CLICK HERE FOR TABLE OF CONTENTS TA40 OCDB (A820) Articulated Dumptruck Maintenance Manual CLICK HERE TO RETURN TO MAIN LIBRARY INDEX CUSTOMER SUPPORT DEPARTMENT Part No. 15275763 SM 2345 06-05 TEREX EQUIPMENT LIMITED MOTHERWELL, SCOTLAND ML1 5RY REF. NO.
The information contained within this Alert must not be made available to third parties not authorised to receive it. Service Information Alert DATE: April 1994 MODEL: General SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS B168 PURPOSE: To advise potentially hazardous condition.
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.
TABLE OF CONTENTS Section No. Description 000 0000 0010 100 0010 0020 0040 110 0030 0050 120 0010 130 0010 0020 140 0020 0040 0060 150 0020 160 0020 0030 0050 165 0015 170 0010 0030 180 0020 0040 0040 190 0000 0270 200 0040 0051 SM No.
TABLE OF CONTENTS Section No.
GENERAL INFORMATION - Technical Data Section 000-0000 SM - 3303 Max 1 450 Body (4-9) Depth 3 220 ( 10-7 ) 3 020 (9-11) 45˚ Vehicle Clearance Turning Diameter 19.5m (64ft) 6 500 (21-4) 65˚ 3 720 (12-2) 5 700 (18-8) 5 370 (17-7) 3 670 (12-0) 3 450 (11-4) 25˚ 3 100 (10-2) 2 240 (7-4) 560 (1-10) 1 810 (5-11) 2 640 (8-8) 3 430 (11-3) 28˚ 2 540 (8-4) 675 (2-3) 525 (1-9) 1 600 (5-3) 3 000 (9-10) 1 970 (6-6) 1 540 (5-0) 10 650 (34-11) Dimensions in mm (ft-in) Fig.
General Information - Technical Data Section 000-0000 Ratios: Torque Converter .................................................... 1.84:1 Transmission .................................... Refer to table below. Gear Ratio km/h mile/h Gear Ratio km/h mile/h Forward 1 2 3 4 5.35 3.45 2.21 1.42 6.0 9.3 14.6 22.7 3.7 5.8 9.1 14.1 Reverse 1 2 3 5.35 2.21 0.97 6.0 14.6 33.3 3.7 9.1 20.7 5 0.97 33.3 20.7 6 0.62 51.7 32.
General Information - Technical Data Section 000-0000 Steering SERVICE CAPACITIES Hydrostatic power steering by two double-acting, cushioned steering cylinders. Actuating pressure for steering operation is supplied by the main hydraulic gear pump. Fuel tank .......................................... 463 litres (122 US gal) Hydraulic System (Steering, Braking & Body) ................ 209 litres (55 US gal) Brake Cooling System .................... 199 litres (52.6 US gal) Cooling System ..................
GENERAL INFORMATION - Welding Procedure Section 000-0010 Welding WARNINGS Before any welding is done on a machine equipped with any electronic systems, disconnect the following (if applicable) in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables and electrical connections at the engine ECM, transmission ECU, body control lever, hydraulics ECU and cab bulkhead to avoid damage to electrical components.
General Information - Welding Procedure Section 000-0010 3. Pre-heat area to 100° C (212° F), measured 3 - 4" either side of repair. Avoid local overheating. 3 - 4" either side of repair prior to gouging. On 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 moisture pick-ups at all times. 5. Allow repair weld to cool slowly. 3.
CHASSIS - Frames Section 100-0010 SM - 1859 Fig. 1 - General Arrangement of Frame Assemblies DESCRIPTION roller bearings. The front and rear frames are all-welded high grade steel fabrications, with rectangular box section beams forming the main side and cross-members. These heavy duty structures are designed to withstand the severe loadings incurred when operating over rough terrain.
Chassis - Frames Section 100-0010 Straightening If the frame is not too badly sprung or twisted, hydraulic straightening and aligning equipment can be used to straighten the frame without dismantling the machine. However, if the frame is severely damaged, it will be necessary to disassemble the machine in order to repair or replace the frame assembly. All straightening operations should be performed without application of heat if possible.
CHASSIS - Articulation and Oscillation Pivot Section 100-0020 SM - 1896 29 16 51 19 52 25 56 50 5,6 56 55 7 20 14 53 27 17 54 56 DETAIL A 42 25 41 45,46,49 39 36,49 45,47,49 1 32 26,56 52,55 30 23 38 26,53 54,55 56 2,3,4 10,26 11 2,3,4 60 33 57,58,59 49,61,62 36,49 40 28 51 43 37,49 51 31 17 19 50 44,48,49 18 13 15 8,9 19 50 16 16 35 14 29 31 24 29 8,9 15 38 30,23 21,22 12 34 25 10,26 45,46,49 1 2 3 4 5 6 7 8 9 10 11 12 13 45,47,49 37,49 - Pivot Assem
Chassis - Articulation and Oscillation Pivot Section 100-0020 THRU-DRIVE DRIVESHAFT Numbers in parentheses refer to Fig. 1, unless otherwise specified. 9. Disconnect mounting hardware securing protective guard (if fitted), from beneath the parking brake disc, to the rear frame. Note: The following procedures assume that only thru-drive components require repair. 10. Release the parking brake by turning the hex-head on the parking brake actuator fully anticlockwise.
Chassis - Articulation and Oscillation Pivot Section 100-0020 22. Remove and discard seal (15) from driveshaft (14). 23. If bearing replacement is required, use a suitable puller or drift to remove rear bearing assembly cone (9) from driveshaft (14). 5. Remove nut (19), thrust washer (16) and brake yoke (18) from driveshaft (14). The distance from the end of the bearing cone (8) to the end of the spline should be approximately 57 mm. 6. Install driveshaft (14) through the housing. 24.
Chassis - Articulation and Oscillation Pivot Section 100-0020 21. Tighten nut (19) until end play on driveshaft (14) can just be felt. Take dial indicator reading of end play. Tighten nut (19) until end play on driveshaft (14) is 0.05 - 0.15 mm (0.002 - 0.006 in). Note: One flat on nut (19) turned is equivalent to 0.025 mm (0.001 in). 33. Install parking brake disc protective guard (if fitted) and secure with bolts, washers and nuts. Tighten nuts to a torque of 73 Nm (54 lbf ft). 34.
Chassis - Articulation and Oscillation Pivot Section 100-0020 transmission yoke and front yoke (17). Remove capscrews and remove driveline from vehicle. 5. Support tractor frame at front and rear with suitably placed stands or timbers so the frame will remain level during and after pin removal. 6. Remove bolts, washers and pins securing steering cylinders to pivot. Secure steering cylinders clear of pivot. 7.
Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 008 4. Remove blocks from rear wheels and blocking from pivot/rear frame assembly. Using lifting equipment, pull pivot/rear frame assembly to align pivot bearing bores and front frame pin bores. Block wheels and block pivot/rear frame assembly to remain level and stationary. 5. Freeze upper and lower pins (40 & 43) to ease installation. 6. Smear lower pin (43) with Extreme Pressure Lithium Complex No.
Chassis - Articulation and Oscillation Pivot Section 100-0020 pivot assembly (1). 7. Fill bearing housings with Extreme Pressure Lithium Complex No. 2 grease (23), through lube fittings (27), until excess grease starts to escape from seal housings (32 & 34). 8. Remove lube fittings (27) and reinstall plugs (28). Store lube fittings (27) on pad on side of pivot assembly (1). 9. Start engine, raise body, lower body safety prop and lower body. 10. Remove wheel blocks. Disconnecting Front and Rear Frames 1.
Chassis - Articulation and Oscillation Pivot Section 100-0020 the pin and pin bores by raising or lowering the pivot/ rear frame assembly. SM - 038 14. Remove bolt (48) and hardened washer (44) securing lower pin (43). 15. Remove lower pin (43). If necessary tap lower pin (43) to ease removal taking care to avoid damaging the pin. 16. Remove blocks from rear wheels and use lifting equipment to pull pivot/rear frame assembly clear of the front frame.
Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 011 5. Install plugs (28) into oscillation bearing grease ports. PAINT DOT 6. Lightly coat 'V' ring (10) and machined surfaces of pivot with Extreme Pressure Multipurpose Grease (26) and, install 'V' ring (10), with lip towards rear, on front of oscillation hub. 7. Using suitable lifting equipment, and taking care to prevent damaging bushes (2) or pivot threads, install pivot assembly (1) into rear frame. Fig.
Chassis - Articulation and Oscillation Pivot Section 100-0020 pre-load from bearing cup and cone assemblies (8 & 9). frame and bearing bores. 17. Remove nut (19) from rear of driveshaft (14), install lockwasher (50) and reinstall nut (19). 7. Apply Loctite 243 (49) to threads of bolt (48). Secure lower pin (43) with bolt (48) and hardened washer (44). Tighten bolt (48) to a torque of 73 Nm (54 lbf ft). 18. Set up dial indicator with pointer positioned on rear end face of driveshaft (14).
Chassis - Articulation and Oscillation Pivot Section 100-0020 9. Remove bolts (7), washers (20), gasket (5) and cover plate (6) from side of oscillation hub to gain access to filler/level plug (25) on pivot assembly (1). Remove filler/level plug (25). 10. Add SAE 80W - 90 E. P. gear oil (24) through filler/ level hole in pivot assembly (1) until the oil is level with the bottom of filler/level hole. 11.
Chassis - Articulation and Oscillation Pivot Section 100-0020 12. Remove lube fittings (27) and reinstall plugs (28). Store grease fittings (27) on pad on side of pivot assembly (1). 7. Remove plug (25) from underside of oscillation hub to drain the cavity between the oscillation hub and pivot assembly (1) of any oil that entered while filling the driveshaft bearing housing. 13. Add Extreme Pressure Multipurpose grease (26) to oscillation bushing lube fittings (55) on top of oscillation hub.
CHASSIS - Hood and Mounting Section 100-0040 SM - 2675 17 18 24 41 19 16 15 1 20 21 23 16 42 43 44 45 14 22 4 3 25 30 2 31 5 9 36 37 8 HOOD 46 34 28 35 9 27 26 48 32 33 7 8 35 40 39 38 29 - Hood - Handle - LH - Bolt - Washer - Bolt - Washer - Grille Subframe - Hinge Assembly - Plate - Bolt - Locknut - Washer 12 13 13 12 11 6 10 1 2 3 4 5 6 7 8 9 10 11 12 2 13 14 15 16 17 18 19 20 21 22 23 24 - Washer - Hoodcatch Kit - Bolt - Locknut - Bolt - Washer - Hardened Washer -
Chassis - Hood and Mounting Section 100-0040 6. Remove hood straps (33) and gas struts (32) from hood. GOALPOST ASSEMBLY 7. Remove bolts (26), washers (27) and nuts (28) securing hinges (8) to frame and lift hood (1) assembly from the machine. Numbers in parentheses refer to Fig. 1. 8. If required, remove bolts (3) and washers (4) securing grille subframe (7) to hood (1). Secure grille subframe (7) clear of hood. 9. If required, remove mounting hardware (5 & 6) securing handle (2) to hood (1).
Chassis - Hood and Mounting Section 100-0040 11. If required, remove locknuts (16), bolts (15), hood stops (20) and springs (21) from goalpost assembly (24). 6. Install washer bottle to mounting bracket on the left hand side of goalpost assembly (24) and secure using mounting hardware as removed during 'Removal'. 12. If required, remove mounting hardware securing hood blanking piece (41) to right hand fender. Remove hood blanking piece (41) from the machine. 7.
ENGINE - Engine and Mounting Section 110-0030 SM - 2676 26 27 43 24 34 17 14 1 16 35 33 12 41 37 40 39 20 36 13 15 38 9 8 28 7 8 2 10 29 23 22 21 25 8 31 32 3 28 ON ENGINE LHS 18 LH 19 RH 9 10 30 31 4 1 2 3 4 5 6 7 8 9 10 11 - Engine - Oil Filter - Coolant Filter - Primary Fuel Filter - Secondary Fuel Filter - Dipstick - Engine Coupling - Snubbing Washer - Washer - Nut - Bolt 12 13 14 15 16 17 18 19 20 21 22 - Bolt - Bolt - 'V' Belt - Bolt - Plate - Screw Assembly - Rear LH Mount
Engine - Engine and Mounting Section 110-0030 210-0000, COOLING SYSTEM. There are two spin-on type fuel filters mounted on the left hand side of engine (1). Primary fuel filter (4) is in the fuel flow and acts as a strainer and secondary fuel filter (5) filters the fuel after having passed through primary fuel filter (4). The word 'Primary' or 'Secondary is cast into the top of the respective adaptor to prevent mismatching. DETROIT DIESEL ELECTRONIC CONTROL (DDEC) Description Refer to Fig. 2.
Engine - Engine and Mounting Section 110-0030 SM - 1840 7 STOP 6 3 1 2 8 P 4 9 1,2 1 2 3 4 5 - 5 6 - Check Engine Light 7 - Stop Engine Light 8 - Diagnostic Request/Stop Engine Override Switch 9 - Diagnostic Test Point Electronic Control Module (ECM) Programmable Read Only Memory (PROM) Electronic Unit Injectors (EUI) Batteries Electronic Foot Pedal Fig. 2 - DDEC Components engine. The fault should be diagnosed and corrected at the earliest opportunity. 7.
Engine - Engine and Mounting Section 110-0030 To allow for the possibility of the engine protection system being activated while the machine is operating in a critical situation, a stop engine override switch (8) is provided. If the switch is pressed and released during rampdown, the 30 second timer will reset, restoring torque to the level immediately following illumination of stop engine (7) and check engine (6) lights. The switch must be pressed and released again to obtain a subsequent override.
Engine - Engine and Mounting Section 110-0030 DDECIII & IV DIAGNOSTIC CODES DDEC Code # (Flashed) PID SID FMI DDEC Description 11 11 12 13 13 14 14 14 15 15 15 16 16 17 17 18 18 21 22 23 23 24 24 25 26 26 27 240 251 251 187 187 187 111 111 52 110 175 52 110 175 111 111 72 51 72 51 91 91 174 174 171 253 254 254 254 65 65 25 61 - 2 10 13 13 0 1 6 4 7 3 4 6 3 3 3 4 4 4 3 5 3 3 4 4 3 4 3 3 4 4 1 11 3 27 27 28 172 105 171 - 3 3 4 28 28 31 31 31 31 31 31 32 32 32 32 172 105 - 51 51 51 52 52 52 238
Engine - Engine and Mounting Section 110-0030 DDEC III & IV DIAGNOSTIC CODES 6 DDEC Code # (Flashed) PID SID FMI DDEC Description 33 34 35 35 36 36 37 37 37 38 38 38 41 42 43 44 44 44 44 44 45 45 46 46 47 47 47 47 47 48 48 48 48 52 53 53 53 54 55 55 55 56 57 58 61 62 62 62 62 62 62 102 102 100 19 100 19 94 18 95 94 18 95 111 52 110 172 175 105 100 19 168 94 102 106 164 18 18 94 106 164 84 92 - - 3 4 3 3 4 4 3 3 3 4 4 4 0 1 1 0 0 0 0 0 1 1 1 1 0 0 0 0 0 1 1 1 1 12 2 12 13 12 12 8 9 12 12 0 0 3 4 3
Engine - Engine and Mounting Section 110-0030 DDEC III & IV DIAGNOSTIC CODES DDEC Code # (Flashed) PID SID FMI 62 62 62 62 62 62 62 - 54 54 55 55 56 56 26 3 4 3 4 3 4 7 62 - 40 7 62 - 53 7 62 - 54 7 62 - 55 7 62 - 56 7 63 63 63 63 63 63 63 63 63 63 63 63 63 63 63 63 64 64 65 65 65 65 65 65 66 66 66 66 66 66 67 67 67 67 103 103 51 51 51 51 107 107 109 109 106 106 57 57 58 58 59 59 60 60 57 57 58 58 59 59 60 60 76 76 76 76 99 99 - 3 4 3 4 3 4 3 4 0 1 0 1 0 1 0 1 8 0 0 1 2 7 3 4
Engine - Engine and Mounting Section 110-0030 DDEC III & IV DIAGNOSTIC CODES DDEC Code # (Flashed) PID SID FMI DDEC Description 67 67 68 68 71 72 72 72 72 73 73 73 20 20 84 84 - 230 230 xxx 65 65 151 226 227 3 4 6 5 1 0 11 0 1 14 11 2 73 73 73 73 73 73 73 74 74 75 75 76 81 81 81 81 81 82 82 82 82 82 83 83 83 83 83 84 84 85 86 86 87 87 88 88 89 89 107 99 70 168 121 98 101 164 173 98 101 164 173 98 101 173 173 73 98 101 190 73 108 73 108 109 20 95 111 227 77 77 77 77 77 232 20 20 - 3 0 1 3 4 7 0
Engine - Engine and Mounting Section 110-0030 REMOVAL Numbers in parentheses refer to Fig. 1. Note: Tag all cables, harnesses, lines and pipes disconnected during removal to aid in installation. WARNINGS 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. High electrical current can cause sparks and personal injury from burns.
Engine - Engine and Mounting Section 110-0030 130-0010, FRONT DRIVELINES. (42) and step (30) from engine (1). 22. Attach suitable lifting equipment to the lifting brackets on the engine and raise lifting equipment to take up the slack. 9. Remove and discard filters (2, 3, 4 & 5) from engine (1), as described in 'Maintenance'. Cover engine inlet ports to prevent entry of dirt. 23.
Engine - Engine and Mounting Section 110-0030 stage. Note: Replace all belts in a set when one is broken or replaced. 7. Install 'V' belts (14) in the grooves of alternator (43) and accessory drive pulley. Note: Alternator belt tension adjustment is made after installation of engine (1) and the radiator assembly. 8. Install air conditioner compressor and drive belt to engine (1). Refer to Section 260-0130, AIR CONDITIONING. Note: Position rubber isolation mounts (28) to their mounts as shown in Fig. 1. 9.
Engine - Engine and Mounting Section 110-0030 16. Remove covers from air cleaner intake pipe and rubber hose on the air cleaner inlet then slide air cleaner assembly towards the hood locating the rubber hose to the inlet pipe. 17. Secure air cleaner assembly to the right hand fender and rubber hose to the inlet pipe with mounting hardware removed during removal. MAINTENANCE Numbers in parentheses refer to Fig. 1.
Engine - Engine and Mounting Section 110-0030 necessary and will distort or crack the adaptor. Tighten oil filters by hand only. excessive loss of coolant. 5. Repeat steps 3 and 4 for second oil filter (2). 1. Close shut off valves at coolant filter (3) inlet and outlet lines and, using filter wrench, remove and discard coolant filter (3) from engine (1). 6. Start and run the engine for a short period and check for oil leaks. If any leaks are noted, have them corrected. 2.
Engine - Engine and Mounting Section 110-0030 to the maximum value. SPECIAL TOOLS Belts should be neither too tight nor too loose. Belts that are too tight impose excess loads on the alternator bearings, shortening both belt and bearing life. A loose belt will slip and may cause damage to accessory components.
ENGINE - Air Cleaner Section 110-0050 SM - 1262 1 2 3 4 5 6 7 - Restriction Indicator Fitting - Body - Latches - Access Cover - Gaskets - Wing Nut - Nut 8 9 10 11 12 13 14 - Cotter Pin Secondary (Safety) Filter Element Primary Filter Element Gasket Clamp Gasket Tube Section 15 16 17 18 19 A B - Funnel Shaped Tubes - Clamp - Dust Cup - Vacuator Valve - Centre Tubes - Air Inlet - Air Outlet Fig. 1 - Cutaway View of Typical Air Cleaner DESCRIPTION AND OPERATION Numbers in parentheses refer to Fig. 1.
Engine - Air Cleaner Section 110-0050 SM - 2677 28 17 25 18 7 26 10 15 16 8 27 6 20 14 21 19 10 2 TO TURBO 2 4 3 4 22 24 23 12 5 3 11 1 5 9 13 1 2 3 4 5 6 7 - Bracket - Bolt - Lockwasher - Washer - Nut - Tube - Hose 8 9 10 11 12 13 14 - Clamp - Elbow - Clamp - Insert - Clamp - Bracket - Bracket 15 16 17 18 19 20 21 - Bolt - Lockwasher - Bolt - Lockwasher - Washer - Clamp - Plate 22 23 24 25 26 27 28 - Bolt - Nut - Clamp - Air Restriction Gauge - Clamp - Clamp - Cap Fig.
Engine - Air Cleaner Section 110-0050 SM - 1263 1 2 3 4 5 6 - Access Cover - Gasket - Wing Nut - Gasket - Primary Filter Element - Nut 7 8 9 10 11 12 - Cotter Pin Secondary (Safety) Filter Element Latches Body Clamp Gasket 13 14 15 16 17 - Tube Section Clamp Dust Cup Vacuator Valve Inlet Cap Fig. 3 - Exploded View of Typical Air Cleaner 4. Slacken clamps (8 & 10) and slide hose (7) clear of the air cleaner assembly. 5.
Engine - Air Cleaner Section 110-0050 2. Unscrew wing nut (3), remove gasket (4) and carefully withdraw primary filter element (5). Inspect gaskets (2 & 4). Replace if damaged. SM - 058 3. Do not disturb secondary (safety) filter element (8). Replace access cover (1) temporarily. 4. The primary filter element (5) should be replaced after a maximum of six cleanings, or annually whichever comes first.
Engine - Air Cleaner Section 110-0050 4. Submerge tube section in the manufacturers recommended solution, or equivalent, and warm water, not to exceed 66° C (150° F). Soak for 30 minutes and agitate for 5 minutes. Rinse clean with clean water and allow body to dry. Note: If plugging is severe, use a solution of 50% Oakite 202 and 50% water, or equivalent, and follow Step 4. 5. Inspect gaskets (12) and replace if damaged. the reliability of the air cleaner’s protection of the engine from airborne dirt.
TRANSMISSION - Transmission and Mounting Section 120-0010 SM - 1842 25 26,27 28 29 30 25 13 12 1 11 6 7 LH 13 RH 6 3 21 15 17 2 3 8 4 9 10 18 19 5 14 - Front Bracket Assembly - Isolation Mount - Snubbing Washer - Washer - Locknut - Bolt - LH Bracket 20 23 5 1 2 3 4 5 6 7 16 22 24 8 9 10 11 12 13 14 - Isolation Mount - Lockwasher - Bolt - Lockwasher - Bolt - RH Bracket - Hardened Washer 15 16 17 18 19 20 21 22 - Dipstick Tube - Bracket - Clamp - Bolt - Washer - Locknut - Bolt - Lo
Transmission - Transmission and Mounting Section 120-0010 SM - 1843 K2 KR KV K4 K3 4 K1 Y 9 2 11 VIEWED FROM THE REAR 10 4 5 1 DETAIL Y 6 1 2 3 4 5 6 7 8 9 10 11 8 7 3 - Retarder Oil Temperature Sensor Main Control Valve Difflock Warning Light Switch Lockup Solenoid Engine Speed Sensor Output Speed Sensor Central Gear Train Sensor Turbine Speed Sensor Oil Temperature Sender (Gauge) Breather Emergency Steering Low Pressure Switch KV, KR, K1 to K4 - Supply ports to Multi-disc Clutches Fig.
Transmission - Transmission and Mounting Section 120-0010 SM - 1826 VALVE BLOCK COVER Y3 Y4 5 Y2 6 Y5 7 Y1 Y6 8 HOUSING 1 2 SYSTEM PRESSURE FROM CONTROL UNIT BREATHER 3 4 1 2 3 4 - Main Pressure Valve 16+2 bar Pressure Reduction Valve 9 bar Lockup Solenoid Lockup Reduction & Shift Valve 5 6 7 8 - Follow-on Slide - Proportional Valve (P1 to P6) - Vibration Damper - Harness Connection Y1 to Y6 - Pressure Regulators Fig.
Transmission - Transmission and Mounting Section 120-0010 intersection of the clutches to be engaged and disengaged becomes possible. This creates fast shiftings without traction force interruption. Note: Before driving in soft or slippery conditions, stop and engage the differential locks. Spinning wheels can result in damage to the transmission and axle differentials. Speedometer Sensor Note: Disengage differential locks when driving on firm ground.
SM 2124 Rev 3 8-03 2nd POWER TAKE-OFF SCHEDULE OF MEASURING POINTS CONVERTER Measurements to be carried out with oil at normal operating temperature of 80° C and operating at full speed. RETARDER 14 WK KV K1 MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE: 1st POWER TAKE-OFF 51 = Before the Convertor - Opening Pressure 8.
E P2 D B Y1 NFS 60 D P3 D Y3 NFS C P4 D B Y2 56 K3 B P5 D B Y4 NFS 58 KV D B Y5 NFS 53 K2 A P6 D B NFS 57 Y6 NFS RV-9 TEMP K NOT SCOPE OF SUPPLY ZF 65 HDV WK-M HYDRAULIC PRESSURE WK-V PRESSURE REDUCTION VALVE 5.5 bar CONVERTER 67 WK 51 H WSV TO THE RETARDER VALVE 5.5 bar 66 52 29 WGV BYPASS VALVE No.
Transmission - Transmission and Mounting Section 120-0010 OPERATION EST-37 Automatic Shift Control The EST-37 transmission is equipped with an electronic control unit (ECU) which continually monitors the transmission and shift system electrical components and warns the operator when a problem develops. It also takes action to prevent damage to the transmission, and provides the serviceman with diagnostic capabilities so that problems can be corrected quickly and easily.
Transmission - Transmission and Mounting Section 120-0010 SM - 1828 SM - 2335 IDLE FULL LOAD/ THROTTLE KICK/HOLD DOWN S T O P 1 2 3 1 - Bars show gear ranges and full display (as shown) indicates driving in automatic mode. 2 - Display shows actual driving direction. 3 - Display shows actual gear in use. Fig. 6 - Accelerator Load Ranges and Kickdown Position Fig.
Transmission - Transmission and Mounting Section 120-0010 Note: In cold weather, the transmission oil should be warmed up by running the engine at idle speed with the gear selector in neutral, since the system will not operate satisfactorily if the oil is too cold. When temporarily stopped, such as for yielding the right-of-way to a loaded machine, the transmission can be left in gear and the machine held stationary with the service brakes.
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
Transmission - Transmission and Mounting Section 120-0010 Display during AEB-Mode - Continued Symbol Meaning Remarks òT transmission oil temperature too high -> cool down transmission FT transmission temperature not in defined range during calibration Transmission stays in neutral, you have to restart the TCU (ignition off/on) FB operating mode not NORMAL or transmission temperature sensor defective or storing of Calibrated values to EEPROM-has failed.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) 17 MEANING OF CODE possible reason for fault detection TCU reaction Checks Remarks S.C.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) 32 MEANING OF CODE possible reason for fault detection TCU reaction Checks S.C.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) 3A MEANING OF CODE possible reason for fault detection TCU reaction Checks S.C. TO BATTERY VOLTAGE OR O.C.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) MEANING OF CODE possible reason for fault detection Checks OP-Mode: substitute clutch CAN signal for reference of engine torque is defective control •engine controller is defective •interference on CAN-Bus •check engine controller •check wire of CAN-Bus •check cable to engine controller OP-Mode: substitute clutch control •check engine controller •check wire of CAN-Bus •check cable to engine controller OP-Mode: substitute clutc
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) 75 MEANING OF CODE possible reason for fault detection TCU reaction Checks Remarks S.C.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) 84 MEANING OF CODE possible reason for fault detection TCU reaction Checks Remarks S.C.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) MEANING OF CODE possible reason for fault detection TCU reaction Checks Remarks 93 O.C. AT RELAY REVERSE WARNING ALARM no reaction TCU detected a wrong voltage at the output pin, that OP-Mode: normal looks like a o.c.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) MEANING OF CODE possible reason for fault detection TCU reaction Checks Remarks 1) A4 S.C. TO GROUND AT WARNING SIGNAL OUTPUT no reaction TCU detected a wrong voltage at the output pin, that OP-Mode: normal looks like a s.c.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) B5 MEANING OF CODE possible reason for fault detection TCU reaction Checks SLIPPAGE AT CLUTCH KV TCU shifts to neutral OP-Mode: limp home if failure at another clutch is pending TCU shifts to neutral OP-Mode: TCU shutdown •check pressure at clutch KV •check main press.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) BE MEANING OF CODE possible reason for fault detection TCU reaction Checks Remarks S.C.
Transmission - Transmission and Mounting Section 120-0010 Fault Code (hex) MEANING OF CODE possible reason for fault detection TCU reaction Checks D5 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 TC
Transmission - Transmission and Mounting Section 120-0010 8.1 Actuator: 1 R 2 G open circuit: short cut to ground: R12 ≈ R1G ≈ R2G ≈ ∞ R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 short cut to battery: R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 8.2 Cable: (for s.c. to ground, G is connected to vehicle ground) (for s.c.
Transmission - Transmission and Mounting Section 120-0010 transmission oil temperature reaches 140° C (284° F). The retarder will automatically disengage when the oil temperature reaches 150° C (302° F) irrespective of engine speed. The speed must be reduced by using the service brakes so that the oil is cooled down. Reduce downgrade travel speed to avoid the oil overheating and possible damage to the transmission.
Transmission - Transmission and Mounting Section 120-0010 SM - 2682 8 9 6 14 25 5 12 24 23 11 10 17 1 12 7 10 14 9 1 2 26 3 27 TO SOL VALVE PORT T 22 C B RETARDER VALVE 4 21 20 19 1 2 3 4 5 6 4 13 A - Adaptor Hose Assembly Hose Assembly Elbow Elbow Hose Assembly 18 7 8 9 10 11 12 13 15,16 - Hose Assembly Hose Assembly Dust Cap Adaptor Elbow Adaptor Adaptor 14 15 16 17 18 19 20 - Diagnostic Nipple Oil Filter Head Filter Cartridge Tee Adaptor Hose Assembly Elbow 21 22 23
Transmission - Transmission and Mounting Section 120-0010 21. Check to make certain that all necessary line and cable disconnections have been made before lifting the transmission. 22. Carefully raise the transmission ensuring that no lines, cables or components foul during removal. When the transmission is clear of the frame assembly, move to a suitable work area and mount securely on a work stand. 23. Remove front isolation mounts (2) from frame mounts and replace if required.
Transmission - Transmission and Mounting Section 120-0010 5. Install brake pump to the transmission power takeoff and secure using mounting hardware removed at Disassembly. Refer to Section 250-0040, BRAKE PUMP. 6. Secure LH bracket (7) and RH bracket (13) to the transmission with bolts (10) and lockwashers (9). 7. Secure front bracket assembly (1) to the transmission with bolts (12) and lockwashers (11). 8.
Transmission - Transmission and Mounting Section 120-0010 17. Prior to installing the cab, ensure that all connections to the transmission, other than cab connections, are connected securely and properly clipped. 18. Install the cab assembly on the front frame. Refer to Section 260-0010, CAB AND MOUNTING. 19. Connect transmission harness at the cab floor and earth strap between LH side of the transmission and the frame. 20. Connect main frame harness and electrical connections at front left hand of the cab.
Transmission - Transmission and Mounting Section 120-0010 SM - 2797 COLD FILL LEVEL MINIMUM ENGINE OFF HOT LEVEL BAND ENGINE RUNNING MAX COLD FILL LEVEL MINIMUM ENGINE RUNNING MIN 152mm (6") Min rectified immediately to prevent damage to the transmission. At each oil change, examine the used oil for evidence of dirt or water. A normal amount of condensation will emulsify in the oil during transmission operation.
Transmission - Transmission and Mounting Section 120-0010 Shift Controller Engine speed sensor (5) and turbine speed sensor (8) gap should be 0.5 - 0.8 mm. Central gear train speed sensor (7) - gap should be 0.3 + /- 0.1 mm. Output speed sensor (6) - gap should be 1.0 - 1.5 mm.
Transmission - Transmission and Mounting Section 120-0010 AEB Starter Procedure ACTION DISPLAY MESSAGE 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’ 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 co
Transmission - Transmission and Mounting Section 120-0010 SM - 3088 POLE PATTERN W1 - X1 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 1 10 7 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 11 8 5 2 12 9 6 3 23 AMP 68 POLE SOCKET POLE PATTERN W1 - X25 POLE PATTERN W1 - X2 POLE PATTERN W1 - X8 2 4 6 8 10 12 14 16 18 20 22 PLUG HOUSING AMPMATE-N-LOCK 12 POLE SOCKET 1 4 2 5 3 6 1 3 5 7
DRIVELINES - Front Drivelines Section 130-0010 SM - 2303 DETAIL A 14 1 4 4 10 13 7 12 A 11 TRANSMISSION ENGINE TO TRAILER FRONT AXLE 1 2 3 4 5 - 8 Driveline Assembly Driveline Assembly Driveline Assembly Capscrew Capscrew 5 2 5 3 6 6 7 8 9 - Capscrew Screw Screw Screw Fig. 1 - Front Drivelines and Mounting DESCRIPTION 10 11 12 13 14 6 9 - Bracket - Bolt - Washer - Bracket - Locknut the components. Numbers in parentheses refer to Fig. 1.
Drivelines - Front Drivelines Section 130-0010 REMOVAL Numbers in parentheses refer to Fig. 1. Note: Extra care should be taken when handling drivelines since carelessness can result in premature failure of the components. Chips, dents, burrs, or any other deformity of universal joints will prevent accurate mating. This will cause misalignment which is accompanied by vibration and excessive wear.
Drivelines - Front Drivelines Section 130-0010 SM - 088 APPLY PRESSURE HERE BY HAND MAXIMUM PERMISSIBLE GAP IS 0.2 mm (0.008 in) STRAIGHT EDGE REMOVE ALL BURRS AND PAINT FROM THESE SURFACES Fig. 2 - Checking Parallelism ASSEMBLY Universal Joint Numbers in parentheses refer to Fig. 1. 1. Place the yoke end of driveline assembly (1) in a soft jawed vice, clamping on the tube of shaft. Note: Do not distort the tube with excessive grip. 2.
Drivelines - Front Drivelines Section 130-0010 With the pry bar, check the universal joints for play. If loose, replace the universal joints. Check the splines at the slip joint and replace the yoke if excessively worn. MAINTENANCE Universal Joints Every 500 Hours: Check the universal joints for wear and replace if required. SPECIAL TOOLS Every 2 000 Hours: Check drivelines for leaks and damage, and replace if required.
DRIVELINES - Rear Drivelines Section 130-0020 SM - 2944 3 2 1 2 6 3 5 4 5 CENTRE AXLE 1 - Driveline Assembly 2 - Capscrew 6 REAR AXLE 3 - Screw 4 - Driveline Assembly 5 - Capscrew 6 - Screw Fig. 1 - Rear Drivelines and Mounting DESCRIPTION Numbers in parentheses refer to Fig. 1. The function of the driveline is to transmit rotating power from one point to another in a smooth and continuous action while allowing a degree of movement or misalignment of the components it connects.
Drivelines - Rear Drivelines Section 130-0020 soft jawed vice. To prevent serious injury or death, DO NOT go under the vehicle when the engine is running. Rotating shafts can be dangerous. You can snag clothes, skin, hair, hands, etc.. 4. Remove screws (3) and universal joint from driveline assembly (1). Disconnecting or removing any of the rear drivelines will make the parking brake ineffective. INSPECTION 1. Position the vehicle in a level work area, apply the parking brake and switch off the engine.
Drivelines - Rear Drivelines Section 130-0020 SM - 088 APPLY PRESSURE HERE BY HAND MAXIMUM PERMISSIBLE GAP IS 0.2 mm (0.008 in) STRAIGHT EDGE REMOVE ALL BURRS AND PAINT FROM THESE SURFACES 2. Apply Loctite 648 to the threads of capscrews (2). Secure universal joints to their mating surfaces with capscrews (2). Tighten capscrews (2) to a torque of 154 Nm (113 lbf ft). 3. Position driveline assembly (4) on the vehicle as shown in Fig.
Drivelines - Rear Drivelines Section 130-0020 DRIVELINE DIAGNOSIS CHART CONDITION Vibration or noise REASON Driveline bent or out of balance REMEDY 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. Check driveline mounting capscrews for tightness.
FRONT AXLE GROUP - Differential Drive Head Section 140-0060 SM - 2729 Fig.
Front Axle Group - Differential Drive Head Section 140-0060 LEGEND FOR FIG.
Front Axle Group - Differential Drive Head Section 140-0060 SM - 033 4 - Bolt 5 - Washer 6 - Bolt 1 - Driveshaft Assembly 2 - Hub 3 - Washer 7 - Oil Filler/Level Plug 8 - Planet Carrier Fig. 2 - Part View of Hub Reduction Unit 3. Pull out driveshaft assembly (1, Fig. 2) from hub to disengage the shaft splines from wheel (30). 4. Cover open end of hub unit to prevent entry of dirt. 5. Repeat steps 1 through 4 for other hub end. 6.
Front Axle Group - Differential Drive Head Section 140-0060 DISASSEMBLY SM - 1204 Numbers in parentheses refer to Fig. 1. WARNING To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely. WARNING When necessary to drive out components during disassembly, be sure to use a soft drift to prevent property damage and personal injury. Helical Gear Housing Disassembly 1.
Front Axle Group - Differential Drive Head Section 140-0060 Note: Shims may have been fitted between end flange (53) and differential housing body (20). These must be replaced on assembly to maintain an operating clearance within the differential assembly. The components contained in the differential unit have been carefully measured and selected to ensure correct operation. DO NOT fit the components in a different sequence to that of the original assembly or attempt to change/introduce shimming.
Front Axle Group - Differential Drive Head Section 140-0060 2. Press inner bearing cone (12A) onto pinion (13). If original pinion (13) and bearings (12 & 64) are being refitted, install original spacers (10 & 11) onto pinion. Note: If new parts are being fitted, install the largest available spacers (10 & 11). This is to ensure that the bearing cannot be over pre-loaded, preventing bearing damage. SM - 1206 PEEN IN THREE PLACES 3.
Front Axle Group - Differential Drive Head Section 140-0060 Note: The force required to maintain rotation should be related in the following manner to determine pre-load. T = F x R, where: T = Torque F = Force to maintain rotation R = Radius of secured cord Pre-load obtained should be between limits of 1.7 - 2.8 Nm (15 - 25 lbf in). If torque reading is less than 1.7 Nm (15 lbf in) then a smaller outer spacer needs to be fitted. If torque obtained is greater than 2.
Front Axle Group - Differential Drive Head Section 140-0060 6. Similarly, install second pair of clutch plates followed by mating cage half (29). SM - 1208 Note: The clutch plates and cage half must be assembled as the original matched set to ensure correct operation of POWR LOK system. If unsure as to which parts complete a set, measure total thickness of clutch plates and cage half for both sides of differential unit. Each total thickness figure must be the same (See Fig. 8). 7.
Front Axle Group - Differential Drive Head Section 140-0060 SM - 1186 alignment of matching marks on gear casing (17) legs and straps (33) to ensure that straps are not transposed. Bearing cups (24) should seat snugly in bores and adjusting nuts (23) should be free to turn with hand pressure only, if not, it may be because of cross threading. Remove and deburr. On no account use additional pressure i.e. hammer. 5. Install washers (34) and temporarily install plain nuts onto studs (55).
Front Axle Group - Differential Drive Head Section 140-0060 SM - 1189 In all cases, action, (if any) to be taken is shown below: Fig. A - Indicates correct mesh. No further action required. Fig. B - Indicates pinion and crownwheel are too far out of mesh. To remedy, move pinion inwards towards crownwheel. To maintain backlash, move crownwheel away from pinion in direction of arrow B. Fig. C - Indicates pinion and crownwheel too far into mesh. To remedy, move pinion outwards away from crownwheel.
Front Axle Group - Differential Drive Head Section 140-0060 TYPICAL PREFERRED TOOTH CONTACT (Pinion member left hand in all cases shown) SM - 1190 HEEL TOE HEEL TOE PINION CONCAVE SIDE CENTRAL TOE CONTACT CROWNWHEEL CONVEX SIDE CENTRAL TOE CONTACT CONVEX SIDE CENTRAL TOE CONTACT CONCAVE SIDE CENTRAL TOE CONTACT Fig. A - Correct Mesh SM - 1191 SM - 1192 PROFILE ERROR To correct; move pinion towards crownwheel in direction of arrow A.
Front Axle Group - Differential Drive Head Section 140-0060 (5). Add 0.076 mm (0.003 in) to measured gap to obtain correct shim (4) pack thickness, providing end play for helical pinion bearings. 12. Remove setscrews (1) and bearing retainer (3). 13. Place selected shim (4) pack on helical gear housing (5) and install bearing retainer (3), spring washers (2) and setscrews (1). Evenly tighten setscrews to a torque of 60 - 65 Nm (44 - 48 lbf ft). 14.
Front Axle Group - Differential Drive Head Section 140-0060 f. The oil seal lip or journal of coupling should be smeared with clean gear oil prior to assembly. If seal is fitted dry, it can burn out in a matter of minutes, before oil reaches it. 2. Install end cap (42) assembly onto differential shaft (43). 3. Apply a small bead of Hylomar sealant around corner of bearing recess in end cap (42) and axle casing (37). 4.
Front Axle Group - Differential Drive Head Section 140-0060 d - Leaks around joints. e - General condition and tightness of nuts and bolts. f - General condition of axle casing. 4. Raise axle until both road wheels are just off the ground then support with suitable stands or timbers. 5. Rotate each hub so that bottom of oil filler/level plugs (7, Fig. 2) are approximately 13 mm (0.5 in) above axle centre line (level with oil filler/level plug).
Front Axle Group - Differential Drive Head Section 140-0060 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO.
CENTRE AXLE - Differential Drive Head Section 150-0020 SM - 2730 51 52 63 64 53 50 49 48 47 73 75 74 77 76 79 78 81 80 82 95 96 46 45 44 43 33 34 35 38 37 97 91 42 84 83 40 41 132 39 89 90 88 87 85 91 100 99 101 102 103 53 98 97 96 52 95 51 104 105 93 92 31 32 30 28 29 26 18 19 110 112 111 1617 15 115 116 117 13 14 12 8 3 12 4 120 9 10 122 123 124 125 7 56 113 114 118 119 121 126 130 131 129 128 Fig.
Centre Axle - Differential Drive Head Section 150-0020 LEGEND FOR FIG.
Centre Axle - Differential Drive Head Section 150-0020 SM - 033 1 2 3 4 - Driveshaft Assembly - Hub - Washer - Bolt 5 6 7 8 - Washer - Bolt - Oil Filler/Level Plug - Planet Carrier Fig. 2 - Part View of Hub Reduction Unit 5. Remove wheel nuts then pull off road wheels. 6. Identify the relationship of both driveline flanges to coupling flange (2) and 3rd differential shaft (73). Disconnect drivelines and secure clear of drive head. Drivelines may be removed if convenient to do so.
Centre Axle - Differential Drive Head Section 150-0020 5. Insert two 5/8 in UNF bolts into two extractor holes provided in gear casing flange and tighten to separate gear casing (39) from axle casing (64). 6. Carefully remove gear casing (39) assembly clear of axle casing (64) and place on a suitable build stool. 7. Remove all traces of gasket material and sealant from axle casing (64) and gear casing (39) flanges. Helical Gear Housing and 3rd Differential Housing from Gear Casing 1.
Centre Axle - Differential Drive Head Section 150-0020 SM - 1196 6. Remove any joint material from the bottom gasket face of helical gear housing (26). Differential Unit 1. Match mark straps (89) as shown in Fig. 3 to ensure correct rebuild position then remove nuts (87) and washers (88). 2. Lift off both straps (89), adjusting nuts (51) and split pins (90). 3. Lift complete differential and crownwheel assembly from gear casing (39). Place assembly on bench with crownwheel (46) teeth uppermost. 4.
Centre Axle - Differential Drive Head Section 150-0020 13. Using hide faced mallet, remove crownwheel (46) from its register on differential housing body (48). 14. Inspect all parts of differential assembly. If there is any wear or damage install new differential unit complete. Renew crownwheel (46) and spiral bevel pinion (33) as a matched pair. Differential Lock Mechanism and 3rd Differential Driveshaft reuse if original pinion bearings are to be reinstalled. 5.
Centre Axle - Differential Drive Head Section 150-0020 SM - 1198 PEEN IN THREE PLACES 5. To obtain correct position of pinion relative to crownwheel, shim (35) thickness is worked out using formula 8.636 mm + A mm + B mm + C mm (0.34 + 0.00A in + 0.00B in + 0.00C in) where as: 8.636 mm (0.034 in) shims selected as nominal. 'A' - Select shim thickness equivalent to figure stamped on end face of spiral bevel pinion (33). 'B' - Select shim thickness equivalent to figure stamped on gear casing (39).
Centre Axle - Differential Drive Head Section 150-0020 If torque obtained is greater than 2.8 Nm (25 lbf in) then a larger outer spacer needs to be fitted. Note: If largest available combination of spacers (111 & 112) is already fitted, then a defect must be present in one or more parts of the assembly and needs to be found and remedied before continuing differential build. 4. When correct pre-load has been achieved, remove end nut (117) and helical gear (116). 5.
Centre Axle - Differential Drive Head Section 150-0020 SM - 1182 SM - 1200 TOTAL THICKNESS EQUAL AT BOTH SIDES OF DIFF Fig. 8 - Measuring Thickness of Clutch Plates and Diff Cage Half SM - 1199 Fig. 9 - Pinion/Diff Wheel Arrangement Fig. 10 - Differential Assembly (91 & 95) then check that cage half (96) and clutch plates will slide in differential housing body (48) by raising and lowering wheel (97). Initial Preparation Before Installing Assembled Differential Unit 11.
Centre Axle - Differential Drive Head Section 150-0020 only, if not, it may be because of cross threading. Remove and deburr. On no account use additional pressure i.e. hammer. SM - 1185 5. Install washers (88) and temporarily install plain nuts onto studs (100). Tighten nuts to a torque of 502 - 542 Nm (370 - 400 lbf ft.). 6. Check freedom of adjusting nuts (51) by unscrewing and refitting, to assist this operation tap straps (89) lightly on top with 1 kg (2 lb) hammer (See Fig. 11). 7.
Centre Axle - Differential Drive Head Section 150-0020 VIEWS SHOWING SPLIT PIN IN POSITION SM - 1188 Checking Crownwheel and Pinion Mesh 1. Apply thin coating of engineers marking compound to several consecutive crownwheel teeth. 2. Turn crownwheel for few revolutions in both directions to make positive tooth contact impression on crownwheel and pinion teeth. INSTALL FROM UNDERNEATH 3. Inspect deposit of marking compound on crownwheel and pinion teeth and compare them with Fig. 16.
Centre Axle - Differential Drive Head Section 150-0020 TYPICAL PREFERRED TOOTH CONTACT (Pinion member left hand in all cases shown) SM - 1190 HEEL TOE HEEL TOE PINION CONCAVE SIDE CENTRAL TOE CONTACT CROWNWHEEL CONVEX SIDE CENTRAL TOE CONTACT CONVEX SIDE CENTRAL TOE CONTACT CONCAVE SIDE CENTRAL TOE CONTACT Fig. A - Correct Mesh SM - 1191 SM - 1192 PROFILE ERROR To correct; move pinion towards crownwheel in direction of arrow A.
Centre Axle - Differential Drive Head Section 150-0020 SM - 1201 HELICAL GEAR TOOL (30A) already on helical pinion (31). 9. Select shim pack (19) of 0.762 mm (0.030 in) thickness and position in helical gear housing (26). HELICAL PINION 10. Place retainer plate (18) on shims and install eight standard type capscrews. Tighten capscrews to a torque of 64 - 72 Nm (47 - 53 lbf ft). 11. Shock load helical pinion bearings using a hide faced mallet. 12.
Centre Axle - Differential Drive Head Section 150-0020 4. Install outer wheel (14) and thrust washer (13). 5. Place outer cage half (12) onto assembly and secure with bolts (126). Evenly tighten bolts to a torque of 98 108 Nm (72 - 80 lbf ft), then fasten in pairs with lockwire. 6. Rotate inner wheel (15) inside cage assembly to ensure all parts move freely. 7. Check security of studs (120) in helical gear housing (26) and tighten to a torque of 33 - 35 Nm (24 - 26 lbf ft) if necessary. 8.
Centre Axle - Differential Drive Head Section 150-0020 (10) and secure with nuts (131) and washers (130). Evenly tighten nuts to a torque of 38 - 43 Nm (28 - 32 lbf ft). 5. Check security of studs (81) in axle casing (64) and tighten to a torque of 26 - 28 Nm (19 - 21 lbf ft) if necessary. Note: Check for a gap of 0.2 mm (0.008 in) maximum between front end cap (3) and 3rd differential housing (10). Bearing (6) must not be pre-loaded. 6. Install new oil seal (77) into rear end cap (76).
Centre Axle - Differential Drive Head Section 150-0020 SM - 2732 Fig. 21 - Setting 3rd Diff Lock Mechanism Final Assembly 1. Carefully feed driveshaft assembly (1, Fig. 2) back into axle casing (64) to locate driveshaft splines in wheel (97). 2. Coat hub mating face of planet carrier (8, Fig. 2) with Loctite 515 then offer planet carrier unit to hub (2, Fig. 2) using suitable lifting gear if required. Ensure planet gear teeth mesh with sun gear. 3. Install bolts (4, Fig. 2) and washers (3, Fig.
Centre Axle - Differential Drive Head Section 150-0020 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. General At first service, then every 1 000 hours (6 months), check the following and repair or replace where necessary: a - Input flange for wear/damage. b - Pinion oil seals for leaks. c - Breather for signs of leakage or dirt ingress. d - Leaks around joints.
Centre Axle - Differential Drive Head Section 150-0020 DIAGNOSIS CHART CONDITION REASON REMEDY Vibration Broken gear teeth, worn bearings Replace gear or bearings Continued noise Worn gears or bearings Replace gears or bearings Overheating Loss of lubricant Replace faulty joint or seal and refill Crownwheel adjustment too tight Readjust Seized bearings Replace bearings Worn diff side gears and pinions Replace diff side gears and pinions Worn or damaged trunnions Replace trunnions Loss o
Centre Axle - Differential Drive Head Section 150-0020 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO.
REAR AXLE GROUP - Differential Drive Head Section 160-0020 SM - 2733 Fig.
Rear Axle Group - Differential Drive Head Section 160-0020 LEGEND FOR FIG.
Rear Axle Group - Differential Drive Head Section 160-0020 SM - 033 4 - Bolt 5 - Washer 6 - Bolt 1 - Driveshaft Assembly 2 - Hub 3 - Washer 7 - Oil Filler/Level Plug 8 - Planet Carrier Fig. 2 - Part View of Hub Reduction Unit 12. Unscrew and remove oil filler/level plug (55) and drain plug (54) to drain oil from drive head. 4. Remove all traces of gasket material from axle casing (6) and gear casing (40) flanges. Driveshafts 5. Remove lifting gear and 'U' bolts from coupling flange (33). 1.
Rear Axle Group - Differential Drive Head Section 160-0020 2. Match mark straps (49) as shown in Fig. 3 to ensure correct rebuild position then remove nuts (51) and washers (50). SM - 2734 3. Lift off two straps (49) and diff bearing adjusting nuts (16). 4. Remove and discard bearing adjusting nut split pins (48) from diff straps (49). 5. Lift complete differential and crownwheel assembly from gear casing (40). Place assembly on bench with crownwheel (11) teeth uppermost. 6.
Rear Axle Group - Differential Drive Head Section 160-0020 setting shims (39). Note: If the original pinion and crownwheel are to be reinstalled, retain the shim pack as a unit for reuse. 2. Remove all traces of sealant from the outer shims (39), pinion bearing housing (24) and gear casing (40). 3. Secure pinion assembly in a vice fitted with soft jaws then remove pinion nut (34). 4. Pull off coupling flange (33), using suitable extraction equipment. 5.
Rear Axle Group - Differential Drive Head Section 160-0020 2. Secure assembly in vice, hold on coupling flange (33). SM - 2737 3. Secure length of cord around pinion bearing cage (24) and attach free end to spring balance. 4. Pull tangentially on spring balance to rotate pinion bearing cage. Note the force required to maintain rotation, ignoring initial starting force. 5. The correct spring balance reading should be between 3.5 - 6 lbs pull (1.5 - 2.75 kg) giving a rolling torque of 15 - 25 lbf in (1.
Rear Axle Group - Differential Drive Head Section 160-0020 SM - 2739 housing body (13), ensuring that bolt holes and matching marks line up. c. Install two bolts (19) diagonally opposite, through crownwheel and differential housing body (13) then allow assembly to cool fully. d. Install end flange (14) aligning matching marks and grooves in end face with those in differential housing body. Install remaining bolts (19) and nuts (18) then tighten to a torque of 155 - 171 Nm (114 - 126 lbf ft). 2.
Rear Axle Group - Differential Drive Head Section 160-0020 into differential housing body (13), making sure that they are free to move vertically in grooves. SM - 2740 6. Similarly, install second pair of clutch plates followed by mating cage half (9). Note: The clutch plates and diff cage half must be assembled as the original matched set to ensure correct operation of POWR LOK system.
Rear Axle Group - Differential Drive Head Section 160-0020 SM - 1186 4. Carefully install two straps and secure with strap nuts (51) and washers (50). Check the alignment of matching marks on gear casing (40) legs and straps (49) to ensure that straps are not transposed. 5. Bearing cups (17) should seat snugly in bores and adjusting nuts (16) should be free to turn with hand pressure only, if not, it may be because of cross threading. Remove and deburr. On no account use additional pressure i.e. hammer. 6.
Rear Axle Group - Differential Drive Head Section 160-0020 washers (50). Note: Ensure matching marks coincide to prevent misalignment of straps (49). 4. Turn adjusting nuts (16) hand tight against bearings (17 & 17A). 5. Tighten nuts (51) to a torque of 502 - 542 Nm (370 - 400 lbf ft) (See Fig. 13). Setting ‘No End Float’ Condition Fig. A - Indicates correct mesh. No further action required. Fig. B - Indicates pinion and crownwheel are too far out of mesh.
Rear Axle Group - Differential Drive Head Section 160-0020 TYPICAL PREFERRED TOOTH CONTACT (Pinion member left hand in all cases shown) SM - 1190 HEEL TOE HEEL TOE PINION CONCAVE SIDE CENTRAL TOE CONTACT CROWNWHEEL CONVEX SIDE CENTRAL TOE CONTACT CONVEX SIDE CENTRAL TOE CONTACT CONCAVE SIDE CENTRAL TOE CONTACT Fig. A - Correct Mesh SM - 1191 SM - 1192 PROFILE ERROR To correct; move pinion towards crownwheel in direction of arrow A.
Rear Axle Group - Differential Drive Head Section 160-0020 INSTALLATION Numbers in parentheses refer to Fig. 1, unless otherwise specified. 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. Drive Head Unit into Axle Casing 1.
Rear Axle Group - Differential Drive Head Section 160-0020 300-0020, LUBRICATION SYSTEM. With new or rebuilt units, drain (preferable after a short run to warm the oil) and refill after 100 hours of operating, then at intervals of 2 000 hours (12 months). Oil Level Check oil levels every 250 hours (monthly), following the procedure below: 1. Drive vehicle onto a level, solid concrete floor, apply the parking brake and switch off the engine. 2.
Rear Axle Group - Differential Drive Head Section 160-0020 DIAGNOSIS CHART CONDITION REASON REMEDY Vibration Broken gear teeth, worn bearings Replace gear or bearings Continued noise Worn gears or bearings Replace gears or bearings Overheating Loss of lubricant Replace faulty joint or seal and refill Crownwheel adjustment too tight Readjust Seized bearings Replace bearings Worn diff side gears and pinions Replace diff side gears and pinions Worn or damaged trunnions Replace trunnions Lo
REAR AXLE GROUP - Axle Group (Hub) Section 160-0030 SM - 2722 4 5 6 10 7 3 2 8 9 13 1 12 11 14 15 16 17 18 19 31 32 33 34 28 23 22 21 20 27 26 24 25 37 36 35 37 38 41 30 29 39 40 1 2 3 4 5 6 7 8 9 10 - Plug - Bolt - Washer - Washer - Planet Gear - Washer - Thrust Button - Circlip - Sun Gear - Bearing Assembly 11 12 13 14 15 16 17 18 19 20 - Retainer Hub Ring Gear Planetary Ring Gear Hub Nut Lock Ring Spring Ring Thrust Washer Screw Planet Carrier Washer 21 22 23 24 25 26 2
Rear Axle Group - Axle Group (Hub) Section 160-0030 DESCRIPTION Numbers in parentheses refer to Fig. 1. The hub gears are driven by a floating sun gear (9) which is splined to driveshaft (24). Sun gear (9) mates with three planet gears (5) mounted in planet carrier (19) which is bolted to hub (38). The ring gear unit (12 & 13) is of the two piece variety and is splined to axle stub (29), it also serves to support outer bearing (10).
Rear Axle Group - Axle Group (Hub) Section 160-0030 Disassembly of Planet Carrier Unit 1. Unscrew and remove planet carrier bolts (2) and washers (1). 2. Using suitable lifting equipment to aid this operation, carefully remove planet carrier (19) assembly from axle. Place on bench and support in upright position with timber blocks to prevent assembly from rolling. 3.
Rear Axle Group - Axle Group (Hub) Section 160-0030 work surface for inspection. 4. Clean any residual sealant from faces of axle stub (29) and axle housing (41). ASSEMBLY AND INSTALLATION Numbers in parentheses refer to Fig. 1, unless otherwise specified. Note: Prior to assembly, lightly lubricate all parts in clean gear oil as specified in Section 300-0020, LUBRICATION SYSTEM, except where other instructions are given. Pack taper bearings with grease (Shell Retinax LX or equivalent).
Rear Axle Group - Axle Group (Hub) Section 160-0030 SM - 2723 29 - Axle Stub 30 - Capscrew 34 - Ring 35 39 40 41 - Capscrew 'O' Ring Brake Assembly Axle Housing Fig. 2 - Brake Assembly/Axle Stub Installation into planet carrier (19) and through first washer (4), planet gear (5) and second washer (6) making sure to line up flat on planet pin (22) with hole in planet carrier (19) for grub screw (18). housing (41). 8. Clean grub screw (18) threads with suitable solvent then apply Loctite 275.
Rear Axle Group - Axle Group (Hub) Section 160-0030 SM - 2724 28 - Hub/Stub Face Seal 31 - Oil Seal Spacer 32 - 'O' Ring 33 - Oil Seal Housing 36 - Capscrew Fig. 3 - Oil Seal Housing Installation grease to aid in reassembly. 2. Using suitable lifting equipment, offer brake assembly (40) up to axle stub and housing (29 & 41) and seat on register. 3.
Rear Axle Group - Axle Group (Hub) Section 160-0030 Note: To aid in assembly, moisten bore and 'O' ring with a weak spirit/water mixture. SM - 2725 hub guide sleeve tool 15500016 onto axle stub (29) (see Fig. 6). 6. Using suitable lifting equipment, lift hub assembly (38) and slide into position on axle. Take care when inserting hub splines into brake assembly (40) so as not to damage plates. 7. Carefully feed hub (38) onto axle stub (29) as far as it will go by sliding it gently forwards.
Rear Axle Group - Axle Group (Hub) Section 160-0030 SM - 2727 Fig. 6 - Hub Assembly Installation Installation of Planet Carrier Unit 1. Clean mating faces of hub (38) and planet carrier (19) with a suitable cleaning agent. Coat hub mating face of planet carrier (19) with Loctite 515 and offer planet carrier (19) unit to hub (38), using suitable lifting equipment. Ensure that planet gear (5) teeth mesh with sun gear (9). then torque tighten to 109 - 121 lbf ft (149 - 164 Nm). 3.
Rear Axle Group - Axle Group (Hub) Section 160-0030 SM - 2728 Fig. 7 - Planet Carrier Installation 5. Add gear oil of the type specified in Section 3000020, LUBRICATION SYSTEM, through the differential oil filler/level hole until level with bottom of hole. 6. Check oil level to bottom of filler/level hole in both hubs (38) and top up as necessary. Leave oil to settle for 15 minutes then check oil level again in both hubs (38) and differential. 7.
Rear Axle Group - Axle Group (Hub) Section 160-0030 300-0020, LUBRICATION SYSTEM. With new or rebuilt units, drain (preferably after a short run to warm the oil) and refill after 100 hours of operating, then at intervals of 2 000 hours (12 months). Note: When refilling centre axle, ensure that 3rd differential unit is primed with 1 litre (1.75 pints) of oil before filling drive head. Oil Level Check Check oil levels every 250 hours (monthly), following the procedure below: 1.
Section 160-0030 AXLE DIAGNOSIS CHART TABLE643 CONDITION REASON REMEDY Noises Insufficient or incorrect lubricant Check level, fill with proper type and grade of lubricant Hub bearings scored or rough Replace bearings Gear teeth in planetary chipped Replace gear Lubricant level too high Correct oil level Lubricant foams excessively Drain and fill with correct type and grade of lubricant Worn or broken oil seal Replace oil seal Restricted breather vent Clean vent Loose nuts or bolts Tig
REAR AXLE GROUP - Wheel Rim and Tyre Section 160-0050 SM - 1176 1 - Flanges 2 - 'O' Ring 3 - Bead Seat Band 4 - Lock Ring 5 - Wheel Rim 6 - Valve Assembly 7 - Cap 8 - Driver 9 - Wheel Nut Fig. 1 - Cutaway View of Wheel Rim DESCRIPTION AND OPERATION The wheel assembly is designed to allow the tyre and rim assembly to be replaced with a pre-assembled tyre and rim.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 REMOVING TYRE AND RIM ASSEMBLY FROM MACHINE SM - 1039 Numbers in parentheses refer to Fig. 1. Note: If tyre and rim assembly is to be replaced preassembled, 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.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 WARNING When lifting tyre from rim, be sure the equipment is of sufficient capacity and properly secured to do the job safely. 1. Remove valve cap and valve core and leave valve open to prevent trapping of air in tyre. Tape valve threads for protection. 2. Remove driver (2) from bead seat band (3) and wheel rim (5). 3. Break outer tyre bead loose with pry bar shown in Fig. 3. 4.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 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. SM - 207 The rim parts used with tubeless tyres form an important part of the air chamber. Therefore, they should be carefully checked for distortion or mutilation that would prevent an effective air seal when the tyre and rim are reassembled.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 2. Install wheel nuts (9) on wheel studs. Gradually tighten nuts opposite each other until all nuts are snug. Torque tighten wheel nuts (9) to 540 Nm (400 lbf ft). Torque tighten wheel nuts (9) again, after 10 hours of machine operation. TYRE INFLATION WARNING To prevent personal injury and property damage, the tyre and rim assembly should be placed in a safety cage before inflating.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 3. Inflate tyres to 5.2 bar (75 lbf/in²) to seat beads and seal the 'O' ring, then adjust to the recommended inflation pressure. SM - 208 4. For recommended operating air pressure, refer to the 'Tyre Inflation Pressures Table'. NITROGEN TYRE INFLATION Note: All Warnings and procedures under 'Tyre Inflation' will apply, except for differences covered by this passage.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 b. Safety relief valve, 8.6 bar (125 lbf/in²), that will assure an upper limit to the pressure available for tyre inflation. c. A 15.2 m (50 ft) length of flexible hose with interconnecting fittings. On the tyre end of the hose is a large bore quick connect/disconnect clip-on chuck. 2. The pressure regulator is connected to a nitrogen compressed gas cylinder available from local suppliers. 3.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 SM - 1041 WARNINGS There is always a possibility of a tyre explosion whenever the smell of burning rubber or excessively hot brakes is detected. The danger is also present when a fire on the machine reaches the tyre and wheel area. Under such conditions, all personnel must avoid approaching the machine in a manner that could result in injury should an explosion actually occur.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 TYRE CARE Prevent Contact with Oil To obtain maximum service from off-highway tyres, the following common-sense precautions should be followed. Prevent tyre contact with petroleum products. Rubber that is exposed to oil, gasoline, or grease becomes soft and spongy and deteriorates rapidly. Always avoid driving machine through a puddle of gasoline, fuel oil, lubricating oil, or grease. Never let a tyre stand in an oil or grease spot overnight.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 Babbit or lead hammers, not sledge hammers, should be used in assembling rim parts. machine is placed in operation. Refer to 'Tyre Inflation Pressures Table'. 'O' rings are seals and should be carefully stored in a cool, dry place where they will not be injured or damaged. Every 50 hours of operation (weekly), torque tighten wheel rim nuts to 540 Nm (400 lbf ft). Check tyres regularly and replace or repair if required.
Rear Axle Group - Wheel Rim and Tyre Section 160-0050 TUBELESS TYRE LEAK DIAGNOSIS TABLE499 Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of leakage, the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be checked using a soap solution. This table lists various causes of air loss and possible remedy. CAUSE REMEDY Defective valve Tighten parts. Replace defective parts. Use valve caps.
BRAKE ASSEMBLY - Oil Cooled Disc Brakes Section 165-0015 DESCRIPTION AND OPERATION Numbers in parentheses refer to Fig. 1. The service brakes are of the enclosed, forced oilcooled multiple disc type. The service brakes are actuated by hydraulic oil as specified in Section 3000020, LUBRICATION SYSTEM. DO NOT use BRAKE FLUID (J 1703). Multiple discs within the brake assemblies are cooled by brake cooling oil as specified in Section 300-0020, LUBRICATION SYSTEM.
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 SM - 2775 1 2 3 4 5 6 7 8 9 10 - Brake Assy (6 Plate) Slack Adjuster Nut Slack Adjuster Seal Slack Adjuster Jam Nut Slack Adjuster Seal Slack Adjuster Screw Wear Indicator Cap 'O' Ring Wear Indicator Pin Drain Plug 11 12 13 14 15 16 17 18 19 20 - 'O' Ring - Plug - 'O' Ring - Bleeder Screw - Brake Inner Cover - Dowel Pin - 'O' Ring - 'O' Ring - Piston Inner Seal - Piston Outer Seal 21 22 23 24 25 26 27 28 29 30 31 - Brake Piston Capscrew Washer
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 SM - 3089 DISASSEMBLY Numbers in parentheses refer to Fig. 1, unless otherwise stated. WARNINGS To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly secured and of sufficient capacity to do the job safely. Fig. 2 - Removing Caps SM - 3090 1. Remove caps (7) from adjusting screws (6) as shown in Fig. 2. 2. Loosen the jam nuts (4) and remove the adjuster screws (6). Fig.
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 5. Remove the wear indicator cap (7) only at this stage. Remove the plugs and fittings for the cooling lines and the actuation lines from the brake inner cover (15). Note locations of plugs and fittings to aid in Assembly. SM - 3093 Fig. 6 - Removing Fittings 6. Remove the capscrews (22) and washers (23) from brake outer cover (24). SM - 3094 Fig. 7 - Removing Capscrews 7.
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 SM - 3097 9. Before separating the brake housing (31) and the brake inner cover (15), ensure that the serial numbers are stamped on both components. If no numbers are found, match mark components to aid in reassembly. Using suitable lifting equipment, lift the brake housing (31) clear of cover (15). 10. Remove piston outer seal (20) from brake housing (31) as shown in Fig. 10. Fig. 10 - Removing Outer Seal SM - 3098 11.
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 3. Install the brake cover 'O' ring (18) and the three 'O' rings (17) on the brake cover (arrowed on Fig. 14). Install the piston inner seal (19) 'O' ring. SM - 3101 Fig. 14 - Installing 'O' Rings 4. Install the piston inner seal (19) over the inner seal 'O' ring. Use a screwdriver with no nicks or burrs to help install the seal (19), being careful not to overstretch the seal. Lubricate the seal with recommended lubricant. SM - 3102 5.
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 SM - 3105 10. Coat threads of guide pins (29) with Loctite 262 and install in piston pressure plate (30). 11. Place piston pressure plate (30) in brake housing (31), with pins (29) facing upwards. 12. Install reaction disc (27) over pressure plate (30) in brake housing (31) as shown in Fig. 18. Fig. 18 - Installing Reaction Disc SM - 3106 13. Next install friction disc (26) on top of reaction disc (27).
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 23. Install pressure gauge assembly to brake actuation port as shown in Fig. 22. SM - 3109 WARNINGS To prevent personal injury and property damage, be sure threads are sealed properly and all gauge assembly components can safely handle at least 2000 lbf/in2 (138 bar). 24. Apply 100 lbf/in2 (7 bar) air pressure to gauge. Back off jam nuts (4) and tighten adjuster screws (6) until they contact piston (21). 25.
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 31 32 33 SM - 3111 34 28 27 26 24 25 37 36 35 37 38 41 30 29 39 40 24 25 26 27 28 29 - Driveshaft Wheel Nut Stud Bearing Assembly Hub/Stub Face Seal Axle Stub 30 31 32 33 34 35 - Capscrew Oil Seal Spacer 'O' Ring Oil Seal Housing Ring Capscrew 36 37 38 39 40 41 - Capscrew - Seal - Hub - 'O' Ring - Brake Assembly - Axle Housing Fig.
Brake Assembly - Oil Cooled Disc Brakes Section 165-0015 drain plugs and drain brake cooling oil from each brake assembly every 1 000 hours of operating. Refill brake coolant tank as described in Section 250-0025, BRAKE COOLANT TANK. SPECIAL TOOLS Refer to Section 300-0070, SERVICE TOOLS, for details of service tools and adhesives required. These tools and adhesives are available from your dealer.
PARKING BRAKE - Parking Brake and Mounting Section 170-0010 SM - 2648 6 7,8 10 11 9 13 4 14 3 5 15 12 2 1 1 2 3 4 5 - Bracket Assembly - Calliper Head Assembly - Slack Adjuster - Bolt - Washer 6 7 8 9 10 - Nut Clevis Pin Cotter Pin Actuator Nut 11 - Washer 12 - Control strap 13 - Cap assembly 14 - Slack adjuster screw 15 - Bolt Fig. 1 - Parking Brake Mounting WARNINGS Use only hydraulic oils meeting specifications outlined in Section 300-0020, LUBRICATION SYSTEM.
Parking Brake - Parking Brake and Mounting Section 170-0010 the ignition is switched off. 170-0030, ACTUATOR. REMOVAL Numbers in parentheses refer to Fig. 1, unless otherwise specified. WARNINGS 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. Hydraulic fluid pressure will remain within the braking system after engine shut down.
Parking Brake - Parking Brake and Mounting Section 170-0010 SM - 1851 18 19 20 12 21 6 11 10 7 8 3 24 2 9 22 1 17 15 16 23 4 14 13 5 1 2 3 4 5 6 - Brake Pad - Bolt - Washer - Piston Seal - Piston - Calliper 7 8 9 10 11 12 - Clevis - Clevis Pin - Cotter Pin - Nut - Washer - Actuator 13 14 15 16 17 18 - Snap Ring - Slack Adjuster - Wave Spring Washer - Washer - Packing - Power Screw Shaft 19 20 21 22 23 24 - Thrust Bearing - Gasket - Cap Assembly - Journal Bearing - Plug - Pressure Relief F
Parking Brake - Parking Brake and Mounting Section 170-0010 SM - 3070 1 7 6 7 5 6 3 4 2 4 8 1 2 3 4 - Bracket Assembly - Torque Plate Side A - Torque Plate Side B - Bolt 5 6 7 8 - Clamp Plate - Hardened Washer - Nut - Park Brake Assembly Fig. 3 - Assembling Parking Brake Mounting to mounting spline of slack adjuster (15). 10. With adjusting screw facing towards actuator (13) slide slack adjuster (15) on power screw shaft (19) aligning slack adjuster (15) arm with clevis (10).
Parking Brake - Parking Brake and Mounting Section 170-0010 15. Use 1.5mm feeler gauge between brake pads in calliper head assembly (2) and brake disc. Turn the adjustment screw (14) on the slack adjuster (3) until the 1.5 mm total clearance is obtained. 7. Remount actuator (9) on cap assembly (22, Fig. 2) and install washers (11) and nuts (10). Tighten nuts (10) finger tight only at this stage. WARNING Do not pressurize actuator until the following instruction has been carried out.
PARKING BRAKE - Actuator Section 170-0030 SM - 2648 6 7,8 10 11 9 13 4 14 3 5 15 12 2 1 1 2 3 4 5 - Bracket Assembly - Calliper Head Assembly - Slack Adjuster - Bolt - Washer 6 7 8 9 10 - Nut Clevis Pin Cotter Pin Actuator Nut 11 - Washer 12 - Control strap 13 - Cap assembly 14 - Slack adjuster screw 15 - Bolt Fig. 1 - Actuator Mounting DESCRIPTION AND OPERATION REMOVAL Numbers in parentheses refer to Fig. 1.
Parking Brake - Actuator Section 170-0030 4. Release spring tension on clevis pin (7) by unscrewing tensioning bolt on slack adjuster (3) until clevis pin (7) feels loose. Remove cotter pin (8) and clevis pin (7) from actuator (9). Note: On engine shutdown the parking brake will automatically apply. Ensure there is sufficient clearance for actuator rod travel. 5. Switch off the engine and place the battery master switch in the 'Off' position. 6. Disconnect and plug hydraulic line from actuator (9).
Parking Brake - Actuator Section 170-0030 SM - 1853 1 2 3 4 5 6 7 8 9 - Actuator Housing - Lockwasher - Nut - Bolt - Lockwasher - Bolt - Retaining Ring - Rod-End - Seeger Circlip 10 11 12 13 14 15 16 17 18 - Tube - Ball - Plunger - Wiper - Gland - U-Cup - 'O' Ring - 'O' Ring - Retaining Ring 19 20 21 22 23 24 25 26 27 28 - U-Sit Ring - Grommet - Joining Nipple - Base - Plunger - Bolt - Bearing - Retaining Ring - Washer - U-Cup 29 30 31 32 33 34 35 36 37 38 - Ball - Bolt - Cap - Nut - 'O' Ring - Bolt
Parking Brake - Actuator Section 170-0030 INSTALLATION WARNING Springs (37 & 38) have been assembled under pressure, therefore pressing should be carried out with the utmost precaution. 5. Press rear cap (31) in approximately 10 mm (0.4 in) by using a solid plate of approximately 130 mm (5 in) diameter. 6. Remove retaining ring (7) from groove in actuator housing (1). 7.
Parking Brake - Actuator Section 170-0030 adjustment screw (14) on the slack adjuster (3) until the 1.5 mm total clearance is obtained. 12. Remove wheel blocks and place the steering lock bar in the 'Stowed' position. 10. Remove feeler gauge and apply brake several times. The automatic slack adjuster will adjust the brake pad clearance with each application, which can be seen by the rotation of the adjustment screw (14). SPECIAL TOOLS 11.
SUSPENSION SYSTEM - Front Suspension Section 180-0020 SM - 2674 19 27 2 14 22 26 2,7,8,9 19,27,33 38,39,40 4 5 7 5 3 33 8 6 23 40 24 9 3 11 6 39 17 25 3 18 25 10 38 32 18 25 1 17 25 16 31 37 30 35 21 25 13 29 28 31 30 25 15 25 21 29 12 34 36 20 1 2 3 4 5 6 7 8 9 10 - Suspension Frame - Snubbing Washer - Shock Absorber - Link - Rubber Mount - Rubber Mount - Rubber Mount - Bolt - Chain - Pin Assembly 11 12 13 14 15 16 17 18 19 20 - Panhard Rod - Bearing - Bush - Bolt - Bol
Suspension System - Front Suspension Section 180-0020 (5 & 6) there are four heavy duty double acting shock absorbers (3) (two off each side) to smooth out the ride. Two chain and shackle assemblies (28) and rubber rebound mounts (7) provide extra retention on rebound. REMOVAL Numbers in parentheses refer to Fig. 1. WARNING To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely. 1.
Suspension System - Front Suspension Section 180-0020 DISASSEMBLY Numbers in parentheses refer to Fig. 1. WARNING To prevent personal injury and property damage, be sure lifting equipment is properly secured and of adequate capacity to do the job safely. 1. Remove locknuts (21), hardened washers (25) and bolts (17) securing front axle assembly on suspension frame (1). Using suitable lifting equipment, remove front axle assembly from suspension frame (1). 2.
Suspension System - Front Suspension Section 180-0020 6. Install link (4) to mounting on tractor frame and secure with bolts (14), hardened washers (26) and locknuts (22). Tighten bolts (14) to a torque of 1136 Nm (820 lbf ft). 7. While rubber mounts are still compressed, install panhard rod (11) to mounting on tractor frame and suspension frame (1) and secure with bolts (16), hardened washers (24) and locknuts (23). Tighten bolts (16) to a torque of 535 Nm (386 lbf ft). 8.
Suspension System - Front Suspension Section 180-0020 SPECIAL TOOLS Refer to Section 300-0070, SERVICE TOOLS, for part numbers of hydraulic jack, power press, press tool and general service tools and sealants required. These tools and sealants are available from your dealer. SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO.
SUSPENSION SYSTEM - Rear Suspension Section 180-0040 SM - 3071 11 12 'A' 5,6 15 12 30 19 12 14 'D' 'C' 2 'A' DETAIL 'C' 24,23 20 26 17 22 25 27 33 29 21 4 DETAIL 'D' 7 16 30 19 8 30 19 29 18 12 13 1 9 10 11 12 'A' 3 9 10 'E' 'A' 'A' 19 14 5,6 30 19 19 8 16 4 'C' 7 'B' 'A' 18 2 16 19 5,6 5,6 31,32 8 'B' 'A' 'B' 'A' 7 29 'A' DETAIL 'B' 7 'A' 'E' 5,6 31,32 16 5,6 1 9 10 19 8 14 12 13 29 12 14 28 DETAIL 'A' TYPICAL 1 2 3 4 5 6 7 8 9 - Bracket
Suspension System - Rear Suspension Section 180-0040 partially raised position 2. Apply the parking brake and switch off the engine. Turn steering wheel several times to relieve any pressure in the steering system. 3. Block front road wheels, place the steering lock bar in the 'Locked' position and the battery master switch in the 'Off' position. 4. Using suitable blocking equipment, block equalizer beams to prevent movement when raising the trailer frame. 5.
Suspension System - Rear Suspension Section 180-0040 1. Install bracket (2) on rear axle with holes on control link (5) mounting lugs to the rear. Apply Loctite 243 to bolts (11) and secure bracket (2) to rear axle with bolts (11) and hardened washers (12). Tighten bolts (11) to a torque of 457 Nm (337 lbf ft). mounting brackets (1 & 3) and frame mounting brackets and secure with bolts (28), hardened washers (12) and locknuts (14). Install bolts (28) with bolt heads to the brackets.
Suspension System - Rear Suspension Section 180-0040 16. Apply Loctite 243 to bolts (26). Install cover plate (25) to equalizer beam (4) and secure with bolts (26) and washers (17). Tighten bolts (26) to a torque of 73 Nm (54 lbf ft). 24. Using suitable lifting equipment, raise trailer frame sufficiently to remove stands and blocking from the axles, articulation pivot and trailer frame. Lower vehicle to the ground and remove lifting equipment.
SUSPENSION SYSTEM - Rear Suspension Section 180-0040 15 12 11 12 5,6 SM - 3295 DETAIL 'C' 30 19 'A' 12 14 'D' 'C' 34 'A' 24,23 22 25 27 21 20 4 DETAIL 'D' 7 30 19 29 18 33 16 19 32 9 10 8 'A' 31 33 8 33 'E' 29 32 'A' 33 1 9 10 16 5,6 19 29 37 33 31 32 'A' 7 33 35 7 'B' 'E' 5,6 39 18 16 19 5,6 5,6 'A' 'A' 'A' 2 33 'B' 30 19 11 12 'A' 3 9 10 'A' 33 32 1 5,6 7 13 29 30 16 19 19 8 51 4 'C' 26 17 8 38 39 DETAIL 'B' 36 'A' 14 50 43 49
Suspension System - Rear Suspension Section 180-0040 REMOVAL Numbers in parentheses refer to Fig. 1. WARNING To prevent personal injury and property damage, be sure wheel chocks, 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, raise the body and install body safety prop to secure body in partially raised position 2. Apply the parking brake and switch off the engine.
Suspension System - Rear Suspension Section 180-0040 26. Remove locknuts (10), hardened washers (9) and bolts (8) securing mounting bracket (3) on the centre axle. Remove mounting bracket (3). 27. Remove locknuts (10), hardened washers (9) and bolts (8 & 18) securing mounting bracket (1) on the centre axle. Remove mounting bracket (1). 28. Remove bolts (11) and hardened washers (12) securing mounting bracket (34) on the centre axle. INSTALLATION Numbers in parentheses refer to Fig. 1.
Suspension System - Rear Suspension Section 180-0040 secure pins (35) in place with washers (38), lockwashers (36) and bolts (37). Note: Ensure that there is at least 2/3 mounting surface area contact. Check contact area using a 0.05 mm (0.002 in) feeler gauge. 13. Using a suitable solvent, clean equalizer beam (4) shaft on the frame. Install new 'V' ring seal (13) and new wear rings (20) on the shaft with flanges to the inside. Ensure mounting holes on the ends of the shaft are clean. 14.
Section 180-0040 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO.
ELECTRICAL SYSTEM - Circuit Diagrams (DDEC IV, 6WG 310) Section 190-0000 COMPONENT DESIGNATIONS A4 - Radio/cassette A5 - Radio/cassette speaker B2 - Coolant temperature sender B7 - Coolant Level sender B13 - Rot'nl speed sensor B15 - Air temperature sender B19 - Throttle position sender B20 - Engine oil temp sender B21 - Trans oil temp sender B22 - Engine oil press sender B24 - Turbo boost sender B25 - Fuel pressure sender B26 - Fuel temperature sender B27 - Synchro reference sender B28 - Timing reference
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) Section 190-0000 DDEC IV COMPONENT AND CABLE DESIGNATIONS STANDARD (DDEC) CABLES 109 - Timing reference sender ground 110 - Timing reference sender supply 111 - Sync reference sender supply 112 - Sync reference sender ground 115 - ECM supply to coolant level sender 120 - Oil temperature sender supply 132 - Air temperature sender supply 133 - Coolant temperature sender supply 150 - ECM to master switch ground 151 - ECM to master switch ground 240 - 24
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) Section 190-0000 FUSES Location Fuse No.
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072A Section 190-0000 4 SM 2126 Rev 2 06-04
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072B Section 190-0000 SM 2126 Rev 2 06-04 5
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072C Section 190-0000 6 SM 2126 Rev 2 06-04
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072D Section 190-0000 SM 2126 Rev 2 06-04 7
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072E Section 190-0000 8 SM 2126 Rev 2 06-04
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072F Section 190-0000 SM 2126 Rev 2 06-04 9
CLICK HERE FOR HORIZONTAL DRAWING Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072G Section 190-0000 10 SM 2126 Rev 2 06-04
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072H Section 190-0000 SM 2126 Rev 2 06-04 11
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072I Section 190-0000 12 SM 2126 Rev 2 06-04
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072J Section 190-0000 SM 2126 Rev 2 06-04 13
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072K Section 190-0000 14 SM 2126 Rev 2 06-04
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072L Section 190-0000 SM 2126 Rev 2 06-04 15
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072M Section 190-0000 16 SM 2126 Rev 2 06-04
Electrical System - Circuit Diagrams (DDEC IV, 6WG 310) 15313937, Rev D SM - 3072N Section 190-0000 * SM 2126 Rev 2 06-04 * * * 17
ELECTRICAL SYSTEM - Switches and Sensors Section 190-0270 SM - 3096 5 4 3 1 HEADER TANK ACCUMULATORS 13 BRAKE MANIFOLD VALVE 11 12 TREADLE VALVE 10 IN 25 20 15 10 7 7 2 FRONT AXLE MANIFOLD BLOCK ON AIR CLEANER THROTTLE PEDAL 6 MAIN HYDRAULIC PUMP 8 14 9 PUMP TRANSMISSION L.H.
Electrical System - Switches and Sensors Section 190-0270 SM - 2685 15 10 RPM x100 1 2 3 4 5 6 20 10 20 30 20 MPH 20 km/h 20 40 25 0 3 4 11 20 5 1 2 20 10 9 0 30 50 STOP STOP 1 2 P 5 6 120 50 TRANS OIL 140 150 TEMP 7 8 - Engine Stop W/L - Engine Check W/L - Tractor Brakes Overstroke W/L - Not Used On This Machine - Not Used On This Machine - Body Up W/L 12 13 18 19 14 15 7 8 9 10 11 12 13 - Trailer Brakes Overstroke W/L Parking Brake Ind/L Tachometer/Hourmeter Fuel G
Electrical System - Switches and Sensors Section 190-0270 (km/h) and miles per hour (mph). A digital odometer is incorporated in the speedometer to record the distance travelled by the vehicle at any given time. Speedometer Calibration 1. Determine the impulse setting required. Reference speedometer calibration table.
Electrical System - Switches and Sensors Section 190-0270 (17, Fig. 2) when pressure drops to 4.8 bar (70 lbf/in2) or lower. Body Body Up Proximity Switch (9) - Mounted on the inside of the trailer left hand frame rail. When the body is raised off the trailer frame, the switch sends a signal to illuminate the 'Amber' body up warning light (6, Fig. 2).
FUEL SYSTEM - Fuel System Section 200-0040 SM - 1895 1 2 3 4 5 6 7 - Fuel Tank - Fuel Supply Line - Primary Filter - Fuel Line - Fuel Pump - Fuel Line - ECM Cooling Plate 8 9 10 11 12 13 14 - Fuel Line - Secondary Filter - Fuel Pressure Sensor - Fuel Temperature Sensor - Shut Off Cock - Fuel Line - Fuel Line 15 16 17 18 19 20 21 - Electronic Unit Injector (EUI) - Fuel Cooler - Mounting Bracket - Mounting Bracket - Bolt - Padlock - Key 22 23 24 25 26 27 28 29 - Fuel Return Line - Restricted Fitting -
Fuel System - Fuel System Section 200-0040 Fuel pump (5) is attached to a drive assembly mounted on the rear side of the gear case at the front LH side of the engine and transfers fuel from fuel tank (1) to the electronic unit injectors (15). When installing fuel lines, it is recommended that connections be tightened only sufficiently to prevent leakage of fuel; thus flared ends of the fuel lines will not become twisted or fractured because of excessive tightening.
Fuel System - Fuel System Section 200-0040 6. Remove fuel strainer (29) from fuel tank (1) and clean with clean diesel fuel. 7. With a suitable container in position, remove drain plug from bowl in the underside of fuel tank (1) and drain fuel from fuel tank (1). Reinstall drain plug and tighten securely when fuel tank (1) is completely drained. 4. Secure the rear of fuel tank (1) assembly to the tractor frame with bolts (25), washers (26), springs (27), washers (26) and locknuts (28), as shown in Fig. 1.
Fuel System - Fuel System Section 200-0040 Every 10 Hours/Daily: Make a visual check for fuel leaks at all engine mounted fuel lines and connections, fuel cooler, and at the fuel tank suction and return lines. Examine lines for leaks and check all fittings, clamps and ties carefully. Make sure that fuel lines are not resting on or touching rotating components, heated surfaces including exhaust manifolds or sharp edges.
Fuel System - Fuel System Section 200-0040 4. If the fuel flow is insufficient for satisfactory engine performance then proceed as follows: SPECIAL TOOLS a. Replace the primary and secondary fuel filters, as described under 'Maintenance'. Start the engine and run it at maximum rev/min and recheck the fuel flow. If fuel flow is still unsatisfactory, perform step 'b'. There are no special tools required for procedures outlined in this section.
FUEL SYSTEM - Electronic Foot Pedal Section 200-0051 SM - 1478 1 2 4 17 5 6 19 7 18 20 3 10 11 8 21,22 9 12 16 15 13 14 1 2 3 4 5 6 - Pedal Assembly - Spring - Pin - 'E' Clip - Spring - Pin 7 8 9 10 11 12 - Bearing - Pedal Stop - Plate - Pivot Block - Bellows - Rod End 13 14 15 16 17 - Spring - Lever Stop - Lever - Sensor - Kickdown Switch 18 19 20 21 22 - Harness - Grommet - Bolt - Nut - Lockwasher Fig.
Fuel System - Electronic Foot Pedal Section 200-0051 REMOVAL INSTALLATION Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. WARNING To prevent personal injury and property damage, be sure wheel blocks are properly secured and of adequate capacity to do the job safely. 1.
COOLING SYSTEM - Cooling System (Series 60 Engine) Section 210-0000 SM - 2664 12 13 2 7 1 14 16 4 8 6 9 15 3 11 5 10 1 2 3 4 - Header Tank - Radiator Assembly - Engine Water Pump - Coolant Filter 5 6 7 8 - Transmission Oil Cooler - Engine Oil Cooler - Thermostat Housing - Make-up Line 9 10 11 12 - Radiator Outlet Pipe - Coolant Pipe - Coolant Pipe - Bypass Line 13 14 15 16 - Radiator Inlet Pipe - Deaeration Lines - Filter Inlet Line - Filter Outlet Line Fig.
Cooling System - Cooling System (Series 60 Engine) Section 210-0000 OPERATION SM - 1221 Numbers in parentheses refer to Fig. 1, unless otherwise specified. Upon starting a cold engine or when the coolant is below operating temperature, the coolant is restricted at thermostat housing (7) and bypass line (12) provides water circulation within the engine during the warm-up period. Note: Engine coolant thermostats start to open at 88° C (190° F) and are fully open at 96° C (205° F).
Cooling System - Cooling System (Series 60 Engine) Section 210-0000 pulled into the turbocharger where it is compressed. It then exits the turbocharger through outlet pipe (4) and enters air-to-air charge cooler (2), mounted on the front of radiator assembly (1), through inlet pipe (3). The hot air travels through a series of tubes in air-to-air charge cooler (2) core, where the air temperature is lowered from approximately 149° C (300° F) to below 38° C (100° F).
Cooling System - Cooling System (Series 60 Engine) Section 210-0000 Every 4 000 Hours Drain, flush and refill the cooling system. Inspect all components that make up the cooling system and make necessary repairs at this time. Note: Mix coolant and water solution at the proper concentration before adding to the cooling system. This should prevent over or under coolant concentration problems.
Cooling System - Cooling System (Series 60 Engine) Section 210-0000 RECOMMENDED COOLANTS Antifreeze Use genuine Detroit Diesel Power Cool or an equivalent ethylene glycol base coolant (low silicate formulation) that meets or exceeds the standard of either the GM 6038-M formulation (GM 1899-M performance) or ASTM D 4985 requirements. A 50% antifreeze/water solution is normally used as a factory fill.
Cooling System - Cooling System (Series 60 Engine) Section 210-0000 ! " !# $ & $ &* the test strips as follows: a. Dip the strip into coolant for one second. Remove and shake briskly to eliminate excess fluid. $ + $ * b. Immediately compare end pad (% glycol) to the colour chart. c. Sixty seconds (one minute) after dipping, compare the nitrite pad.
COOLING SYSTEM - Brake Cooling System Schematic Section 210-0005 DESCRIPTION Numbers in parentheses refer to Figs. 2 through 5. The braking system on the machine uses brake cooling oil to cool the brake packs. This cooling oil is separate from the hydraulic oil used in the main hydraulic systems. A brief description of the individual components used in the brake cooling system are listed below. Detailed service and operating instructions can be found in the relevant component sections of this manual.
Cooling System - Brake Cooling System Schematic Section 210-0005 Mounted on the disc brake oil cooler casing on the right hand fender, the two speed control valve regulates the fan speed of the disc brake oil cooler. The two speed control valve is supplied by the rear section of the triple gear pump (1), via pressure relief valve (4). Disc Brake Oil Cooler (6) Refer to Section 210-0050, DISC BRAKE OIL COOLER. The disc brake oil cooler is mounted on the right hand fender adjacent to the main hydraulic tank.
Cooling System - Brake Cooling System Schematic Section 210-0005 SM - 1335 FITTING NUT TUBE 'O' RING 'O' RING SLEEVE SERVICE TOOLS It is recommended that the following tools are used when carrying out pressure or temperature checks during maintenance procedures. These tools, along with other general service tools, are available from your dealer. Refer to Section 300-0070, SERVICE TOOLS, for part numbers of these tools.
FRONT AXLE BRAKE PACKS CENTRE AXLE BRAKE PACKS TO BRAKE MANIFOLD VALVE 3 ENGINE COOLING FAN 6 PRIORITY UNLOADER VALVE 8 A 7 1 5 4 2 HYDRAULIC TANK 5 6 7 8 - Two Speed Control Valve Disc Brake Oil Cooler Motor/Triple Pump Assembly Low Pressure Relief Valve PRESSURE TEST POINTS A - Brake Cooling System Pressure Fig.
SM 2154 Rev 1 10-03 REAR AXLE BRAKE PACKS FRONT AXLE BRAKE PACKS CENTRE AXLE BRAKE PACKS TO BRAKE MANIFOLD VALVE 3 6 PRIORITY UNLOADER VALVE 8 A 7 1 5 4 2 HYDRAULIC TANK - Two Speed Control Valve Disc Brake Oil Cooler Motor/Triple Pump Assembly Low Pressure Relief Valve PRESSURE TEST POINTS A - Brake Cooling System Pressure 5 Fig.
FRONT AXLE BRAKE PACKS CENTRE AXLE BRAKE PACKS TO BRAKE MANIFOLD VALVE 3 ENGINE COOLING FAN 6 * PRIORITY UNLOADER VALVE 8 * * A * 7 1 5 4 2 HYDRAULIC TANK 5 6 7 8 - Two Speed Control Valve Disc Brake Oil Cooler Motor/Triple Pump Assembly Low Pressure Relief Valve PRESSURE TEST POINTS A - Brake Cooling System Pressure Fig.
COOLING SYSTEM - Cooling Fan and Motor Section 210-0010 SM - 2662 9 10 7 1 11 8 2 5 6 4 3 1 2 3 4 5 6 7 8 - Radiator - Fan - Fan Motor - Fan Hub Adaptor - Motor Carrier Frame - Fan Guard - Bolt - Lockwasher 9 - Split Pin 10 - Slotted Nut 11 - Washer Fig. 1 - Exploded View Of Hydraulic Fan Drive DESCRIPTION AND OPERATION Numbers in parentheses refer to Fig. 1. Note: The rate of fan speed change and maximum fan speed is preset to the cooling needs of the engine.
COOLING SYSTEM - Cooling Fan and Motor Section 210-0010 triple pump is returned to tank, reducing oil flow through fan motor (3) therefore decreasing fan speed. The hydraulic fan drive system has a failsafe feature, ie. if the electrical signal to the low temperature unloader valve fails, the valve will close causing maximum oil flow through fan motor (3), driving fan (2) at maximum speed. REMOVAL Numbers in parentheses refer to Fig. 1.
COOLING SYSTEM - Cooling Fan and Motor Section 210-0010 SM - 2661 1 20 1 2 3 4 5 - End Cap - Rotor - Spring - Pin - Vane 2 19 3 4 18 5 6 17 6 7 8 9 10 7 8 9 10 16 15 14 - Cam Ring - Pressure Plate - Seal - Housing - Bearing 11 12 13 14 15 11 13 - Key - Shaft - Retaining Ring - Retaining Ring - Seal 12 16 17 18 19 20 - Seal - Dowel Pin - Seal - Bearing - Screw Fig. 2 - Sectional View Of Hydraulic Motor 4. Install the two dowel pins (17) and two 10-24 UNC2B screws on the cam ring (6).
COOLING SYSTEM - Cooling Fan and Motor Section 210-0010 (7) and lockwashers (8). Torque tighten bolts (7) to 54 - 61 Nm (40 - 45 lbf ft). 3. Install fan (2) and motor (3) assembly to motor carrier frame (5) and secure using bolts, nuts and washers. 4. Using suitable lifting equipment, position motor carrier assembly on the radiator assembly and secure using bolts, nuts and washers. 2. Replace the cartridge assembly (2-6). 3. Reassemble the motor.
COOLING SYSTEM - Cooling Fan and Motor Section 210-0010 4. DO NOT operate a machine with a damaged fan assembly. Replace a damaged fan as soon as the fault is noted. Every 10 Hours/Daily Check the fan and motor for debris or damage. Clean or replace as required. 5. DO NOT disassemble ANY fan assembly or associated parts that are still within the warranty coverage period. Note: The fan is a non-serviceable component. However, the following instructions must be strictly adhered to: 6.
Cooling System - Radiator and Mounting Section 210-0040 SM - 3334 50 47 50 1 23 24 23 5 29 51 2 3 27 28 25 23 7 8 23 23 6 8 9 24 21 20 14 22 13 4 1 2 3 4 5 6 7 8 9 10 11 12 13 - Top Baffle - LH Baffle - RH Baffle - Bottom Baffle - Support Bracket - Rubber Mounting - Bolt - Snubbing Washer - Locknut - Bolt - Washer - Locknut - Bolt 16 17 18 51 14 15 16 17 18 19 20 21 22 23 24 25 26 31 23 37 38 46 47 48 49 48 47 46 - Washer - Locknut - Bushing - Connector - Elbow - Connector - Shu
Cooling System - Radiator and Mounting Section 210-0040 SM - 3335 2 4 5 18 7 15 14 13 16 17 8 9 10 11 12 1 21 6 3 20 19 2 1 2 3 4 5 6 - Radiator Core Joint LH Tank RH Tank Top Column Bottom Column 7 8 9 10 11 - Fan Plate Assy Fan Motor Carrier Frame Fan Guard Assy Fan Hub Adaptor 12 13 14 15 16 - Fan Drive Motor - Washer - Slotted Nut - Split Pin - Bolt 17 18 19 20 21 - Lockwasher - Charge Cooler Assy - Bolt - Lockwasher - Washer Fig.
Cooling System - Radiator and Mounting Section 210-0040 6. Remove locknuts (46), lockwashers (47), washers (48) and rubber mountings (49) securing brace rods (51) to assembly. SM - 1216 7. Remove locknuts (50) and lockwashers (47) securing brace rods to the radiator assembly. Remove brace rods (51). 8. Ensure fuel lines connected to fuel cooler mounted at front of radiator assembly are identified for ease of installation and with suitable containers available to catch leakage, disconnect fuel lines.
Cooling System - Radiator and Mounting Section 210-0040 20. If required, remove bolts (13), washers (14) and locknuts (15) securing bottom baffle (4) on the vehicle. Note: If Header Tank (36) requires to be removed, follow steps 21 through 26. 21. With suitable container in position, remove lower drain plug from header tank (36) to ensure coolant has been drained from header tank (36). When all coolant has been drained, apply Loctite 225 to drain plug and reinstall in header tank (36). 22.
Cooling System - Radiator and Mounting Section 210-0040 for possible damage. Repair any damage discovered if equipped to do so, or, have repairs made at a reputable radiator repair shop. 3. Clean radiator LH tank (3) and RH tank (4) of all traces of corrosion, scale and old joint material. ASSEMBLY Numbers in parentheses refer to Fig. 2, unless otherwise specified. Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATION. 1.
Cooling System - Radiator and Mounting Section 210-0040 secure with hoses (6, Fig. 3), elbow (7, Fig. 3) and clamps (5, Fig. 3). 14. Fit header tank (36) to goalpost and secure using bolts (39), nuts (37) and washers (38). 5. Install coolant outlet pipe (26) between engine water pump inlet and bottom port on radiator assembly and secure with hoses (24) and clamps (23). 15.
Cooling System - Radiator and Mounting Section 210-0040 26. Remove wheel blocks from road wheels. CLEANING Internal Cleaning - Water Tubes If scale deposits are present inside the water tubes of the radiator, it is necessary to use a suitable scale remover such as 'Powdered Scale Solvent', or equivalent. This material is a free-flowing powder, inhibited to prevent attack on the cooling system materials. WARNING Take care to avoid contact of skin or eyes with the solvent.
Cooling System - Radiator and Mounting SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO.
COOLING SYSTEM - Low Temperature Unloader Valve Section 210-0045 DESCRIPTION SM - 2742 The low temperature unloader valve can be identified as item 3 in Section 210-0005, COOLING SYSTEM SCHEMATIC. Numbers in parentheses refer to Fig. 1.
Cooling System - Low Temperature Unloader Valve Section 210-0045 1. Engine coolant temperature reaches 96°C (205°F). 2. Engine oil temperature reaches 110°C (230°F). 3. Air intake temperature reaches 66°C (151°F). Follow directly from the checking procedure for the Priority Unloader Valve. Refer to Section 250-0075, PRIORITY UNLOADER VALVE. 1. Fit pressure gauge to the diagnostic check point on the brake manifold valve (port P1). 4. Transmission retarder requested.
Cooling System - Low Temperature Unloader Valve Section 210-0045 solenoid fails to energise, hydraulic pressure will be allowed to rise at the inlet port (P). This will default the engine cooling fan to run constant at the higher speed setting, thus safeguarding the engine against high operating temperatures. Solenoid Coil Rating: 22 Watt continuous. 2. The solenoid cartridge valve (1) to which the solenoid is attached. Failure is only likely to occur due to contamination in the system.
Cooling System - Low Temperature Unloader Valve Section 210-0045 2. Check port threads and make sure they are not damaged or stripped. INSTALLATION Numbers in parentheses refer to Fig. 1. 3. Check solenoid valve (1) seat and control spool. Ensure they are not worn, nicked, cracked or scored. Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. 4. Check relief valve (2) for damage.
COOLING SYSTEM - Low Pressure Relief Valve Section 210-0046 DESCRIPTION SM - 2778 1 Numbers in parentheses refer to Fig. 1. The low pressure relief valve can be identified as item 8 in Section 210-0005, COOLING SYSTEM SCHEMATIC. 2 Mounted to the engine side of the brake coolant tank, the low pressure relief valve houses three separate relief valve cartridges (1). The low pressure relief valve is installed between the motor/triple pump and the six brake packs (two per axle).
Cooling System - Low Pressure Relief Valve Section 210-0046 bottom of the brake coolant tank. Install a length of hose on remote drain fitting, open drain cock and drain oil into a suitable container. Close drain cock, remove hose and reinstall blanking cap. 4. Clean low pressure relief valve body and surrounding area with a suitable solvent. Ensure that no contaminant is allowed to enter the internal galleries.
COOLING SYSTEM - Disc Brake Oil Cooler Section 210-0050 SM - 2746 5 6 4 1 2 8 7 4 3 5 15 9 11 10 12 13 12 14 1 2 3 4 5 - Bolt - Front Cover - Oil Cooler - Adaptor - Anti-Vibration Mounting 6 7 8 9 10 - Casing Fan Fan Plate Assembly Rear Guard Assembly Hydraulic Motor 11 12 13 14 15 - Bolt - Washer - Isolation Mount - Locknut - Bolt Fig. 1 - Exploded View Of Disc Brake Oil Cooler DESCRIPTION AND OPERATION REMOVAL Numbers in parentheses refer to Fig. 1.
Cooling System - Disc Brake Oil Cooler Section 210-0050 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. Remove blanking cap from remote drain line at the bottom of the brake coolant tank.
Cooling System - Disc Brake Oil Cooler Section 210-0050 9. Place the battery master switch in the 'On' position, and start the engine. Top up oil levels in hydraulic tank and brake coolant tank as required. Bring hydraulic oil to operating temperature. TORQUE SPECIFICATIONS. WARNING To prevent personal injury and property damage, make sure blocking or lifting equipment is properly secured and of adequate capacity to do the job safely. 10.
COOLING SYSTEM - Transmission Oil Cooler Section 210-0060 SM - 3336 5,6 5,6 13,15 3 14,15 2,6 4 8 6 2 6 16 11 11 1 9,10 9,10 7 6 18 17 12 19 20 1 2 3 4 5 - Oil Cooler Assembly - Hose - Water Inlet Pipe - Water Outlet Pipe - Hose 6 7 8 9 10 - Clamp - Oil Inlet Line - Oil Outlet Line - Bolt - Lockwasher 11 12 13 14 15 - Adaptor - Plate - Elbow - Elbow - 'O'-Ring 16 17 18 19 20 - Temp. switch - Clamp - Spacer - Split Bushing - Bolt Fig.
Cooling System - Transmission Oil Cooler Section 210-0060 SM - 2432 5 3 4 1 4 2 5 6 3 1 - Heat Exchanger 2 - Water Inlet Flange 3 - Water Outlet Flange 4 - 'O' Ring 5 - Bolt 6 - Plug Fig. 2 - Exploded View of Transmission Oil Cooler 1. Position the vehicle in a level work area, apply the parking brake and switch off the engine. Turn steering wheel several times to relieve any pressure in the steering circuit. 2. Block all road wheels and place the battery master switch in the 'Off' position. 3.
Cooling System - Transmission Oil Cooler Section 210-0060 11. Loosen clamps (6) securing hoses (2) to water inlet pipe (3) and water outlet pipe (4). Slide hoses (2) along pipes to break connection at cooler flanges. 12. Support oil cooler assembly (1) with suitable lifting equipment and remove bolts (9) and lockwashers (10) securing oil cooler assembly (1) to its mounting. Remove oil cooler assembly (1) from the vehicle. 13.
Cooling System - Transmission Oil Cooler Section 210-0060 with bolts (5). Tighten bolts (5) alternately to give an even seal around cooler flange area. 3. Install new 'O' ring (4) to water outlet flange (3) and align flange to heat exchanger (1), as match marked at 'Disassembly'. 7. Remove blanking caps from oil cooler assembly (1). If removed, install adaptors (11) in oil cooler assembly (1). 8. Install oil inlet line (7) to adaptor (11) in oil cooler assembly (1). Do not tighten securely at this point.
Cooling System - Transmission Oil Cooler Section 210-0060 * SM 1922 Rev 2 11-04 * * * 5
COOLING SYSTEM - Hydraulic Oil Cooler Section 210-0100 SM - 1882 B A HYDRAULIC CONTROL VALVE 27 26 25 B 26 27 24 31 A 20 8 7 22 33 32 6 10 23 A 8 A A 16 A 34 A 10 19 12 10 15 18 A 15 1 5 13 12 12 6 15 17 12 14 11 12 19 15 2 A B 10 21 A 35 16 29 A A B 30 B A 28 3 18 4 2 9 7 1 2 3 4 5 6 7 8 9 - Bracket - Elbow - Bracket - Hydraulic Oil Cooler - Bracket - Fleximount - Oil Outlet Line - Oil Inlet Line - Bracket 10 11 12 13 14 15 16 17 18 - Washer -
Cooling System - Hydraulic Oil Cooler Section 210-0100 1. Position the vehicle in a level work area, ensure the body is fully lowered, apply the parking brake and switch off the engine. Turn steering wheel several times to relieve any pressure in the steering circuit. 14. If required remove bolts (32), lockwasher (33) and split flanges (34) securing diverter tube (31). Remove diverter tube (31), discard 'O' ring (35) and blank off open end. 2.
Cooling System - Hydraulic Oil Cooler Section 210-0100 3. Connect hydraulic filter line (28) to diverter tube (31). Remove blanking caps from hydraulic lines and connect hydraulic filter line (28) to diverter tube. 13. Connect oil inlet line (8) to elbow (2) in top of hydraulic oil cooler (4) and oil outlet line to elbow (2) in bottom port. 4. Tighten bolts (32), lockwasher (33) at split flange fitting on diverter tube (31) after correct line installation has been obtained. 14.
STEERING SYSTEM - Steering System Schematic Section 220-0000 DESCRIPTION Numbers in parentheses refer to Fig. 1. The operation of the steering system is hydrostatic. That is to say, there is no mechanical connection between the steering column and the steered wheels. Instead there are hydraulic pipes and lines between the steering components and the steering cylinders. Actuating pressure for steering operation is supplied by main hydraulic pump (2).
RIGHT HAND CYLINDER CL 8 8 R L P 7 T 5 R LS EF P PP HP LS HT T BODY HOIST SYSTEM L A CONDITION BASED ON ENGINE SHUTDOWN - Hydraulic Tank - Main Hydraulic Pump - Emergency Steering Pump - Emergency Valve - Flow Amplifier Valve - Check Valve - Steering Valve - Steering Cylinders 6 4 2 3 1 PRESSURE TEST POINT A - Steering System Pressure Fig.
Steering System - Steering System Schematic Section 220-0000 System relief valve is set to control maximum working pressure in the steering system to 206 bar (3 000 lbf/in²). bearings permit a limited amount of cylinder misalignment when travelling over rough terrain. Priority spool directs oil supply from the pump when engine is running, to steering valve port 'P' and through the 'EF' passage to the body control valve.
Steering System - Steering System Schematic Section 220-0000 below the pump suction line to prevent air entering the system. 2. Remove wheel blocks from all road wheels, start the engine and let it idle. Add oil to the hydraulic tank as required. When the hydraulic tank is filled to the maximum level and oil is clear proceed as follows: a. Turn the steering wheel from lock to lock to bleed the air in the steering cylinders and lines.
Steering System - Steering System Schematic Section 220-0000 AMPLIFIER VALVE DIAGNOSIS TABLE627 CONDITION REASON REMEDY Too few steering wheel turns from stop to stop Dirty, leaky or missing check valve Clean or renew check valve Steering over-reacting Amplifier spool stuck in open position Disassemble and check amplifier spool movement Too many steering wheel turns from stop to stop Amplifier spool stuck in closed position Disassemble and check amplifier spool movement Steering too slow Prolo
Steering System - Steering System Schematic Section 220-0000 STEERING VALVE DIAGNOSIS TABLE626 CONDITION REASON REMEDY Steering wheel does not centre Binding in steering linkage to valve Align as required Worn gear wheel Replace parts Broken neutral position springs Replace neutral position springs, drain and flush system Burrs on sleeve or spool Disassemble and repair or replace parts Apparent inability to steer when wheel is turned slowly Dirt in system Drain and flush system.
STEERING SYSTEM - Steering Valve Section 220-0090 SM - 534 1 2 3 4 5 6 - Seal Ring - Valve Housing - Check Valve Ball - Bushing - 'O' Ring - Kin Ring 7 8 9 10 11 12 - Bearing Assembly - Ring - Spool - Cross Pin - Sleeve - Neutral Position Spring 13 14 15 16 17 18 - Driveshaft - Spacer - 'O' Ring - Distributor Plate - Gear Wheel - Gear Rim 19 20 21 22 23 24 - 'O' Ring - End Cover - Washer - Roll Pin - Bolt - Bolt Fig.
Steering System - Steering Valve Section 220-0090 SM - 1849 7 8 18 5 9 19 6 10 11 20 21 3 22 14 4 2 15 1 16 17 13 12 1 2 3 4 5 6 - Steering Valve - Bellows - Steering Column - Bracket - Bolt - Washer 7 8 9 10 11 12 - Bolt - Washer - Rubber Mount - Washer - Locknut - Coupling 13 14 15 16 17 - Flex Coupling - Steering Shaft - Bolt - Washer - Nut 18 19 20 21 22 - Bracket - Bearing Assembly - Bolt - Lockwasher - Nitrile Seal Fig.
Steering System - Steering Valve Section 220-0090 SM - 536 1 2 3 4 5 6 - Seal Ring - Valve Housing - Check Valve Ball - Bushing - 'O' Ring - Kin Ring 7 8 9 10 11 12 - Bearing Assembly - Ring - Spool - Cross Pin - Sleeve - Neutral Position Spring 13 14 15 16 17 18 - Driveshaft - Spacer - 'O' Ring - Distributor Plate - Gear Wheel - Gear Rim 19 20 21 22 23 24 - 'O' Ring - End Cover - Washer - Roll Pin - Bolt - Bolt Fig.
Steering System - Steering Valve Section 220-0090 from sleeve (11) and spool (9). SM - 537 10. Carefully remove spool (9) from sleeve (11) and press neutral position springs (12) from spool (9). 11. Remove and discard seal ring (1), 'O' ring (5) and kin ring (6) from valve housing (2). INSPECTION 1. Clean all parts in a suitable solvent and dry with clean, lint free cloths. 2. Check all parts for wear or damage and replace if necessary. ASSEMBLY Numbers in parentheses refer to Figs. 1 & 3.
Steering System - Steering Valve Section 220-0090 SM - 538 22. Install new 'O' rings (19) in gear rim (18). Install gear wheel (17) and gear rim (18) on driveshaft (13). Note: Install gear wheel (17) on driveshaft (13) so that a tooth base in gear wheel (17) is positioned in relation to the shaft slot, as shown in Fig. 6. Turn gear rim (18) to line up the seven through holes to valve housing (2). 23. Install spacer (14) in gear wheel (17). 24. Install end cover (20) in position on valve housing (2).
Steering System - Steering Valve Section 220-0090 3. Tighten bolt (5), washer (16), nut (17) and coupling (12) onto steering column (3). Slide bellows (2) down over steering column (3) and tuck lower lip under cab floor plate. 4. Connect all hydraulic lines to steering valve (1) as tagged at removal. 5. Fill hydraulic tank with hydraulic oil, as specified in Section 300-0020, LUBRICATION SYSTEM. Refer to 'Filling and Bleeding The Steering System'. 6.
Steering System - Steering Valve Section 220-0090 ! "! " % ! * ! *! $ ! * * * ! $ ! * * + ! ! / $ ; < $ " * ! <= ! *! * ! *! **! != ; $ ; ; < @! ! #$ ! ! / $ ; <> /
STEERING SYSTEM - Flow Amplifier Valve Section 220-0100 SM - 528 L R LS EF HP PP HT CL CR 1 2 3 4 5 - System Relief Valve - Counter Pressure & Anti-cavitation Valve - Orifice - Orifice - Shock & Anti-cavitation Valve 6 7 8 9 10 - Directional Spool - Priority Spool - Amplifier Spool - Check Valve - Orifice - Steering Valve Left Turn Oil - Steering Valve Right Turn Oil - Load Sensing Pressure - Excess Flow - Pump Supply - Pilot Pressure - Return To Tank - Left Turn Cylinder Oil Supply - Right Turn Cylin
Steering System - Flow Amplifier Valve Section 220-0100 SM - 529 B PP A HP EF P LS HT T C D R E CL F L A B C D E F LS EF - Counter Pressure and Anti-cavitation Valve - System Relief Valve - Priority Spool - Shock and Anti-cavitation Valve - Amplifier Spool - Directional Spool - Load Sensing Pressure - Excess Flow HP PP P HT T R CL CR L CR - Pump Supply - Pilot Pressure - Pump Supply To Steering valve - Return To Tank - Steering valve Tank Return - Steering valve Right Turn Oil - Left Turn Cyli
Steering System - Flow Amplifier Valve Section 220-0100 SM - 6666A R L P 7 T 5 R LS EF P PP HP LS HT T L A 5 - Flow Amplifier Valve 7 - Steering Valve 8 - Steering Cylinders SUPPLY FROM MAIN HYDRAULIC PUMP TANK Fig. 3 - Hydraulic Schematic - Neutral Position Orifice (3) meters oil in the left hand end of amplifier spool (8). During right or left hand turns this oil will balance amplifier spool (8).
Steering System - Flow Amplifier Valve Section 220-0100 SM - 6666B LEFT HAND CYLINDER CR RIGHT HAND CYLINDER CL 8 8 R P L 7 T 5 R LS EF P PP HP LS HT T L A 5 - Flow Amplifier Valve 7 - Steering Valve 8 - Steering Cylinders SUPPLY FROM MAIN HYDRAULIC PUMP TANK Fig. 4 - Hydraulic Schematic - Right Turn In this condition, the body control valve has priority over the steering valve.
Steering System - Flow Amplifier Valve Section 220-0100 SM - 6666C LEFT HAND CYLINDER CR RIGHT HAND CYLINDER CL 8 8 R P L 7 T 5 R LS EF P PP HP LS HT T L A 5 - Flow Amplifier Valve 7 - Steering Valve 8 - Steering Cylinders SUPPLY FROM MAIN HYDRAULIC PUMP TANK Fig. 5 - Hydraulic Schematic - Left Turn the right hand end of directional spool (6). This pressure moves directional spool (6) to the left allowing a pilot pressure to act on the right hand end of amplifier spool (8).
Steering System - Flow Amplifier Valve Section 220-0100 5. Clean outer area of the flow amplifier valve with a suitable solvent. Ensure all hydraulic lines connected to the flow amplifier valve are identified for ease of installation and, with suitable containers available to catch leakage, disconnect hydraulic lines. Fit blanking caps to all open lines and fittings. 6. Remove spring stop (27), springs (28 & 29) and spring guide (30) from directional spool (6). 6.
Steering System - Flow Amplifier Valve Section 220-0100 SM - 533 1 2 3 4 5 6 7 8 9 - System Relief Valve - Counter Pressure & Anti-cavitation Valve - Orifice - Orifice - Shock & Anti-cavitation Valve - Directional Spool - Priority Spool - Amplifier Spool - Check Valve 10 11 12 13 14 15 16 17 18 - Orifice - Throttle Check Valve - Orifice - Cover - Cover - Screw - Lockwasher - Screw - Lockwasher 19 20 21 22 23 24 25 26 27 - 'O' Ring - 'O' Ring - Plate - Plate - Spring Stop - Spring - 'O' Ring - Spring -
Steering System - Flow Amplifier Valve Section 220-0100 position in place on cover (14) end of housing (36). 10. Secure cover (14) on housing (36) with lockwashers (16 & 18) and screws (15 & 17). Tighten screws (15) to a torque of 80 ± 10 Nm (710 ± 90 lbf in) and screws (17) to 25 ± 5 Nm (220 ± 45 lbf in). 11. Install spring (24) and spring stop (23) on priority spool (7) at cover (13) end of housing (36). 12.
Steering System - Flow Amplifier Valve Section 220-0100 c. Install plug (31) in housing (36) and tighten to a torque of 60 ± 5 Nm (530 ± 45 lbf in). 5. Repeat steps 2 and 3 to ensure pressure reading remains constant. SPECIAL TOOLS There are no special tools required for the 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.
Steering System - Flow Amplifier Valve Section 220-0100 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. 1&6 1&6 1&6 1&6 1&6 1&6 1&6 1&6 1&6 ITEM NO.
STEERING SYSTEM - Steering Cylinder Section 220-0120 SM - 406 Steering Lock Bar 1 2 3 4 5 6 7 - Cylinder Body - Piston Rod - Piston - End Cap - Spherical Bearing - Circlip - 'O' Ring 8 9 10 11 12 13 - Rod Seal - Wiper - Bearing Ring - Grub Screw - Piston Seal - 'O' Ring 14 15 16 17 18 19 - Backup Ring - Cushion Sleeve - Lube Fitting - Pin - Pin - Spacer 20 21 22 23 24 25 - Seal (if fitted) - Seal (if fitted) - Bolt - Hardened Washer - Locknut - Washer Fig.
Steering System - Steering Cylinder Section 220-0120 1. Position the vehicle in a level work area, apply the parking brake and switch off the engine. Turn steering wheel in both directions several times to relieve any pressure in the steering circuit. 2. Block all road wheels and place battery master switch in the 'Off' position. 3. Support steering cylinder with blocks or suitable lifting device. 4. Position a suitable oil container at line ends of one cylinder.
Steering System - Steering Cylinder Section 220-0120 ASSEMBLY Numbers in parentheses refer to Fig. 1. WARNING To prevent personal injury and property damage, be sure lifting equipment is properly secured and of adequate capacity to do the job safely. 12. Push piston rod (2) to the mid-stroke position and, using special tool which can be fabricated as shown in Fig. 2, tighten end cap (4) to a torque of 542 Nm (400 lbf ft). INSTALLATION Numbers in parentheses refer to Fig. 1. 1.
Steering System - Steering Cylinder Section 220-0120 8. Place the battery master switch in the 'On' position, remove all wheel blocks, start the engine and operate the steering from lock to lock several times to purge air from the steering lines. Check steering lines and fittings for leaks and tighten as required. MAINTENANCE Visually inspect steering cylinders and mounting regularly for leaks and damage. Repair/replace as required. Lubricate cylinder pins every 50 hours through lube fittings (16, Fig.
Steering System - Steering Cylinder Section 220-0120 !" # $%* ! + :; <=:>? @ " * SM 1393 Rev 1 2-00 * * * 5
STEERING SYSTEM - Emergency Valve Section 220-0140 SM - 542 1 2 3 4 5 - Retainer - Cage - Spool - Spring Ring - Spring 6 7 8 9 - Spring 'O' Ring 'O' Ring 'O' Ring 10 11 12 13 - 'O' Ring 'O' Ring Backup Washer Backup Washer 14 15 16 17 - Backup Washer Backup Washer Sealing Washer 'O' Ring Fig. 1 - Sectional View of Emergency Valve DESCRIPTION SM - 543 The Emergency Valve can be identified as item 4 in Section 220-0000, STEERING SYSTEM SCHEMATIC.
Steering System - Emergency Valve Section 220-0140 SM - 544 Emergency Steering FLOW AMPLIFIER INLET Numbers and letters in parentheses refer to Fig. 1. Refer to Fig. 3 for hydraulic schematic of emergency valve during emergency steering. In the event of loss of pressure from the steering pump, springs (5 & 6) return spool (3) to the left. The emergency steering pump draws oil from the hydraulic tank and pumps it to port 'B' of the emergency valve.
BODY SYSTEM - Body System Schematic Section 230-0000 DESCRIPTION Numbers in parentheses refer to Figs. 2 through 5. Oil supply to the body hoist system is by common components to both the body and steering systems. Refer to Section 220-0000, STEERING SYSTEM SCHEMATIC. A relief valve assembly at the pressure inlet, opens and allows oil to flow through hydraulic oil cooler (4) and back to hydraulic tank (1) when pressure in the hydraulic system exceeds 172 bar (2 500 lbf/in²).
Body System - Body System Schematic Section 230-0000 Pressure Test Points There are two pressure check points within the body hoist system. Pressure readings at these points should be as follows: Test Point A - Located in the manifold at the rear left hand side of the tractor frame. The pressure is taken off the outlet tube from port 'EF' in the flow amplifier valve. System Relief Pressure - 172 bar (2 500 lbf/in²) Test Point B - Located in tee piece at port 'U' of pilot supply valve (5).
Body System - Body System Schematic Section 230-0000 BODY SYSTEM DIAGNOSIS CONDITION Body raise time too slow, should be 16 sec, loaded. Hydraulic oil pressure too low, should be 172 bar (2 500 lbf/in²). Body lower time too slow, should be 12 sec in 'Power Down' REASON Worn pump. Pump output should be as specified in Section 000-0000, GENERAL INFORMATION. Pump cavitation REMEDY Repair or replace pump.
Fig.
SM 1407 Rev 2 11-01 B T2 U2 5 30 bar 3 45 bar 3 FROM BRAKING SYSTEM L T P1 R P1 T1 T2 P A 4 1 FROM EF PORT IN FLOW AMPLIFIER VALVE SM - 1848B 5 Section 230-0000 COLOUR CODES Red - Pressurized Oil Blue - Exhaust or Return Oil Green - Intake Oil Orange - Pilot Pressure Yellow - Static Oil U1 2 P2 COMPONENTS 1 - Hydraulic Tank 2 - Body Control Valve 3 - Body Cylinders 4 - Hydraulic Oil Cooler 5 - Pilot Supply Valve T1 Body System - Body System Schematic Fig.
Fig.
SM 1407 Rev 2 11-01 B * T2 U2 5 30 bar 3 45 bar 3 FROM BRAKING SYSTEM L * * COMPONENTS 1 - Hydraulic Tank 2 - Body Control Valve 3 - Body Cylinders 4 - Hydraulic Oil Cooler 5 - Pilot Supply Valve R T1 U1 2 P2 P1 T2 T1 P A 4 1 FROM EF PORT IN FLOW AMPLIFIER VALVE SM - 1848D 7 Section 230-0000 COLOUR CODES Red - Pressurized Oil Blue - Exhaust or Return Oil Green - Intake Oil Orange - Pilot Pressure Yellow - Static Oil T P1 Body System - Body System Schematic * Fig.
BODY SYSTEM - Hydraulic Tank Section 230-0040 SM - 2413 8 4 7 9 5 6 24 1 28 2,3 14 27 29 5 15 10 6 16 17 18 7 12 25 26 23 11 13,32 19 22 21 20 30 16 17 18 31 1 2 3 4 5 6 7 8 9 - Hydraulic Tank - Filler Cap - Gasket - Access Cover - Bolt - Lockwasher - Gasket - Breather - Nipple 10 11 12 13 14 15 16 17 18 - Access Cover - Sight Gauge - Strainer - Filter Assembly - Bolt - Washer - Spring - Washer - Locknut 19 20 21 22 23 24 25 26 27 - Bolt - Washer - Bolt - Lockwasher - Fender B
Body System - Hydraulic Tank Section 230-0040 SM - 1847 SUPPLY TO BRAKE MANIFOLD VALVE SUPPLY TO FLOW AMPLIFIER VALVE SUPPLY TO EMERGENCY VALVE RETURN TO TANK 4 5 3 2 1 1 - Hydraulic Tank 2 - Main Hydraulic Pump 3 - Emergency Pump 4 - Brake Pump 5 - Hydraulic Oil Cooler Fig. 2 - Hydraulic Schematic of Hydraulic Tank OPERATION Numbers in parentheses refer to Fig. 1, unless otherwise specified. Refer to Fig. 2 for hydraulic schematic of hydraulic tank.
Body System - Hydraulic Tank Section 230-0040 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. Checking Oil Level 1. Operate the body hoist and steering systems several times to bring the oil to correct operating 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.
Body System - Hydraulic Tank Section 230-0040 3. Remove blanking cap from remote drain assembly (31) on the bottom of hydraulic tank (1). Install a length of hose on remote drain fitting, open drain cock and drain hydraulic oil into a suitable container. Close drain cock, remove hose and reinstall blanking cap on remote drain assembly (31). 4. Remove bolts (5), lockwashers (6), access cover (4) and gasket (7) from top of hydraulic tank (1). Discard gasket (7). 5.
Body System - Hydraulic Tank Section 230-0040 Disassembly Installation Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. 1. Remove internal components from hydraulic tank (1) as described under 'Maintenance'. Note: Tighten all fasteners without special torques specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. 2. Remove padlock (33) and filler cap (2) from hydraulic tank (1).
BODY SYSTEM - Main Hydraulic Pump Section 230-0050 SM - 3366 4 5 21 1 12 10 9 8 14 6 13 8 9 18 20 19 7 7 11 2 15 3 16 17 8.5 mm 3 19 10 mm APP.
Body System - Main Hydraulic Pump Section 230-0050 As driveshaft and gear (11) rotates, driven gear (12) rotates in the opposite direction. Pockets between the drive and driven gear teeth carry oil from inlet port 'A', around gear housing (2) ID, to outlet port 'B'. As the gear teeth re-mesh, oil is forced out of outlet port 'B' to the body control valve. Refer to Section 230-0060, BODY CONTROL VALVE.
Body System - Main Hydraulic Pump Section 230-0050 INSPECTION SM - 1865 Numbers in parentheses refer to Figs. 1. 7 1. Clean all parts in a suitable solvent and dry with compressed air. 2. Check driveshaft and gear (11) and driven gear (12) carefully for wear. Remove burrs or light score marks from gear faces and teeth with an India stone. Heavy scoring, grooving or burring of gear teeth OD requires gear replacement. Nicked, grooved or fretted gear tooth mating surfaces also requires gear replacement.
Body System - Main Hydraulic Pump Section 230-0050 Note: Ensure bearings (7) are pressed to insertion depth indicated in Fig. 4. SM - 1866 2. Install new lip seals (20) and location sleeve (19) to front cover (2), as shown in Fig. 1. BEARING (ITEM 7) 3. Apply a thin film of grease on new wear plate seal (8) and backup seal (9) and install in wear plate (14), as shown in Fig. 5. BODY HOUSING (ITEM 1) 4. Install wear plate (14) into body housing (1) bore, with wear plate seal (8) facing down. 1.50/1.
Body System - Main Hydraulic Pump Section 230-0050 SM - 1868 3. Remove cap from the inlet line and install a new 'O' ring in the split flange fitting. Secure inlet line to inlet port 'A' on the pump with bolts and lockwashers, as removed during removal. 4. Before connecting the outlet line to outlet port 'B' on the pump, fill the pump with hydraulic oil as specified in Section 300-0020, LUBRICATION SYSTEM. 5. Remove cap from the outlet line and install a new 'O' ring in the split flange fitting.
Body System - Main Hydraulic Pump Section 230-0050 the hydraulic oil should be drained and replaced. Refer to Section 230-0040, HYDRAULIC TANK, for hydraulic oil change procedures. in Section 230-0060, BODY CONTROL VALVE. Note: Always use accurate pressure gauges when adjusting the relief valve. Refer to Section 300-0020, LUBRICATION SYSTEM, for recommended periodic oil change periods and oil specifications. Check pump mounting and hydraulic line connections for leaks.
BODY SYSTEM - Body Control Valve Section 230-0060 SM - 1879 25 20 45 17 13,14 24 23 13,14 46 26 21 12 18 19 10 9 8 6 15 16 A B 20 47 22 41 1 7 6 5 4 3 29 30 31 32 2 3 3 44 3 5 C 33 34 D 35 36 37 28 E 38 F 27 24 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 11 - Control Spool - Retainer - 'O' Ring - Spool Cap - 'O' Ring - Spring Retainer - Spring - Washer - Shoulder Screw - End Cap - Seal Retainer - Capscrew - Pressure Reducing Valve - Capscrew - Shim (if fitted) 16 17 18
Body System - Body Control Valve Section 230-0060 such that the pressure into the end cap moves the spool to the 'Power Down' position. Further selection of the joystick, beyond the ramp position, allows full current to reach the pressure reducing valve such that full pilot pressure is seen in the end cap. Full selection then occurs and the 'Float' position is achieved. The four positions of the control spool are 'Raise', 'Hold', 'Lower' (Power Down) and 'Float'.
Body System - Body Control Valve Section 230-0060 (2 500 lbf/in²). Should oil at the inlet side of the valve exceed 172 bar (2 500 lbf/in²), pilot poppet (33) will be forced off its seat. Oil will flow through an internal passage and exit from port 'A' to the hydraulic oil tank. When pressure is relieved, tension of spring (32) will force pilot poppet (33) to re-seat. REMOVAL Numbers in parentheses refer to Fig. 1.
Body System - Body Control Valve Section 230-0060 7. Remove capscrews (12) securing end cap (10) assembly to valve housing (41). Remove end cap (10). If required, remove bolts (45) and end plate (46) from end cap (10). Remove and discard 'O' ring (47). 8. Carefully withdraw spool and spring pack assembly from valve housing (41). Remove and discard 'O' rings (3 & 5). 3. If either poppet (33) or relief valve (37) are damaged, BOTH parts should be replaced by new parts.
Body System - Body Control Valve Section 230-0060 (20) to end caps (10 & 17) using capscrews (22). 8. Install pressure reducing valves (13) to mounting blocks (20) and secure using capscrews (14). Tighten capscrews (14) to a torque of 2 Nm (1.5 lbf ft). Relief Valve 1. Install new 'O' rings (38 & 39) on relief valve (37) assembly. Install relief valve (37) assembly into relief valve bore in valve housing (41).
Body System - Body Control Valve Section 230-0060 SERVICE TOOLS 5. Check body control valve assembly and hydraulic lines for leaks. Tighten as required. There are no special tools required for the procedures outlined in this section. Refer to Section 300-0070, SERVICE TOOLS, for part numbers of general service tools and adhesives. These tools and adhesives are available from your dealer. 6. Remove all blocking from road wheels and place steering lock bar in the stowed position.
BODY SYSTEM - Body Control Joystick Section 230-0081 DESCRIPTION The body control joystick is mounted on the right hand side dash panel, between the transmission shift controller and the document location. SM - 2718 1 2 OPERATION The body control joystick controls the hydraulic control valve operation, by means of electrical signals to the pressure reducing valves, which in turn operates the body hoist cylinders.
Body System - Body Control Joystick Section 230-0081 the 'Off' position. 7. Reconnect harness (3) to connector port on the bottom of the body control joystick (1). 3. Disconnect harness (3) from connector port on the bottom of body control joystick (1). 4. Support body control joystick (1) and remove screws (2) securing body control joystick (1) to mounting bracket on the underside of the right hand dash panel. 9. Remove wheel blocks and place the steering lock bar in the 'Stowed' position. 5.
BODY SYSTEM - Pilot Supply Valve Section 230-0121 SM - 1870 19 19 19 18 16 15 14 13 17 1 12 11 2 3 5 4 9 10 7 8 6 19 23 23 25 CRADLE ASSEMBLY 26 21 28 20 22 24 27 23 24 TO BRAKING SYSTEM TO BODY CONTROL VALVE TO BODY CONTROL VALVE 1 2 3 4 5 6 - Valve Body Spring Cover 'O' Ring Control Spring Spring Guide Control Spool 7 8 9 10 11 12 - Plug - 'O' Ring - Seat - 'O' Ring - Spacer - Pilot 13 14 15 16 17 18 FROM BRAKING SYSTEM - Spring - 'O' Ring - Plug - Plug - 'O' Ring - Adapto
Body System - Pilot Supply Valve Section 230-0121 REMOVAL DISASSEMBLY Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. WARNING To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely. 1. Position the vehicle in a level work area, apply the parking brake and switch off the engine.
Body System - Pilot Supply Valve Section 230-0121 ASSEMBLY Numbers in parentheses refer to Fig. 1. 1. Install new 'O' ring (3) to spring cover (2). Install control spool (6), spring guide (5) and control spring (4) into its bore in valve body (1). 2. Install pilot (12) and spring (13) into its bore in valve body (1). Install new 'O' ring (14) to spring guide (15) and install in valve body (1). 3. Install new 'O' ring (8) to plug (7).
BODY SYSTEM - Body Cylinder Section 230-0130 SM - 3337 21 22 23 7 29 6 10 18 8 3 2 9 4 5 1 11 17 14 13 15 14 16 19 20 12 28 27 25 22 21 23 28 27 24 26 26 PIN MTG. - LOWER PIN MTG.
Body System - Body Cylinder Section 230-0130 switch off the engine. Turn steering wheel in both directions several times to relieve any pressure in the steering circuit. (1) and piston rod (2) end. Press out spherical bearings (21). 3. Remove lock ring (10) from end cap (3). 2. Block all road wheels and place battery master switch in the 'Off' position. 3. Position a suitable oil container at line ends of the cylinder.
Body System - Body Cylinder Section 230-0130 4. Check spherical bearing (21) for wear and replace if necessary. ASSEMBLY Numbers in parentheses refer to Fig. 1. WARNING To prevent personal injury and property damage, be sure lifting equipment is properly secured and of adequate capacity to do the job safely. 1. Press spherical bearing (21) in base end of cylinder body (1) and piston rod (2) end. Secure spherical bearings (21) with circlips (22).
Body System - Body Cylinder Section 230-0130 upper pin (25) to the body with washer (27) and bolt (28). Tighten bolt (28) to a torque of 66 Nm (49 lbf ft). 4. Remove blanking caps from hydraulic lines and connect the lines to the cylinder ports as tagged during removal. 5. Lubricate pins at lube fittings (23) with lubricant as specified in Section 300-0020, LUBRICATION SYSTEM. 6. Repeat steps 1 through 5 for installation of the opposite cylinder. 7. Check oil level in hydraulic tank and add oil as required.
Body System - Body Cylinder Section 230-0130 SM - 410 25.4 (1.0) SQUARE SILVER STEEL EN3B MILD STEEL OUTER SHELL TO BE SECURED TO INNER BODY WITH 2BA CAPSCREWS Dimensions in mm (in) Fig. 3 - Piston Torque Tool SPECIAL TORQUE SPECIFICATIONS TABLE070 TORQUE FIG. NO. ITEM NO.
BRAKING SYSTEM - Braking System Schematic Section 250-0000 DESCRIPTION Numbers in parentheses refer to Figs. 2 through 5. The hydraulic braking system is of closed centre design wherein constant pressure is stored in accumulators and is regulated as required to retard or stop the machine. A brief description of the individual components used in the braking system are listed below. Detailed service and operating instructions can be found in the relevant component sections of this manual.
Braking System - Braking System Schematic Section 250-0000 Note: Never drive a pump in the wrong direction of rotation, as pump seizure may result. Accumulator pressure is monitored by pressure switches (4) in the brake lines. Brake Manifold Valve (2) Treadle Valve (6) Refer to Section 250-0050, BRAKE MANIFOLD VALVE. Refer to Section 250-0070, TREADLE VALVE. The brake manifold valve is mounted off the cradle assembly at the rear of the cab alongside the directional control valve.
Braking System - Braking System Schematic Section 250-0000 CHECKING SYSTEM PRESSURE WARNINGS 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. Hydraulic fluid pressure will remain within the system after engine shut down. Operate the treadle pedal continuously until the pressure has dissipated before carrying out any work on the braking system or serious injury could result. 1.
Braking System - Braking System Schematic Section 250-0000 2. Check oil level in both tanks and add oil if low. Oil should be halfway up sight gauge on both tanks. WARNING 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. 3. Ensure gear shift selector is in neutral, block all road wheels, secure shipping bar in position and release the park/emergency brake. 4.
Braking System - Braking System Schematic Section 250-0000 BRAKING SYSTEM DIAGNOSIS CONDITION REASON REMEDY Inadequate braking Low System Pressure Check oil level Check oil condition Check for leakage Check system pressure and adjust as required Treadle valve delivery pressure below normal Check front and rear brake circuits Check treadle valve operation Check for leakage (modular assembly) Brake surfaces inefficient Check friction disc wear Check brake packs for leakage Replace seals or component
P PARKING BRAKE 8 b a A B TO PILOT SUPPLY VALVE PORT 'P1' (BODY SYSTEM) A 9 B CENTRE AXLE SERVICE BRAKES REF.
SM 2155 Rev 1 10-03 FRONT AXLE SERVICE BRAKES REAR AXLE SERVICE BRAKES T P PARKING BRAKE 8 b a A B TO PILOT SUPPLY VALVE PORT 'P1' (BODY SYSTEM) A 9 B CENTRE AXLE SERVICE BRAKES REF.
P PARKING BRAKE 8 b a A B TO PILOT SUPPLY VALVE PORT 'P1' (BODY SYSTEM) A 9 B CENTRE AXLE SERVICE BRAKES REF.
SM 2155 Rev 1 10-03 FRONT AXLE SERVICE BRAKES REAR AXLE SERVICE BRAKES T P PARKING BRAKE 8 b a A B TO PILOT SUPPLY VALVE PORT 'P1' (BODY SYSTEM) A 9 B CENTRE AXLE SERVICE BRAKES REF.
BRAKING SYSTEM - Brake Coolant Tank Section 250-0025 SM - 2747 10 9 38 36 37 DETAIL A 24 7 28 25 15 8 29 36 25 26 27 17 16 35 20 2,3 31 33 32 30 18 1 13,14 19 34 6 22 21 23 22 23 21 A 4 7 8 11 12 5 A 1 2 3 4 5 6 7 8 9 10 - Brake Coolant Tank - Latch - Cap Assembly - Gasket - Cover - Sight Gauge - Bolt - Lockwasher - Nipple - Breather 11 12 13 14 15 16 17 18 19 20 - Seal - Drain Valve - Filter Assembly - Element - Cover Plate Assy - Gasket - Walkway Plate - Heatshield - Heatsh
Braking System - Brake Coolant Tank Section 250-0025 TO BRAKE PACKS REAR CENTRE SM - 2748 FRONT 6 FROM BRAKE PACKS REAR CENTRE FRONT FROM HYDRAULIC TANK 5 4 7 1 TO HYDRAULIC TANK 1 - Brake Coolant Tank 2 - Strainer TO HYDRAULIC TANK 3 2 3 - Filter 4 - Motor/Triple Pump 5 - Disc Brake Oil Cooler 6 - Low Pressure Relief Valve 7 - Manifold Block Fig. 2 - Hydraulic Schematic of Brake Coolant Tank strainer (34) before it is pumped through the brake cooling circuit.
Braking System - Brake Coolant Tank Section 250-0025 3. Check oil level and add if low. Sight gauge (6) should show half full. If oil is required remove padlock, open latch (2) and remove filler cap (3) from brake coolant tank (1) and fill brake coolant tank with oil specified in Section 300-0020, LUBRICATION SYSTEM. Install filler cap (3) on brake coolant tank (1) and secure with latch (2) and padlock. Replacing Brake Cooling Oil Brake cooling oil should be changed every 1 000 hours.
Braking System - Brake Coolant Tank Section 250-0025 5. Remove bolts (7), lockwashers (8), access cover (5) and gasket (4) from front of brake coolant tank (1). Discard gasket (4). 6. Unscrew and remove strainer (34) from the inside of brake coolant tank (1). WARNING Splashing liquid. Wear a suitable face shield when using compressed air to dry hydraulic tank and components. 7. Clean out the inside of brake coolant tank (1) and strainer (34) with a suitable solvent and dry with compressed air. 8.
Braking System - Brake Coolant Tank Section 250-0025 4. Remove sight gauge (6) from brake coolant tank (1). 5. Remove bolts (21) and washers (22 & 23) securing heatshields (18 & 19) to brake coolant tank (1). Remove heatshields (18 & 19). (28) and manifold block (30) on tank, using fasteners removed at 'Disassembly'. Installation Numbers in parentheses refer to Fig. 1. 6. Remove screws (29) securing low pressure relief valve (28) to brake coolant tank (1). Remove valve (28).
BRAKING SYSTEM - Triple Pump Section 250-0040 SM - 2763 9 8 12 2 1 11 5 16 6 7 4 10 15 3 14 13 1 2 3 4 5 6 - Mounting Flange - Seal - Front Seals - Rear Seals - Bolt - Washer 7 8 9 10 11 - Bolt - Bolt - Front Cover - Driveshaft & Gear - Driven Gear 12 13 14 15 16 - Front Pump Housing - Connecting Shaft - 'O' Ring - Rear Pumps - Bolt Fig. 1 - Exploded View of Triple Pump DESCRIPTION Numbers in parentheses refer to Fig. 1.
Braking System - Triple Pump Section 250-0040 SM - 338 TO BRAKE COOLING CIRCUIT INLET SM - 2764 TO ENGINE COOLING CIRCUIT DRIVE GEAR TO BRAKE CIRCUIT OUTLET DRIVEN GEAR HYDRAULIC TANK Fig. 2 - Typical Pump Operation opposite direction. The pockets between the gear teeth carry oil from the inlet port around the gear housing ID to the pump outlet port. As the gear teeth re-mesh, this oil is forced out of the outlet port of the gear housing.
Braking System - Triple Pump Section 250-0040 4. Tap front pump housing (12) with a soft hammer if required to separate from rear pumps (15). If front pump housing (12) must be pried off, use care to avoid damaging machined surfaces. 8. Install hydraulic connectors and adaptors to correct ports and orientation. INSTALLATION 5. Separate mounting flange (1) from front cover (9) by removing bolts (7). If it must be pried loose, use care to prevent damage to machined surfaces.
Braking System - Triple Pump Section 250-0040 foreign matter. SPECIAL TOOLS FAILURE MODES 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. It is not recommended giving the triple gear pump a major overhaul, however replacement seal kits are available. Typical failure modes of triple pump are illustrated in table below.
BRAKING SYSTEM - Motor/Triple Pump Assembly Section 250-0045 DESCRIPTION SM - 2761 Numbers in parentheses refer to Fig. 1. The motor/ triple pump (1) can be identified as item 7 in Section 210-0005, COOLING SYSTEM SCHEMATIC. 2 1 3 Mounted off brackets on the left hand frame rail, adjacent to the brake coolant tank, the motor/triple pump assembly consists of three pump elements coupled to a single direction hydraulic motor. The hydraulic motor within the assembly is protected by a relief valve (2).
Braking System - Motor/Triple Pump Assembly Section 250-0045 4. Remove blanking cap from remote drain line at the bottom of the brake coolant tank. Install a length of hose on remote drain fitting, open drain cock and drain brake cooling oil into a suitable container. Close drain cock, remove hose and reinstall blanking cap. surfaces may be damaged. 5. Clean motor/triple pump (1) assembly and surrounding area with a suitable solvent.
Braking System - Motor/Triple Pump Assembly Section 250-0045 connections, as described in Section 250-0000, BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings where used. 7. Remove all blocking from road wheels and place steering lock bar in the 'Stowed' position. 1. Secure motor/triple pump (1) assembly to brackets with mounting hardware as removed at 'Removal'. FAULT DIAGNOSIS 2. Remove blanking caps from hydraulic lines and install lines to motor/triple pump as identified during 'Removal'.
BRAKING SYSTEM - Brake Manifold Valve Section 250-0050 SM - 2749 PY 6 ACC1 P ACC2 5,18 7 P2 PS1 P1 1 8 PS2 T 9 PS3 A 10 P 20 B 16 14 12 19 11 2 17 15 3 13 4 1 2 3 4 5 - Valve Body - Solenoid Cartridge - Solenoid Coil - Locknut - Plug 6 7 8 9 10 - Retainer - 'O' Ring - Spring - Check Ball - Seat 11 12 13 14 15 - 'O' Ring - 'O' Ring - Backup Rings - 'O' Ring - Backup Rings 16 17 18 19 20 - 'O' Ring - Backup Rings - 'O' Ring - Plug - Park Brake Pressure Switch Fig.
Braking System - Brake Manifold Valve Section 250-0050 SM - 2750 TO PORT 'P2' TREADLE VALVE 3 PS3 TO DIRECTIONAL CONTROL VALVE FROM PARKING BRAKE FROM PRIORITY UNLOADER VALVE/TO PILOT SUPPLY VALVE (BODY HOIST SYSTEM) TO PORT 'P1' TREADLE VALVE TO BRAKE ACCUMULATOR TO BRAKE ACCUMULATOR P2 2 A P1 B T TO DIAGNOSTIC PRESSURE CHECK POINT P P PY ACC1 ACC2 PS1 PS2 2 - Brake Manifold Valve 3 - Parking Brake Pressure Switch Fig.
Braking System - Brake Manifold Valve Section 250-0050 SM - 2751 3 PS3 FROM DIRECTIONAL CONTROL VALVE TO PARKING BRAKE FROM PRIORITY UNLOADER VALVE/TO PILOT SUPPLY VALVE (BODY HOIST SYSTEM) TO PORT 'P1' TREADLE VALVE TO BRAKE ACCUMULATOR TO BRAKE ACCUMULATOR TO PORT 'P2' TREADLE VALVE P2 2 A P1 B T TO DIAGNOSTIC PRESSURE CHECK POINT P P PY ACC1 ACC2 PS1 PS2 2 - Brake Manifold Valve 3 - Parking Brake Pressure Switch Fig.
Braking System - Brake Manifold Valve Section 250-0050 rings (13, 15 & 17) on solenoid cartridge (2) as shown in Fig. 1. SM - 1508 6 2. Install solenoid cartridge (2) assembly in valve body (1) and tighten securely. Install solenoid coil (3) on solenoid cartridge (2) and secure with locknut (4). 3. Rotate valve body (1) in vice until retainer (6) face is up. Install new 'O' ring (18) on plug (5) and install plug (5) assembly in valve body (1). 4.
Braking System - Brake Manifold Valve Section 250-0050 10. Place steering lock bar in the 'Stowed' position. replacement of parts only. MAINTENANCE SPECIAL TOOLS Inspect the brake manifold valve regularly for any signs of leakage or damage and repair/replace as required. 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.
BRAKING SYSTEM - Accumulator Section 250-0060 SM - 277 1 1A 1B 1C 1D - Charging Valve - Cap - Core - 'O' Ring - Locknut 1E 1F 2 3 4 - Body - 'O' Ring - Screw - Lockwasher - Protector 5 6 7 8 - Piston - Backup Rings - 'V' Section Ring - Wear Rings 9 10 11 12 - 'O' Ring - End Cap - Pad - Cylinder Fig. 1 - Exploded View of Accumulator DESCRIPTION Numbers in parentheses refer to Fig. 1.
Braking System - Accumulator Section 250-0060 SM - 1273 WARNING Hydraulic fluid pressure will remain within the system after engine shut down. Operate the treadle pedal continuously until the pressure has dissipated before carrying out any work on the braking system or serious injury could result. Testing Charging Valve For Leakage Numbers in parentheses refer to Fig. 1. 1. Remove screws (2), lockwashers (3), protector (4) and pads (11) from accumulator. 2.
Braking System - Accumulator Section 250-0060 7. Close cylinder valve (4) and open bleeder valve (10) to dissipate gauge pressure. Close bleeder valve (10) after pressure is relieved. If the accumulator needs charged, leave line (1) and valve chuck (2) attached to charging valve (1, Fig. 1)). Charge the accumulator as described under 'Charging The Accumulator'. 8. If precharge pressure is correct, rotate 'T' handle anticlockwise until it stops. Tighten locknut (1D, Fig. 1) on charging valve (1, Fig.
Braking System - Accumulator Section 250-0060 REMOVAL SM - 278 Numbers in parentheses refer to Fig. 3, unless otherwise specified. WARNINGS 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. Accumulators are charged with Nitrogen. The service pressure is 55 bar (800 lbf/in²) at 21° C (70o F).
Braking System - Accumulator Section 250-0060 3. Use an inspection lamp to check the bore of accumulator cylinder (12) for scratches or scoring. Minor nicks, scratches or light scoring of the bore can be removed by using crocus cloth. Dress the bore until all apparent imperfections have been removed. Replace complete accumulator assembly if the inside of cylinder (12) is excessively scored or worn. 4. Inspect threads in end cap (10) and threads in cylinder (12) for damage.
Braking System - Accumulator Section 250-0060 [ =\ ; ] ! ]$^ << _$ _ %: ` { ] | "@+ ] + | | | ] + @ | + ] ! @ | ! !+ ! ! ! "@ " " ! |! + !! | + | !" + | ! + @ ! | | !| | " !@
BRAKING SYSTEM - Two Speed Control Valve Section 250-0065 DESCRIPTION Numbers in parentheses refer to Fig. 1. The two speed control valve can be identified as item 5 in Section 210-0005, COOLING SYSTEM SCHEMATIC. SM - 2752 6 1 5 2 3 4 Mounted on the disc brake oil cooler casing on the right hand fender, the two speed control valve regulates the fan speed of the disc brake oil cooler.
Braking System - Two Speed Control Valve Section 250-0065 WARNING To prevent personal injury and property damage, ensure wheel blocks and steering locking bar is installed prior to executing functional checks. 1. Position the vehicle in a level work area, apply the parking brake and switch off the engine. 2. Disconnect electrical harness from temperature switch at front axle manifold block (switch nearest manifold block). Refer to Section 190-0270, SWITCHES AND SENSORS. 3. Start engine and allow to idle. 4.
Braking System - Two Speed Control Valve Section 250-0065 open lines. regulator cartridge (2) valves prior to re-assembly. 7. Remove electrical harness connector from solenoid (1). 2. Install flow regulator cartridge (2) into valve body (3) and torque to 75 Nm (55 lbf ft). 8. Remove bolts (6) and washers (4 & 5) securing two speed control valve to disc brake oil cooler casing. Remove two speed control valve from casing. 3.
Braking System - Two Speed Control Valve Section 250-0065 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.
BRAKING SYSTEM - Treadle Valve Section 250-0070 SM - 2766 1 2 3 28 4 26,27 5 24,25 6 22,23 7 8 21 20 19 18 9 17 16 15 10 14 11 13 12 1 2 3 4 5 6 7 - Pedal Assembly Pivot Pin Actuator Base Adjusting Screw Boot Piston Guide Piston 8 9 10 11 12 13 14 - Valve Body - Pilot - Valve Body - Upper - Capscrew - Valve Body - Lower - Plug - Return Spring - Spool - Regulator Spool - Lower 15 16 17 18 19 20 21 - 'O' Ring - Regulator Spool - Upper - Spring Seat - Regulator Spring - Return Spring - Pis
Braking System - Treadle Valve Section 250-0070 SM - 2767 TO FRONT BRAKES B1 SM - 2768 6 6 PX PX P1 SUPPLY FROM BRAKE MANIFOLD FROM FRONT BRAKES B1 TO REAR BRAKES B2 7 P2 T2 Fig. 2 - Normal Service Brake Application DESCRIPTION Numbers in parentheses refer to Fig. 1. Note: The treadle valve can be identified as item 6 in Section 250-0000, BRAKING SYSTEM SCHEMATIC.
Braking System - Treadle Valve Section 250-0070 SM - 2769 6 PX TO FRONT BRAKES B1 P1 SM - 2770 SUPPLY FROM DIRECTIONAL CONTROL VALVE PX TO TANK VIA DIRECTIONAL CONTROL VALVE SUPPLY FROM BRAKE MANIFOLD P1 SUPPLY FROM BRAKE MANIFOLD 6 FROM FRONT BRAKES B1 T1 T1 TO REAR BRAKES B2 7 P2 SUPPLY FROM BRAKE MANIFOLD T2 Fig. 4 - Park/Emergency Brake Application metering notches become exposed to the inlet pressure ports.
Braking System - Treadle Valve Section 250-0070 leakage is not coming from there. 3. Treadle valve holds pressure when in the neutral position. 6. Clean treadle valve assembly and surrounding area with a suitable solvent. Ensure all hydraulic lines connected to the treadle valve are identified for ease of installation and, with suitable containers available to catch leakage, disconnect hydraulic lines. Fit blanking caps to all open lines and treadle valve ports. 4.
Braking System - Treadle Valve Section 250-0070 11. With valve assembly horizontal, remove capscrews and separate pilot valve body (8) from upper valve body (9). Remove capscrews (10) and separate lower valve body (11) from upper valve body (9). 12. With the pilot valve body (8) upright on the work bench, hold with one hand and push the actuator piston (7) down with the other hand until piston guide (6) pops loose. 13.
Braking System - Treadle Valve Section 250-0070 until 12.7 mm (0.5 in) of screws protrude below insert flanges. Make sure that both screws are adjusted to the same dimension. 5. If removed, install capscrews into pedal (1) and install washers and nuts onto capscrews. Screw nuts on flush with the ends of capscrews and set the assembly aside. Piston Guide 1. Install Polypak seal (24) and backup ring (25) into seal groove of piston guide (6). See Fig. 6.
Braking System - Treadle Valve Section 250-0070 8. Install new 'O' ring on plug (12) and install into the counter bore on the bottom of lower valve body (11). Tighten plug (12) to a torque of 17 - 20 Nm (150 - 180 lbf in). 9. Lightly lubricate 'O' ring (15) and install into the counter bore in the top end of lower valve body (11). 10. Assemble lower valve body (11) to upper valve body (9) assembly, with correct port orientation as shown in Fig. 1, and secure with capscrews (10).
Braking System - Treadle Valve Section 250-0070 FINAL ASSEMBLY Numbers in parentheses refer to Fig. 1. 1. Remove pivot pin (2) from actuator base (3). 2. Install boot (5) over lip of pilot valve body (8) and over head of adjusting bolt (4). Apply a light coating of Loctite Activator 710 between head of adjusting bolt (4) and boot (5). Apply Loctite 410 adhesive to boot (5) and head of adjusting bolt (4). 3.
Braking System - Treadle Valve Section 250-0070 SM - 2771 PX PILOT G3 FRONT BRAKE PRESSURE PX SIMULATED BRAKE VOLUME 170 ± 3.5 bar (2 465 ± 50lbf/in²) M G1 T1 P1 SUPPLY P RETURN B1 RETURN P2 T2 B2 G2 D1 P2 REAR BRAKE PRESSURE SUPPLY P1 Fig. 7 - Typical Test Fixture SM - 1238 SCREWDRIVER OR PRY BAR to the treadle valve assembly as noted at 'Removal'. 4. Connect electrical connections to the stop light pressure switch as noted at 'Removal'. 5.
Braking System - Treadle Valve Section 250-0070 emergency control. SM - 1239 10. Shut off engine and check hydraulic tank oil level. Replenish as necessary. 11. Position floor mat on cab floor and ensure that the pedal assembly is free to operate. Shim Stock 0.64 mm (0.025 in) SERVICE Numbers in parentheses refer to Fig. 1.
Braking System - Treadle Valve Section 250-0070 17. Install boot (5) over lip of valve body and over head of adjusting bolt (4). Apply a light coating of Loctite Activator 710 between head of adjusting bolt (4) and boot (5). Apply Loctite 410 adhesive to boot (5)and head of adjusting bolt (4). 18. Insert pivot pin (2) through the hole in actuator base (3), through the holes in 'U' bolts, and through the pivot pin hole in the other side of actuator base (3).
BRAKING SYSTEM - Priority Unloader Valve Section 250-0075 DESCRIPTION SM - 2755 The priority unloader valve can be identified as item 10 in Section 250-0000, BRAKING SYSTEM SCHEMATIC. Numbers in parentheses refer to Fig. 1. Located on the right hand side of the hydraulic cradle, the priority unloader valve comprises of an aluminium body (3) with an integral check valve (2) and unloader relief valve (1).
Braking System - Priority Unloader Valve Section 250-0075 2. Start truck and allow pressures to increase with engine at low idle, until all warning lights are extinguished. 3. Take note of the gauge reading; this is the pressure setting of the priority unloader valve. Valve should be set at 170 bar (2465 lbf/in²). 4. If pressure setting is too low after following steps 1 through 3: (a) Ensure engine is operating at low idle. (b) Loosen lock nut on unloader relief valve (1).
Braking System - Priority Unloader Valve Section 250-0075 ports and orientation. connections for leaks and tighten as required. INSTALLATION 6. Remove all blocking from road wheels and place steering lock bar in the stowed position. Numbers in parentheses refer to Fig. 1. FAULT DIAGNOSIS Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. Refer to following fault diagnosis chart.
BRAKING SYSTEM - Directional Control Valve Section 250-0090 SM - 2309 P A B b a T 7 4 9 8 1 5 7 10 b a 6 6 3 11 12 11 2 3 13 1 2 3 4 - Valve Body Unit - End Cover - Spool - Spring End Cap 5 6 7 8 - Spring End Cap - Slide Washer - Spring - Spacer 9 10 11 12 13 - Allen Bolt - Allen Bolt - 'O' Ring - 'O' Ring - Sub Plate Fig. 1 - Directional Control Valve DESCRIPTION Numbers and letters in parentheses refer to Fig. 1.
Braking System - Directional Control Valve Section 250-0090 SM - 2310 SM - 2311 FROM BRAKE MANIFOLD VALVE T P FROM BRAKE MANIFOLD VALVE T 8 b P b a B a A TO 'Px' PORT TREADLE VALVE Fig. 2 - Directional Control Valve - De-energised movement under the influence of compressed spring (7) links port 'B' to port 'T' permitting a controlled bleed down of the applied service brakes to tank at port 'T'.
Braking System - Directional Control Valve Section 250-0090 5. Release and remove mounting hardware and remove directional control valve from the vehicle. Move directional control valve to a clean area for disassembly. DISASSEMBLY/ASSEMBLY Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.
Braking System - Directional Control Valve Section 250-0090 8. Repeat all braking and engine shut down cycles several times and check for appropriate application/ release cycle several times. Check for appropriate warning light indications. 2. Remove blanking caps from hydraulic lines and fittings and connect to directional control valve as recorded at removal. 3. Secure cover plate to the cradle assembly with mounting hardware removed at removal. 9.
BRAKING SYSTEM - Pressure Relief Valve Section 250-0120 DESCRIPTION Numbers in parentheses refer to Fig. 1. The pressure relief valve can be identified as item 4 in Section 2100005, COOLING SYSTEM SCHEMATIC. SM - 2759 1 Mounted on the disc brake oil cooler casing on the right hand fender, the pressure relief valve houses a direct acting relief valve cartridge (2). The pressure relief valve is installed between the triple gear pump and the two speed control valve.
Braking System - Pressure Relief Valve Section 250-0120 damaged or stripped. during removal. 3. Check relief valve cartridge (2) for damage. Ensure valve seat is not worn, scored or cracked. 3. Fill hydraulic oil tank with hydraulic oil as specified in Section 300-0020, LUBRICATION SYSTEM. Refer to Section 230-0040, HYDRAULIC TANK, for hydraulic oil levels. Install filler cap on hydraulic tank filler neck. It is not recommended that the cartridge assembly is disassembled for maintenance purposes.
CAB - Cab and Mounting Section 260-0010 SM - 1841 1 11 12 13 16 4 7 8 6 2 3 3 2 15 9 14 4 5 FRONT MOUNTING 1 2 3 4 - Cab Assembly - Isolation Mount - Washer - Locknut 10 REAR MOUNTING 5 6 7 8 - Bolt - Bolt - Hardened Washer - Rear Window Guard 9 10 11 12 - Spill Guard - Support - Bolt - Lockwasher 13 14 15 16 - Locknut - Bolt - Lockwasher - Firewall Barrier Mat Fig. 1 - Cab and Mounting DESCRIPTION Numbers in parentheses refer to Fig. 1.
Cab - Cab and Mounting Section 260-0010 REMOVAL Numbers in parentheses refer to Fig. 1. WARNING To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely. Note: Tag all lines, cables and linkages disconnected during removal to aid in installation. 1. Position the vehicle in a level work area, apply the parking brake and switch off the engine.
Cab - Cab and Mounting Section 260-0010 exhaust stack, carefully lift spill guard (9) from unit. 18. Disconnect ball joint and clips securing hood release cable to goalpost and lock mechanism. 19. Remove mounting hardware securing air cleaner assembly to right hand fender. Slacken mounting clamp at air cleaner intake pipe and draw air cleaner, complete with rubber hose, away from intake pipe and cowl. Cover open ends to prevent entry of dirt. 20.
Cab - Cab and Mounting Section 260-0010 17. Fill the cooling system with coolant specified in Section 300-0020, LUBRICATION SYSTEM. 18. Connect electrical connections and cables in reverse order to removal, with battery earth cable last. 19. 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 connections for leaks. Ensure electrical systems and gear shift are functioning properly. 4.
Cab - Cab and Mounting Section 260-0010 SERVICE TOOLS Refer to Section 300-0070, SERVICE TOOLS, for part numbers of the glass removal tool, adhesive bonding kit and other general service tools required. These tools are available from your dealer. SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO.
OPERATORS COMPARTMENT - Driver Seat and Mounting Section 260-0090 SM - 2486 1 2 3 4 5 6 7 8 9 10 11 - Seat Frame - Backrest Cushion - Seat Cushion - Screw - Screw - Backrest - Cover - Cover - Lap Belt - Nut - Spacer 12 13 14 15 16 17 18 19 20 - Bushing - Plug - Slide Adjuster Rail - Shock Absorber - Horizontal - Locking Lever - Bowden Cable - Adjuster Control Unit - Handle - Horizontal Isolator Unit 21 22 23 24 25 26 27 28 29 - Compressor Connecting Cable Air Hose Lever Bowden Cable Shock Absorber -
Operator's Compartment - Driver Seat and Mounting Section 260-0090 A retractable lap belt (9) is secured to the seat assembly using nuts and spacers. A push button allows quick release of lap belt (9). 8. Set fore/aft isolator (C) position to suit driving conditions, (forward position - unlocked, rearmost position - locked). The following is the list of controls to adjust the seat: A. Height and weight adjustment. B. Horizontal adjustment (sliderails). C.
Operator's Compartment - Driver Seat and Mounting Section 260-0090 4. Remove screws (5) securing backrest cushion (2) to seat frame (1). Remove backrest cushion (2). 5. Remove screws (4) securing seat cushion (3) to seat frame (1). Remove seat cushion (3). 6. Pull up horizontal adjustment (B) lever and slide seat assembly rearwards. Hold captive nuts using a suitable spanner and remove front allen screws (33). 7. Pull up horizontal adjustment (B) lever and slide seat assembly forwards.
Operator's Compartment - Driver Seat and Mounting Section 260-0090 4. Identify and tag and disconnect electrical plug connections (7 & 8). Unfasten cable tie on the rocker. 3. Pull suspension assembly up to its highest position and block securely. 5. Pull suspension assembly up to its highest position and block securely. 4. Unhook bowden wires (5 & 6) from level controller (7). 6. Unscrew lower nut (9) and remove micro encapsulated cylinder screw (10) and retaining clamp (11). 7.
Operator's Compartment - Driver Seat and Mounting Section 260-0090 INSPECTION INSTALLATION Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. 1. Inspect air lines, shock absorbers (15 & 26), compressor (21), level controller (28) and air spring (30) for leaks and damage and replace if required. Note: Tighten all fasteners without special torques specified to torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. 2.
Operator's Compartment - Driver Seat and Mounting Section 260-0090 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO.
OPERATORS COMPARTMENT - Air Conditioning Section 260-0130 SM - 2430 2 1 D 3 IN S OUT 4 5 3 - Receiver Drier 4 - Expansion Valve 1 - Compressor 2 - Condenser 5 - Evaporator Fig. 1 - Typical Air Conditioning Flow Diagram DESCRIPTION Temperature Control Switch A thermostat switch senses the temperature of the evaporator and engages or disengages the compressor clutch. The control for this switch is located in the cab.
Operators Compartment - Air Conditioning Section 260-0130 slow down this radiation of heat. Cooling fins are located on the condenser tubes and fans are used to circulate cool air around the condenser tubes. Keep all leaves, paper, dirt, etc. clear from the condenser and condenser filter. The cooling fins should be straight to permit free flow of air. The condenser is sometimes located ahead of the engine radiator and blockage of air flow through the radiator also affects the condenser.
Operators Compartment - Air Conditioning Section 260-0130 REMOVAL Numbers in parentheses refer to Fig. 2, unless otherwise stated. WARNINGS Always wear goggles or glasses to protect your eyes when working around R-134a. R-134a boils at sea level temperatures of -29.8° C (-21.6° F), which means that direct contact with your skin will produce frostbite. Exercise extreme care when handling R-134a. If R-134a contacts your skin, wash immediately with plenty of warm water.
Operators Compartment - Air Conditioning Section 260-0130 SM - 1862B AIR CONDITIONER OUTER BOX 5 3 2 17 16 14 13 1 11 14 15 13 8 7 6 9 28 33 19 26 25 27 33 37 10 36 31 36 35 33 22 26 33 24 12 27 26 23 29 34 21 30 18 31 31 33 1 2 3 5 6 7 8 9 10 - Air Conditioner - Screw - Lockwasher - Refrigerant Hose - Refrigerant Hose - Refrigerant Hose - Refrigerant Hose - Refrigerant Hose - Refrigerant Hose 11 12 13 14 15 16 17 18 19 - Condenser - Compressor - Bolt - Lockwasher - Washer
Operators Compartment - Air Conditioning Section 260-0130 SM - 1862A 42 41 40 MOUNTING A-A 44 DETAIL INSIDE CAB 39 43 A 38 48 47 47 A 4 EXPLODED VIEW ON FRONT OF AIR CONDITIONER BOX 46 45 4 38 39 40 41 42 - Harness Harness Harness Bolt Lockwasher Washer 43 44 45 46 47 48 - Cover - Blower Unit - Bolt - Lockwasher - Control Cable - Water Valve Fig.
Operators Compartment - Air Conditioning Section 260-0130 16. Slacken nuts (26) and lockwasher (27) on adjuster rod (24) to release tension on 'V' belt (18). 17. Slacken locknut (33) on bolt (34). 'V' belt (18) should now be free to slide off of groove in compressor (12). 18. Slacken nut (26) on bolt (28). Remove locknut (33) and spacer and slide adjuster block (25) clear of compressor (12). Remove bolt (28), lockwasher (27), nut (26) and adjuster rod assembly (24) from mounting bracket (19). 19.
Operators Compartment - Air Conditioning Section 260-0130 12. Fit compressor (12) to mounting bracket (19) and secure with bolt (34), washer (23) and locknut (33). Do not fully tighten at this stage. Note: If fan guard, Poly 'V' fan belt and compressor 'V' belt (18) were removed, proceed with steps 11 & 12. 13. Install new 'V' belt (18) onto rear groove on engine fan pulley and fit to rear groove on compressor (12). 14. Refit Poly 'V' fan belt and adjust tension.
Operators Compartment - Air Conditioning Section 260-0130 4. Ensure all hoses and hose clamps are free from contact with sharp metal, moving parts or near to manifolds. 5. Inspect condensation drain lines for debris, sharp bends or breaks. 6. Inspect the clutch wire from the thermostat for bare spots. 7. Inspect bolts and nuts on the compressor and mounting bracket for proper tightness. 8. Inspect and clean outside and inside cab air filters periodically, depending on dust conditions.
Operators Compartment - Air Conditioning Section 260-0130 Only new oil should be used, because oil that has been exposed to the air will have absorbed water (hygroscopic). Recommended Equipment Required: Portable High Vacuum Charging Station Suitable Canister or Standard Service Manifold (Refer to Fig. 4) Use only refrigerant oil as specified in Section 300-0020, LUBRICATION SYSTEM.
Operators Compartment - Air Conditioning Section 260-0130 gauge (A). The vacuum gauge (A) should remain at this value when vacuum pressure valve (1) is closed to indicate that there are no leaks. CHARGING THE SYSTEM 8. Open the low side hand valve on the manifold and vacuum pressure valve (1) and watch that the gauges start to register that a vacuum is being drawn. If the gauges do not register the vacuum then a blockage is present. Open the high side and pump down until a vacuum of 10 mb is achieved.
Operators Compartment - Air Conditioning Section 260-0130 air in the yellow supply hose, replacing the air with R134a. This is done in a few seconds. Tighten yellow supply hose. Note: Occasionally bubbles are noticed during clutch cycling or system start-up. This is a normal condition. 12. Open low side of R-134a gauges slowly. When gauge reads zero open both sides completely. Vacuum in the system will draw R-134a gas into the system. Hold until both gauge readings equalize. 5.
Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS CONDITION TABLE158 PROBLEM REMEDY Loose Adjust belt to 12 mm (0.
Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS (CONT.
Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS (CONT.) CONDITION PROBLEM REMEDY Overcharge of refrigerant Purge system as necessary Air in system Evacuate and re-charge Condenser clogged Clean condenser Undercharge of refrigerant Complete charge Bad compressor valve plate or gasket Repair or replace Restriction in drier Replace drier Restriction in lines Clean lines Restriction in expansion valve Replace expansion valve and drier 6.
BODY - Body and Mounting Section 270-0010 SM - 1845 1 14 15 13 1 12 11 9 1 8 10 8 9 16 22 3 17 21 20 6 5 18 19 4 7 1 2 3 4 5 6 - Body - Bushing - Body Hinge Pin - Shim - Bolt - Washer 7 8 9 10 11 12 - Grease Fitting Bolt Washer Body Pad Shim Shim 13 14 15 16 17 - Locknut Spacer Plate Plate Bracket 2 18 19 20 21 22 - Plate Proximity Switch Bolt Washer Locknut Fig.
Body - Body and Mounting Section 270-0010 started downward from the fully raised position by gravity. When the body starts lowering by gravity, the joystick can be released and internal valve springs will move the joystick to the 'HOLD' position. 'HOLD' - Moving the joystick to this position while the body is being raised or lowered traps the oil in the body hoists to stop and hold the body at any desired height. The joystick will remain in the 'HOLD' position when released.
Body - Body and Mounting Section 270-0010 the trailer frame. Install body hinge pins (3) and shims (4) and secure with bolts (5) and washers (6). of the load, resulting in uneven load distribution along the chassis. 4. Secure body cylinders to body (1) assembly with pins and mounting hardware removed during removal. Refer to Section 230-0130, BODY CYLINDER. 1. Raise body (1) clear of the trailer frame and lay body pads (10) (metal face down) roughly in position on the frame. 5.
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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 and Maintenance Manual before starting, operating or servicing this vehicle. Always follow procedures and safety precautions detailed throughout this manual. Always attach a DO NOT OPERATE or similar warning sign to the ignition switch or a prominent control before cleaning, lubricating or servicing the vehicle.
Miscellaneous - Lubrication System Section 300-0020 SM - 3461 19 26 8 25 34 35 17 9 15 20 40 18 37 36 7 5 4 22 3 22 22 19 21 10 21 11 29 31 30 14 11 21 1 23 24 6 21 20 14 21 33 2 16 32 27 10 38 19 11 28 21 22 21 39 14 19 22 12 21 20 22 12 19 14 39 13 14 20 13 19 Lubrication and Servicing Points LUBRICATION AND SERVICE CHART Interval Ref.
Miscellaneous - Lubrication System Section 300-0020 LUBRICATION AND SERVICE CHART (Continued) Interval Ref. Hours Points 20 23 24 250 28 30 31 36 37 500 750 1 000 2000 2 250 4 000 6 000 25 26 5 2 8 15 19 20 27 29 32 33 38 38 1 7 21/22 27 36 37 18 40 3 34 35 Identification Differentials Primary Fuel Filter Secondary Fuel Filter Oscillation Pivot Parking Brake Slack Adjuster Parking Brake Pads Service Brake Pads (TA35) Fuel Cooler Charge Air Cooler No.
Miscellaneous - Lubrication System Section 300-0020 Notes on 'Lubrication and Service Chart' Note - Capacities given are approximate - work to dipstick, sight gauges or level plugs. Note 1 - Lubricate slowly until excess lube is seen. Note 2 - Remove plugs and fit lube fittings. Lubricate slowly until excess lube is seen. Remove fittings and refit plugs. Note 3 - Check with the engine idling and the transmission at its normal operating temperature.
Miscellaneous - Lubrication System Section 300-0020 Brake Coolant Tank (TA40 only) - Check oil level and add if low. Radiator - Check coolant level and add if low. Fill the radiator header tank with coolant until coolant reaches the bottom of the filler neck and holds at that level. Note: Any time a significant amount of coolant is added, the coolant inhibitor MUST be checked. If the concentration is low, engine damage will result.
Miscellaneous - Lubrication System Section 300-0020 Note: Low Maintenance drivelines can be identified by having plugs fitted to the spiders, not grease nipples. Note: When service is required, remove plug and fit grease nipple. Grease spider and refit plug when finished. Use Type K lubricating grease in accordance to DIN 51825-KP2-K-40. Axles (Dana) - Drain lubricant and refill to level plugs. Note: When refilling centre axle ensure that 3rd differential unit is primed with 1 litre (1.
Miscellaneous - Lubrication System Section 300-0020 * - Capacities given are approximate, work to dipstick, sight gauges or level plugs. Note 2 - Hydraulic Transmission Oil meeting Specification EMS19058 is also suitable for use in the hydraulic system. ** - Refer to the 'Lubrication and Service Chart' for the different applications. DO NOT use on the Articulation bearings. Note 3 - Axles have limited slip differentials.
MISCELLANEOUS - Service Tools Section 300-0070 INTRODUCTION Series 60 Engine Contained in this section are recommended service tools and equipment required for maintenance, overhaul and troubleshooting. In certain instances, both Metric and Imperial equivalents of the same tools are listed. DDEC IV Electronic Diagnostic 15275098 - Detroit Diesel Multi Kit, consisting of PROLINK Diagnostic Data Reader and cables, Detroit Diesel 6 pin Adaptor Cable and Multi-Cartridge.
Miscellaneous - Service Tools Section 300-0070 15270295 - Valve Button Retainer Expander 15270248 - Valve Guide Installer 15270250 - Valve Guide Remover 15270251 - Valve Seat Insert Installer (Exhaust) 15270247 - Valve Seat Insert Installer (Intake) 15270240 - Valve Seat Remover (Exhaust) 15270241 - Valve Seat Insert Remover (Intake) 15270252 - Valve Spring Compressor (head installed) 15270257 - Valve Stem Seal Installer 15270296 - Head Bolt Resurface 15270304 - Injector Timing Tool 15270302 - Rocker Arms a
Miscellaneous - Service Tools Section 300-0070 15269101 - Thrust Nut Tool 15269089 - Oil Seal Bumper Tool 15269090 - Hub Spanner 15272390 - Hub Seal Tool 15500012 - Large Face Seal Insertion Tool 15500013 - Small Face Seal Insertion Tool 15500014 - Plate Centralising Tool 15500015 - Ring Gear Alignment Tool 15500016 - Hub Guide Sleeve 15500439 - Setting Gauge 15271107 - Puller 15269895 - Insert 15269898 - Handle 15275464 - Driver 15269899 - 220V Hot Air Blower 15269900 - 110V Hot Air Blower 15269929 - Lif
Miscellaneous - Service Tools Section 300-0070 15269096 - Power Press 15269097 - Press Tool Steering Valve 15270173 - 'O' Ring and Kin Ring Assembly Tool 15270174 - Driveshaft Mounting Fork Nitrogen Charging 09359489 - Charging Assembly Cooling and Air Conditioning 15270181 15269816 15269817 15269844 - Coolant Test Strips Refractometer - °C Scale Refractometer - °F Scale Portable High Vacuum Charging Station - R-134a Gas 15269845 - Halogen Leak Tester Cab 15271016 - Glass Removal Tool 15271017 - Bondin
Miscellaneous - Service Tools Section 300-0070 SM - 408 SQUARE SILVER STEEL EN3B OUTER SHELL TO BE SECURED TO INNER BODY WITH 2BA CAPSCREWS DOM TUBE Dimensions in mm (inches) Fig. 2 - Piston Torque Tool (Section 220-0120, STEERING CYLINDER) SM - 409 DRILL 13 (0.51) x 25 (0.984) DEEP 19 (0.75) SQUARE SECURE ALUMINIUM COLLAR WITH 3 M8 CAP SCREWS FIT (2) B & T BUSH 12 (0.472) ID - 18 (0.708) OD AND (2) DOWELS 12 (0.472) ID. DRIVE FIT DOWEL IN BUSH. Dimensions in mm (in) Fig.
Miscellaneous - Service Tools Section 300-0070 SM - 410 25.4 (1.0) SQUARE SILVER STEEL EN3B MILD STEEL OUTER SHELL TO BE SECURED TO INNER BODY WITH 2BA CAPSCREWS Dimensions in mm (in) Fig.
MISCELLANEOUS - Standard Bolt and Nut Torque Specifications Section 300-0080 and to establish a uniform value to which these fasteners can be safely tightened, the following torque tables have been compiled. WARNING Some fasteners are important attaching parts which could affect the performance of vital components and systems, and/or, could result in major repair expense. Fasteners should be replaced with parts of the same part number, or with equivalent parts, if replacement becomes necessary.
Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 ! " # $&( )* +/ 4 6 6 4 6 6 4 6 6 4 6 6 4 6 6 : : : : :! :! : : : : : : : : : : :
Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 $ &// : : :! : : : : : : : : : :! !: : !: :! !: : : : : :! : : : : : : :! : : : : : : : : : : : : : : : : : : : : : : : : : : : :
Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 SELF-LOCKING FASTENERS been used. Do not use a self-locking fastener more than five times. Self-locking fasteners develop a measured gripping action or torque and provide a renewed locking action after being removed and reinstalled to their original mating part. The self-locking fasteners used on this equipment meet specifications necessary to allow the fasteners to be reused up to five times.
MISCELLANEOUS - Unit Storage Section 300-0090 GENERAL The storage of machines for short periods of time or during the off-season is an important item if major damage to components is to be avoided. Failure to take the necessary steps to protect the various assemblies while the machine is being stored can result in an expensive overhaul job and delay in returning the machine to work.
Miscellaneous - Unit Storage Section 300-0090 2. BATTERIES - Install batteries and check for a full charge. Charge batteries as required. EXTENDED STORAGE - Over Six Months When a machine is to be stored for a period over SIX MONTHS, the following procedure must be followed: 3. TYRES - Inflate tyres to the proper pressures. Refer to Section 140-0040, WHEEL RIM AND TYRE, of this manual. Note: These steps are in addition to those given previously under 'Extended Storage - Under Six Months'. 4.
