRAKE PARTS
Inoperative brakes Check brakes. Refer to Section 165-0010,
BRAKE PARTS
Pedal angle out of adjustment Check for proper pedal angle
Air in system Bleed air from system. Refer to Section
165-0010, BRAKE PARTS
Inoperative treadle valve. Replace treadle valve
Piston (24) sticking, spring
(7) broken
Back pressure on return line Remove restriction
excessive
No brakes No oil in hydraulic system Add oil to tank
Broken/damaged hydraulic line Replace broken/damaged line
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
BRAKE PARTS
No accumulator Check accumulator pre-charge pressure.
pre-charge pressure Refer to Section 250-0060,
ACCUMULATOR
No pump pressure Check pump operation
Worn brakes Replace brake pads and discs
Inoperative treadle valve. Replace treadle valve
Piston (24) binding, broken
spring (21)
Pedal kickback when brakes Air in system Bleed air from system. Refer to Section
are applied 165-0010, BRAKE PARTS

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 5 End Plug 1-7 10 - 60 lbf in
1 2 Nut 68 - 81 50 - 60
1 31 Screw 24 - 30 18 - 22

* * * *

SM 2208 3-03 9
OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010

SM - 2880

14,18 20,21

19
15

16
17

22
13 13
12 12 20,21
11 11

31, 32
33, 34

CAB - R.H.S.

RH LH LH RH
27
30
23
29 28 29

6 2 6
23 3
4 10
24 25
6 5 LH

1 26 9 8
7
6
RH
26

1 - Pin 10 - Nut 18 - Grease (EMS19014) 26 - Locknut


2 - Retainer Plate 11 - Mirror Arm 19 - Window Guard 27 - Mud Flap
3 - Washer 12 - Mirror 20 - Bolt 28 - Plate
4 - Lockwasher 13 - Mirror - Wide Angle 21 - Washer 29 - Screw
5 - Bolt 14 - Ball 22 - Storage Box 30 - Washer
6 - Spring Pin 15 - Washer 23 - Cab Support 31 - Heat Shield
7 - Cab Safety Prop 16 - Spring 24 - Cab Pin 32 - Bolt
8 - Pin Assembly 17 - Locknut 25 - Bolt 33 - Washer
9 - Bolt 34 - Nut
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 in the battery box, and a cab raise
(23) to damp structure-borne noise and vibration. It cylinder (7, Fig. 2) are used to raise the cab.
conforms with ISO/SAE, ROPS (Roll Over Protective
Structure) and FOPS (Falling Object Protective
Structure) requirements as standard. WARNING
Never operate the machine while the cab is
ROPS - ISO 3471, SAE J1040 APR 88 tilted. Always ensure the cab is fully lowered
FOPS - ISO 3449, SAE J231 and properly secured before operating the
machine.

WARNING Cab assembly is spacious and offers outstanding


The protection offered by the roll over and visibility through large areas of tinted safety glass.
falling object protective structure may be Access to cab assembly is from the left hand side with
impaired if it has been subjected to any open tread steps, platform and handrail.
modification or damage.
The cab interior, trimmed with noise-absorbent

SM 2209 9-05 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

material, is extensively thermally insulated and a


heater/filter/pressurizer and demisting unit keeps WARNINGS
internal air fresh and dust free. Sliding windows provide To prevent personal injury and property
additional ventilation. Air conditioning is fitted as damage, be sure wheel chocks, blocking
standard. Refer to Section 260-0130, AIR materials and lifting equipment are properly
CONDITIONING. secured and of adequate capacity to do the job
safely.
Note: Access from the cab, in the case of an emergency,
can be gained by breaking any of the windows using the Hydraulic fluid pressure will remain within
hammer provided (mounted on back pillar). the system after engine shutdown. Operate the
brake pedal continuously until the pressure has
REMOVAL dissipated before disconnecting any hoses.
Numbers in parentheses refer to Fig. 1. 1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
Note: Identify and tag all cables, harnesses, lines and
linkages disconnected from cab assembly during 2. Operate the brake pedal continuously to relieve
removal to aid in installation. pressure in the system.

3. Block all road wheels, place the battery master


switch in the 'Off' position and lift the hood assembly.

2 SM 2209 9-05
Operators Compartment - Cab and Mounting
Section 260-0010
4. Disconnect the electrical cables in the following Disconnect earth strap at rear right hand cab support
order to prevent damage to the electrical components: (23).

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 (6) to allow right hand pins (24)
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
Section 300-0080, STANDARD BOLT AND NUT
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
To prevent personal injury and property
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 (23) for damage and replace if


WARNINGS 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 (24) and spring pins (6), 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 2209 9-05 3
Operators Compartment - Cab and Mounting
Section 260-0010
Using hand pump (1, Fig. 2) to control lowering of cab, SM - 2881
gently lower cab until cab brackets align with cab
supports (23). Install pins (1) and secure with spring
pins (6).

8. Install front right hand tyre and rim assembly. Refer


to Section 160-0050, WHEEL RIM AND TYRE.
1
9. Secure the heater hoses to the front of the cab as
identified at removal. 3

10. Connect air conditioning lines and charge air


conditioning system. Refer to Section 260-0130, AIR
CONDITIONING.

11. Connect electrical harnesses at cab bulkhead as


identified at removal.
2
12. Connect cables to alternator (earth cable last).

13. Connect cables to battery terminal posts (earth


cable last).

14. Place the battery master switch in the 'On' position,


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 in battery box, into cab hand
pump (1).

TILTING THE CAB 5. Using hand pump (1), charge the cab raise cylinder
Numbers in parentheses refer to Fig. 2, unless (7) sufficiently to allow left hand pins (1, Fig. 1) to be
otherwise stated. removed. Hold cylinder (7) in this position by locking
hand valve on hand pump (1).

WARNINGS 6. Remove spring pins (6, Fig. 1), then drive out pins
To prevent damage, always ensure hood is (1, Fig. 1). Carefully raise or lower the cab as
raised before tilting or lowering the cab. necessary to facilitate removal of pins (1, Fig. 1).

Never work near or under an unblocked 7. Once pins (1, Fig. 1) have been safely removed,
or unsupported cab. Always use the cab safety continue to raise the cab using hand pump (1) until the
prop. cab safety prop (1, Fig. 3) can be fitted.

1. Position the vehicle in a level work area, apply the 8. Remove pin assembly (8, Fig. 1) to allow cab safety
parking brake and switch off the engine. prop (1, Fig. 3) to swing down to a vertical position on
top of the front left hand cab leg.
2. Operate the brake pedal continuously to relieve
pressure in the hydraulic system. 9. Lock the cab safety prop (1, Fig. 3) in position using
pin assembly (8, Fig. 1), locating through holes on
3. Block all road wheels, place the battery master bracket at front left hand cab leg.
switch in the 'Off' position and lift the hood assembly.
10. Lock off hand valve on hand pump (1). Remove

4 SM 2209 9-05
Operators Compartment - Cab and Mounting
Section 260-0010
lever (6) from pump (1) and place in the stowed 2. Remove mirror arm bracket (11) and ball bearings
position. (14) from mounting brackets.

3. Repeat steps 1 and 2 for other mirror arm bracket


LOWERING THE CAB (11).
Numbers in parentheses refer to Fig. 2, unless
otherwise stated.
MIRROR ARMS

WARNINGS Installation
To prevent damage, always ensure hood is Numbers in parentheses refer to Fig. 1.
raised before tilting or lowering the cab.
Note: Tighten all fasteners without special torques
Never work near or under an unblocked specified to standard torques listed in
or unsupported cab. Always use the cab safety Section 300-0080, STANDARD BOLT AND NUT
prop. TORQUE SPECIFICATIONS.

1. Remove pin assembly (8, Fig. 1) from bracket at


front left hand cab leg. Place cab safety prop (1, Fig. 3) WARNING
in stowed position by locating pin assembly (8, Fig. 1) To prevent personal injury and property
in bracket under cab. damage, be sure blocking materials and lifting
equipment are properly secured and of
2. Slowly open hand valve on hand pump (1) to allow adequate capacity to do the job safely.
cab to gently lower. Rate of descent is controlled by
the hand valve on pump (1). 1. Coat ball bearings (14) with grease (18) and locate in
mounting brackets.
3. Lower cab until holes in cab brackets line up with
holes in cab supports (2, Fig. 3). Hold cylinder (7) in 2. Locate mirror arm bracket (11) to mounting brackets
this position by locking hand valve on hand pump (1). and install hardened washers (15), springs (16) and
locknuts (17) as shown in Fig. 1.
4. Install pins (1, Fig. 1) through cab brackets and cab
supports (2, Fig. 3). Secure pins in position with spring 3. Set mirror bracket spring (16) pressure as follows;
pins (6, Fig. 1). a. rotate mirror arm (11) until ball bearings (14) are
out of their detent.
5. Lower the hood and place the battery master switch b. tighten locknut (17) until spring (16) is almost
in the 'On' position before closing the battery box. completely compressed (typical two places).
c. swing arm until it seats in detent.
6. Ensure parking brake is applied and remove wheel d. check the other two detent positions
blocks from all road wheels.
4. Repeat steps 1, 2 and 3 for other mirror arm bracket
(11).
MIRROR ARMS
Removal REPLACING GLASS
Numbers in parentheses refer to Fig. 1. Note: When replacing broken glass, it is the users
responsibility to ensure that the replacement glass
meets the required specifications. Replacement glass
WARNING can be purchased from your dealer.
To prevent personal injury and property
damage, be sure blocking materials and lifting The rear glass, left and right hand side glasses and
equipment are properly secured and of front windscreen are held in place by a bonding
adequate capacity to do the job safely. adhesive.

1. Support mirror arm bracket (11) and remove locknuts To replace a glass assembly, proceed as follows:
(17), hardened washers (15) and springs (16) securing
mirror arm assembly to mounting brackets. Note: Ensure the glass is supported adequately before

SM 2209 9-05 5
Operators Compartment - Cab and Mounting
Section 260-0010
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
8. Ensuring the glass is adequately supported, allow kit and other general service tools required. These
the sealing adhesive to set properly. tools are available from your dealer.

* * * *

6 SM 2209 9-05
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
Numbers in parentheses refer to Fig. 1.
only reacts when the driver sits on the seat. When
WARNING unoccupied, the seat sinks to the lowest position to
allow easier access.
By Law, seat belts must be provided. Always
wear seat belts when travelling in the vehicle.
A retractable seat belt (4) is secured to the seat
assembly using nuts and spacers. A push button
The seat assembly consists of a seat cushion (3) and
allows quick release of seat belt (4).
backrest cushion (2) mounted to backrest (8) and seat

SM 2210 4-03 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.
Numbers in parentheses refer to Fig. 2.
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 2210 4-03
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
1. Position the vehicle in a level work area, apply the Horizontal Shock Absorber
parking brake and switch off the engine.
Numbers in parentheses refer to Fig. 3.
2. Block all road wheels and place the battery master
Note: Remove seat assembly as described in
switch in the 'Off' position.
'Disassembly'
3. Disconnect harness connector at the rear of the
1. Remove pop-out buttons (1) and remove access
seat.
cover (2) to allow access to suspension assembly.
4. Push down height and weight adjustment (1) handle
2. Unclip hooked end of shock absorber (4) from
to release the air from the seat air suspension system.
horizontal spring assembly.
5. Remove bolts (34), washers (35), lock washers (36)
3. Remove circlip (3) and lever out shock absorber (4)
and nuts (37) securing complete seat assembly to the
from rocker shaft and slide off of mounting pin.
cab seat base. Remove seat assembly from vehicle
using suitable lifting equipment.
4. Remove spacer (5) from mounting pin.

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).
Vertical Shock Absorber
5. Pull up horizontal adjustment (2, Fig. 2.) lever and
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 2210 4-03 3
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
Note: Inscription must face upwards when assembling 3. Remove pressurised airline (5) from compressor (6).
shock absorber (7).
4. Identify and tag and disconnect electrical plug
SM - 2488 connections (7 & 8). Unfasten cable tie on the rocker.

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


Numbers in parentheses refer to Fig. 5. Numbers in parentheses refer to Fig. 6.

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 2210 4-03
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
3. Pull suspension assembly up to its highest position slide seat assembly rearwards. Hold captive nuts using
and block securely. a suitable spanner and install front allen screws.
Tighten allen screws to a torque of 25 Nm (18 lbf ft).
4. Unhook bowden wires (5 & 6) from level controller (7).
3. Install seat cushion (3) to seat frame (1) and secure
5. Identify and tag and disconnect electrical plug using screws.
connections (8 & 9).
4. Install backrest cushion (2) to seat frame (1) and
6. Identify and tag and disconnect pressurised airlines secure using screws.
(10) from air suspension unit (11). Unfasten cable tie on
the rocker. 5. Refit headrest (5) to seat frame (1).

7. Remove screw (12), push out pin (13) and release 6. Position lap belt (4) to seat assembly and secure
roll up belt (17). using nuts and spacers as removed at 'Disassembly'.
Tighten nuts to a torque of 50 Nm (36 lbf ft). Refit
8. Remove nuts (14) and manoeuvre level controller (7) covers (6 & 7).
until studs are free from mounting holes.

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
specified to torques listed in Section 300-0080,
11. Reassembly is done in the reverse order. STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Note: Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).

WARNINGS
INSPECTION To prevent personal injury and property
Numbers in parentheses refer to Fig. 1. damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
1. Inspect air lines, shock absorbers (15 & 26), secured and of adequate capacity to do the job
compressor (21), level controller (28) and air spring safely.
(30) for leaks and damage and replace if required.

2. Check all brackets and frame for cracks and/or 1. Using suitable lifting equipment, position seat
damage. Repair or replace as necessary. assembly on the cab seat base and secure using bolts
(34), washers (35), nuts (37) and lock washers (36).
3. Check springs for fatigue or damage and replace as
required. 2. Reconnect harness at the rear of the seat.

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.
specified to torques listed in Section 300-0080,
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 2210 4-03 5
Operator's Compartment - Driver Seat and Mounting
Section 260-0090

SPECIAL TORQUE SPECIFICATIONS


TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 # Nut 50 36
1 # Allen Screw 25 18
5 14 Nut 25 18

MAINTENANCE
Numbers in parentheses refer to Fig. 1.

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 2210 4-03
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 2211 Rev1 10-04 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 2211 Rev1 10-04


Operators Compartment - Air Conditioning
Section 260-0130

REMOVAL 5. When satisfied that the system is completely


discharged, tag refrigerant hoses (8 & 9) to aid in
Numbers in parentheses refer to Fig. 2, unless
installation and carefully disconnect hoses from cab
otherwise stated.
firewall. Cap fittings at front of cab and refrigerant
hoses (8 & 9) to prevent foreign matter from entering
the system.
WARNINGS
Always wear goggles or glasses to protect your
6. Remove fasteners securing front cover (36, Fig. 3)
eyes when working around R-134a.
and end plate (19, Fig. 3) to main weldment (18, Fig.
R-134a boils at sea level temperatures of
3).
-29.8 C (-21.6 F), which means that direct
contact with your skin will produce frostbite.
7. Remove heater hoses from front of cab, which
Exercise extreme care when handling R-134a. If
connect to water inlet hose (24, Fig. 3) and water outlet
R-134a contacts your skin, wash immediately
hose (23, Fig. 3). Cap open ports and hoses to prevent
with plenty of warm water. Remove any
foreign matter from entering the system.
contaminated clothing with caution as it may
adhere to the skin. If blistering or continued
8. Unhook control assembly cable (40, Fig. 3) at main
irritation occurs obtain immediate medical
weldment (18, Fig. 3).
attention.
9. If necessary to remove main weldment (18, Fig. 3)
If you get the slightest trace of R-134a in
from cab, be sure to disconnect any remaining
your eye, flood the eye immediately with cool
harnesses, hoses or ducting before withdrawing main
water; then treat with mineral oil or clear
weldment (18, Fig. 3) from cab.
petroleum jelly followed by boric acid rinse.
Report to a hospital or doctor as soon as
Note: The blower assembly mounting (35, Fig. 3),
possible.
thermostat (21, Fig. 3) and heat exchangers (31,32,
Fig. 3) can be accessed without removing the main
The chemicals of R-134a when burned
produce gases that will damage the respiratory weldment (18, Fig. 3) from cab.
system if inhaled. NEVER SMOKE in an area
where R-134a is used or stored. Use hot water 10. Tag refrigerant hoses (7 & 8) to aid in installation
or an approved heated charge cylinder as a heat and carefully disconnect hoses from receiver/drier (4).
source if required to force R-134a into the Cap receiver/drier (4) fittings and refrigerant hoses (7 &
system. If using water, do not exceed 52 C 8) to prevent foreign matter from entering the system.
(125 F). Never use direct flame or electric
heaters in direct contact with the R-134a 11. Support receiver/drier (4) and remove clamps
container. High temperatures may result in securing receiver/drier (4) to mounting bracket (14).
raising the pressure to a dangerous level.
12. Tag refrigerant hoses (6 & 7) to aid in installation
and carefully disconnect hoses at condenser (5). Cap
To prevent personal injury and property
condenser (5) fittings and refrigerant hoses to prevent
damage, be sure wheel blocks, blocking
ingress of foreign matter.
materials and lifting equipment are properly
secured and of adequate capacity to do the job
13. If required, support air conditioner condenser (5)
safely.
and remove bolts (15), lockwashers (16) and washers
(17) securing condenser (5) to radiator assembly.
1. Position the vehicle in a level work area, apply the
Remove condenser (5) from vehicle.
parking brake and switch off the engine.
14. Tag refrigerant hoses (6 & 9) to aid in installation
2. Block all road wheels and place the battery master
and carefully disconnect hoses from compressor (1).
switch in the 'Off' position.
Cap compressor (1) fittings and refrigerant hoses (6 &
9) to prevent foreign matter from entering the system.
3. Pull on handle (inside battery box) to release hood
catch and raise the hood.
15. Disconnect electrical connection from
compressor (1) clutch.
4. Discharge the air conditioning system as described
under 'Discharging The System'.

SM 2211 Rev1 10-04 3


Operators Compartment - Air Conditioning
Section 260-0130

SM - 2886

10
CAB 9
FIREWALL

12

11
12
1

26
5 8 6 26
25

11 27 20
3 22
26 23
24
21
28
18
2 13
19
10
10 10
7

17
16 4
15 14

1 - Compressor 8 - Refrigerant Hose 15 - Bolt 22 - Washer


2 - Compressor Bracket 9 - Refrigerant Hose 16 - Lockwasher 23 - Lockwasher
3 - Drive Belt 10 - 'O' Ring 17 - Washer 24 - Bolt
4 - Receiver/Drier 11 - 'O' Ring 18 - Lockwasher 25 - Bolt
5 - Condenser 12 - 'O' Ring 19 - Adjuster Bracket 26 - Washer
6 - Refrigerant Hose 13 - Washer 20 - Bolt 27 - Nut
7 - Refrigerant Hose 14 - Bracket 21 - Nut 28 - Bolt

Fig. 2 - Air Conditioner Lines and Mounting

16. Slacken nut (21) and bolt (20). Adjust bolt (20) to fan guard assembly to radiator assembly. Refer to
release tension on drive belt (3). Section 210-0040, RADIATOR AND MOUNTING.

17. Drive belt (3) should now be free to slide off the 20. If required, remove bolts (28), lockwashers (18),
groove in compressor (1). washers (13) and bracket (2) from engine.

18. Support compressor (1) and remove bolts (25), 21. If required, remove bolts (24), lockwashers (23),
washers (26) and nuts (27) securing compressor (1) to washers (22) and bracket (19).
bracket (2). Remove compressor (1) from the vehicle.
Note: If fitted, coolant filter will have to be removed.
Note: If drive belt (3) does not require replacement do
not remove from engine pulley. If drive belt (3) requires 22. If required, disconnect all clamps and clips
replacement, proceed with steps 19 and 20. securing refrigerant hoses and harnesses to the
vehicle. Remove hoses and harnesses from the
19. If required, remove mounting hardware securing vehicle.
4 SM 2211 Rev1 10-04
Operators Compartment - Air Conditioning
Section 260-0130

SM - 3318

Fig. 3 - Air Conditioner Lines and Mounting

SM 2211 Rev1 10-04 5


Operators Compartment - Air Conditioning
Section 260-0130

LEGEND FOR FIG. 3


1 - Heater/Air-Con Assy 13 - Nut Insert 25 - Water Valve Assy 37 - Recirculation Filter
2 - Grommet 14 - Allen Screw 26 - Jubilee Clip 38 - Coil Seal
3 - Seal 15 - Allen Screw 27 - Demist Flap Assy 39 - Coil Seal
4 - Grommet 16 - Clamp Plate 28 - Cable Bracket 40 - Control Assy Cable
5 - Screw 17 - Clamp Plate 29 - Pivot Bracket 41 - Louver
6 - Grommet 18 - Main Weldment 30 - Fresh Air Flap Assy 42 - Drain Tube Assy
7 - 'O' Ring 19 - End Plate 31 - Evaporator 43 - Control Knob
8 - 'O' Ring 20 - Valve 32 - Heater Coil 44 - Potentiometer Assy
9 - Control Arm 21 - Thermostat 33 - Manifold 45 - Air Con Switch
10 - Control Arm 22 - Water Outlet Pipe 34 - Manifold 46 - Fan Speed Switch
11 - Nut Insert 23 - Water Outlet Hose 35 - Blower Assy Mounting 47 - Control Panel
12 - Binary Switch 24 - Water Inlet Hose 36 - Front Panel Assy

INSTALLATION 7. If removed, install receiver/drier (4) to mounting


Numbers in parentheses refer to Fig. 2, unless bracket (14) and secure with clamps.
otherwise stated.
8. Remove caps from end of refrigerant hoses (7 & 8)
Note: Tighten all fasteners to standard torques and ports on receiver/drier (4) and connect hoses to
specified in Section 300-0080, STANDARD BOLT AND ports as tagged at removal.
NUT TORQUE SPECIFICATIONS.
9. If removed, install condenser (5) to radiator
Note: Renew all 'O' rings where necessary (10, 11 & assembly and secure with bolts (15), lockwashers (16)
12). and washers (17).

10. Remove caps and connect refrigerant hoses


WARNING (6 & 7) to condenser (5) ports as tagged at removal.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 11. If removed, install bracket (19) to engine and
materials and lifting equipment are properly secure with bolts (24), lockwashers (23) and washers
secured and of adequate capacity to do the job (22). If applicable, install coolant filter to bracket (19).
safely.
12. If removed, install compressor bracket (2) to
1. If main weldment (18, Fig. 3) was removed, install in engine and secure using bolts (28), lockwashers (18)
cab and reconnect harnesses, hoses and air ducting as and washers (13) as shown in Fig. 2.
noted during removal.
13. Fit compressor (1) to compressor bracket (2) and
2. Attach control assembly cable (40, Fig. 3) as noted secure with bolts (25), washers (26) and locknuts (27).
during removal. Do not fully tighten at this stage.

3. Reconnect heater hoses to front of cab and connect Note: If fan guard and compressor drive belt (3) were
to water inlet hose (24, Fig. 3) and water outlet hose removed, proceed with steps 14 & 15.
(23, Fig. 3), as identified at removal.
14. Install new drive belt (3) onto engine pulley and fit
4. Once all necessary connections have been made, to groove on compressor (1).
secure front cover (36, Fig. 3) and end plate (19, Fig. 3)
to main weldment (18, Fig. 3) using fasteners 15. Adjust tension of compressor drive belt with nut
previously removed. (21) on adjuster bolt (20) until there is approximately an
inward deflection of 10 mm (0.4 in) at the centre of
5. Remove caps from end of refrigerant hoses (8 & 9) drive belt (3). Fully tighten all mounting hardware.
and ports at front of cab and connect hoses to ports as
tagged at removal. 16. Remove caps from end of refrigerant hoses (6 & 9)
and ports on compressor (1) and connect hoses to
6. Route refrigerant hoses (8 & 9) along the LH side of ports as tagged at removal.
the engine securing with clamps removed during
removal. 17. Connect electrical connection to compressor (1)
clutch.

6 SM 2211 Rev1 10-04


Operators Compartment - Air Conditioning
Section 260-0130
18. 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
19. 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
20. 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.
21. 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 dust or by washing in soapy water.
blistering 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 300-
possible. 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 Maintenance of drive belts
where R-134a is used or stored. Use hot water 1. Listen for 'ticking' sound - they mean interference
or an approved heated charge cylinder as a heat with the belts. Visually inspect for bent or damaged
source if required to force R-134a into the belt guards.
system. If using water, do not exceed 52 C
(125 F). Never use direct flame or electric 2. Replace all belts in a mismatched set at one time
heaters in direct contact with the R-134a to ensure even load distribution.
container. High temperatures may result in
raising the pressure to a dangerous level. 3. Periodically check tension and keep belts tight.

1. Periodically clean the condenser coil of debris and - The ideal tension is the lowest tension at which the
dirt using water or air pressure. A partially blocked belt will not slip under peak load conditions.
condenser coil can reduce the life of the compressor - Check belt tension frequently during the first 24 - 48
belt and/or clutch. hours of run-in operation.
- Initial belt tension should be 533 N (120 lbf)

SM 2211 Rev1 10-04 7


Operators Compartment - Air Conditioning
Section 260-0130
dropping to 422 N (95 lbf) after the first 48 hours. If any component is replaced the following amount of
- There should be a freeplay of 10 mm in the belt. oil should be added to the system;
- Do not over tension belts.
- Keep belts free from foreign material that may Condenser add 1 fl oz (28.4 ml)
cause slippage. Drier add 1 fl oz (28.4 ml)
- Inspect the drive periodically. Re-tension belts if Evaporator add 3 fl oz (85.2 ml)
they are slipping. Compressor add 4.4 fl oz (125 ml)
- Maintain sheave alignment with a strong straight
edge tool while tensioning belts. The oil should be added to the oil filling port of the
compressor before the evacuation procedure is started
4. Never attempt to correct belt slippage by using a or by using an oil injector when the system is being
belt dressing. The dressing may cause softening and charged, observing the following good practises:
deterioration.
a. Only pour the amount required from the container
5. If belt slips, even when properly tensioned, check for straight into a CLEAN measuring jug and
overload, worn sheave grooves or oil or grease on the immediately pour the oil into the compressor.
belts. b. Re-cap container tightly as soon as the required
amount has been taken (never leave an oil container
6. Never pry a drive belt or force it into the sheave open).
groove. Loosen the drive belt tightener prior to c. Do not mix different oils.
installation.
Only new oil should be used, because oil that has
7. A belt that has operated while rolled over in the been exposed to the air will have absorbed water
sheave groove may be damaged - replace it. (hygroscopic).

8. Store belts in a cool, dry place. If stored on a Use only refrigerant oil as specified in Section
machine, relieve all belt tension by loosening the 300-0020, LUBRICATION SYSTEM.
drive belt tightener.

9. Never attempt to check or adjust belts while they are System Leak Testing
running. Recommended Equipment Required:
Electronic Leak Detector

Refrigerant Oil Switch off the engine and check all connections
throughout the system for leaks. A large leak point will
have an oily or greasy appearance. The refrigerant
WARNINGS carries compressor oil with it and deposits it around the
To prevent personal injury always wear rubber leak area. Check all such points for loose connections
gloves when handling refrigerant oils. and tighten.

Too much refrigerant oil will dampen the Using a suitable leak detector, search for leaks around
cooling effect and too little refrigerant oil may all joints, connections, seals and control devices. If a
lead to compressor failure. If in doubt flush leak is located, purge the system of refrigerant and
the system. repair. Fully evacuate and charge the system to make
it operational.
Oil is required to lubricate the compressor. The oil
mixes with the refrigerant and is carried around the
system. The compressor is supplied with an oil DISCHARGING THE SYSTEM
charge. However, additional oil is required, the Note: Refer to all WARNINGS listed under
amount depending on the length of refrigerant hose 'Maintenance' prior to discharging the system.
being used. The quantity added should be calculated
using the following equation: Recommended Equipment Required:
Portable High Vacuum Charging Station
Amount of oil to add in fl oz. = Suitable Canister
(0.47 x total length of hoses in m) - 2.15 or Standard Service Manifold (Refer to Fig. 4)

8 SM 2211 Rev1 10-04


Operators Compartment - Air Conditioning
Section 260-0130
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.

10. Tighten down (turn clockwise) both high and low


WARNING side valves on the gauge manifold to the closed
The vehicle must not be running during this position, remove the service hose (yellow) from the
procedure. Be sure to have adequate ventilation vacuum connection (6) on vacuum pump and switch
during this operation. Do not discharge the pump 'Off'.
refrigerant near an open flame.
11. Connect the service hose (yellow) to the R-134a
Numbers and letters in parentheses refer to Fig. 4. cylinder. Open the cylinder valve and then purge air
from the hose at the manifold connection.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. 12. Open the low side hand valve on the manifold
slowly, until low pressure gauge (B) is at bottle
2. Block all road wheels and place the battery master pressure. Watch the high side manifold gauge (C) rise
switch in the 'Off' position. to ensure that no blockage is present. Close the
manifold valve and cylinder, then disconnect the hose
3. Pull on handle to release hood catch and raise the from the cylinder.
hood.
13. Connect the service hose (yellow) to the Nitrogen
4. Connect the service hose (yellow) to the centre cylinder. Open the neck valve on the cylinder and set
access port on the manifold gauge and to the vacuum the regulator pressure such that it is higher than the
connection (6) on vacuum pump. Ensure that the system pressure then purge the hose. Open the low
system is empty before connecting the vacuum so that side hand valve on the manifold, as the pressure
refrigerant does not enter the pump. rises open the high side hand valve on the manifold
and allow a system pressure of 10 bar (150 psig) to
5. Tighten down (turn clockwise) both high and low side be reached. Close all the valves. Using a suitable
valves on the gauge manifold to the closed position. electronic leak detector, check all joints in the air
Remove protective caps from the service ports on the conditioning system for leaks. Tighten any loose
compressor. joints and re-test if necessary.

6. Connect both service hoses from the two fittings (2 14. Vent the refrigerant mix to atmosphere by
& 3) in the bottom of the manifold to the two service removing the service hose (yellow) from the Nitrogen
ports on the compressor. High side (red) to compressor cylinder and opening the low side hand valve on the
discharge valve, low side (blue) to compressor suction manifold. Re-evacuate the system to below 6 mb
valve. (steps 7 to 10).

7. Switch vacuum pump on, open vacuum pressure 15. Lower hood assembly and remove wheel blocks.
valve (1) until less than 6 mb is reached on vacuum
gauge (A). The vacuum gauge (A) should remain at
this value when vacuum pressure valve (1) is closed CHARGING THE SYSTEM
to indicate that there are no leaks. Note: Refer to all WARNINGS listed under
'Maintenance' prior to charging the system.
8. Open the low side hand valve on the manifold and
vacuum pressure valve (1) and watch that the Recommended Equipment Required:
gauges start to register that a vacuum is being drawn. Portable High Vacuum Charging Station
If the gauges do not register the vacuum thena Electronic Leak Detector
blockage is present. Open the high side and pump or Standard Service Manifold (Refer to Fig. 4)
down until a vacuum of 10 mb is achieved.

SM 2211 Rev1 10-04 9


Operators Compartment - Air Conditioning
Section 260-0130

For New Or Completely Empty System 8. Start vacuum pump to evacuate the complete air
conditioning system.
Note: The charging procedure must be done in ambient
temperatures above 15.5 C (60 F) with the R-134a
9. Run vacuum pump for approximately 30 minutes.
canister temperature equal to the outside ambient
Ideal gauge readings should be 29.92 inches of
temperature.
mercury. The pressure will vary with altitude; it will be
approximately 0.03 bar (0.5 lbf/in) less for each 305 m
1. Shut off engine and block all road wheels.
(1 000 ft) of elevation.
2. Pull on handle to release hood catch and raise the
10. Before disconnecting power supply from vacuum
hood.
pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
3. Remove protective caps from 'quick coupler' valves
R-134a source.
on rear of compressor.
11. Open R-134a source. Loosen, but do not remove,
4. Connect low pressure gauge hose (blue hose and
yellow supply hose at manifold on gauges to remove all
gauge) to suction side or low side fitting on
air in the yellow supply hose, replacing the air with R-
compressor. The suction side can be identified by the
134a. This is done in a few seconds. Tighten yellow
size of the hose connected to the fitting. This will be
supply hose.
the largest diameter hose of the system.
12. Open low side of R-134a gauges slowly. When
5. Connect the high pressure gauge hose (red hose and
gauge reads zero open both sides completely. Vacuum
gauge) to discharge or high side fitting on compressor.
in the system will draw R-134a gas into the system.
6. Connect yellow supply hose to suction port on
Hold until both gauge readings equalize.
vacuum pump.
Note: Never charge with liquid R-134a. Charge on
7. Open both sides of gauges, low and high, completely.
the low pressure side only.
SM - 2424

B C D Final Charging Of The System


1. Start the engine and run at engine idle speed.

4 2. Turn the air conditioning system on with the


2 3
thermostat set on maximum cooling and fan on high
SUC DIS R speed.
ACCESS E
F
PORT R 3. At this point a visual inspection must be made of
I the sight glass on top of the receiver-drier. Allow
G
E charging to continue until 1.1 kg (2.43 lbs) of refrigerant
A R has been added. The charging process can be speeded
A
N up by running the engine at a fast idle.
T
4. The sight glass on top of the receiver/drier will be
VACUUM PUMP
substantially free of bubbles.

Note: It is normal for bubbles to increase during clutch


6
1 5 cycling or system start-up.

Gauges: Valves: 5. With the system completely charged, shut off the
A - Vacuum Gauge 1 - Vacuum Pressure engine. Close the valve on the R-134a canister and
B - Low Pressure Gauge 2 - Suction Line remove the yellow supply hose. Remove both the low
C - High Pressure Gauge 3 - Discharge Line
D - Charging Cylinder 4 - Refrigerant Gas pressure (blue) hose and high pressure (red) hose from
Pressure Gauge 5 - Refrigerant Liquid the filling ports on the compressor.
Port:
6 - Vacuum Connection Note: Some R-134a will escape as the hoses are being
Fig. 4 - Standard Service Manifold removed.

10 SM 2211 Rev1 10-04


Operators Compartment - Air Conditioning
Section 260-0130
The system is completely charged when; 4. Check the cab fresh air inlet filter for blockage.

a. the suction pressure on the gauge is approx. 5. Check that, with the ignition switch on (engine not
20 - 30 psig at 25 C ambient. running), the blower operates over whole speed range
b. the correct weight of refrigerant has been added i.e.
1.1 kg (2.43 lbs). 6. Check that, with the ignition switch on (engine not
c. the correct sub-cooling can be measured at the running), the blower and air conditioning switched on,
condenser, approx. 5 - 7 C. the compressor clutch engages.

6. Replace protective caps on hoses and valve fittings. Charge level:


Note: It is not possible to check refrigerant charge
7. Lower hood assembly and remove wheel blocks. level with R134a systems. Any bubbles seen at the
sight glass on the receiver drier may be bubbles of oil
and are perfectly normal.
TROUBLESHOOTING
Fault finding:
Preliminary Checks Refer to Troubleshooting table
Before any checks are carried out on the refrigerant Important: Refer to appropriate removal and installation
circuit the following checks should be made: procedures before working on any system component.

1. Check the compressor drive belt is serviceable and


correctly tensioned. SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
2. Check the condenser and engine radiator are not numbers of special tools referenced in this section and
blocked by debris. Clean with compressed air or water general service tools and sealants required. These
if necessary. tools and sealants are available from your dealer.

3. Check that the condenser fins are not flattened or


damaged, the fins must allow air to pass freely.

SM 2211 Rev1 10-04 11


Operators Compartment - Air Conditioning
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

12 SM 2211 Rev1 10-04


Operators Compartment - Air Conditioning
Section 260-0130

AIR CONDITIONING TROUBLESHOOTING (CONTINUED)


CONDITION PROBLEM REMEDY
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

SM 2211 Rev1 10-04 13


Operators Compartment - Air Conditioning
Section 260-0130

AIR CONDITIONING TROUBLESHOOTING (CONTINUED)


CONDITION PROBLEM REMEDY
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

* * * *

14 SM 2211 Rev1 10-04


BODY - Body and Mounting
Section 270-0010

SM - 2883

10

1
6

15
5
13
4

7 A A

8
A
14
17
BODY
18 1
19 3

21
16
8
17
18
11
20 2
22 12 9
L.H. FRAME RAIL

1 - Body 5 - Shim 9 - Shim 13 - Washer 18 - Washer


2 - Bushing 6 - Shim 10 - Locknut 14 - Lube Fitting 19 - Bolt
3 - Hinge Pin 7 - Washer 11 - Spacer 15 - Bolt 20 - Plate
4 - Body Pad 8 - Bolt 12 - Plate 16 - Proximity Switch 21 - Plate
17 - Locknut 22 - Bolt
Fig. 1 - Exploded View of Body and Mounting

DESCRIPTION OPERATION
The standard body is an all welded construction with The body control lever, mounted on the right hand dash
all wear plates fabricated from high hardness panel, controls the main hydraulic valve assembly.
(min. 360 BHN) 1 000 MPa (145 000 lbf/in2) yield
strength steel. Angled lower body sides reduce body When the body control lever is operated, a voltage is
impacts when loading and a tailshute angle of 25 sent to the hydraulic ECU, which converts voltage to
provides good retention when travelling without a current. This current controls the body raise and lower
tailgate. Refer to Section 000-0000, GENERAL proportional pressure control valves, producing a pilot
INFORMATION for body capacities. pressure to shift the control spool in the main hydraulic
valve. This allows the flow of oil to reach the body
The body is pivoted at the rear of the trailer frame and cylinders, to either raise or lower the body. Refer to
is operated by two single stage, double acting hoist Section 230-0000, BODY SYSTEM SCHEMATIC and
cylinders which are cushioned at both ends of the Section 215-0050, MAIN HYDRAULIC VALVE.
stroke to reduce impact shocks. The hoist cylinders
raise the body to a tipping angle of 65 in The three operating positions of the joystick from front
12 seconds and powerdown the body in 7.5 seconds. to rear are as follows:

Power Down - Pushing the lever forward provides


hydraulic force to power-down the body. Pushing the

SM 2212 4-03 1
Body - Body and Mounting
Section 270-0010
lever fully forward will engage the electric detent. When
the body reaches the body proximity switch, the lever
REMOVAL
springs back to 'NEUTRAL' and power down is ramped Numbers in parentheses refer to Fig. 1.
back to allow the body to float down onto the chassis.

Neutral - If the body is above the body proximity WARNINGS


switch, the lever in this position will stop and hold the To prevent personal injury and property
body at any desired height. If the body is below the damage, be sure wheel blocks, blocking
proximity switch, the hydraulic ECU defaults the materials and lifting equipment are properly
control spool in the main hydraulic valve to the neutral secured and of adequate capacity to do the job
position and energises the float solenoid, allowing the safely.
body to float down onto the chassis. The body should
be fully lowered and in the 'NEUTRAL' position while Hydraulic fluid pressure will remain
the machine is in motion. The lever will remain in the within the body hoist system after engine
'NEUTRAL' position when released. shutdown. To prevent personal injury and
property damage, press and release the brake
Raise - Pulling the lever back and holding it in this treadle valve continuously to relieve pressure in
position directs oil to extend the body hoists and raise the system.
the body. When released, the lever will spring back to
the 'NEUTRAL' position. WARNING
means of electrical signals to the pressure reducing Exercise extreme caution when lowering
valves, which in turn operates the body hoist cylinders. the cylinders from the body. The cylinders will
The four operating positions of the joystick from front swing out sharply as they leave their
to rear are as follows: mountings.

A body lower emergency switch in the cab is 1. Position the vehicle in a level work area, ensure the
connected directly to the float solenoid, within the main body is fully lowered, apply the parking brake and
hydraulic valve, to enable the lowering of the body in switch off the engine.
the event of an engine, hydraulic or hydraulic ECU
failure. The cause of the failure must be investigated 2. Relieve stored hydraulic pressure in accumulators
and corrected. (x3), by pressing and releasing brake treadle valve
continuously, until all accumulator pressure is relieved.
Note: The body must remain lowered with lever in the
'NEUTRAL' position until it is necessary to operate the 3. Block all road wheels, place the steering lock bar in
body again. Failure to comply to this could result in the 'Locked' position and the battery master switch in
overheating the hydraulic oil and failure of the hydraulic the 'Off' position.
system components.
4. Remove upper pins securing the body cylinders to
Note: A proximity sensor prevents the body being fully body (1) assembly and secure body cylinders clear of
powered down onto the chassis. At a predetermined the body. Refer to Section 230-0130, BODY
height, the sensor automatically energises the float CYLINDER.
solenoid on the main hydraulic valve assembly.
Note: Body lifting lugs can be fabricated as shown in
Note: If an electrical failure occurs, the main hydraulic Fig. 2.
valve assembly will automatically default to the 'HOLD'
condition. The cause of the electrical fault must be 5. Secure lifting lugs to body (1) using suitable bolts.
investigated and corrected. Using appropriate lifting equipment, sling body (1)
assembly at the four lifting points and take an initial
strain.
WARNING
Never work under or near an unblocked or Note: Approximate weight of body (1) assembly is
unsupported raised body. Always use the body 4 400 kg (9 700 lb).
safety prop. The body safety prop must only be
used when the body is empty. 6. Remove bolts (15) and washers (13) securing hinge
pins (3) in place. Remove hinge pins (3) and shims (9)
from body (1).

2 SM 2212 4-03
Body - Body and Mounting
Section 270-0010
7. Remove body (1) assembly from the vehicle. BODY SHIMMING PROCEDURE
Numbers in parentheses refer to Fig. 1.
8. Remove bushing (2) from body hinge bores.
Note: Tighten all fasteners to standard torques listed in
INSTALLATION Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
Numbers in parentheses refer to Fig. 1.
Note: When it becomes necessary, body pads (4)
Note: Tighten all fasteners to standard torques listed in
should be replaced as a set to maintain load
Section 300-0080, STANDARD BOLT AND NUT
distribution along the frame. Existing body pads will
TORQUE SPECIFICATIONS.
have taken a compression 'set' and a new pad,
shimmed to match existing pads, will not carry its
share of the load, resulting in uneven load distribution
WARNING
along the frame.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
1. Raise body (1) clear of the trailer frame and lay
materials and lifting equipment are properly
body pads (4) (metal face down) roughly in position on
secured and of adequate capacity to do the job
the frame.
safely.
2. Lower body (1) assembly onto body pads (4).
1. Inspect bushing (2) for damage and replace if
necessary. Install bushing (2) in body hinge bores.
3. Centralise body (1) assembly to the frame and
place shims (5 & 6) under the front two body pads (4)
Note: Body lifting lugs can be fabricated as shown in
until all other pads are clear of body (1) assembly.
Fig. 2.
4. Slide shims (5 & 6) under remaining body pads (4)
2. Secure lifting lugs to body (1) using suitable bolts.
until they just make contact with body (1) assembly.
Using appropriate lifting equipment, sling body (1)
assembly and position over the trailer frame.
5. Raise body (1) assembly and install body pads (4)
and shim packs (5 & 6) to their relative brackets on
Note: Approximate weight of body (1) assembly is
body (1) assembly securing with bolts (8), washers (7)
4 400 kg (9 700 lb).
and locknuts (10).
3. Align hinge pin bores in body (1) assembly with bores
6. Lower body (1) assembly to the frame and check the
in the trailer frame. Install hinge pins (3) and shims (9) and
shimming.
secure with bolts (15) and washers (17).
7. Install body guide plates (12) with spacers (11) to
4. Secure body cylinders to body (1) assembly with
mounting brackets on body (1) assembly. Set gap
pins and mounting hardware removed during removal.
between plates (12) and the frame at 5 - 10 mm
Refer to Section 230-0130, BODY CYLINDER for
(0.2 - 0.4 in). Secure plates (12) and spacers (11) to
instructions.
mounting brackets with bolts (8).
5. Lubricate hinge pins (3) through lube fitting (14) with
lubricant specified in Section 300-0020, LUBRICATION
SYSTEM. Lubricate slowly until excess lube is seen.

6. Install body pads (4) and body guide plates (12) on


body (1) assembly as described under 'Body
Shimming Procedure'.

7. Remove lifting equipment from body (1) assembly


and blocks from all road wheels.

8. Place the battery master switch in the 'On' position,


start the engine and check for correct operation of body
(1) assembly.

SM 2212 4-03 3
Body - Body and Mounting
Section 270-0010

MAINTENANCE SM - 1630

Lubricate the body hinge pins and body cylinder pins at 64 DIA HOLE
the intervals stated and with lubricant specified in BURN
Section 300-0020, LUBRICATION SYSTEM. Lubricate 8
R4
slowly until excess lube is seen.

SPECIAL TOOLS
Special tools can be fabricated as shown in Fig. 2.
96
Refer to Section 300-0070, SERVICE TOOLS, for part
19.5
numbers of the general service tools required. These 6 6

0
2 PLACES 2 PLACES

10
tools are available from your dealer.
40

114
R 20

71
31

48 16

1 HOLE DRILL THRO'


21 MM DIA

Fig. 2 - Body Lifting Lug

* * * *

4 SM 2212 4-03
MISCELLANEOUS - Lubrication System
Section 300-0020

LUBRICATION AND SERVICE


SAFETY PRECAUTIONS
Do not allow unauthorized 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 2204 Rev 3 09-04 1


Miscellaneous - Lubrication System
Section 300-0020

SM - 3299

19 31 19 19
5 18 1 32 4 30 15 20 10 23 3 23 10 11 22 15 11 35 12 20 15 13

33 17 14 16 34 6 7 23 15 10 29 2 28 25 11 9 21 27 23 20 15 23 12 35 15 13
19 19 19

Lubrication and Servicing Points

LUBRICATION AND SERVICE CHART


Interval Ref. No. of
Hours Points Identification Service Instructions Points Lubricant Service/Quantities
1 Engine Check oil level. Add if low. 1 EO As Required
2 Transmission Check oil level. Add if low. 1 EO As Required
3 Hydraulic Tank Check oil level. Add if low. 1 HO As Required
4 Radiator Header Tank Check coolant level. Add if low. 1 - See Page 4
10 6 Fuel Filter/Water Separator Drain. 1 - -
(Daily) 7 Air Filter Restriction Gauge Check. Replace element if required. 1 - See Note 5
18 Drive Belts Check for damage. - - See Engine Manual
32 Fuel Tank Check fuel level. Add if low. 1 - As Required
- Engine Crankcase Breather Inspect and clean if required. 1 - -
- Cooling Fans Check for damage. - - -
- Hydraulic Filter Restriction Indicator Check. Replace element if required. 1 - -
- Tyres Check condition and pressure. 6 - Sec 160-0050
- Hood Check air intake/vents for blockage. 3 - -
- General Check for debris, leaks and damage. - - -
50 14 Battery Electrolyte Check level. Add if low. 2 - As Required
(Weekly) 15 Wheel Rim Nuts Check torque. (Torque Seal) 72 - 590 Nm (435 lbf ft)
30 Cab Ventilation Filter Inspect and clean if required. 1 - -
10 Steering Cylinder Pins Lube. 4 EP, NLGI See Note 1
11 Body Cylinder Pins Lube. 4 EP, NLGI See Note 1
35 Spherical Bearings Lube. 2 EP, NLGI See Note 1
9 Oscillation Bushes Lube. 2 EP, NLGI See Note 1
12 Suspension Beam Bushings Lube. 2 EP, NLGI See Note 1
250 13 Body Hinge Pins Lube. 2 EP, NLGI See Note 1
(Monthly) - Differential Breathers Clean if required. 3 - -
21 Oscillation Pivot Check end float. Adjust if required. 1 - -
25 Articulation Bearings Lube. 2 EP, NLGI See Note 1
27 Parking Brake Pads Check wear. Replace if required. 2 - -
- Service Brake Pads Check wear. Replace if required. 24 - -
- Transmission Cooler Clean and inspect fins. 1 - See Note 3

2 SM 2204 Rev 3 09-04


Miscellaneous - Lubrication System
Section 300-0020

LUBRICATION AND SERVICE CHART (CONTINUED)


Interval Ref. No. of
Hours Points Identification Service Instructions Points Lubricant Service/Quantities
- Transmission Breather Clean if required. 1 - -
250 5 Radiator and Charge Air Cooler Clean and inspect fins. 1 - See Note 3
(Monthly) 19 Wheel Planetaries Check oil level. Add if low. 6 EPL As Required
20 Differentials Check oil level. Add if low. 3 EPL As Required
1 Engine Drain oil and refill. 1 EO See Page 5
500 16 Engine Oil Filter Replace. 1 - -
(3 Monthly) 32 Fuel Tank Clean filler neck, screen & cap. 1 - -
- Engine Air Cleaner Clean inlet screen. - - -
2 Transmission Drain oil and refill. 1 EO See Page 5
6 Fuel Filter/Water Separator Replace. 1 - -
17 Coolant Filter Replace. 1 - See engine manual
19 Wheel Planetaries Drain oil and refill. 6 EPL See Page 5
1 000 20 Differentials Drain oil and refill. 3 EPL See Note 2
(6 Monthly) 22 Driveshaft Bearings Check oil level. Add if low. 1 EPL To fill plug. See
Note 4.
28 Transmission Oil Filters Replace. 2 - -
29 Transmission Internal Oil Filter Clean. 1 - -
30 Cab Ventilation Filter Replace. 1 - -
- Hinges Lube. 2 - See Note 1
32 Fuel Tank Replace cap filter/cartridge. 1 - -
- Hydraulic Tank Breather Replace 1 - -
1 Engine Steam clean. 1 - -
3 Hydraulic Tank Drain oil and refill. 1 HO See Page 5
25 Articulation Pivot Nut Check torque. 1 - 1 425 Nm
(1 050 lbf ft)
31 Hydraulic Oil Filter Replace. 1 - See Page 5
2 000 3 Strainer Clean 1 -
(Annually) 23 Drivelines (Low Maintenance) Check for leaks and damage. - - See Page 5
- Engine Mounting Bolts Check torque. (Torque Seal) 4 - 298 Nm (220 lbf ft)
- Transmission Mounting Bolts Check torque. (Torque Seal) 3 - Sec. 120-0010
- Turbocharger Mounting Nuts Check torque. (Torque Seal) 4 - 65 Nm (50 lbf ft)
- Engine Water Pump Inspect drain hole. Clean if required. 1 -
4 000 33 Air Conditioning Compressor Drain, flush and refill 1 PAG Oil See Page 5
7 500 5 Cooling System Check concentrate, add booster - - See Page 5

Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and
'Miscellaneous Servicing' contained on the following pages.
Notes on Lubrication and Service Chart Note 5 - Change safety element after every third
primary element service.
Note - Capacities given are approximate - work to
dipstick, sight gauges or level plugs. EO - Engine Oil. Refer to 'Recommended
Lubricants' and 'Engine Oil Drain Intervals'.
Note 1 - Lubricate slowly until excess lube is seen.
HO - Hydraulic Transmission Oil. Refer to
Note 2 - Capacity of front and rear differentials is 'Recommended Lubricants'.
17 litres (4.5 US gal). Capacity of centre
differential is 18.5 litres (4.9 US gal). This EPL - Extreme Pressure Gear Lubricant spec.
includes 1.5 litre (3.2 pints) for priming the MIL-L-2105D.
3rd differential unit. EP, NLGI- Extreme Pressure Lithium No. 2 Grease
Note 3 - Clean radiator and cooler fins more often (without 'Molybdenum').
when operating under extremely dusty PAG Oil - Polyalklene Glycol (PAG) Compressor
conditions. Lubricating Oil - Low Viscosity (ISO46).
Note 4 - Remove plug from port on underside of
oscillation hub. Plug is removed to drain the
cavity of any oil that enters the cavity when
filling. Remove grommet and level plug on
side of oscillation hub. Add oil if required.
Refit all plugs.

SM 2204 Rev 3 09-04 3


Miscellaneous - Lubrication System
Section 300-0020

MISCELLANEOUS SERVICING AFTER FIRST 500 HOURS OF


OPERATING NEW OR REBUILT
WHEN REQUIRED COMPONENTS
Seat Belts - Inspect for damage. Replace if required.
Transmission - Drain oil, replace filter, clean internal
Windscreen Wipers And Washers - Replace wiper
filter and finger magnet. Refill transmission.
blades and top up reservoirs.
Note: When refilling transmission ensure that
transmission cooler is primed to prevent damage.
Wheel Rim Nuts - After first 10 hours of operation re-
torque nuts to 590 Nm (435 lbf ft). Check torque every
Differentials - Drain oil and refill to level plug.
50 hours (weekly) thereafter.
Note: When refilling centre axle ensure that 3rd.
differential unit is primed with 1.5 litre (3.2 pints) of oil
EVERY 10 HOURS OF OPERATION before filling drivehead.
(DAILY)
Planetaries - Drain oil and refill to level plug.
Walk Around Inspection - Inspect the vehicle as
described in Section 4 of the Operators Handbook.
EVERY 250 HOURS OF OPERATION
Engine - Visually check engine for damage, loose or (MONTHLY)
frayed belts and listen for any unusual noises.
Oil Can Points - Oil working parts with engine oil.
Engine Air Cleaner - Change air cleaner element only
when air restriction gauge locks up in the red. Service
General Inspection - Check entire dumptruck for
vacuator valves daily. Inspect and remove any
leaks, loose bolts and nuts or damaged parts. Examine
obstructions from the vacuator valve lips which should
the dumptruck, particularly the chassis, for cracks or
be open and pliablewith the engine stopped.
broken welds. Repair where necessary.
Note: Service air cleaners more often when operating
under extremely dusty conditions.
Engine Air Intake - Check air intake system for wear
points or damage to piping, loose clamps and leaks.
Engine Crankcase - Check oil level and add oil if low.
With the engine off, the oil should be between the lower
Service Brakes - Check pads and discs for wear and
and upper marks on the dipstick, up to the upper mark
adjust or replace where necessary. Test for proper
is preferable.
function.
Note: This service interval applies to normal driving.
Transmission - Check oil level and add oil if low.
Check the pads more frequently under more severe
Refer to Section 120-0010, TRANSMISSION AND
conditions. Thickness of pad friction material should
MOUNTING, for correct oil level check procedure.
never be allowed to wear below 3 mm (0.12 in).
Hydraulic Tank - Check oil level and add oil if low.
Parking Brake - Check pads and disc for wear. Adjust
With the engine off and the body down the oil should be
or replace if required. Test for proper function. Friction
visible in the sight gauge.
material thickness should never be allowed to wear
below 3 mm (0.12 in).
Radiator Header Tank - Check coolant level when cold
and add if low. Fill the radiator header tank with coolant
until coolant reaches the bottom of the filler neck and EVERY 1 000 HOURS OF OPERATION (6
holds that level. MONTHS)
Note: Any time a significant amount of coolant is
added, the coolant concentration MUST be checked. Differential -Drain oil and refill to level plug.
Failure to use recommended coolant and to maintain Note: When refilling centre axle ensure that 3rd.
mixture at sufficient concentration levels can result in differential unit is primed with 1.5 litres (3.2 pints) of
damage to the cooling system and its related oil before filling drivehead.
components. Always maintain concentrations at
recommended levels. Refer to 'Recommended Planetaries - Drain oil and refill to level plug.
Coolants'. Section 210-0000, COOLING SYSTEM.

4 SM 2204 Rev 3 09-04


Miscellaneous - Lubrication System
Section 300-0020

EVERY 2 000 HOURS OF OPERATION ENGINES AND TRANSMISSIONS


(ANNUALLY) All information contained in the 'Lubrication and Service
Hydraulic Oil Tank - Drain oil, remove and clean filter Chart' was extracted from the relevant manufacturers
screen assemblies. Reinstall filter screens and refill Operators Manual and was correct at time of
tank. publication. User should ensure that information
contained in this chart, regarding Engines and
Hydraulic Oil Filter - Clean filter housing and install Transmissions, reflects the information shown in the
new element when filter restriction gauge reads in red relevant manufacturers Operators Manuals, supplied
zone, or after 2 000 hours of operation, whichever with the machine. Maintenance procedures should be
comes first. carried out in conjunction with any additional
procedures contained in the relevant manufacturers
Drivelines - Visually check Low Maintenance 'Operation and Maintenance Manual', at the intervals
drivelines for leaking or damaged seals. specified.
Note: Low Maintenance drivelines can be identified
by having plugs fitted to the spiders, not grease
nipples.

RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE
Engine Crankcase Engine Oil with 1.00% 41 litre CH-4 15W-40
(Including Filters) sulphated ash limit is (10.8 US gal) (See Note 1)
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission Engine Oil with 1.85% 63 litre (See Note 2) CH-4 15W-40
(Including cooler) max. sulphated ash limit (16.6 US gal) See Trans.
Oil Table.
Transmission Engine Oil with 1.85% 8.25 litre (See Note 2) CH-4 15W-40
Cooler max. sulphated ash limit (2.18 US gal) See Trans.
Oil Table.
Hydraulic System Hydraulic Transmission Oil 202 litre See Hydraulic Oil Table
(Including Lines) (53.4 US gal) (See Note 3)
Cooling System TEREX Pro-Cool 54 litre
(14.3 US gal)
Differential Extreme Pressure 17 litre each MIL-L-2105 D GL-5 80W-90 LS
(Front & Rear) Gear Lubricant (4.5 US gal) (See Note 4)
Differential Extreme Pressure 18.5 litre MIL-L-2105 D GL-5 80W-90 LS
(Centre) Gear Lubricant (4.9 US gal) (See Note 4)
Planetaries Extreme Pressure 3 litre each MIL-L-2105 D GL-5 80W-90 LS
Gear Lubricant (0.8 US gal) (See Note 4)
Fuel Tank Diesel Fuel Oil with 390 litre DIN EN590
max. sulphur 0.5% (103 US gal)
Grease Nipples Extreme Pressure No.2
Lithium Grease Consistency
Driveshaft through Extreme Pressure (See Note 4 - Page 3) MIL-L-2105 D GL-5 80W-90
Bearings Gear Lubricant
Articulation Extreme Pressure No.2
Bearings Lithium Grease Consistency
Air Conditioning Polyalklene Glycol (PAG) 0.125 litre ISO46
Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10
Low Viscosity

SM 2204 Rev 3 09-04 5


Miscellaneous - Lubrication System
Section 300-0020

* - Capacities given are approximate, work to dipstick, Note 3 - Hydraulic Transmission Oil meeting
sight gauges or level plugs. Specification EMS19058 is suitable for use in the
hydraulic system.
Note 1 - The use of low viscosity oils, such as 10W-30
or 5W-30, can be used to aid in starting the engine and Note 4 - Axles have limited slip differentials. If use of
providing sufficient oil flow at low ambient standard SAE 90 oil results in very loud noise and
temperatures. Continuous use of low viscosity oils can jerking of the wheels when driving slowly round sharp
decrease engine life due to wear. corners, an EP oil with limited slip additives should be
used.
Note 2 - Operation below the minimum temperatures
listed for the oil used without proper preheat or warm-up Note 5 - Automatic Transmission Fluids (ATF) may
results in greatly reduced transmission life. Proper only be used when the ambient temperature is less
warm-up requires 20 minutes minimum operation in than -10 C (14 F). Should the temperature increase, it
neutral (with engine at part throttle) before operating the is necessary to switch to engine oil.
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
TRANSMISSION OIL

ENGINE OIL

(See Note 5)

Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.

6 SM 2204 Rev 3 09-04


Miscellaneous - Lubrication System
Section 300-0020

ENGINE OIL DRAIN INTERVALS


Engine oil drain intervals are dependant on working
environment and oil type used. Refer to table below for
engine manufacturer's recommended oil drain intervals.

ENGINE OIL DRAIN INTERVALS BY DUTY CYCLE (HOURS)


Severe Heavy Medium Light
Fuel Consumption > 13 gal/hr 10 to 13 gal/hr 8.5 to 10 gal/hr < 8.5 gal/hr
API CF-4 150 200 250 300
API CG-4 250 300 400 500
API CH-4 or ACEA E5 300 350 500 600
CES20076 or CES20077 350 400 550 700

* * * *

SM 2204 Rev 3 09-04 7


MISCELLANEOUS - Service Tools
Section 300-0070

INTRODUCTION 15500624 - Inline Connector (Individual Spare)


Contained in this section are recommended service 15500716 - Deutsch Cable (Individual Spare)
tools and equipment required for maintenance, 15500388 - QuickCheck II Kit (For use with palm top) -
overhaul and troubleshooting. In certain instances, Includes; Adaptors, Software and Cables.
both Metric and Imperial equivalents of the same
tools are listed. The following tools are recommended for Engine
Maintenance Procedures. These tools should be used
Note: A tool may be of one piece construction or in conjunction with procedures outlined in the engine
consist of a number of parts. manufacturers service manual.

General 15270076 - Vacuum Gauge


15270075 - Dial Depth Gauge
*15269784 - Multi-Gauge - Pressure range of 30 in of
15270006 - Connecting Rod Checking Fixture
vacuum to 5 000 lbf/in
15269956 - Standard Puller
15269785 - Non-contact Infrared Thermometer
15269958 - Piston Ring Expander
15271082 - ORFS 'O' Ring Kit
15270078 - Manometer
15268968 - Strap Type Filter Wrench
15269959 - Main Bearing Cap Puller
15268969 - Socket Type Filter Wrench
15270081 - Pressure Gauge
15268970 - Universal Belt Tension Gauge
15269960 - Dial Gauge Attachment
15269858 - Digital Tachometer
15270009 - Threaded Insert Kit
15269859 - Multimeter
15269962 - Dial Bore Gauge Kit
15269813 - Water Manometer
15270079 - Manometer Tool
15269802 - Dial Indicator Gauge - Metric
15270042 - Pressure Gauge (0 - 160 lbf/in)
15269803 - Dial Indicator Gauge - Imperial
15270010 - Crack Detection Kit
15269804 - Magnetic Base for Dial Indicator Gauge
15270082 - Pressure Gauge (0 - 300 lbf/in)
15269805 - Micrometer - 0 to 25 mm
15269971 - Connecting Rod Guide Pins
15269806 - Micrometer - 0 to 1 in
15269966 - Cylinder Liner Puller Plate
15269860 - 92 Piece Heavy Equipment Tool Kit
15269961 - Dial Indicator Gauge
15269861 - Torque Wrench - 3/8 in drive,
15269973 - Oil Seal Guide
20 - 100 Nm (15 - 80 lbf ft) range
15269974 - Oil Seal Guide
15269862 - Torque Wrench - 1/2 in drive,
15269975 - Pulley Installation Tool
60 - 330 Nm (45 - 250 lbf ft) range
15269980 - Regulator Retainer Plug Driver
15269863 - Torque Wrench - 3/8 in drive,
15269981 - Oil Seal Guide
4 - 20 Nm (40 - 180 lbf in) range
15269982 - Torque Wrench - lb in
15269864 - Torque Wrench - 3/4 in drive,
15269985 - Flywheel Housing Alignment Plate
300 - 1 000 Nm (200 - 750 lbf ft) range
15270070 - Coupling Puller
15269865 - Torque Wrench - 3/4 in drive,
15270004 - Magnetic Base
700 - 1 500 Nm (500 - 1 000 lbf ft) range
15269994 - Cylinder Head Lifting Bracket
15269866 - Torque Multiplier - 1/2 in to 1 in drive,
25:1 Ratio, 3 000 Nm (2 200 lbf ft) range 15270084 - Blowby Check Tool
15269996 - Injector Puller
* - The following items should be added to the 15269997 - Piston Ring Compressor
multi-gauge to enable the gauge to be used on 15269999 - Gauge Block
diagnostic test points: 15270072 - Drive Gear Driver
15018226 - Diagnostic Coupling 15270020 - Needle Bearing Kit
00118748 - Connector (2 off) 15270021 - Bearing Installation Tool
15004085 - Hose Assembly (-4 HP, 84 in long) 15269984 - Engine Barring Tool
15270003 - Cylinder Liner Clamping Tool
Engine 15274125 - Cooling System Test Kit
15274126 - Refractometer
QSM - Electronic Diagnostic Tooling 15274129 - Hose Adaptor
15500622 - Insite Kit - Includes Insite program and 15274130 - Hose Adaptor
inline adaptor. Note; 15500716 Deutsch 15274127 - Belt Tension Gauge
Cable should be added to this kit. 15274128 - Hose Assembly Tools
15500623 - Insite Program (Individual Spare) 15274060 - Heavy Duty Cam Gear Puller Kit
15274131 - Wrench, Air Impact

SM 2206 Rev 2 07-04 1


Miscellaneous - Service Tools
Section 300-0070
15274138 - Installer, Valve Guide 15274098 - Kit, Counterbore Ledge Cutter
15274146 - Adaptor, Fuel Restriction 15274099 - Cutter Plate
15274141 - Lubriplate 105 Lubricant 15274100 - Clamp On Current Probe
15274136 - Kit, Torque Wrench 15274101 - Injector Puller/driver
15274139 - Pliers, Boot 15274102 - Kit, Hydraulic Actuator
15274142 - Lamp, 100W Black Light Kit 15274103 - Kit, Hydraulic Cylinder Support
15274143 - Charger Set International 15274104 - Kit, Cam Bushing I/R
15274135 - Kit, Guide Pin 15274105 - Kit, Rail Pressure Response
15274140 - Fixture, Pulley Alignment 15274106 - Kit, Pulley Installation Adaptor
15274134 - Kit, Inline II Datalink Adaptor 15274107 - Socket, Deep Flank Drive
15274059 - Liner Puller 15274108 - Template, Cylinder Head Capscrew
15274061 - Injector Protrusion Comparator 15274109 - Torque Angle Gauge
15274062 - Tube, Fuel Line Sight #12 15274110 - Small Bushing Driver Set
15274063 - Pilot, Oil Seal Puller Drills 15274111 - Kit,CNG Wastegate Test
15274064 - Kit, Turbo Rebuild 15274112 - Fixture, Cam Follower Assy R/I
15274065 - Digital Tachometer Kit 15274113 - Validator, Torque Wrench
15274066 - Bent Wrench 15274114 - Kit, Cylinder Head Leak Test
15274067 - Adaptor, Fuel Line Sight #16 Hose 15274115 - Kit, Charge Air Cooler Tester
15274068 - Gear Puller, Jaw 15274116 - Module, Vacuum Pressure
15274069 - Guide, Valve Installation 15274117 - Meter, Automotive
15274070 - Expander, Fan Hub Seal 15274118 - Puller, STC Injector
15274071 - Capscrew, Pulley Puller 15274119 - Driver, Thermostat Seal
15274072 - Driver, Regulator Valve Seat 15274120 - Sensor Break-out Kit
15274073 - Gauge, Cylinder Liner Ring 15274121 - Counterbore Salvage Kit
15274074 - Tube, Fuel Line Sight 15274122 - Installer, Oil Capacitor
15274075 - Cam Guide Expander - Large Dia 15274123 - Kit, Wiring Repair, Basic
15274076 - Fluorescent Tracer 15274133 - Cable, Throttle Breakout
15274077 - Expander, Accessory Drive Shaft Seal
15274078 - Fuel Pump S Wrench Transmission
15274079 - Kit, Torque Wrench
The following tools are recommended for Transmission
15274080 - Fitting Quick Connect
Maintenance Procedures. These tools should be used
15274081 - Fitting Quick Connect in conjunction with procedures outlined in the
15274082 - Tube, Cooling System Sight transmission manufacturers service manual.
15274083 - Tube, Cooling System Sight
15274084 - Tube, Cooling System Sight 15270087 - Straight Pin
15274148 - Wrench, Dial Type Torque 15270195 - Ring
15274144 - Wrench, Nylon Strap Filter 15270196 - Threaded Insert
15274145 - Gauge, Torque Angle 15270092 - Puller
15274147 - Wrench, Crows Foot 13 mm 15270093 - Puller
15274124 - Set, Torx Plus Driver 15270098 - Driver
15274137 - Bit, Screw Driver 15270197 - Driver
15274085 - Engine Parts Rack 15270198 - Driver
15274086 - Gauge, Belt Tension 15270199 - Driver
15274087 - Socket, Engine Position Sensor 15270200 - Driver
15274088 - Kit, Combustion Gas Leak Test 15270201 - Driver
15274132 - Test Fluid 15270104 - Driver
15274089 - Thermocouple Wire Kit 15270202 - Driver
15274090 - Engine Coolant Analyser 15270203 - Driver
15274091 - Gauge, Belt Tension 15270204 - Driver
15274092 - Wrench, CELECT Torque 15270112 - Measuring Pin
15274093 - Screwdriver, CELECT 15270115 - Set of Eye Bolts
15274094 - Puller, Water Pump Pulley 15270205 - Back-off Screws - M10
15274095 - Adjuster, STC Tappet 15270119 - Adjusting Screws - M10
15274096 - Super Chip Vacuum Kit 15270206 - Back-off Screws - M8
15274097 - Gauge, Cyl. Head Capscrew Length 15270116 - Adjusting Screws - M8

2 SM 2206 Rev 2 07-04


Miscellaneous - Service Tools
Section 300-0070

15270207 - Back-off Screws - M12 15275086 - Driver


15270208 - Adjusting Screws - M5 15269898 - Driver Handle
15270209 - Adjusting Screws - M12 15269899 - Hot Air Blower - 220 V, 50 Hz
15270210 - Adjusting Screws - M12 x 1.5 15269900 - Hot Air Blower - 127 V, 60 Hz
15269899 - Hot Air Blower 220 V 15269928 - Back-off Screw - M14
15269900 - Hot Air Blower 110 V 15269929 - Lifting Pliers
15270211 - Backup Tool 15269930 - Grab Sleeve
15270120 - Clamping Yoke 15269931 - Sleeve
15269942 - Handle 15269932 - Basic Set Rollex 1
15270212 - Hoist 15269933 - Grab Sleeve 'Super'
15270213 - Pulling Hook 15269934 - Measuring Shaft
15270214 - Ring Nut 15269935 - Thrust Washer
15270215 - Hoist 15269936 - Measuring Piston
15270216 - Internal Puller 15269937 - Shims - 120 mm Diameter
15270217 - Backup Tool 15270204 - Driver
15270218 - Mounting Rail 15269939 - Measuring Ring
15270127 - Guide Plate 15269940 - Driver
15270131 - Pry Bar 15269941 - Driver
15270219 - Adjusting Spanner 15269942 - Driver Handle
15270220 - Hook Spanner 15269943 - Socket
15270221 - Hook Spanner 15269944 - Hook Spanner
15270222 - Insert for Torque Spanner 15269945 - Insert
15270223 - Extension 15269946 - Puller Set
15270224 - Extension 15269947 - Shims
15270225 - Hook Spanner 15269948 - Straightedge - 600 mm
15270226 - Hook Spanner 15269949 - Pry Bars - Set of 2
15270227 - Pressing Sleeve 15269950 - Driver
15270228 - Pressing Ring 15275085 - Driver
15270229 - Pressure Piece
15270230 - Backup Ring Hydraulic Control System
15270231 - Test Cover 15500834 - IQAN Develop Change Interface
15270139 - Striker Contact Local Dealer - Hydraulic ECU Electronic
15270233 - Internal Snap Ring Pliers Diagnostic Software.
15270145 - External Snap Ring Pliers
15270234 - Two Leg Puller Nitrogen Charging/Inflation
15270149 - Two Leg Puller 15269121 - Nitrogen Tyre Inflation Kit
15270150 - Three Leg Puller 09359489 - Charging Assembly
15270151 - PR-78A Tester
15270311 - Harness Cooling and Air Conditioning
15270153 - Foil
15269814 - DCA4 Test Kit - Metric Version
15270725 - PR-68 Tester
15269815 - DCA4 Test Kit - US Gallon Version
15269943 - Spanner
15269816 - Refractometer - C Scale
15271103 - Hook Spanner
15269817 - Refractometer - F Scale
15271105 - Hook Spanner
15269844 - Portable High Vacuum Charging
15272559 - Ring Clamp
Station - R-134a Gas
15272560 - Bearing Puller
15269845 - Halogen Leak Tester
15272561 - Bearing Remover
15273664 - AEB Starter
Cab
15271016 - Glass Removal Tool
Axles and Differentials 15271017 - Bonding Kit (Quick Dry)
15269893 - Pin Spanner - M95 x 1.5
15269894 - Wheel Bolt Puller - Basic Set
15269895 - Insert - M22 x 1.5
15269896 - Driver

SM 2206 Rev 2 07-04 3


Miscellaneous - Service Tools
Section 300-0070

Adhesives and Sealants Fabricated Tools


15500552 - Torque Seal The service tools shown in Figs. 1 through 6 can be
15269103 - Loctite 221 fabricated as shown.
09362529 - Loctite 225 15023696 - Loctite 635
09029849 - Loctite 243 09371048 - Loctite 638
15500690 - Loctite 262 15269107 - Loctite 641
09244598 - Loctite 270 15269108 - Loctite Superclean Safety Solvent 706
09985300 - Loctite 271 15229541 - Loctite Activator 'N'
15269104 - Loctite 275 09243825 - Loctite Activator 'T'
15269245 - Loctite 277 09175039 - General Adhesive
15233715 - Loctite Prism 406 15269114 - Tectyl 280 Wax Based Rust Preventive
15269111 - Loctite Prism 410 09380475 - Hylosil RTV Silicone Compound
15269105 - Loctite 515
09007209 - Loctite 574 (50 ml)
09379518 - Loctite 574 (160 ml)
15269106 - Loctite 577 (Superflex)
15270244 - Loctite 592 - Pipe Sealer with Teflon

SM - 625

Fig. 1 - Centring Spring Installation Tool


(Section 220-0090, STEERING VALVE)

SM - 407

DRILL
RAD
DEEP

RAD TYP
BURN OUT

SQUARE

SECURE ALUMINIUM DRILL AND REAM THROUGH


COLLAR WITH (3) M8 AND FIT 8 (0.31)
CAP SCREWS HARDENED DOWEL
TORQUE PINS 2 PLACES

Dimensions in mm (inches)
Fig. 2 - End Cap Torque Tool (Section 220-0120, STEERING CYLINDER)

4 SM 2206 Rev 2 07-04


Miscellaneous - Service Tools
Section 300-0070

SM - 633

SILVER STEEL
SQUARE

OUTER SHIELD TO BE SECURED DOM TUBE


TO INNER BODY WITH 2BA CAPSCREWS

Dimensions in mm (inches)
Fig. 3 - Piston Torque Tool (Section 220-0120, STEERING CYLINDER)

SM - 2469

50 25
160 (6.299) (1.9680) (0.984)

10
90 (3.54) DRILL 13 (0.51) 11
RAD (0.394)
X 25 (0.984) (0.433)
DEEP

10 (0.394)
RAD TYP
150 (5.90) DIA

110 (4.33) DIA


120 (4.724)

(3.154 - 0.000 )

(4.724 - 0.005 )
+0.002

120.00 - 0.13
(1.9680)
80.10 - 0.00
+0.05
94 (3.7)

+
50

+
19 (0.75)
SQUARE

SECURE ALUMINIUM FIT 2 OFF B&T BUSH 12 (0.472) ID


COLLAR WITH (3) M8 25 65 18 (0.708) OD AND 2 OFF 12 DIA DOWEL
CAP SCREWS (0.984) (2.560) DRIVE FIT IN BUSH
110 (4.33)

Dimensions in mm (in)
Fig. 4 - End Cap Torque Tool (Section 230-0130, BODY CYLINDER)

SM 2206 Rev 2 07-04 5


Miscellaneous - Service Tools
Section 300-0070
SM - 2470

89 (3.5)
38.1 (1.5)

(0.375)
9.525

DIA
(0.470)
11.938
124.45 - 0.000 (4.899 - 0.000 )
+0.005

DIA
90 - 0.05 (3.543 - 0.002 )
SILVER STEEL

136 (5.35)
+
25.4 (1.0)
SQUARE

+0.13
+

(0.500)
12.7
EN3B

DIA
MILD STEEL

OUTER SHELL TO BE SECURED DOM TUBE


TO INNER BODY WITH 2BA CAP SCREWS 10.16 25.4
(0.4) (1.0)

Dimensions in mm (in)
Fig. 5 - Piston Torque Tool (Section 230-0130, BODY CYLINDER)

SM - 1630
64 DIA HOLE
BURN
8
R4

96
19.5
6 6
0

2 PLACES 2 PLACES
10

40
114

R 20

71
31

48 16

1 HOLE DRILL THRO'


21 MM DIA
Fig. 6 - Body Lifting Lug Dimensions
(Section 270-0010, BODY AND MOUNTING)

* * * *

6 SM 2206 Rev 2 07-04


MISCELLANEOUS - Axle Bolt and Nut Torque Specifications
Section 300-0080

TORQUE LIMITS IN Nm (lbf ft)


Friction coefficient total 0.125 for screws and nuts
without after treatment as well as for phosphated
nuts.
Tighten by hand!

If nothing special is indicated, select correct Torque


Limits from the following tabulations -

Metric ISO Thread DIN 13 TABLE161

6.9 8.8 10.9 12.9

Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)

M6 8 (5.9) 9.5 (7) 13 (9.6) 16 (11.8)


M8 19 (14) 23 (16.9) 32 (23.6) 39 (28.8)
M 10 39 (28.8) 46 (33.9) 64 (47.2) 77 (56.8)
M 12 67 (49.4) 80 (59) 110 (81.1) 135 (99.6)
M 14 105 (77) 125 (92) 180 (133) 215 (159)
M 16 165 (122) 195 (144) 275 (203) 330 (243)
M 18 225 (166) 270 (199) 390 (288) 455 (336)
M 20 325 (240) 385 (284) 540 (398) 650 (479)
M 22 435 (321) 510 (376) 720 (531) 870 (642)
M 24 560 (413) 660 (487) 930 (686) 1 100 (812)
M 27 830 (612) 980 (723) 1 400 (1 033) 1 650 (1 217)
M 30 1 100 (811) 1 350 (996) 1 850 (1 365) 2 250 (1 660

Metric ISO Fine Thread DIN 13 TABLE162

6.9 8.8 10.9 12.9

Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)


M8x2 21 (15.5) 25 (18.4) 35 (25.8) 42 (31)
M 10 x 1.25 41 (30.3) 49 (36.1) 68 (50.2) 82 (60.5)
M 12 x 1.25 74 (54.6) 88 (64.9) 125 (92.2) 150 (110.6)
M 12 x 1.5 70 (51.6) 83 (61.2) 115 (84.8) 140 (103.3)
M 14 x 1.5 115 (85) 140 (103) 195 (144) 235 (173)
M 16 x 1.5 175 (129) 210 (155) 295 (218) 340 (251)
M 18 x 1.5 255 (188) 305 (225) 425 (314) 510 (376)
M 20 x 1.5 360 (266) 425 (314) 600 (443) 720 (531)
M 22 x 1.5 480 (354) 570 (420) 800 (590) 960 (708)
M 24 x 2 610 (450) 720 (531) 1 000 (738) 1 200 (885)
M 27 x 2 890 (656) 1 050 (774) 1 500 (1 106) 1 800 (1 328)
M 30 x 2 1 250 (922) 1 450 (1 070) 2 050 (1 512) 2 500 (1 844)

SM 1521 10-98 1
Miscellaneous - Axle Bolt and Nut Torque Specifications
Section 300-0080
Friction coefficient total 0.14 for screws and nuts
without after treatment as well as for phosphated
nuts.
Tighten by hand!

If nothing special is indicated, select correct Torque


Limits from the following tabulations -

Metric ISO Thread DIN 13 TABLE163

6.9 8.8 10.9 12.9

Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)


M6 8.5 (6.3) 10 (7.4) 14 (10.3) 17 (12.5)
M8 21 (15.5) 25 (18.4) 35 (25.8) 41 (30.2)
M 10 41 (30.2) 49 (36.1) 69 (50.9) 83 (61.2)
M 12 72 (53.1) 86 (63.4) 120 (88.5) 145 (106.9)
M 14 115 (85) 135 (100) 190 (140) 230 (170)
M 16 180 (133) 210 (155) 295 (218) 355 (262)
M 18 245 (181) 290 (214) 400 (295) 485 (358)
M 20 345 (255) 410 (302) 580 (428) 690 (509)
M 22 465 (343) 550 (406) 780 (575) 930 (686)
M 24 600 (443) 710 (524) 1 000 (738) 1 200 (885)
M 27 890 (656) 1 050 (774) 1 500 (1 106) 1 800 (1 328)
M 30 1 200 (885) 1 450 (1 070) 2 000 (1 475) 2 400 (1 770)

Metric ISO Fine Thread DIN 13 TABLE164

6.9 8.8 10.9 12.9

Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)


M8x1 23 (17) 27 (19.9) 38 (28) 45 (33.2)
M 10 x 1.25 44 (32.5) 52 (38.4) 73 (53.8) 88 (65)
M 12 x 1.25 80 (59) 95 (70) 135 (99) 160 (118)
M 12 x 1.5 76 (56.1) 90 (66.4) 125 (92) 150 (111)
M 14 x 1.5 125 (92) 150 (111) 210 (155) 250 (184)
M 16 x 1.5 190 (140) 225 (166) 315 (232) 380 (280)
M 18 x 1.5 275 (203) 325 (240) 460 (339) 550 (406)
M 20 x 1.5 385 (284) 460 (339) 640 (472) 770 (568)
M 22 x 1.5 520 (384) 610 (450) 860 (634) 1 050 (774)
M 24 x 2 650 (479) 780 (575) 1 100 (811) 1 300 (959)
M 27 x 2 970 (715) 1 150 (848) 1 600 (1 180) 1 950 (1 438)
M 30 x 2 1 350 (997) 1 600 (1 180) 2 250 (1 660) 2 700 (1 991)

* * * *

2 SM 1521 10-98
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. order to provide a safety factor to compensate for the
The torque values shown in the following variation in the accuracy of torque wrenches, skill of
tables should be used in all cases, unless the assembler, and variance in fractional conditions.
otherwise specified elsewhere in this manual, All torque values are for lubricated threads. The
in order to avoid possible personal injury or term 'lubricated' includes the application of thread
property 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 Applicable Torque Values SAE Bolt Head Symbols
Range

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
(eg. SAE 4140, 8642 & 5157) Rockwell "C" 28-34 GM 290-M
Medium Carbon Alloy
(eg. SAE 4140, 8642 & 5147) Rockwell "C" 32-38 GM 300-M

2 SM 1238 2-98
Miscellaneous - Standard Bolt and Nut Torque Specifications
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
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080

SELF-LOCKING FASTENERS has been used. Do not use a self-locking fastener


Self-locking fasteners develop a measured gripping more 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 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/in)
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

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