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TEREX Equipment Limited Maintenance Manual
TEREX Equipment Limited Maintenance Manual
15503430
SM889/892/
894/897/908/ CLICK HERE FOR TABLE OF CONTENTS
920
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TEREX Equipment Limited Maintenance Manual Re-Order
TA25 - TA27 - TA30
Issued by;
Customer Support Department
Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
Scotland
www.terex.com
MAINTENANCE MANUAL
Technical Assistance:
http://constructionsupport.terex.com
SM889/892/894/897/908/920
For further information on the subject matter detailed within this Maintenance Manual,
please refer to Terex Equipment Limited Operator Handbooks and Product Parts
Books.
The illustrations, technical information, data and descriptive text in this manual, to the
best of our knowledge, were correct at the time of print. The right to change
specifications, equipment and maintenance instructions at any time without notice, is
reserved as part of the Terex Equipment Limited policy of continuous development
and improvement of the product.
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.
It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the possible
hazardous consequences of each way. Consequently, no such broad evaluation has been undertaken.
Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must first satisfy
themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the service
method he/she selects.
Hazard Classification
A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following
signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard. Signal
words used without the safety alert symbol relate to property damage and protection only. All are used as
attention getting devices throughout this manual as well as on deals and labels fixed to the machinery to assist in
potential hazard recognition and prevention.
CAUTION used without the safety alert symbol indicates a potentially hazardous
CAUTION
situation which, if not avoided, may result in property damage.
WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardise
the integrity of the machine and could result in property damage or serious personal injury.
SM 2495 03-07
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TABLE OF CONTENTS
* * * *
2 685
Max. (8-10)
Body 1 240
Depth (4-1) 2 895
(9-6)
45˚
6 015
65˚ (19-9)
SAE Turning Radius 8 470mm (27-9)
Clearing Radius 8 950mm (29-4)
5 000
(16-5)
4 930
(16-2)
3 450
(11-3) GENERATION
3 420
(11-2)
3 120 2 740
(10-3) (8-11)
2 175
(7-0)
405 725
(1-6) (2-3)
1 580
(5-3)
2 200 2 400 1 310 2 945 1 690 1 410
(7-2) (7-9) (4-4) (9-8) (5-6) (4-9)
2 895 9 755
(9-6) (32-0)
ENGINE
overspeed. Blocked filter indicator and filter bypass system
Make/Model .............................................. Cummins QSM11 provide valve block with additional protection from unfiltered
Type ............. Four cycle diesel, turbocharged with air-to-air oil.
charge cooling, water-cooled. Electronic management.
Pressures:
Gross power at 1 800 rev/min ................... 224 kW (300 hp) Main ........................................ 16 + 2 bar (232 + 30 lbf/in²)
Net power at 2 100 rev/min ....................... 221 kW (296 hp) Lockup (Wk) ........................... 14 ± 1 bar (190 ± 15 lbf/in²)
Converter 'IN' .......... 10.5 bar (152 lbf/in²) at 2 300 rev/min
Note: Gross power rated to SAE J1995 Jun 90. Engine
Converter 'OUT' .......... 4.8 bar (70 lbf/in²) at 2 300 rev/min
emission meets USA EPA/CARB Tier III and EU NRMM
Converter Relief Valve ........................ 8.5 bar (123 lbf/in²)
(non-road mobile machinery) Tier III directive.
Retarder ................................................. 5.5 bar (80 lbf/in²)
Maximum Torque ... 1 424 Nm (1 050 lbf ft) at 1 400 rev/min Temperatures:
Number of cylinders/configuration .......................... 6, in line Normal ................................... 80° - 110° C (176° - 230° F)
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in) Maximum (Retarder Mode) ....................... 145° C (293° F)
Piston Displacement .............................. 10.8 litres (661 in³) Stall Speed .............................................. 1 718 ± 50 rev/min
Air cleaner .................................... Dry type, double element Ratios:
Starting ..................................................................... Electric Torque Converter .................................................... 1.84:1
Maximum Speed (No load) ............................ 2 350 rev/min Transmission ..................................... Refer to table below
Maximum Speed (Full load) ........................... 2 100 rev/min
Idle Speed ......................................................... 750 rev/min
Safe Operating Angle .................................. 43°/94% Grade Forward
Gear 1 2 3 4 5 6
TRANSMISSION
km/h 5.6 8.7 13.6 21.1 31.0 51.0
Make/Model .................................... ZF 6WG 260 Automatic
with manual override. The transmission assembly consists
mile/h 3.5 5.4 8.5 13.1 19.3 31.7
of a torque converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. Automatic Reverse
shifting throughout the range, with kickdown feature. Lockup
action in all forward gears. A torque proportioning output
Gear 1 2 3
differential transmits drive permanently to front and rear km/h 5.6 13.6 31.0
axles. This differential may be locked by the driver for use in mile/h 3.5 8.5 19.3
difficult traction conditions. Optional integral hydraulic
retarder which automatically operates should the engine
SM 2559 10-07 1
General Information - Technical Data TA25
Section 000-0000
AXLES HYDRAULIC SYSTEM
Three axles in permanent all-wheel drive with differential Braking, steering and body hoist systems are controlled by
coupling between each axle to prevent driveline wind-up. a main hydraulic valve mounted on frame. Systems are
Heavy duty axles with fully-floating axle shafts and outboard supplied with oil from a common tank by the main hydraulic
planetary reduction gearing. pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
Transverse differential locks are activated by a request from line.
the foot operated switch.
Pump:
Type ......................................................................... Piston
Ratios: Capacity at 2 100 rev/min ....... 4.9 litre/s (77.4 US gal/min)
2 SM 2559 10-07
General Information - Technical Data TA25
Section 000-0000
* * * *
SM 2559 10-07 3
General Information - Technical Data TA27
Section 000-0000
SM - 3319
2 685
Max. (8-10)
Body 1 240
Depth (4-1) 2 895
(9-6)
45˚
6 015
65˚ (19-9)
SAE Turning Radius 8 470mm (27-9)
Clearing Radius 8 950mm (29-4)
5 000
(16-5)
4 930
(16-2)
3 450
(11-3) GENERATION
3 420
(11-2)
3 120 2 740
(10-3) (8-11)
2 175
(7-0)
405 725
(1-6) (2-3)
1 580
(5-3)
2 200 2 400 1 310 2 945 1 690 1 410
(7-2) (7-9) (4-4) (9-8) (5-6) (4-9)
2 895 9 755
(9-6) (32-0)
ENGINE
overspeed. Blocked filter indicator and filter bypass system
Make/Model .............................................. Cummins QSM11 provide valve block with additional protection from unfiltered
Type ............. Four cycle diesel, turbocharged with air-to-air oil.
charge cooling, water-cooled. Electronic management.
Pressures:
Gross power at 1 800 rev/min ................... 272 kW (365 hp) Main ........................................ 16 + 2 bar (232 + 30 lbf/in²)
Net power at 2 100 rev/min ....................... 238 kW (319 hp) Lockup (Wk) ........................... 14 ± 1 bar (190 ± 15 lbf/in²)
Converter 'IN' .......... 10.5 bar (152 lbf/in²) at 2 300 rev/min
Note: Gross power rated to SAE J1995 Jun 90. Engine
Converter 'OUT' .......... 4.8 bar (70 lbf/in²) at 2 300 rev/min
emission meets USA EPA/CARB Tier III and EU NRMM
Converter Relief Valve ........................ 8.5 bar (123 lbf/in²)
(non-road mobile machinery) Tier III directive.
Retarder ................................................. 5.5 bar (80 lbf/in²)
Maximum Torque ... 1 673 Nm (1 234 lbf ft) at 1 400 rev/min Temperatures:
Number of cylinders/configuration .......................... 6, in line Normal ................................... 80° - 110° C (176° - 230° F)
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in) Maximum (Retarder Mode) ....................... 145° C (293° F)
Piston Displacement .............................. 10.8 litres (661 in³) Stall Speed .............................................. 1 718 ± 50 rev/min
Air cleaner .................................... Dry type, double element Ratios:
Starting ..................................................................... Electric Torque Converter .................................................... 1.84:1
Maximum Speed (No load) ............................ 2 350 rev/min Transmission ..................................... Refer to table below
Maximum Speed (Full load) ........................... 2 100 rev/min
Idle Speed ......................................................... 750 rev/min
Safe Operating Angle .................................. 43°/94% Grade Forward
Gear 1 2 3 4 5 6
TRANSMISSION
km/h 5.6 8.7 13.6 21.1 31.0 51.0
Make/Model .................................... ZF 6WG 260 Automatic
with manual override. The transmission assembly consists
mile/h 3.5 5.4 8.5 13.1 19.3 31.7
of a torque converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. Automatic Reverse
shifting throughout the range, with kickdown feature. Lockup
action in all forward gears. A torque proportioning output
Gear 1 2 3
differential transmits drive permanently to front and rear km/h 5.6 13.6 31.0
axles. This differential may be locked by the driver for use in mile/h 3.5 8.5 19.3
difficult traction conditions. Optional integral hydraulic
retarder which automatically operates should the engine
SM 2474 Rev1 10-07 1
General Information - Technical Data TA27
Section 000-0000
AXLES HYDRAULIC SYSTEM
Three axles in permanent all-wheel drive with differential Braking, steering and body hoist systems are controlled by
coupling between each axle to prevent driveline wind-up. a main hydraulic valve mounted on frame. Systems are
Heavy duty axles with fully-floating axle shafts and outboard supplied with oil from a common tank by the main hydraulic
planetary reduction gearing. pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
Transverse differential locks are activated by a request from line.
the foot operated switch.
Pump:
Type ......................................................................... Piston
Ratios: Capacity at 2 100 rev/min ....... 4.9 litre/s (77.4 US gal/min)
* * * *
2 685
Max. (8-10)
Body 1 445
Depth (4-9) 2 895
(9-6)
45˚
6 110
65˚ (20-0)
SAE Turning Radius 8 470mm (27-9)
Clearing Radius 8 950mm (29-4)
5 010
(16-5)
4 920
(16-2)
3 450
(11-3) GENERATION
3 420
(11-2)
3 325 2 895
(10-10) (9-6)
2 175
(7-0)
405 725
(1-6) (2-3)
1 580
(5-3)
2 200 2 400 1 310 2 945 1 690 1 410
(7-2) (7-9) (4-4) (9-8) (5-6) (4-9)
2 895 9 755
(9-6) (32-0)
ENGINE
overspeed. Blocked filter indicator and filter bypass system
Make/Model .............................................. Cummins QSM11 provide valve block with additional protection from unfiltered
Type ............. Four cycle diesel, turbocharged with air-to-air oil.
charge cooling, water-cooled. Electronic management.
Pressures:
Gross power at 1 800 rev/min ................... 287 kW (385 hp) Main ........................................ 16 + 2 bar (232 + 30 lbf/in²)
Net power at 2 100 rev/min ....................... 248 kW (333 hp) Lockup (Wk) ........................... 12 ± 2 bar (174 ± 30 lbf/in²)
Converter 'IN' .......... 10.5 bar (152 lbf/in²) at 2 300 rev/min
Note: Gross power rated to SAE J1995 Jun 90. Engine
Converter 'OUT' .......... 4.8 bar (70 lbf/in²) at 2 300 rev/min
emission meets USA EPA/CARB Tier III and EU NRMM
Converter Relief Valve ........................ 8.5 bar (123 lbf/in²)
(non-road mobile machinery) Tier III directive.
Retarder ................................................. 5.5 bar (80 lbf/in²)
Maximum Torque ... 1 775 Nm (1 309 lbf ft) at 1 400 rev/min Temperatures:
Number of cylinders/configuration .......................... 6, in line Normal ................................... 80° - 110° C (176° - 230° F)
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in) Maximum (Retarder Mode) ....................... 145° C (293° F)
Piston Displacement .............................. 10.8 litres (661 in³) Stall Speed .............................................. 1 805 ± 50 rev/min
Air cleaner .................................... Dry type, double element Ratios:
Starting ..................................................................... Electric Torque Converter .................................................... 1.84:1
Maximum Speed (No load) ............................ 2 350 rev/min Transmission ..................................... Refer to table below
Maximum Speed (Full load) ........................... 2 100 rev/min
Idle Speed ......................................................... 750 rev/min
Safe Operating Angle .................................. 39°/81% Grade Forward
Gear 1 2 3 4 5 6
TRANSMISSION
km/h 5.6 8.7 13.6 21.1 31.0 51.0
Make/Model ............................ ZF 6WG 310 RPC Automatic
with manual override. The transmission assembly consists
mile/h 3.5 5.4 8.5 13.1 19.3 31.7
of a torque converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. Automatic Reverse
shifting throughout the range, with kickdown feature. Lockup
action in all forward gears. A torque proportioning output
Gear 1 2 3
differential transmits drive permanently to front and rear km/h 5.6 13.6 31.0
axles. This differential may be locked by the driver for use in mile/h 3.5 8.5 19.3
difficult traction conditions. Standard integral hydraulic
retarder which automatically operates should the engine
SM 2462 Rev1 10-07 1
General Information - Technical Data TA30
Section 000-0000
AXLES HYDRAULIC SYSTEM
Three axles in permanent all-wheel drive with differential Braking, steering and body hoist systems are controlled by
coupling between each axle to prevent driveline wind-up. a main hydraulic valve mounted on frame. Systems are
Heavy duty axles with fully-floating axle shafts and outboard supplied with oil from a common tank by the main hydraulic
planetary reduction gearing. pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
Transverse differential locks are activated by a request from line.
the foot operated switch. Locking of transverse differential
locks is actuated simultaneously with the transmission Pump:
output differential lock. Type ......................................................................... Piston
Capacity at 2 100 rev/min ....... 4.9 litre/s (77.4 US gal/min)
Ratios:
Differential ............................................................. 3.875:1 Brakes
Planetary ................................................................. 5.71:1
Total Reduction ..................................................... 22.12:1 Full hydraulic braking system with enclosed, oil-immersed
multiple discs on each wheel. Independent circuits for front
and rear brake systems. Warning lights and audible alarm
SUSPENSION indicate low brake system pressure. Brake system
Front: Axle is carried on the leading arms of a sub-frame conforms to ISO 3450, SAE J1473.
which pivots on the main frame. Suspension is by rubber
elements with four heavy duty hydraulic dampers. Actuating Pressure ................ 60 ± 5.2 bar (870 ± 75 lbf/in²)
Rear: Each axle is coupled to the frame by three rubber-
bushed links with lateral restraint by a transverse link.
Braking surface (tractor) ............ 22000 mm2 (34.1 in2)/brake
Pivoting inter-axle balance beams equalise load on each
Braking surface (trailer) ............. 22000 mm2 (34.1 in2)/brake
axle. Suspension movement is cushioned by rubber/metal
laminated compression units between each axle and
Parking: Spring-applied, hydraulic-released disc on
underside of balance beam ends. Pivot points on rear
rear driveline.
suspension linkages are rubber-bushed and maintenance-
free.
Emergency: Automatic application of driveline brake
WHEELS AND TYRES should pressure fall in main brake hydraulic
system. Service brakes may also be applied
Wheels: ............ 5-piece earthmover rims with 12 stud fixing using the parking-emergency brake control.
Size:
Standard ....................... 25 x 19.50 in for 23.5 R25** tyres Retardation: Hydraulic retarder integral with transmission.
Optional .................... 25 x 22.00 in for 750/65 R25** tyres
Tyres: Steering
Standard ........................................................... 23.5 R25**
Optional ........................................................ 750/65 R25** Hydrostatic power steering by two single-stage, double-
acting, cushioned steering cylinders. Emergency steering
Inflation Pressures (Bridgestone): pressure is provided by a ground driven pump mounted on
Front Rear the rear of the transmission. An audible alarm and warning
23.5 R25** ...... 4.75 bar (69 lbf/in²) 4.75 bar (69 lbf/in²) light indicates should the emergency system activate.
750/65 R25** .. 3.25 bar (47 lbf/in²) 3.25 bar (47 lbf/in²) Conforms to ISO 5010, SAE J53.
Inflation Pressures (Michelin): System Pressure ................................ 241 bar (3 500 lbf/in²)
Front Rear Steering Angle to either side ............................................ 45°
23.5 R25** ........ 4.0 bar (58 lbf/in²) 4.0 bar (58 lbf/in²) Lock to Lock Turns, steering wheel .................................... 4
750/65 R25** .... 3.0 bar (44 lbf/in²) 3.0 bar (44 lbf/in²)
Body Hoist
Inflation Pressures (Pirelli): Two single-stage, double-acting hoist rams, cushioned at
Front Rear both ends of stroke. Electro servo assisted hoist control.
23.5 R25** ........ 4.8 bar (70 lbf/in²) 4.8 bar (70 lbf/in²)
System Pressure ................................. 220 bar (3 200 lbf/in²)
Inflation Pressures (Continental): Control Valve ....................... Pilot Operated, Closed Centre
Front Rear Body Raise Time (loaded) .......................................... 12 sec
23.5 R25** ........ 5.0 bar (73 lbf/in²) 5.0 bar (73 lbf/in²) Body Lower Time (power down) ................................ 7.5 sec
Welding
WARNING
Welding and flame cutting cadmium plated
WARNINGS metals produce odourless fumes which are
Before any welding is done on a machine toxic. Recommended industrial hygiene
equipped with any electronic systems, practice for protection of the welding operator
disconnect the following (if applicable) in this from the cadmium fumes and metallic oxides
order: Battery earth cable, battery supply requires enclosure ventilation specifically
cable, alternator earth cables, alternator supply designed for the welding process. A
cables and electrical connections at the engine respiratory protective device such as the
ECM, transmission ECU, body control lever, M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
hydraulics ECU and cab bulkhead to avoid will provide protection against cadmium,
damage to electrical components. Turn off fumes and metallic oxides. The 'Gasfoe'
battery master switch to isolate the batteries respirator has been approved by the U.S.
before disconnecting any components. Bureau of Mines: Approval number 23B-10,
After welding connect all of the above in the and is designed to protect against gases,
reverse order. vapours, and/or metal fumes.
SM 2172 10-02 1
General Information - Welding Procedure
Section 000-0010
3. Pre-heat area to 100° C (212° F), measured 3 - 4" 3 - 4" either side of repair prior to gouging. On
either side of repair. Avoid local overheating. completion of gouging grind to remove thin carbon
layer.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from 2. Apply dye-penetrant check to ensure crack has
moisture pick-ups at all times. been completely removed.
5. Allow repair weld to cool slowly. 3. Pre-heat area to 200° C (392° F), measured 3 - 4"
either side of repair. Avoid local overheating.
6. Grind and blend repair to original contour. Paint
heat damaged areas. 4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the 5. On completion of welding, post-heat repair area to
welds joining steel castings. 400° C (752° F), measure 3 - 4" either side of repair.
1. Completely ARC-AIR gouge or grind out the crack 6. If welding has to be interrupted for any reason, e.g.
until sound metal is reached. If ARC-AIR method is overnight, post-heat immediately as in Step 5.
employed, pre-heat area to 200° C (392° F), measure
* * * *
2 SM 2172 10-02
CHASSIS - Frames
Section 100-0010
SM - 2783
SM 2170 9-02 1
Chassis - Frames
Section 100-0010
Welding
WARNING
Welding and flame cutting cadmium plated
metals produce odourless fumes which are
WARNINGS
toxic. Recommended industrial hygiene
Before any welding is done on a machine
practice for protection of the welding operator
equipped with the Quantum Electronic Fuel
from the cadmium fumes and metallic oxides
System, disconnect the following in this order:
requires enclosure ventilation specifically
Battery earth cable, battery supply cable,
designed for the welding process. A respiratory
alternator earth cables, alternator supply
protective device such as the M.S.A. 'Gasfoe'
cables, body hydraulics joystick and electrical
respirator with G.M.A. cartridge will provide
connections at the engine ECM, transmission
protection against cadmium, fumes and
ECU and hydraulics ECU to avoid damage to
metallic oxides. The 'Gasfoe' respirator has
electrical components. Turn off battery master
been approved by the U.S. Bureau of Mines:
switch to isolate the batteries before
Approval number 23B-10, and is designed to
disconnecting any components.
protect against gases, vapours, and/or metal
After welding connect all of the above in the
fumes.
reverse order.
Note: The current from the welding rod always follows
the path of least resistance. If, for example, the ground
clamp is attached to the rear frame when welding is
Before any welding is done ensure all paint has
performed on the front frame, the current must pass a
been removed from the area to be welded.
frame connection to return to the welding machine.
Failure to do so may result in hazardous fumes
Since the pivot coupling offers the least resistance but
being given off from the paint.
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
cause welding blotches on their wearing surfaces and
Note: Always fasten the welding machines ground
increase the wear rate of these components.
cable to the piece/frame being welded if possible.
2 SM 2170 9-02
Section 100-0010
To keep rust and corrosion to a minimum, periodic
WARNING painting of abrasions and other exposed metal areas
Welding, burning, heating or dressing surfaces on the frames is highly recommended.
previously painted using polyurethane paint
produces fumes which are toxic. Surfaces must If painting of a frame is required, thoroughly clean the
be prepared using paint stripper prior to area areas to be painted. Apply a primer coat of
being reworked. Recommended Industrial polyurethane red oxide and then a finish coat of
Hygiene and Safety Rules should be followed polyurethane enamel.
for protection of the welding operator from the
fumes.
* * * *
SM 2170 9-02 3
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CHASSIS - Articulation and Oscillation Pivot
Section 100-0020
SM - 3109
25 52
29
50 51 56 56
16 5,6 55
19 7
20 53
14 8,9 27
54
56
17 DETAIL A
42 25
41
45,46,49 39
36,49
45,47,49
1
32
30 26,56 26,53
23 52,55 54,55 10,26
56
38 11
2,3,4 2,3,4
33 60
57,58,59
49,61,62 36,49 40 28 18
51 13
15 8,9 51
31 63
17
50 16
19
19 64-68
44,48,49 43 37,49 16
29
31
14 24 8,9
35 29 15
38
30,23 21,22
34 12
25
10,26
DESCRIPTION AND OPERATION connecting the drive between the front and rear frames.
The articulation and oscillation pivot allows the front
and rear frames to rotate horizontally (articulation) and Articulation bearings, oscillation bushes, pivot
tilt laterally (oscillation) with respect to each other. It is driveshaft bearing and associated parts can be
also the main load bearing coupling between the two removed, inspected and replaced or renewed by
frames. The pivot assembly houses the driveshaft following the procedures outlined in this section.
SM 2273 03-04 1
Chassis - Articulation and Oscillation Pivot
Section 100-0020
14. Prise out and discard seal (15) from front of the
Removal and Disassembly
housing.
1. Position the vehicle on a level work area and apply
parking brake. 15. Lift out front bearing assembly cup (8) from front
of the housing.
2. Raise body and install body safety prop to secure
body in partially raised position. 16. If bearing replacement is required, use a suitable
puller to remove front and rear bearing assembly
3. Shut down engine and block all wheels securely. cups (8) from the housing.
4. Identify the relationship of the driveline caps to the Note: If either bearing assembly cup or cone (8 or 9)
transmission yoke and front yoke (17). Remove need replacing, they must be replaced as a set.
capscrews and remove driveline from vehicle.
17. If retaining rings (31) need replacing, use a
Note: Take extra care when handling drivelines as suitable drift or puller to remove them from the housing.
any deformity on a rotating mass creates vibration
and excessive wear during any operation. 18.Temporarily install front yoke (17) fully onto front of
driveshaft (14) and suitably restrain to resist rotation.
5. Remove wheel blocks, start engine and steer
vehicle into a full left-hand lock. Shut down engine 19. Remove mounting hardware securing parking
and block all wheels securely. brake disc to brake yoke (18) and remove brake disc.
6. Remove Lockplate (16) , 2 0ff Front bolts (19) & 20. Remove Lockplate (16) , 2 off Rear bolts (19) ,
Front thrust collar (50). Rear Thrust collar (63) & Brake yoke (18) from
driveshaft (14). Identify front and rear ends of
7. Remove and discard 'O' rings (29 & 51) from Thrust driveshaft (14).
collar (50).
21. Remove and discard 'O' rings (29 & 51) from Rear
8. Place a suitable container under the front of the Thrust collar (63).
pivot and pull front yoke (17) from driveshaft (14).
2 SM 2273 03-04
Chassis - Articulation and Oscillation Pivot
Section 100-0020
9 SM - 3143
14
22. Remove and discard seal (15) from driveshaft (14).
Inspection
Note: If either bearing assembly cup or cone (8 or 9) 7. Insert driveshaft (14) into truck end of pivot casing
need replacing, they must be replaced as a set. until bearing assembly cone (9) seats firmly in the
bearing asembly cup (8).
3. Inspect splines of driveshaft (14) and yokes
(17 & 18) for nicks, burrs or excessive wear. Replace 8. Apply loctite (3) to new seal (15) and fit over the
if wear is excessive or splines are nicked. Burrs may driveshaft (14) with seal 'Lip' to bearing side.Press seal
be removed with a fine file or medium India stone. home using a mandrel.
4. Check yokes (17 & 18) for damage in region 9. Apply grease to splines of Front yoke (17) and slide
polished by oil seal lip; even slight damage in this onto the drive shaft (14).
area can cause leakage. Very slight marks may be
polished out with fine emery cloth but it is essential 10. Fit new 'O'-rings ( 29 & 51) to Front thrust collar
that polishing marks are parallel to the seal lip. (50) and fit collar over stub end of driveshaft (14) (align
mating holes). Fit 2 off front bolts (19).
5. Replace all seals and 'O' rings with new parts.
11. Tighten Front bolts (19) ; alternately 1/4 - 1/2 turns,
drawing driveshaft (14) hard against the inner face of
Assembly and Installation Front thrust collar (50). Shaft will be visible through
1. If removed, use a suitable driver and install retaining inspection hole on the collar.
rings (31) into housing, ensuring that they butt hard
against abutment shoulders. 12. Lock Front yoke (17) from rotation by a suitable
method / bar acting on the ground. Torque front bolts
2. Using a suitable driver, install front bearing cup (8) (19) to 54Nm/39 Ibf ft.
into tractor end of pivot casing. Ensure it is firmly
seated & that a 0.05mm (0.002") feeler gauge cannot 13. Using special mandrel (15270104) home locking
be inserted between cup and mating face. plate (16) onto Bolts (19). Remove the clamping bar.
3. Check rear bearing cup (8) is firmly seated in the 14. Slide Rear bearing asembly cone (9) onto rear end
body end of the pivot casing, again ensuring 0.05mm of drive shaft (14) until it seats in bearing assembly
(0.002") feeler gauge cannot be inserted between cup cup (8).
and mating face.
15. Position clamping bar assembly and screw central
4. Lightly oil both bearing assembly cones (9) with SAE bolt hard against bolts (19) of front thrust collar (50),
80W - 90 E. P. gear oil (24). enabling body end bearing to be fully seated home.
5. Support driveshaft (14) in a suitable fixture & tap one 16. Using mandrel and heavy hammer, drive Rear
Bearing assembly cone (9) onto driveshaft (14) using a bearing assembly cone, fully into cup. Now remove
tubular mandrel. clamp bar assembly from front end.
SM 2273 03-04 3
Chassis - Articulation and Oscillation Pivot
Section 100-0020
Sm 3144
'A'
'B' 'D' DEPTH
SHAFT MICROMETER
17. Take remaining seal (15), apply loctite (3) and fit
over drive shaft with seal 'Lip' to bearing side. Press 22. The actual free air space 'E' to be shimmed
seal home using a mandrel. between end of drive shaft (14) and compression face
of Thrust collar (63) equals:
18. Apply grease to splines of brake yoke (18) and
slide onto drive shaft (14). Ensure milled slots of E='D' - 'C'.
driving flanges are aligned with those of brake yoke.
23. Now add 0.6mm (0.024") to dimension 'E' to allow
Note : For Measurment letters- refer to fig. 3, unless for oversize shims. This value is dimension 'F'
otherwise stated. (End float will be determined by subtraction).
19. Before fitting of Rear Thrust collar (63) record 24. Remove Rear bolts (19) and Rear thrust collar (63)
Measurements as stated: from pivot body end and chap drive shaft (14) to free
bearing.
i) Measure total width 'A' of Rear thrust collar (63)
25. Calculate the nominal combination of minimum
ii) Using Depth micrometer, measure inner bore depth number if shims (64) to achieve the size nearest to
'B' of collar (63) and record value. dimension 'F'. Record the appropriate part numbers and
total nominal thickness value.
iii) Subtract 'B' from 'A' to determine recess dimension
'C'. 26. Select the shims (64) and measure the total actual
thickness of the combination. Record this value.
20. Fit Rear thrust collar (63) without 'O'-rings onto
Drive shaft (14) and tighten Rear bolts (19) to a nominal 27. Place the shim pack (64) in the rear thrust collar
torque of 15Nm/11Ibf ft. (63) , lock off the Brake yoke (18) from rotation by
suitable method / bar on ground. Torque bolts (19) to
Note : a gap should be visible between end of shaft full torque.
and inner face of collar.
28. Remove the clamp and spin the yoke (18) to
21. Using a Depth micrometer, measure distance 'D' ensure driveshaft (14) free rotation.
from collar (63) outer face to end face of drive shaft
(14) via the hole in the collar and record the value. 29. Take a magnetic clock gauge located on the flange
of pivot casing, needle acting on rear thrust collar (63)
4 SM 2273 03-04
Chassis - Articulation and Oscillation Pivot
Section 100-0020
end face. Check Brake yoke (18) float movement.
43. Remove plug (25) from underside of oscillation hub
30. Take reading obtained and subtract a figure to drain the cavity between the oscillation hub and
sufficient to give an end float in the range 0.05mm - pivot assembly (1) of any oil that entered while filling
0.15mm (0.002" - 0.006"), reduce shim pack (64) the driveshaft bearing housing.
accordingly.
44. Install plug (25) into filler/level hole on pivot
31. Remove Rear thrust collar (63) and shims (64) and assembly (1). Install gasket (5) and cover plate (6) on
re-assemble with the apporpriate shims. Ensure 'O'- side of oscillation hub, secure with bolts (7) and
rings (29 & 51) are now fitted. washers (20).
32. Lock Brake yoke (18) flange as before ,applying 45. Install plug (25) into cavity drain port on underside
alternate 1/4 -1/2 turns on bolts (19). Torque to 54 Nm of oscillation hub.
(39 Ibf ft).
46. Install parking brake disc protective guard (if fitted)
33. Remove the locking bar and confirm that the and secure with bolts, washers and nuts. Tighten nuts
driveshaft (14) end float is in the range 0.05mm - to a torque of 73 Nm (54 lbf ft).
0.15mm (0.002" - 0.006") by moving the brake yoke
(18) for and aft against the clock gauge. 47. Start engine, raise body, lower body safety prop
and lower body.
34. Adjust and refit the shim pack (63) as necessary.
48. Remove wheel blocks.
35. Float set correctly; Drive home locking plate (16)
using a mandrel (15270104) . Re-check the end float.
ARTICULATION COMPONENTS
36. Install parking brake disc on brake yoke (18) and Numbers in parentheses refer to Fig. 1, unless
secure with bolts and washers. Tighten bolts to a otherwise specified.
torque of 73 Nm (54 lbf ft).
Note: The following procedures assume that only
37. Install parking brake assembly to mounting components associated with articulation require repair.
brackets and secure with bolts, washers and nuts.
Refer to Section 170-0010, PARKING BRAKE AND Note: It is essential that the grease used for articulation
MOUNTING. components is Extreme Pressure Lithium Complex No. 2
(23), as specified in Section 300-0020, LUBRICATION
38. Apply parking brake by turning the hex-head on the SYSTEM.
parking brake actuator fully clockwise.
Note: Tighten all fasteners without special torques
39. Apply Loctite 638 to the threads of capscrews used specified to torques listed in Section 300-0080,
to mount driveline to brake yoke (18). Align match STANDARD BOLT AND NUT TORQUE
marks and install driveline. Tighten capscrews to a SPECIFICATIONS.
torque of 153 Nm (113 lbf ft).
SM 2273 03-04 5
Chassis - Articulation and Oscillation Pivot
Section 100-0020
SM - 008
9. Remove bolt (62), washer (61), large nut (42) and
washer (41) securing upper pin (40).
3. Shut down engine and block all wheels securely. 14. Remove spacer (39) noting orientation to ensure
correct installation.
4. Identify the relationship of the driveline caps to the
transmission yoke and front yoke (17). Remove
capscrews and remove driveline from vehicle. Disassembly
1. Identify seal housings (32, 33, 34 & 35) to ensure
5. Support tractor frame at front and rear with suitably correct location on assembly/installation.
placed stands or timbers so the frame will remain level
during and after pin removal. Note: Seal housings (32, 33, 34 & 35) are not
interchangeable.
6. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of 2. Remove bolts (46 & 47), washers (45), seal housings
pivot. (32, 33, 34 & 35) and upper and lower shims (38).
7. Release the parking brake by turning the hex-head 3. Prise out and discard seals (36 & 37) from the
on the parking brake actuator fully anticlockwise. housings.
6 SM 2273 03-04
Chassis - Articulation and Oscillation Pivot
Section 100-0020
and allow to dry. Connecting Front and Rear Frames
1. Install spacer (39) in upper outer seal housing (32),
2. Check bearing assemblies (30) and spacers, and as noted on removal.
pins (40 & 43) for wear or damage. Renew as
necessary. 2. Smear bearing and pin bores with Extreme Pressure
Lithium Complex No. 2 grease (23).
Note: Bearing assemblies (30) and spacers must be
renewed as a matched set. 3. Attach suitable lifting equipment to pivot/rear frame
assembly. Lifting equipment must prevent pivot from
3. Replace all seals with new parts. oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame
Assembly pin bores. Raise lifting equipment to support pivot/rear
frame assembly.
1. Apply Loctite 243 (49) sparingly to bore of seal
housings (32, 33, 34 & 35). 4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull
2. Using a suitable driver, install seals (36 & 37) into pivot/rear frame assembly to align pivot bearing bores
seal housings (32, 33, 34 & 35) ensuring that the metal and front frame pin bores. Block wheels and block
ring on inside of the seals are not disturbed, and, that pivot/rear frame assembly to remain level and
they are located towards the inside of seal housing. stationary.
3. Apply Loctite 243 (49) to threads of outer seal 5. Freeze upper and lower pins (40 & 43) to ease
housing bolts (46). installation.
4. Place outer seal housings (32 & 34) in position 6. Smear lower pin (43) with Extreme Pressure Lithium
ensuring that grease relief hole in seal housings are Complex No. 2 grease (23) and install through front
directly opposite bearing grease port on pivot. Secure frame and bearing bores.
with bolts (46) and washers (45). Tighten bolts (46) to a
torque of 94 Nm (68 lbf ft). Note: It may be necessary to relieve binding between
the pin and pin bores by raising or lowering pivot/rear
Note: Bearing assemblies (30) and spacers are a frame assembly.
matched set, never interchange cups, cones or
spacers between sets. 7. Apply Loctite 243 (49) to threads of bolt (48) and
secure lower pin (43) with bolt (48) and hardened
5. Using Extreme Pressure Lithium Complex No. 2 washer (44). Tighten bolt (48) to a torque of 73 Nm
grease (23), pack bearing assemblies (30), including (54 lbf ft).
end faces, and install bearings.
8. Smear upper pin (40) with Extreme Pressure Lithium
6. Place inner seal housings (33 & 35) temporarily in Complex No. 2 grease (23) and install through front
position and secure with bolts (47) and washers (45). frame and bearing bores.
Tighten bolts (47) to a torque of 16 Nm (12 lbf ft).
9. Apply Loctite 243 (49) to threads of bolt (62). Secure
7. Using feeler gauges, as shown in Fig. 4, measure upper pin (40) with bolt (62), washer (61), large nut (42)
the dimension between the inner pivot faces and seal and washer (41). Tighten nut (42) to a torque of 1 425
housings (33 & 35). Measure at 3 positions equally Nm (1 050 lbf ft).
spaced around seal housings and determine average
dimension, this is the size of shims (38) required.
Final Assembly
8. Remove bolts (47), washers (45) and inner seal 1. Apply parking brake by turning the hex-head on the
housings (33 & 35). parking brake actuator fully clockwise.
9. Install shims (38) as calculated at Step 7, reinstall 2. Remove lifting equipment from pivot/rear frame
inner seal housings (33 & 35) and secure with bolts assembly.
(47) and washers (45). Tighten bolts (47) to a torque of
94 Nm (68 lbf ft). 3. Remove stands or timbers from front frame.
SM 2273 03-04 7
Chassis - Articulation and Oscillation Pivot
Section 100-0020
SM - 038
4. Apply Loctite 270 to the threads of capscrews used
to mount driveline between transmission yoke and front
yoke (17). Align match marks and install driveline.
Tighten capscrews to a torque of 153 Nm (113 lbf ft).
OSCILLATION COMPONENTS
Disconnecting Front and Rear Frames
Numbers in parentheses refer to Fig. 1.
1. Position the vehicle on a level work area and apply
Note: The following procedure assumes that only parking brake.
components associated with oscillation require repair.
2. Raise body and install body safety prop to secure
Note: It is necessary to disconnect the front and rear body in partially raised position.
frames at the articulation point to service the
oscillation components. 3. Shut down engine and block all wheels securely.
Note: It is essential that the grease used for 4. Depress and release brake pedal continuously to
oscillation components is Extreme Pressure relieve the pressure in the braking system.
Multipurpose Grease (26), as specified in Section 300-
0020, LUBRICATION SYSTEM. 5. Carefully loosen brake lines at base of both
accumulators to check that the pressure has
Note: Tighten all fasteners without special torques released. Re-tighten brake lines.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE 6. Tag all hydraulic lines and electrical wiring between
SPECIFICATIONS. front and rear frames to ensure correct assembly/
installation. Disconnect all hydraulic lines and plug
openings to prevent ingress of dirt. Disconnect
WARNINGS electrical wiring and any other attachments which could
To prevent personal injury and property damage, be damaged on separation of front and rear frames.
be sure wheel blocks, blocking materials and
8 SM 2273 03-04
Chassis - Articulation and Oscillation Pivot
Section 100-0020
7. Identify the relationship of the driveline caps to the securing guard to the rear frame. Refer to
transmission yoke and front yoke (17). Remove Section 170-0010, PARKING BRAKE AND
capscrews and remove driveline from the vehicle. MOUNTING.
8. Support tractor frame at front and rear with suitably 2. Remove mounting hardware securing parking brake
placed stands or timbers to keep the frame level during assembly to mounting bracket on frame. Remove and
and after pin removal. secure parking brake assembly clear of brake disc.
9. Remove bolts, washers and pins securing steering 3. Identify the relationship of the driveline caps to
cylinders to pivot. Secure steering cylinders clear of brake yoke (18). Remove capscrews, disconnect
pivot. driveline and secure clear of brake yoke (18).
10. Release the parking brake by turning the hex- 4. Remove mounting hardware securing parking brake
head on the parking brake actuator fully anticlockwise. disc to brake yoke (18) and remove brake disc.
11. Attach suitable lifting equipment to pivot/rear frame 6. Remove Rear bolts (19), Lockplate (16) & Rear
assembly. Lifting equipment must prevent pivot from thrust collar (63). Pull brake yoke (18) from driveshaft
oscillating after separation, and, be capable of pulling (14) .
pivot/rear assembly clear of front frame. Raise lifting
equipment to support pivot/rear frame assembly. 7. Remove adaptor (57), connector (58), elbow (59)
and pipe assembly (60) from oscillation hub.
12. Remove bolt, washer, large nut (42) and washer
(41) securing upper pin (40). 8. Remove bolts (22) and washers (21) securing
locking plate (12). Remove locking plate (12).
13. Remove upper pin (40). If necessary tap upper pin
(40) to ease removal taking care to avoid damaging 9. Restrain pivot assembly (1) to prevent it oscillating,
the threads. by placing a heavy bar between the steering cylinder
mountings. Lock the bar in position using suitable
Note: It may be necessary to relieve binding between trestles or stands. See Fig. 5.
the pin and pin bores by raising or lowering the pivot/
rear frame assembly. 10. Using a suitable tool, remove thrust nut (11). If
wear area of thrust nut (11) is damaged, replace thrust
14. Remove bolt (48) and hardened washer (44) nut (11).
securing lower pin (43). 11. Insert an M20 eyebolt into tapped pad provided on
top of pivot assembly (1) and attach suitable lifting
15. Remove lower pin (43). If necessary tap lower pin equipment.
(43) to ease removal taking care to avoid damaging the 12. Remove pivot restraining bar.
pin.
13. Using lifting equipment, carefully pull pivot
16. Remove blocks from rear wheels and use lifting assembly (1) clear of oscillation hub. Place pivot
equipment to pull pivot/rear frame assembly clear of assembly (1) in a suitable work area for further
the front frame. After moving, block pivot/rear frame disassembly.
assembly and block the wheels.
14. Note position of front 'V' ring (10) to aid in
17. Remove spacer (39) noting orientation to ensure 'Installation'. Remove and discard 'V' ring (10).
correct installation. Cover articulation bearings to
prevent ingress of dirt. 15. Inspect nylon oscillation bushes (2) as described in
'Inspection'. If bushes are to be renewed, proceed with
step 16.
Disassembly
1. Remove protective guard (if fitted) from beneath 16. Remove nylon oscillation bushes (2) with hammer
parking brake disc by removing mounting hardware and chisel.
SM 2273 03-04 9
Chassis - Articulation and Oscillation Pivot
Section 100-0020
Note: The suggested method is to make an axial cut 7. Using suitable lifting equipment, and taking care to
along the bush then to lever the bush in order to prevent damaging bushes (2) or pivot threads, install
collapse it upon itself. pivot assembly (1) into rear frame.
2. Inspect nylon oscillation bushes for wear, scoring, 9 . a) Restrain pivot assembly (1) to prevent it
erosion and 'out of round'. Pay particular attention to oscillating, by placing a heavy bar between the steering
the thrust faces of the bushes which should also be cylinder mountings. Lock the bar in position using
inspected for cracking/splitting. Renew if required. suitable trestles or stands. See Fig. 5.
3. Replace all seals with new parts. b) Secure a suitable tool to pivot thrust nut (11) and
tighten thrust nut (11) until there is no end float/
Assembly clearance at thrust face of either bush. Slacken thrust
nut (11) until pin of the locking plate (12) can be
Numbers in parentheses refer to Fig. 1. inserted in the first available hole in the thrust nut (11).
Note: Tighten all fasteners without special torques c) Secure locking plate (12) with bolts (22) and
specified to torques listed in Section 300-0080, lockwashers (21). Torque tighten bolts (22) to 94 Nm
STANDARD BOLT AND NUT TORQUE (69 lbf ft).
SPECIFICATIONS.
10. Install adaptor (57), connector (58), elbow (59) and
pipe assembly (60) to oscillation hub.
WARNING
To prevent personal injury and property 11. Install brake yoke (18) on driveshaft (14) until it
damage, be sure wheel blocks are properly butts against bearing assembly cup and cone (8 & 9).
secured and of adequate capacity to do the job
safely. 12. Install parking brake disc on brake yoke (18) and
secure with bolts, washers and nuts. Tighten bolts to a
1. Wipe bush housing clean using a suitable solvent torque of 73 Nm (54 lbf ft).
and allow to dry.
13. Install rear of driveshaft (14).
2. Apply Loctite 648 (3) and Loc Quick Primer (4) and
align new bushes (2) to housing with grease holes 14. install Brake yoke (18) , Rear thrust collar (63)
aligned vertically and identification 'PAINT DOT' at Top ensuring 'O'-rings (29& 51) are in place , shim pack (64)
Dead Centre. Refer to Fig. 6. Drift bushes (2) into and bolts (19).
housing using hammer with soft packing for protection.
10 SM 2273 03-04
Chassis - Articulation and Oscillation Pivot
Section 100-0020
15. Lock off Brake yoke flange as before (18) with 8. Smear upper pin (40) with Extreme Pressure Lithium
suitable clamping method. Torque bolts (19) to 73 Nm Complex No. 2 grease (23) and install through front
(Ibf ft) frame and bearing bores.
Note: It may be necessary to relieve binding between 7. Align steering cylinder bores and mounting pin bores
the pin and pin bores by raising or lowering pivot/rear on pivot. Install pins and secure with bolts and washers.
frame assembly. Tighten bolts to a torque of 73 Nm (54 lbf ft).
6. Smear lower pin (43) with Extreme Pressure Lithium 8. Connect hydraulic lines and electrical wiring as
Complex No. 2 grease (23) and install through front noted on disassembly.
frame and bearing bores.
9. Remove bolts (7), washers (20), gasket (5) and
7. Apply Loctite 243 (49) to threads of bolt (48). Secure cover plate (6) from side of oscillation hub to gain
lower pin (43) with bolt (48) and hardened washer (44). access to filler/level plug (25) on pivot assembly (1).
Tighten bolt (48) to a torque of 73 Nm Remove filler/level plug (25).
(54 lbf ft).
SM 2273 03-04 11
Chassis - Articulation and Oscillation Pivot
Section 100-0020
(26) to oscillation bushing lube fittings (55) on top of
10. Add SAE 80W - 90 E. P. gear oil (24) through filler/ oscillation hub. Lube until excess grease in seen.
level hole in pivot assembly (1) until the oil is level with
the bottom of filler/level hole.
WARNING
11. Remove plug (25) from underside of oscillation hub To prevent personal injury and property
to drain the cavity between the oscillation hub and damage, be sure wheel blocks are properly
pivot assembly (1) of any oil that entered while filling secured and of adequate capacity to do the job
the driveshaft bearing housing. safely.
12. Install plug (25) in filler/level hole on pivot Every 250 hours, check the end float/clearance at the
assembly (1). Install gasket (5) and cover plate (6) on thrust face of the oscillation bushes. Any clearance
side of oscillation hub, secure with bolts (7) and found must be removed by adjustment of the thrust
washers (20). nut, as described in step 9 of 'Assembly' procedure.
13. Install plug (25) in cavity drain port on underside of Note: A practical method of establishing the effective
oscillation hub. adjustment of the thrust nut is to use movement of the
machines body in the raised position. Move the body
14. Remove plugs (28) from articulation bearing grease from fully raised to almost fully raised while watching
ports and replace with lube fittings (27). the effect of this action on the frame and pivot
arrangement. Any slackness between the thrust nut
Note: Lube fittings (27) are stored on pad on side of and thrust faces will be clearly visible movement of the
pivot assembly (1). frame.
15. Fill bearing housings with Extreme Pressure Every 1 000 hours (6 months), follow the procedure
Lithium Complex No. 2 grease (23) through lube fittings given below to check the oil level in the driveshaft
(27) until excess grease starts to escape from seal bearing housing, and, lubricate the articulation and
housings (32 & 34). oscillation bearings.
16. Remove lube fittings (27) and reinstall plugs (28). Note: It is essential that the grease used for
Store grease fittings (27) on pad on side of pivot articulation components is Extreme Pressure Lithium
assembly (1). Complex No. 2 grease (23), as specified in Section
300-0020, LUBRICATION SYSTEM.
17. Add Extreme Pressure Multipurpose grease (26) to
oscillation bushing lube fittings (55) on top of oscillation 1. Position the vehicle on a level work area and apply
hub. Lube until excess grease in seen. parking brake.
18. Install parking brake disc protective guard (if fitted) 2. Raise body and install body safety prop to secure
and secure with bolts, washers and nuts. Tighten nuts body in partially raised position.
to a torque of 73 Nm (54 lbf ft).
3. Shut down engine and block all wheels securely.
19. Start engine to charge hydraulic systems, raise
body, lower body safety prop and lower the body. 4. Remove protective guard (if fitted) from beneath
parking brake disc by removing nuts, washers and
20. Bleed the braking system as described in Section bolts securing guard to rear frame.
165-0010, BRAKE PARTS.
5. Remove bolts (7), washers (20), gasket (5) and
21. Remove wheel blocks. cover plate (6) from side of oscillation hub to gain
access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).
MAINTENANCE
Numbers in parentheses refer to Fig. 1. 6. Add SAE 80W - 90 E. P. gear oil (24) through filler/
level hole in pivot assembly (1) until the oil is level with
Every 250 hours, oscillation bushes must be the bottom of filler/level hole.
lubricated. Add Extreme Pressure Multipurpose grease
12 SM 2273 03-04
Section 100-0020
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the thrust nut tool and general service tools
and adhesives required for procedures outlined in this
section. These tools and adhesives are available from
your dealer.
SM 2273 03-04 13
Chassis - Articulation and Oscillation Pivot
Section 100-0020
* * * *
14 SM 2273 03-04
CHASSIS - Hood and Mounting
Section 100-0040
SM - 2785
38
35
35 36 37 19
34 9,10,11
30 29 31 20
31
32
21
31
22
33
18
32
29 28 23
9
24
1 9
10 25
26
16
11
12 IN BATTERY BOX
27 12 15
39
7 14
8 13
6 17
7
4
5
2 3
HOOD 2. Block all road wheels and place the battery master
switch in the 'Off' position.
Removal
Numbers in parentheses refer to Fig. 1. 3. Remove bolts, washers, lockwashers and nuts
securing grille (27) to grille subframe. Secure grille
(27) clear of hood (1).
WARNING
To prevent personal injury and property 4. Pull cable assembly (16), handle inside battery box,
damage, be sure blocking materials and lifting to release hood catch and lift up hood (1). Secure
equipment are properly secured and of hood (1) in raised position using suitable lifting
adequate capacity to do the job safely. equipment.
1. Position the machine on a level surface, apply the 5. Carefully remove bolts, washers and nuts securing
parking brake and switch off the engine. hood retaining straps (14) and gas struts (15).
SM 2173 10-02 1
Chassis - Hood and Mounting
Section 100-0040
Remove fasteners, hood retaining straps (14) and gas GOALPOST SUPPORT ASSEMBLY
struts (15) from hood (1).
Removal
6. Remove bolts (39), washers (13) and nuts (17) Numbers in parentheses refer to Fig. 1.
securing hinge assemblies (2) to frame. Carefully lift
hood (1) assembly from the machine.
WARNING
7. If required, remove mounting hardware securing To prevent personal injury and property
grille subframe to hood (1). Secure grille subframe damage, be sure blocking materials and lifting
clear of hood (1). equipment are properly secured and of
adequate capacity to do the job safely.
8. If required, remove bolts (10) and washers (11)
securing handles (9) to hood (1). Secure handles (9) 1. Position the machine on a level surface, apply the
clear of hood (1). parking brake and switch off the engine.
Installation 2. Block all road wheels and place the battery master
switch in the off position.
Numbers in parentheses refer to Fig. 1.
3. Pull cable assembly (16), handle inside battery box,
Note: Tighten all fasteners to torques listed in to release hood catch and lift up hood (1). Secure
Section 300-0080, STANDARD BOLT AND NUT hood (1) in raised position.
TORQUE SPECIFICATIONS.
4. Remove mounting hardware securing washer bottle
to mounting bracket on the left hand side of goalpost
WARNING support assembly (18). Secure washer bottle clear of
To prevent personal injury and property goalpost support assembly (18).
damage, be sure blocking materials and lifting
equipment are properly secured and of 5. Remove plate and mounting hardware securing
adequate capacity to do the job safely. transmission oil cooler to goalpost support assembly
(18). If required, disconnect transmission oil cooler
1. If removed, secure handles (9) to hood (1) using hoses.
bolts (10) and washers (11).
6. Remove mounting hardware securing air cleaner
2. If removed, secure grille subframe to hood (1) using intake tube to goalpost support assembly (18).
mounting hardware as removed at 'Removal'.
7. With a suitable container available to catch leakage,
3. Using suitable lifting equipment, lift and position remove drain plug from radiator header tank and drain
hood (1) on the machine and align holes in hinge coolant. Apply Loctite 225 to drain plug and reinstall in
assemblies (2) with mounting holes on frame. Secure header tank.
hood (1) using bolts (39), washers (13) and nuts (17).
8. Ensure all cooling lines connected to header tank
4. Carefully install hood straps (14) and gas struts (15) are identified for ease of installation and with suitable
using mounting hardware as removed at 'Removal'. containers available to catch leakage, disconnect
cooling lines. Fit blanking caps to all open lines.
5. With lifting equipment still in place, lower hood (1) to
match with goalpost support assembly (18). Remove 9. Disconnect electrical harness from coolant level
lifting equipment. sensor in header tank. Note routing of all hoses and
harnesses attached to and through goalpost support
6. If required, adjust fitment of hood (1) to frame at assembly (18) and disconnect.
hinge assemblies (2) and adjustment rod (6).
10. Disconnect hood cable (16) ball joint from cam
7. Install grille (27) to hood (1) and secure using bolts, plate assembly (33) and secure cable (16) clear of
washers, lockwashers and nuts. hood catch mechanism.
8. Remove wheel blocks. 11. Check to make certain that all necessary line and
2 SM 2173 10-02
Chassis - Hood and Mounting
Section 100-0040
cable disconnections have been made, before lifting 6. Fit plate and mounting hardware securing
goalpost support assembly (18). transmission oil cooler to goalpost support assembly
(18) as removed during 'Removal'. If necessary,
12. Attach suitable lifting equipment to goalpost reconnect transmission oil cooler hoses. Ensure
support assembly (18). Remove bolts (23), washers transmission oil cooler contains sufficient oil. Refer to
(24 & 25) and locknuts (26) securing goalpost support Section 210-0060, TRANSMISSION OIL COOLER.
assembly (18) to its mounting. Lift goalpost support
assembly (18) from the machine. 7. Install washer bottle to mounting bracket on the left
hand side of goalpost support assembly (18) and
13. If required, remove locknuts (22), bolts (19), hood secure using mounting hardware as removed during
stops (20) and springs (21) from goalpost support 'Removal'.
assembly (18).
8. Secure air cleaner intake tube to goalpost support
14. If required, remove bolts (30), washers (31) and assembly (18) using mounting hardware as removed
nuts (29) securing hood catch mechanism (28 - 38) to during 'Removal'.
goalpost support assembly (18). Remove hood catch
mechanism (28 - 38). 9. Remove blanking caps from all cooling lines and
connect cooling lines to radiator header tank as tagged
at 'Removal'.
Installation
Numbers in parentheses refer to Fig. 1. 10. Connect electrical harness to coolant level sensor
in header tank. Secure all hoses and harnesses to and
Note: Tighten all fasteners to torques listed in through goalpost support assembly (18) following
Section 300-0080, STANDARD BOLT AND NUT routing as noted at 'Removal'.
TORQUE SPECIFICATIONS.
11. Fill radiator header tank with coolant as specified
in Section 210-0000, COOLING SYSTEM.
WARNING
To prevent personal injury and property 12. Lubricate hood catch mechanism. Use grease as
damage, be sure blocking materials and lifting specified in Section 300-0020, LUBRICATION
equipment are properly secured and of SYSTEM.
adequate capacity to do the job safely.
13. Lower hood assembly and check for correct
1. If removed, secure hood catch mechanism (28 - 38) alignment between hood (1) and goalpost support
to goalpost support assembly (18) with mounting assembly (18) and for operation of hood catch
hardware as removed at 'Removal'. mechanism.
2. If removed, secure hood stops (20) and springs (21) 14. Remove wheel blocks.
to goalpost support assembly (18) with bolts (19) and
locknuts (22).
MAINTENANCE
3. Using suitable lifting equipment, lift and position Periodically check bolts (39), washers (13) and
goalpost support assembly (18) on the machine. locknuts (17) and tighten when necessary.
Secure goalpost support assembly (18) to its mounting
with bolts (23), washers (24 & 25) and locknuts (26). Periodically check condition of hood catch mechanism
and adjust and lubricate when necessary.
4. Remove lifting equipment.
5. Connect hood cable (16) ball joint to cam plate SPECIAL TOOLS
assembly (33) and secure cable (16) using clips There are no special tools required for procedures
removed during 'Removal'. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
adhesives are available from your dealer.
* * * *
SM 2173 10-02 3
THIS PAGE IS INTENTIONALLY LEFT BLANK
ENGINE - Engine and Mounting
Section 110-0030
SM - 3273
52 53
45 51
50
46 48 49 54
1 31
47 79,80
81,82 43
42
20 41
23 38 30 29
77
18
19
21 19 28 27
78
16 10
9 6
12
2 13 16
15
22
24
40
14 44
39 25 14
40
8 15
7 12
17 11 17
60
32
61
62 63,64,65,66,67
DESCRIPTION correct fuel output and timing for optimum power, fuel
economy and emissions.
Numbers in parentheses refer to Fig. 1.
The Quantum Electronic Fuel System also takes
For engine make, model and specification, refer to
action to prevent damage to the engine and, provides
Section 000-0000, GENERAL INFORMATION. For
the serviceman with diagnostic capabilities so that
engine servicing and repair data refer to the engine
problems can be corrected quickly and easily.
manufacturers service manual.
1. Electronic Control Module (ECM) - Receives
The engine is mounted to the tractor frame at three
electronic inputs from the driver as well as from
points by a mounting bracket at the front of engine (8)
mounted sensors that provide information
and two rear mounts (7). Rubber isolation mounts (14)
electronically, such as oil pressure and temperature
through engine mounts provide sufficient flexibility to
and intake manifold pressure. This information is used
absorb varying engine vibration and torsional loads.
to control both the quantity of fuel injected and injection
timing.
Lube oil filter (3) and fuel filter (4) are remote mounted
in the battery box on the left hand side of machine. The
2. Programmable Read Only Memory (PROM) -
filters are of the throw away, spin-on type. Oil supplied
Located in the ECM and encoded with the operating
by the engine oil pump passes through oil filter (3)
software. Additional information is programmed into the
before reaching the various moving parts of engine (1).
EEPROM. This information controls the horsepower
Fuel drawn from the fuel tank passes through fuel filter
rating, torque curve, maximum engine speed and
(4) before reaching the fuel pump.
engine protection devices. The ECM processes this
information and sends electronic signals to the
Engine coolant filter (5) is a replaceable spin-on type
Electronic Fuel System Injectors where the precise
element mounted on the left hand side of engine (1).
amount of fuel is injected into the engine.
Refer to Section 210-0000, COOLING SYSTEM.
3. Electronic Fuel System Injectors - The injector is
QUANTUM ELECTRONIC FUEL SYSTEM a lightweight, compact unit that injects diesel fuel
directly into the combustion chamber. The amount of
Description fuel injected and the beginning of injection timing is
Refer to Fig. 2. determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.
WARNING
The injector performs four functions:
Before any welding is done on a machine
equipped with the Quantum Electronic Fuel
a - Creates the high fuel pressure required for efficient
System, disconnect the following in this order:
injection.
Battery earth cable, battery supply cable,
b - Meters and injects the exact amount of fuel required
alternator earth cables, alternator supply cables
to handle the load.
and electrical connections at the engine ECM,
c - Atomizes the fuel for mixing with the air in the
transmission ECU, body control lever,
combustion chamber.
hydraulics ECU and cab bulkhead to avoid
d - Permits continuous fuel flow for component cooling.
damage to electrical components. Turn off
battery master switch to isolate the batteries
Electronic fuel system injectors are self compensating
before disconnecting any components.
and virtually eliminate engine tune-ups.
After welding connect all of the above in the
Note: Never apply 12 V directly to terminals on the
reverse order.
injector as it will burn out. Before removing injectors,
the fuel passages must be blown out to prevent fuel
The engine is equipped with Quantum Electronic Fuel
flow from entering the cylinder head.
System which controls the timing and amount of fuel
injection by the electronic fuel system injectors. The
4. Batteries - Two 12 volt maintenance free batteries
system also monitors several engine functions using
supply the machine with electrical power to operate all
electrical sensors which send electrical signals to the
electrical components.
electronic control module (ECM). The ECM then
computes the incoming data and determines the
SM - 3734
6 7
3
2 STOP P
1
9
8
10 11
1,2
4
LO
HI
5. Electronic Foot Pedal - The electronic foot pedal 8. Diagnostic Test Point - Plug in connector for
provides an electrical signal to the engine's fuel control diagnostic data reader (DDR).
system in proportion to the degree of pedal actuation.
9. Maintenance Light - The maintenance light will
Note: The engine MUST be started with foot 'OFF' the illuminate when it is time to change the engine oil. The
electronic foot pedal. maintenance monitor continuously monitors the time
the engine has been operating and the amount of fuel
Do not place engine under full load at full speed burned to determine when it is time to change oil.
immediately after starting. Always allow the engine to
fully circulate lubricant and warm up gradually before Note: Whenever an electrical fault has occurred, the
operating at full speed and full load. Operate engine at maintenance monitor data can be inaccurate.
top rated speed when maximum power is needed for
the load. 10. Engine Diagnostic Switch - To check for active
codes:
6. Stop Engine Light - When the 'Stop Engine' light
comes on, the computer has detected a major a - turn the ignition key switch to the 'OFF' ('0') position.
malfunction in the engine that requires immediate
b - press the diagnostic switch to the 'ON' position.
attention. It is the operators responsibility to shut down
the engine to avoid serious damage. c - turn the ignition key switch to position '1'.
7. Check Engine Light - When the 'Check Engine' light If no active codes are recorded, both the 'Stop' and
comes on, the computer has detected a fault in the 'Check' lights will illuminate and stay on.
engine. The fault should be diagnosed and corrected at
the earliest opportunity. If active codes are recorded the 'Stop' and 'Check'
Operation WARNING
Numbers in parentheses refer to Fig. 2. The operator of a Quantum-equipped vehicle
must not attempt to use or read a data reader of
When the 'Stop' light on the dash panel illuminates, the any kind while the vehicle is operating. Doing
ECM (1) has detected a major malfunction in the so can result in loss of control, which may
engine that requires immediate attention. It is the cause vehicle damage and may result in
operators responsibility to shut down the engine to personal injury.
avoid serious damage.
The operator can check for active faults by turning the
The machine is equipped with an engine protection ignition key switch to the 'OFF' position, switching the
derate system, which records fault codes and diagnostic switch (10) 'ON' and then turning the ignition
illuminates appropriate warning lights when an out-of- key switch to position '1'.
range condition associated with any of the following
sensors is found: If no active fault codes are recorded, both 'Stop' (7) and
• Coolant temperature 'Check' (6) lights will come on and stay on. If active
codes are recorded, both lights will come on
• Coolant level momentarily. The amber 'Check' (6) and red 'Stop' (7)
• Intake manifold temperature lights will begin to flash the code of the recorded fault.
• Oil pressure The fault codes flash in the following sequence: the
• Oil temperature amber light flashes once, then there is a pause where
both lights are off. Then the numbers of the recorded
The engine power and speed will be gradually reduced
fault code flash in red. There is a pause between each
depending on the level of severity of the out-of-range
number. When the number is done, the amber light
condition. The operator MUST shut down the engine to
flashes again. e.g. amber flashes once - pause - red
avoid serious damage.
flashes twice - pause - red flashes three times - pause
- red flashes five times - pause - amber flashes once,
The engine should not be restarted after it has been
indicates fault code 235. The number will repeat in the
shut down after activation of the engine protection
same sequence until the the system is advanced to
derate system unless the problem has been diagnosed
the next active fault code by diagnostic request switch
and corrected.
(11), or the diagnostic switch (10) is switched to the
'OFF' position. Refer to 'Electronic Fuel System
Whenever the 'Stop' (7) or 'Check' (6) light comes on,
Diagnostic Codes' table for fault code descriptions.
the Electronic Fuel System computer will determine
where the problem is and will store this information in
1 FLASH 2 FLASHES 3 FLASHES 5 FLASHES 1 FLASH
its memory. If the malfunction is intermittent, the lights
will come on and go off as the computer senses the
changing engine condition. AMBER RED RED RED AMBER
(CEL) (SEL) (SEL) (SEL) (CEL)
CODE 235
SM - 3735
Note: Maintenance monitor is designed to alert the 6. The maintenance light will flash three times. This
operator of the need for a routine maintenance stop. means the maintenance monitor is reset.
Maintenance records must still be maintained for Note: If the maintenance light does not flash as
historical purposes. described, the reset sequence must be performed
again.
Note: Whenever an electrical fault has occurred, the
maintenance monitor data can be inaccurate. 7. Turn key to position '0'.
'Severe' oil drain interval duty cycle is the default 8. Remove blocks from road wheels.
setting for the maintenance monitor, however this can
be adjusted by using diagnostic tools, to suit duty Alternative method of resetting maintenance monitor is
cycle and oil type used. Engine oil drain intervals are as follows:
dependant on working environment and oil type used.
Refer to 'Engine oil drain intervals by duty cycle 1. Park machine on level ground, block road wheels,
(Hours)' table below. Refer to Section 300-0020, apply parking brake and switch off engine.
LUBRICATION SYSTEM for recommended oil type.
2. Turn keyswitch to position '1'.
The maintenance monitor will alert the operator of the
need to change oil by flashing the maintenance light for 3. Press engine diagnostic switch on.
approximately 12 seconds after key-on. The flashing
sequence will be three quick flashes, followed by a 4. Press and hold throttle pedal at 100% for 3 seconds,
pause. This flash sequence will go through five cycles then release.
in the 12 second period. This sequence will occur at
every key-on until the maintenance monitor has been 5. Press throttle pedal 100% on then off quickly, twice.
reset.
Note: The diagnostic switch must be OFF for the 6. Press and hold throttle pedal at 100% for 3 seconds,
flashing sequence to occur. then release.
Resetting the Maintenance Monitor - There are two 7. The maintenance light will flash three times.
ways to reset the maintenance monitor, depending on Note: If the maintenance light does not flash as
the engine ECU calibration. described, the reset sequence must be performed
again.
1. Park machine on level ground, block road wheels,
apply parking brake and switch off engine. 8. Press engine diagnostic switch off.
3. Press engine diagnostic switch on for a minimum of 10. Remove blocks from road wheels.
8. Remove hood and goalpost from the vehicle. Refer 19. Identify fuel lines for ease of installation and with a
to Section 100-0040, HOOD AND MOUNTING. suitable container in position, disconnect fuel lines
from the engine (1). Cap open line ends and fittings.
Note: Radiator header tank will be removed as part of
20. Identify all electrical harnesses and cables for ease
24. Remove locknuts (17), snubbing washers (15 ) and 8. Turn the adjusting screw (4, Fig. 3) anticlockwise to
bolts (16) securing engine (1) to the frame through front release tension. Remove alternator belt (2).
mounting bracket (8) and rear mounting brackets (7).
9. Remove alternator mounting capscrew (3, Fig. 3)
25. Check to make certain that all necessary line and and adjustment link locking capscrew (2, Fig. 3).
electrical disconnections have been made before lifting Remove alternator.
engine (1).
10. Disconnect the electrical connector (78) harness to
26. Carefully lift engine (1) clear of the frame, remove fan clutch (27).
to a suitable work area and mount securely on a work
stand. 11. Remove nut (29), washers (30) and studs (38)
securing fan (28) and clutch (27) to engine (1) fan hub.
DISASSEMBLY 12. Remove both fan (28) and clutch (27) together from
Numbers in parentheses refer to Fig. 1. the engine (1).
1. Remove bolts (11 & 13) and washers (12) securing 13. Loosen fan idler pulley shaft locknut. Loosen the
front mounting bracket (8) to engine (1). Remove front adjusting link to slacken the fan belt (6). Remove fan
mounting bracket (8). belt (6).
2. Remove bolts (9) and washers (10) securing rear 14. Remove bracket supporting hoses from top of
mounts to engine (1). Remove mounts (7). flywheel housing.
1 - Locknut 3 - Capscrew
2 - Capscrew 4 - Adjusting Screw
Fig. 3 - Alternator Mounting
INSPECTION 10. Fit alternator belt (2) between alternator pulley and
accessory drive pulley. Turn adjusting screw (4, Fig. 3)
Numbers in parentheses refer to Fig. 1.
clockwise to increase belt tension; anticlockwise to
decrease belt tension. Refer to Engine Operation and
1. Inspect rubber isolation mounts (14) for damage and
Maintenance Manual for correct alternator belt (2)
replace if required.
tension.
2. Check mounting brackets (7 & 8) and mounting
11. Tighten the adjusting screw locknut (1, Fig. 3)
brackets on the front frame for cracks and/or damage.
against the retainer. Tighten the adjustment link locking
Repair or replace as necessary.
capscrew (2, Fig. 3) to 59 lbf ft (80 Nm).
3. Inspect engine coupling (23) for damage and repair
12. Tighten the alternator mounting capscrew (3, Fig. 3)
or replace as required.
to 35 lbf ft (47 Nm).
5. Install air cooler pipes from engine turbocharger and 18. Ensure shut-off valve at the bottom of the radiator
engine inlet manifold to charge air cooler mounted on assembly and any drain cocks on engine (1) water
the radiator assembly. Refer to Section 210-0040, jacket are securely closed. Ensure shut off cocks at
RADIATOR AND MOUNTING. coolant filter (5) are open to allow flow through the filter.
6. Install air cleaner intake pipe and exhaust piping to 19. Fill the cooling system with coolant. Refer to
engine turbocharger. Section 210-0000, COOLING SYSTEM.
7. Remove caps from heater lines and fittings and 20. Fill the engine with lubricant through oil filler to the
connect heater lines to engine (1) as identified at top mark on dipstick. Refer to Section 300-0020,
removal. LUBRICATION SYSTEM for oil specification.
8. Remove caps from fuel lines and fittings and 21. Fill transmission oil cooler with oil. Refer to Section
connect fuel lines to engine (1) as identified at removal. 210-0060, TRANSMISSION OIL COOLER.
9. Connect all electrical harnesses and cables to 22. Check all line and pipe connections for leaks prior
engine (1) (with the exception of battery connections) to starting the vehicle. Tighten as required.
as identified at removal.
23. Install hood assembly on the vehicle. Refer to
10. Connect air conditioner lines at the compressor as Section 100-0040, HOOD AND MOUNTING.
identified at removal. On completion of engine
installation the air conditioning system will require to 24. Using hydraulic hand pump inside battery box,
be charged. Refer to Section 260-0130, AIR lower cab and secure. Refer to Section 260-0010, CAB
CONDITIONING. AND MOUNTING.
11. Install the goalpost and radiator header tank 25. Switch the battery master switch to the 'On'
assembly on the vehicle. Refer to Section 100-0040, position, start up the engine and check for leaks.
HOOD AND MOUNTING. Tighten lines, pipes and fittings and top up all systems
as required.
12. Ensure all cooling lines to radiator assembly,
engine (1) and radiator header tank are correctly 26. Using suitable lifting equipment position front guard
connected. Refer to Section 210-0040, RADIATOR plate under the engine and secure to the frame with
AND MOUNTING. mounting hardware removed during removal.
13. Remove covers from air cleaner intake pipe and 27. Using suitable lifting equipment position engine
rubber hose on the air cleaner inlet then slide air sump guard under the engine and secure to the frame
cleaner assembly towards the cab locating the rubber with mounting hardware removed during removal.
hose to the inlet pipe.
28. Remove wheel blocks from all road wheels.
14. Secure air cleaner assembly to the battery box,
rubber hose to the inlet pipe and intake tube to
goalpost assembly with mounting hardware removed MAINTENANCE
during removal. Numbers in parentheses refer to Fig. 1.
15. Install transmission oil cooler on the vehicle. Refer Note: Carry out the following maintenance procedures
to Section 210-0060, TRANSMISSION OIL COOLER. in conjunction with additional procedures listed in
Section 300-0020, LUBRICATION SYSTEM.
16. Connect battery positive connections to battery
terminals. Connect battery earth connections to battery
terminals. Every 10 Hours (Daily)
Engine (1) - Visually check engine for damage, loose
17. Ensure all lines, harnesses and cables are secured or frayed belts and listen for any unusual noises.
with clips and clamps as removed during removal. Check coolant level and air cleaner restriction. Check
Cooling Fan (28) - Visually inspect the fan for cracks Apply a light film of clean lubricating oil to the gasket
or damaged blades. Check the fan to make sure that surface of the new filter and install the filter on the filter
mounting bolts (29) are secure. Tighten bolts as head. Turn the filter until the gasket contacts the filter
required. Replace any fan that is damaged. head surface. Tighten the filter an additional 1/2 to 3/4
of a turn, or as specified by the filter manufacturer.
Every 500 Hours Start the engine and operate at idle speed to inspect
Engine Oil and Lube Oil Filter (3) - Replace the for leaks at the filter and oil drain plug. Shut off the
lubricating oil and oil filter (3). engine, wait approximately ten minutes to let the oil
drain back to the sump and check the oil level again.
Add oil as necessary to bring the level to the high (H)
Note: Mechanical tightening of the filter is not 7. Start the engine and check for leaks. If any leaks are
recommended and may result in seal and/or cartridge noted, have them corrected. Add coolant as required.
damage. Tighten filter by hand only. Refer to Section 210-0000, COOLING SYSTEM.
2. Close shut off valves at coolant filter (5) inlet and SPECIAL TOOLS
outlet lines and, using filter wrench, remove and Refer to Section 300-0070, SERVICE TOOLS, for part
discard coolant filter (5) from engine (1). numbers of service tools which should be used in
conjunction with procedures outlined in the engine
manufacturers service manual, and, general service
tools required. These tools are available from your
dealer.
* * * *
SM - 2790
2,3
1
5
7
6
SWE
SM 2175 10-02 1
Engine - Cooling Fan
Section 110-0040
REMOVAL
Numbers in parentheses refer to Fig. 1. WARNING
To prevent personal injury and property
damage, make sure blocking or lifting
WARNINGS equipment is properly secured and of adequate
To prevent personal injury and property capacity to do the job safely.
damage, make sure blocking or lifting
equipment is properly secured and of adequate 1. Install EST fan drive (5) on fan (4) mounting surface
capacity to do the job safely. of housing and secure in place with lockwashers (2)
and nuts (3).
Personal injury can result from a fan blade 2. Using suitable lifting equipment, position fan (4)
failure. Never pull or pry on the fan as this can assembly on the machine and secure to engine with
damage the blades and lead to fan failure. bolts (1). Torque tighten bolts (1) to 31 Nm (23 lbf ft).
1. Position the machine on a level work area, ensure Note: Ensure there is even clearance, all the way
the body is fully lowered, apply the parking brake and round, between fan (4) and the fan shroud.
switch off the engine. Operate the steering several
times to discharge the steering system. 3. Connect harness (7) at the connector on the fan
drive (5) braided cable.
2. Block all road wheels and place the battery master
switch in the off position. 4. If removed, install radiator on machine. Refer to
Section 210-0040, RADIATOR, HEADER TANK AND
3. If required, remove mounting hardware securing MOUNTING. Install fan guards to the fan shroud and
hood assembly to the machine and, using suitable secure with mounting hardware, as removed at
lifting equipment, remove hood assembly. Refer to 'Removal'.
Section 100-0040, HOOD AND MOUNTING.
5. If removed, position the hood assembly on the
4. Remove mounting hardware securing fan guards to machine using a suitable lifting device. Secure hood
the fan shroud. Remove fan guards from the machine. assembly on the machine with mounting hardware, as
If required remove radiator from the machine. Refer to removed at 'Removal'. Refer to Section 100-0040,
Section 210-0040, RADIATOR, HEADER TANK AND HOOD AND MOUNTING.
MOUNTING.
6. Start the engine and check for correct operation of
5. Disconnect harness (7) at the connector on the fan the fan. Refer to 'Testing' procedures contained in this
drive (5) braided cable. section.
6. Support fan (4) assembly with suitable lifting 7. Remove wheel blocks.
equipment and remove bolts (1) securing fan (4)
assembly to the engine. Remove fan (4) assembly
from the machine. TESTING
7. Remove nuts (3) and lockwashers (2) securing EST Static Test
fan drive (5) to fan (4) mounting surface of housing. Note: This test will only determine if the fan drive has
Remove EST fan drive (5) from housing. seized or is very close to seizure.
Note: Tighten all fasteners without special torques Note: Rotation without resistance indicates a fault.
specified, to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. Basic Dynamic Test - Cut In/Cut Out
Note: This test is carried out with the machine static
and secured at rest.
2 SM 2175 10-02
Engine - Cooling Fan
Section 110-0040
After the machine has stood for approximately 30 2. Maintain engine speed at 2 100 rev/min and
minutes with the engine stopped, start the engine and disconnect harness at the connector on the fan drive
increase engine speed to 2 100 rev/min. braided cable. Fan should automatically engage to full
flow speed.
Initially the fan noise should be loud (cut in), but before
a further minute has elapsed, the fan noise should
significantly reduce (cut out). MAINTENANCE
Every 10 Hours/Daily
Basic Dynamic Test - Fan Drive Operation Check the fan for cracks or damaged blades. Clean or
Note: This test is carried out with the machine static replace as required.
and secured at rest.
Note: This DST fan is a non-serviceable component.
1. Place a cardboard, or alternative material, sheet However, the following instructions must be strictly
over the radiator front with an approximate 100 mm adhered to:
(4 in) diameter hole in the sheet, in line with the centre
of the fan drive. 1. DO NOT clean around fan drive with steam or high
pressure jet.
2. Start the engine and increase engine speed to
2 100 rev/min. 2. DO NOT tamper with modulation control mechanism
for ANY reason.
3. Fan noise should initially be loud and reduce
significantly before 1 minute has elapsed. 3. DO NOT add any fluids or lubricants to the drive.
4. Maintain engine speed at 2 100 rev/min. Fan drive 4. DO NOT restrict fan rotation during engine operation
should 'cut in' (engage) before coolant temperature for ANY reason.
gauge indicates excessive coolant temperature.
5. DO NOT operate a machine with a damaged fan
5. Return engine speed to idle, quickly remove the assembly. Replace a damaged fan as soon as the fault
sheet in front of the radiator and bring engine speed is noted.
back up to 2 100 rev/min. Fan speed should 'cut out'
(disengage) within 1 minute. 6. DO NOT disassemble ANY fan assembly or
associated parts that are still within the warranty
coverage period.
Failsafe Check
Note: This test is carried out with the machine static 7. IMMEDIATELY investigate and correct ANY
and secured at rest. Hood should be raised and operator complaint involving drive or cooling system
secured. performance.
* * * *
SM 2175 10-02 3
THIS PAGE IS INTENTIONALLY LEFT BLANK
ENGINE - Air Cleaner
Section 110-0050
SM - 2791
5
1
4 3
SM 2176 11-02 1
Engine - Air Cleaner
Section 110-0050
SM - 2792
19 18 1716
24
9 2513 10
15 16
11
14
1 13
12
2
20 8
23
3
4
22 21
18
17 5
19 6
protection of the engine from airborne dirt. It protects the 'Off' position.
the engine from dirt admitted by a damaged primary
element (2), or dirt that might be dropped into air 3. Pull on handle to release hood catch and lift up the
cleaner assembly while changing primary element (2). hood.
2 SM 2176 11-02
Engine - Air Cleaner
Section 110-0050
7. Blank off all open ends with tape or cardboard to b. Check that air cleaner mounting bracket (21) is
prevent entry of dirt. secure and that air cleaner is mounted securely.
Disassembly
Numbers in parentheses refer to Fig. 1, unless WARNING
otherwise specified. Always shutdown the engine before servicing
air cleaner.
Note: Air cleaner body (1) should be thoroughly
cleaned twice a year. Do not apply heat in any form to Check air restriction gauge (2, Fig. 2) daily (every 10
air cleaner body (1). hours). The air cleaner elements should be serviced
only when the maximum allowable restriction has been
1. Release latches on cover assembly (6) and remove reached, as indicated by air cleaner restriction gauge
cover assembly from air cleaner body (1). (2, Fig. 2). The elements should not be serviced on the
basis of visual observation as this would lead to over
2. Remove primary element (2) and safety element (3) service. When restriction readings finally indicate a
from air cleaner body (1). change, remove primary element (2) carefully and
clean/replace as required. Refer to 'Primary Element'.
3. Open mounting bands (5) and remove from air
cleaner body (1). Never attempt to clean safety element (3). Change
safety element (3) after every third primary element (2)
4. Slacken clamp (20, Fig. 2) and remove air intake service.
tube (1, Fig. 2), complete with retaining bracket (14,
Fig. 2) and seal (15, Fig. 2), from air cleaner body (1). Make sure vacuator valve (4) is not damaged or
plugged and that the joint with cover assembly (6) is
5. Blank off air cleaner body (1) outlets with tape or not broken. If vacuator valve (4) is lost or damaged,
cardboard. Reach inside body with a compressed air replace it to maintain pre-cleaner efficiency and normal
nozzle or brush and remove dust from the body. filter element service life.
6. Remove all loose dust from air cleaner body (1) and Check condition of clamps (8 & 23, Fig. 2), elbow
remove tape or cardboard from body outlets. (7, Fig. 2) and air intake tubes (1 & 9, Fig. 2). Tighten/
replace as necessary.
Assembly/Installation
Numbers in parentheses refer to Fig. 2, unless Primary Element
otherwise specified. Numbers in parentheses refer to Fig. 1.
Note: Tighten all fasteners to standard torques listed Although a paper primary element (2) is used, it is
in Section 300-0080, STANDARD BOLT AND NUT possible to remove excess dirt by tapping element.
TORQUE SPECIFICATIONS.
1. Release latches on cover assembly (6) and remove
Assembly and installation of the air cleaner assembly cover assembly from air cleaner body (1).
is the reverse of disassembly and removal. Reset air
restriction gauge (2). 2. Remove primary element (2) from air cleaner body (1)
and clean/replace. It is advised to replace the element
Following installation, but before starting the engine, rather than attempt to clean thoroughly.
the following system checks should be carried out:
3. Using a damp cloth and a suitable solvent, wipe out
a. Check air intake tube (9) for defects and that clamps all excess dust from air cleaner body (1) and allow to
(8 & 23) (and those supplied with the engine) are dry.
securely tightened to ensure that there are no leaks in
the system. 4. Install primary element (2) in air cleaner body (1).
SM 2176 11-02 3
Engine - Air Cleaner
Section 110-0050
5. Install cover assembly (6) on air cleaner body (1) (air cleaner outlet) increases. This vacuum is generally
and secure with latches. measured as 'restriction in mm (inches) of water'.
* * * *
4 SM 2176 11-02
TRANSMISSION - Transmission and Mounting
Section 120-0010
SM - 3364
11
17
16
2 15
14
5 12 LH
3 13 RH
4
16
22
10
10
CROSSMEMBER ON FRONT FRAME
1 6 8 23
8 9 24
7 25
26
27
21 19
20 28
18
SM - 2794
1
2
10 4
11
RHS
8
1 - Oil Temperature Sender (Gauge)
2 - Main Control Valve 7
3 - Transmission Difflock Solenoid
4 - Lockup Solenoid
5 - Engine Speed Sensor
6 - Output Speed Sensor
7 - Central Gear Train Sensor
8 - Turbine Speed Sensor
9 - Trans. Cooler Fan Drive Temp. Sensor
10 - Breather
11 - Retarder Oil Temperature Sensor 3
SM - 1826
VALVE BLOCK
COVER
Y3 Y4
Y2 Y5 6
Y1 Y6
2 1
HOUSING
SYSTEM PRESSURE FROM
CONTROL UNIT BREATHER
Fig. 3 - Sectional View of Typical Control Unit with Lockup Clutch (Wk)
Lockup Clutch (Wk) clutches. These clutches are controlled via the six
The transmission lockup clutch is automatically proportional valves (6, Fig. 3). Each proportional valve
engaged. Engine speed is picked up by turbine speed (6, Fig. 3) is composed of a pressure regulator (Y1 to
sensor (8) which sends a signal to energise lockup Y6, Fig.3), follow-on slide (5, Fig. 3) and vibration
solenoid (3, Fig. 3) when turbine speed reaches a damper (7, Fig. 3).
predetermined level. Energising lockup solenoid
(3, Fig. 3) will move lockup valve (4, Fig. 3) across, The control pressure of 9 bar for the actuation of the
allowing oil to flow through the valve to engage lockup. follow-on slides (5, Fig. 3) is created by the pressure
reduction valve (2, Fig. 3). The pressure oil (16+2
bar) is directed via the follow-on slide (5, Fig. 3) to
Gear Selection the respective clutch.
The transmission can be engaged and disengaged
under load by means of hydraulically controlled multi- Due to the direct proportional control with separate
disc clutches. All gears run in antifriction bearings and pressure modulation for each clutch, the pressures to
are constantly meshed. The gears, bearings and the clutches, which are taking place in the gear
clutches are lubricated with cooled oil. change, are controlled. In this way, a hydraulic
intersection of the clutches to be engaged and
The transmission is equipped with six multi-disc disengaged becomes possible. This creates fast
5 6
A1 B1 A2 B2
3 CT1 CT2
1
INLET
1
CT3 T2
2
2
CT4 TRANS
SUMP
4
3
4
7
TO 'TS' PORT ON
MAIN HYDRAULIC
VALVE
TRANSMISSION
PILOT PRESSURE
MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE: 1st POWER TAKE-OFF
58
56
Section 120-0010
R3 • •
N
CLUTCH KR K4 K1 K3 KV K2
POS. VALVE F E D C B A
SM - 1824
POINTS 55 60 56 58 53 57
5
6
Section 120-0010
Transmission - Transmission and Mounting
SM - 2570
KR K4 K1 K3 KV K2
F 55 E 60 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D
Fig. 7 - Oil Circulation Diagram for Typical Transmission with Lockup Clutch and Retarder
RV-9
TEMP
16 15
WITH RETARDER
RT-V
LEGEND:
FILLING POSITON IN THE CABIN TRANSMISSION PUMP = MAIN PRESSURE
63 = CONTROLLED MAIN PRESSURE
= PILOT PRESSURE
= CONVERTER INLET PRESSURE
SM 2177 Rev3 03-07
33 34
RT OIL SUMP
Transmission - Transmission and Mounting
Section 120-0010
SM - 2798 SM - 2335
S
T
O
P
1 2 3
FULL LOAD/THROTTLE
2 - Display shows actual driving direction.
KICK/HOLD DOWN 3 - Display shows actual gear in use.
Fig. 8 - Accelerator Load Ranges and Kickdown Position Fig. 9 - Dashboard Display
'NEUTRAL' and the parking brake applied when starting 2. Kickdown can be selected from 2nd automatic, when
the engine, or whenever the machine is left unattended. the transmission will downshift to 1st gear, depending
upon vehicle speed.
When shifting from 'NEUTRAL' to start from a
standstill, or to reverse direction, decelerate the engine When the kickdown is released the transmission will
to idle speed before selecting the proper gear. When upshift to 2nd automatic, provided that the forward
'REVERSE' is selected, the 'Reverse Alarm' sounds speed has increased sufficiently to allow this to
and the 'Reverse Light' illuminates to warn personnel to happen, and that the shift lever is in the automatic
the rear of the machine that reverse gear has been mode.
selected.
A dashboard display is provided which indicates gear
During reversing operations it is recommended to selected and driving direction as follows (See Fig. 9):
reduce engine speed, use only 1st or 2nd gear and
never exceed 10 km/h (6.2 mile/h). Manual Mode - When driving with shift selector in
manual range, the bars only are shown in position 1,
The electronic control system distinguishes between and, driving direction and gear selected are indicated
the throttle position (or load ranges) depending on the in positions 2 and 3.
governor position (injection pump). On a light throttle
opening, the transmission will give earlier upshifts and Automatic Mode - When driving with shift selector in
later downshifts than when operating at full throttle. automatic range, a full display of bars and arrows are
shown in position 1, and, driving direction and gear
A kickdown facility (See Fig. 8), which can be used selected are indicated in positions 2 and 3.
when automatic mode is selected, allows for the
possibility of selecting a lower gear by pressing down Under certain conditions the transmission may start
fully on the throttle pedal and holding. This can be used to 'hunt' between gears when in automatic mode. The
to provide a downshift on demand provided that the transmission changes up and down between two
vehicle speed is within the range allowable. That is, the gears at short intervals because there is not
vehicle is not travelling at a speed that would result in sufficient power to sustain driving in the higher gear,
the engine overspeeding in the lower gear. but is sufficient for upshifting from the lower gear. By
When driving with kickdown, the transmission will give using the shift display, it can be established which
earlier downshifts and later upshifts. To disengage the gears are involved and in these circumstances the
transmission kickdown, release the throttle pedal and lower gear should be selected using the shift control
allow it to return to a light throttle position. lever. Automatic mode should be reselected at the
earliest opportunity.
When operating in automatic range with the display
indicating that the transmission has downshifted to 2nd During machine operation, watch for wide deviations
gear, there are two options for providing a further from normal readings on the transmission oil
downshift as conditions indicate. temperature gauge. If the gauge shows the oil
temperature rising above 120° C (248° F) during normal
1. 1st gear can be manually selected by pushing the operation, or above 145° C (293° F) during retarder
shift lever to the left. operation, the machine must be stopped and inspected
8 SM 2177 Rev3 03-07
Transmission - Transmission and Mounting
Section 120-0010
for external oil leakage. If no leaks are found, shift to
'NEUTRAL' and operate the engine at 1 200 - 1 500 rev/ WARNING
min. If the transmission oil temperature does not
Always select the correct drive direction and
decrease into the normal zone within 2 or 3 minutes,
gear before releasing the parking brake.
the cause of the overheating should be corrected
before the machine is operated further.
WARNINGS
Note: In cold weather, the transmission oil should be Never allow the machine to coast with the
warmed up by running the engine at idle speed with the transmission in 'NEUTRAL'.
gear selector in neutral, since the system will not
When running down a gradient the engine
operate satisfactorily if the oil is too cold.
speed should not be allowed to drop below
1 200 rev/min, at which point, lockup would
When temporarily stopped, such as for yielding the
disengage preventing retarder operation.
right-of-way to a loaded machine, the transmission
can be left in gear and the machine held stationary with In the event of a loss of electric power to the
the service brakes. gear shift control, the transmission will
automatically shift to 'NEUTRAL'. If this occurs,
When stopped for a more extended period with the stop the machine using the service brakes and
engine left running, shift to 'NEUTRAL' to avoid apply the parking brake. Do not operate until
unnecessary heat buildup, and apply the parking brake. the fault has been repaired.
Always select 'NEUTRAL' and apply the parking
brake before leaving the operators seat.
The AEB-Starter is a tool to start the AEB (automatic filling parameter adjustment) of ergopower transmissions
with ease. Connect AEB-Starter to plug X25 located below dash adjacent to TCU.
15 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2 TCU shifts transmission • check cables from TCU Fault is taken back if
SHIFT LEVER to neutral if selector to shift lever 2 TCU detects a valid
TCU detected a wrong signal combination for the active •check signal neutral signal for the
direction OP-Mode: transmission combinations of shift lever direction at the shift
• cable from shift lever 2 to TCU is broken shutdown if selector positions F-N-R lever
• cable is defective and is contacted to battery active
voltage or vehicle ground
• shift lever is defective
16 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal • check cables from TCU
feedback axle connection measured by TCU to feedback axle
and output signal axle connection don't fit connection switch
• axle can't be connected/disconnected due to •check signals of the
mechanical problem feedback axle connection
• one of the cables from feedback axle connection -
switch to TCU is broken
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire
harness of the gearbox
74 S.C. TO BATTERY VOLTAGE AT CLUTCH K2 TCU shifts to neutral • check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K2 valve is too high. if failure at another • check connectors from
• cable / connector is defective and has contact to clutch is pending gearbox to TCU
battery voltage TCU shifts to neutral • check regulator resistance 1)
• cable / connector is defective and has contact to OP-Mode: TCU shutdown • check internal wire
another regulator output of the TCU harness of the gearbox
• regulator has an internal defect
D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 •check cables and fault codes no. 21
TCU measures more than 6V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
•check power supply at
pin AU1 (should be
approx. 5V)
D2 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS see fault codes no. 21 •check cables and fault codes no. 21
TCU measures less than 4V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
•check power supply at
pin AU1 (should be
approx. 5V)
D3 LOW POWER AT BATTERY shift to neutral •check power supply
measured voltage at power supply is lower OP-Mode: TCU shutdown battery
than 18 V •check cables from
batteries to TCU
• check connectors from
batteries to TCU
D4 HIGH POWER AT BATTERY shift to neutral •check power supply
measured voltage at power supply is higher OP-Mode: TCU shutdown battery
than 32.5 V •check cables from
batteries to TCU
• check connectors from
batteries to TCU
8.1 Actuator:
1
2
G
P (power supply)
TCU
1 2 Actuator / Sensor
C (chassis)
Gnd
SM - 2795
8
12
13
14
5
7 10 2
3
1 4
11 8
12. Identify, tag and disconnect hydraulic lines at the 17. Identify, tag and disconnect all remaining lines and
main hydraulic valve. Cap lines and ports to prevent fixtures necessary to allow removal of the transmission
entry of dirt. from the vehicle.
13. Identify, tag and disconnect transmission oil cooler 18. Attach suitable lifting equipment to the lifting points
lines from the transmission. Cap lines and ports to on transmission and raise lifting equipment to take up
prevent entry of dirt. the slack.
14. Identify, tag and disconnect hydraulic lines (6, 7, 8, 19. Remove locknut (10), hardened washer (22), bolt
9 & 10, Fig. 12) at the diff-lock/retarder valve. Cap (11) and snubbing washer (17) securing LH bracket (12)
lines and ports to prevent entry of dirt. to frame mounts.
15. Identify, tag and disconnect hydraulic lines at the 20. Remove locknut (10), hardened washer (22), bolt
hydraulic tank. Cap lines and ports to prevent entry of (11) and snubbing washer (17) securing RH bracket
dirt. (13) to frame mounts.
16. Identify and tag diagnostic hose assemblies (22 & 21. Remove locknuts (10), washers (8) and bolts (9)
23, Fig. 12) to aid in installation. Disconnect hose securing front bracket assembly to frame mounts.
assemblies (22 & 23, Fig. 12) and cap open ends and
tee (21, Fig. 12) and adaptor (26, Fig. 12) to prevent 22. Check to make certain that all necessary line and
SM - 2796
21 13
5
12
23
11 6
1
11
7
17 2
1
22 26
18 10
3,4
8 25
19 20
TO DIAGNOSTIC
MANIFOLD PLATE
TO 'TS' PORT
ON HYD. VALVE
9 TO AXLE DIFF-LOCK
24
27
15 16
MANIFOLD
(REAR OF FRONT FRAME)
MANIFOLD
14 (REAR FRAME)
cable disconnections have been made before lifting the (5, Fig. 12) securing diff-lock/retarder valve to bracket
transmission. assembly and remove valve.
23. Carefully raise the transmission ensuring that no 2. If required, pressure reducing valve (2, Fig. 12),
lines, cables or components foul during removal. The solenoid cartridges (3, Fig. 12) and coils (4, Fig. 12)
transmission may have to be pushed forward to allow can be removed from diff-lock/retarder valve.
output yoke to clear rear of frame. When the
transmission is clear of the frame assembly, move to a 3. Remove bolts (14), lockwashers (15) and LH bracket
suitable work area and mount securely on a work (12) from the transmission. Remove isolation mount
stand. (16) from LH bracket (12) and replace if required.
3. Check condition of all electrical harnesses and 8. Secure diff-lock/retarder valve (1, Fig. 12) to bracket
connections and repair/replace as required. Check assembly (20, Fig. 12) with mounting hardware
condition of all hydraulic lines on the transmission removed during Disassembly.
and replace if damaged.
9. Mount bracket assembly (20, Fig. 12) and diff-lock/
retarder valve (1, Fig. 12) to transmission with
ASSEMBLY fasteners removed during Disassembly.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
INSTALLATION
Note: Tighten all fasteners without special torques Numbers in parentheses refer to Fig. 1, unless
specified to standard torques listed in Section 300- otherwise specified.
0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
1. Install new gasket (19) on dipstick tube (18) 300-0080, STANDARD BOLT AND NUT TORQUE
assembly and secure assembly to the transmission
SM 2177 Rev3 03-07 27
Transmission - Transmission and Mounting
Section 120-0010
SPECIFICATIONS.
10. Remove blanking caps and connect lines to main
Note: Tighten all hydraulic lines fitted with ORFS hydraulic valve, as identified at removal.
connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings 11. Remove blanking caps and connect hydraulic lines
where used. to the hydraulic pump, as identified at removal.
1. Lubricate isolation mounts (16) with water or a 14. Connect all drivelines to the transmission and
suitable rubber lubricant and install in front frame secure with mounting hardware removed during
mounts, with spigots to the underside of the mounts. removal. Refer to Section 130-0010, DRIVELINES.
2. Attach suitable lifting equipment to transmission 15. Prior to installing the cab, ensure that all connections
lifting points and carefully position the transmission to the transmission, other than cab connections, are
assembly in the frame. Take care to avoid snagging connected securely and properly clipped.
any lines, harnesses or components attached to the
transmission. 16. Install the cab assembly on the front frame. Refer
to Section 260-0010, CAB AND MOUNTING.
3. Secure rear mounting brackets (12 & 13) to frame
mounts with bolts (11), snubbing washers (17), hardened 17. Connect all harnesses and electrical connections at
washers (22) and locknuts (10), as shown in Fig. 1. front of the cab.
Tighten bolts (11) to a torque of 920 Nm (679 lbf ft).
18. Fill hydraulic tank with hydraulic oil specified in
4. Secure front bracket assembly to frame mounts with Section 300-0020, LUBRICATION SYSTEM. Refer to
bolts (9), washers (8) and locknuts (10). Tighten bolts Section 230-0040, HYDRAULIC TANK for fill level
(9) to a torque of 920 Nm (679 lbf ft). and procedure.
5. Remove lifting equipment from lifting points on 19. Fill transmission with engine oil specified in Section
transmission. 300-0020, LUBRICATION SYSTEM. Check the oil
level as described under 'Oil Level Check'.
6. Remove blanking caps from hose assemblies Note: Transmission oil cooler should be primed when
(22 & 23, Fig. 12), tee (21, Fig. 12) and adaptor (26, refilling transmission. Refer to Section 210-0060,
Fig. 12) and connect hose assemby (22, Fig. 12) to TRANSMISSION OIL COOLER.
adaptor (26, Fig. 12), and hose assembly (23, Fig. 12)
to tee (21, Fig. 12). 20. Connect the following cables and connectors in the
order given to prevent serious damage to the engines
7. Remove blanking caps from hydraulic tank hose electrical components.
assemblies and ports, and connect hose assemblies to
the hydraulic tank. a- Hydraulics ECU
b- Body control lever
8. Remove blanking caps from hose assemblies c- Engine ECM connectors
(6, 7, 8, 9 & 10, Fig. 12) and ports at diff-lock/retarder d- Transmission ECU (Est-37) connector
valve. Connect hose assemblies to the diff-lock/ e- Alternator supply cables
retarder valve. f- Alternator earth cables
g- Battery supply cables
9. Remove blanking caps from transmission oil cooler h- Battery earth cables
lines and retarder ports and connect oil cooler lines.
Refer to Section 210-0060, TRANSMISSION OIL 21. Turn the battery master switch to the 'On' position,
COOLER. start the engine and make an operational check of all
Oil Level Check 1. Position the vehicle on a level work area, apply the
parking brake and block all road wheels securely.
Oil and Filter Change At each oil change, examine the used oil for evidence
of dirt or water. A normal amount of condensation will
emulsify in the oil during transmission operation.
WARNING
However, if there is evidence of water or engine coolant
When changing filter cartridges, it is imperative in the oil, the cause must be established and rectified
that new filter cartridges are the same part immediately to prevent damage to the transmission. Oil
number and colour as the original cartridges. should be added to transmission as described in
'Topping Up Oil'.
The transmission oil and filter cartridges should be
changed every 1 000 hours, or sooner, depending on
operating conditions. Clean oil filter head when AEB Starter
changing filter cartridges. Also, the oil must be The AEB Starter is an electronic tool used to calibrate
changed whenever there are traces of dirt or evidence the transmission to ensure optimum shift comfort. It is
of high temperature indicated by discoloration or strong recommended to run the AEB Starter after the first 500
odour. hours of transmission operation. The AEB Starter
should also be run if shift quality deteriorates, or
The internal filter and finger magnet at the lower front whenever the transmission, electronic control unit
left hand of the sump should be removed and cleaned (ECU) or shift lever are replaced. The procedure for
with mineral spirits at each oil and filter change. Metal running the AEB Starter is detailed in the table on
particles in the oil (except for the minute particles previous page. Refer to table on page 10 for typical
normally trapped in the oil filters) indicate damage has codes displayed during AEB mode.
occurred in the transmission. When these particles are
found in the filters, the cause must be established and Note: Connect the AEB Starter to plug X25 located
rectified immediately to prevent damage to the below the instructor seat, adjacent to the ECU.
transmission.
4. Output speed sensor (6). Check across pins 21 & Shift Controller
22. Resistance should be 5 mega ohms.
To troubleshoot the shift controller, continuity checks
The installation of the speed sensors can also be can be easily done by removing plug X2, selecting
checked by measuring the gap between the sensor and position and measuring across following pins:
the gear tooth: Neutral - Pins 2 & 5
Forward - Pins 2 & 4
Engine speed sensor (5) and turbine speed sensor (8) - Reverse - Pins 2 & 6
gap should be 0.5 - 0.8 mm.
Up - Pins 2 & 7
Central gear train speed sensor (7) - gap should be 0.3 Down - Pins 2 & 8
+
/- 0.1 mm. Button - Pins 2 & 10
* * * *
32 SM 2177 Rev3 03-07
DRIVELINES - Front and Rear Drivelines
Section 130-0010
SM - 2799
15
13 14
12
15 2 3
ENGINE
TRANSMISSION
10
1
10
5 9 8
6
TO
TRAILER
FRONT AXLE
11 11 10 10
4 7
1 - Driveline Assembly 6 - Screw 11 - Capscrew
2 - Universal Joint 7 - Driveline Assembly 12 - Anti-flail Guard
3 - Screw 8 - Universal Joint 13 - Bolt
4 - Driveline Assembly 9 - Screw 14 - Washer
5 - Universal Joint 10 - Capscrew 15 - Bracket
The function of the driveline is to transmit rotating Note: Extra care should be taken when handling the
power from one point to another in a smooth and drivelines since chips, dents, burrs or deformity on any
continuous action while allowing a degree of rotating mass creates vibration and excessive wear
movement or misalignment of the components it during any operation.
connects.
There are three driveline assemblies installed between
The drivelines must operate through constantly various components in the tractor frame as follows:
changing relative angles between the components
they are mounted to and must also be capable of Driveline assembly (1) is connected between the
changing length while transmitting torque. engine drive and transmission input drive.
A typical driveline consists of universal joints which Driveline assembly (4) is connected between the front
allow some misalignment and permit the driveline to axle drive flange and transmission final drive.
pivot in any direction, and, a light rigid hollow slip yoke
and splined shaft assembly forming a slip joint. Driveline assembly (7) connects the rear final drive of
the transmission to the articulation and oscillation
The slip joint accommodates length variations pivot.
SM 2178 11-02 1
Drivelines - Front and Rear Drivelines
Section 130-0010
SM - 2800
1 4
7 8
7 8
OSCILLATION
PIVOT
There are two driveline assemblies connecting the 1. Position the vehicle in a level work area, apply the
centre and rear axles to the drive supplied from the parking brake and switch off the engine.
transmission, through the pivot drive arrangement, as
follows: 2. Block all road wheels and place the battery master
switch in the 'Off' position.
Driveline assembly (1, Fig. 2) is connected between
the oscillation pivot drive arrangement and the centre Note: Access to remove driveline assembly (1) can be
axle. obtained by tilting the cab. Refer to Section 260-0010,
CAB AND MOUNTING.
Driveline assembly (4, Fig. 2) is connected between
the centre axle and the rear axle. 3. Remove bolts (13) and washers (14) securing anti-
flail guard (12) to bracket (15). Remove anti-flail guard
(12).
REMOVAL
Numbers in parentheses refer to Fig. 1, unless 4. Remove bracket (15) over driveline assembly (1)
otherwise specified. from engine flywheel housing.
Note: Extra care should be taken when handling 5. Match mark universal joint (2) and their mating
drivelines since carelessness can result in premature surfaces to ensure correct mating alignment when
failure of the components. Chips, dents, burrs, or any installing driveline assembly (1).
other deformity of universal joints will prevent accurate
mating. This will cause misalignment which is 6. Support driveline (1) with suitable lifting equipment
accompanied by vibration and excessive wear. and remove capscrews (10) securing universal joints
(2) to their mating components. Remove driveline
assembly (1). If necessary tap driveline assembly (1)
WARNINGS from its mating components with a soft faced hammer.
To prevent personal injury and property
damage, be sure wheel blocks, blocking Note: Access to driveline assemblies (4 & 7) can be
materials and lifting equipment are properly obtained from underneath the vehicle.
secured and of adequate capacity to do the job
safely. 7. Match mark universal joints (5 & 8) and their mating
surfaces to ensure correct mating alignment when
installing driveline assemblies (4 & 7).
To prevent serious injury or death, DO NOT go
under the vehicle when the engine is running. 8. Remove capscrews (11) securing universal joints (5)
Rotating shafts can be dangerous. You can to their mating components and remove driveline
snag clothes, skin, hair, hands, etc.. assembly (4). If necessary tap driveline assembly (4)
2 SM 2178 11-02
Drivelines - Front and Rear Drivelines
Section 130-0010
from its mating components with a soft faced hammer. SM - 088
9. Remove capscrews (10) securing universal joints APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
(8) to their mating components and remove driveline
assembly (7). If necessary tap driveline assembly (7)
from its mating components with a soft faced hammer.
STRAIGHT EDGE
Note: Access to driveline assemblies (1 & 4, Fig. 2)
can be obtained from underneath the vehicle.
SM 2178 11-02 3
Drivelines - Front and Rear Drivelines
Section 130-0010
otherwise specified. 8. Secure anti-flail guard (12) to bracket (15) with bolts
(13) and washers (14).
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section 9. Position driveline assembly (1, Fig. 2) on the vehicle
300-0080, STANDARD BOLT AND NUT TORQUE as shown and align match marks on universal joints (2,
SPECIFICATIONS. Fig. 2) with those on its mating surfaces.
Note: Extra care should be taken when handling 10. Apply Loctite 648 to the threads of capscrews
drivelines since carelessness can result in premature (7, Fig. 2) and secure universal joints (2, Fig. 2) to its
failure of the components. Chips, dents, burrs, or any mating surfaces with capscrews (7, Fig. 2). Tighten
other deformity of wing bearings will prevent accurate capscrews (7, Fig. 2) to a torque of 153 Nm
mating. This will cause misalignment which is (113 lbf ft).
accompanied by vibration and excessive wear.
11. Position driveline assembly (4, Fig. 2) on the
vehicle as shown and align match marks on universal
WARNINGS joints (5, Fig. 2) with those on its mating surfaces.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 12. Apply Loctite 648 to the threads of capscrews
materials and lifting equipment are properly (8, Fig. 2) and secure universal joints (5, Fig. 2) to its
secured and of adequate capacity to do the job mating surfaces with capscrews (8, Fig. 2). Tighten
safely. capscrews (8, Fig. 2) to a torque of 153 Nm
(113 lbf ft).
To prevent serious injury or death, DO
NOT go under the vehicle when the engine is 13. Lower the cab, place the battery master switch in
running. Rotating shafts can be dangerous. the 'On' position, ensure the parking brake is applied
You can snag clothes, skin, hair, hands, etc.. and start the engine. Remove wheel blocks from all
road wheels.
1. Position driveline assembly (7) on the vehicle as
shown in Fig. 1 and align match marks on universal
joints (8) with those on its mating surfaces. MAINTENANCE
Every 500 hours, check the universal joints for wear
2. Apply Loctite 648 to the threads of capscrews (10) and replace if required.
and secure universal joints (8) to its mating surfaces
with capscrews (10). Tighten capscrews (10) to a Every 2 000 hours, check drivelines for leaks and
torque of 153 Nm (113 lbf ft). damage, and replace if required.
4 SM 2178 11-02
Drivelines - Front and Rear Drivelines
Section 130-0010
* * * *
SM 2178 11-02 5
THIS PAGE IS INTENTIONALLY LEFT BLANK
Front Axle Group - Axle Group (Hub)
Section 140-0020
SM - 3640
SM 2494 03-07 1
Front Axle Group - Axle Group (Hub)
Section 140-0020
2 SM 2494 03-07
Front Axle Group - Axle Group (Hub)
Section 140-0020
15. Locate 2-off fabricated tool (Fig. 3) over bolts SM - 3667
securing hub carrier (50) to the axle housing 62) and
secure into the 2-off locating holes which are capped
on the rear face of the wheel hub (41).
SM - 3666
16. Prior to removal of slotted nut (19) it will be 18. Remove steel discs and inner discs (36 & 37) from
necessary to heat the nut to release the loctite bond. the assembly. Pins (35) can also be removed once the
Using a special tool (15503031) or suitable powered discs have been removed.
tool, remove slotted nut (19). Refer to Fig. 4 & 5.
16. Locate fabricated tool onto bolts (25) and screw 19. Seal ring (39) should be removed from the bore of
the wheel hub (41) as should o-ring (40).
SM - 3669
wheel hub (26) away from the wheel hub (41). Refer to
Fig. 6. Bearing (24) should come out during this step.
17. Cylinder (27), piston (29), seal ring (28), o-ring (34) ,
SM - 3661
SM 2494 03-07 3
Front Axle Group - Axle Group (Hub)
Section 140-0020
housing (62) can be removed, along with washers (42). 2. Fit sealring (59) and o-ring (61). Secure sealring in
place with snapring (60).
24. Remove seal ring (59), o-ring (60) and o-ring (61)
from the hub carrier (50). 3. Secure hub carrier (50) on a suitable table. Fit NBR
seal (49) and spindle ring (48). Ensure each is fully
INSPECTION home without causing damage to the components.
Numbers in parentheses refer to Fig. 1.
Note: Bearing (24) should be preheated, prior to fitting
Thoroughly clean all parts with a suitable solvent and onto the hub carrier (50).
dry with compressed air. Inspect all parts for damage
or excessive wear and replace where necessary. 4. Secure roller bearing (47) inner race to the hub
Inspect thrust washers (32) to make sure they are free carrier (50), again ensure it is fully home. Refer to
of burrs and are absolutely flat. Replace all 'O' rings. Fig.9.
SM - 3642
ASSEMBLY AND INSTALLATION
Numbers in parentheses refer to Fig. 1 unless Bearing
otherwise stated.
Spindle Ring
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section 300-
0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
WARNINGS
To prevent personal injury and property Fig. 9 - Hub Carrier Assembly - Brg
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 5. Grease o-ring (40) with a thin layer of grease to aid
secured and of adequate capacity to do the job installation. Fit o-ring (40) on hub carrier (50) as shown
safely. in Fig. 10.
SM - 3643
SM - 3641
Oil 'X'
Groove
Fig. 10 - Hub Carrier Assembly - O-ring
4 SM 2494 03-07
Front Axle Group - Axle Group (Hub)
Section 140-0020
SM - 3644 SM - 3644
Hub Carrier
o-ring
Fig. 12 - Brg Outer Race Install SM - 3644 11. Assemble alternately; inner discs (37) with steel
discs (36). Ensure that all oil channel holes line up and
that one of the oil channels is in the top position. Refer
to Fig. 15
SM - 3648
Oil Channels
SM - 3645
Measuring Tangs
Hub Carrier
Opening
10. Fit o-ring (38) then locate pins (35) and dowel pins
(9) into mating holes on the hub carrier (50). Refer to
Fig. 14.
Fig. 16- Orientate Measuring Tang and Hole
SM 2494 03-07 5
Front Axle Group - Axle Group (Hub)
Section 140-0020
12. Spray hub carrier with 'Wolfrakote' Paste prior to SM - 3652
assembly of the piston (29) and cylinder (27) to the hub
carrier (50) assembly. Refer to Fig. 17.
SM - 3650
Coating
16. Assemble wheel hub (26) onto wheel hub (41) and
fit bearing (24) onto carrier (50). Ensure that punched
Fig. 17- Coating Hub assembly marks on outer diameter of both wheel hubs
(26 & 41) line up. Refer to Figs. 20 & 21.
13. Locate seal ring (30) to brake piston (29). Ensure
correct orientation of seal ring (30). SM - 3653
SM - 3651
Top
Oil Hole
Line Marks
SM - 3654
Preheated Bearing
Bleed Bore
6 SM 2494 03-07
Front Axle Group - Axle Group (Hub)
Section 140-0020
17. Assemble ring gear and ring gear carrier (21 & 22), SM - 3658
18. Take ring gear assembly and locate over the hub
carrier (50). Refer to Fig. 22.
SPINDLE
"X1"
"X2"
Fig. 25 - Bearing Preload
Fig. 23 - Shim Measurement
26. Once the preload has been confirmed, re-install
22. The second measurement should be with the ring shim (20) and slotted nut (19) , coat engagement face
gear carrier (22) fixed in place. This should be noted as of nut with loctite 262.
dimension 'X2'
27. Taking special tool (15503031) torque slotted nut
23. Shim (20) thickness 'd' should fall within the (19) to a value of 2000 ± 120Nm (1475 ±88 Ibf ft).
following dimensions , refer to Fig 24. : Refer to Fig. 26 & 27.
'd' Max = X1 - X2 28. Once the slotted nut (19) has been secured. Mark
'd' Min = (X1 - X2) - 0.12 the position of the nut with a yellow colour point. Refer
to Fig. 25.
SM 2494 03-07 7
Front Axle Group - Axle Group (Hub)
Section 140-0020
SM - 3660 32. Insert sun gear shaft (63) into the planetary cage
assembly. Refer to Fig. 29.
SM - 3662
Cover 24. Refit road wheels, securing with wheel nuts (64).
Remove stands or timber supports and lower the
machine to the ground. Fully tighten wheel nuts to a
Fig. 28 - Cover Detail torque of 600 Nm (442 lbf ft). Remove blocks from the
wheels.
8 SM 2494 03-07
Front Axle Group - Axle Group (Hub)
Section 140-0020
Sm 3352
2
Note: Wheel nuts should be checked and tightened if
necessary, after the first 10 hours of operation. Check
torque every 50 hours (weekly) thereafter. OIL
LEVEL
MAINTENANCE
Proper lubrication of the axle group is essential if axles
are to deliver the service intended. Section
300-0020, LUBRICATION SYSTEM gives full
information on the proper lubrication intervals and the
lubricant which should be used.
2000 Hours
The multi-discs should be checked for wear. Refer to
Fig. 33 for detail. Should brake wear depth measured
be 100mm or less i.e. brake wear across disc set of
3mm or greater, then the discs should be replaced.
Brake wear should be measured with the brake applied.
Measurement is made by removing plug (1, Fig 31) and
inserting depth gauge through. Replace and torque plug
when measurement is completed.
Fig. 31 - View of Planetary Fill / Drain points
SM 2494 03-07 9
Front Axle Group - Axle Group (Hub)
Section 140-0020
SM - 3723 AXLE DIAGNOSIS
Noises originating in the tyres, transmission, brakes or
drivelines might be attributed by mistake to the axle
components, therefore, all possible sources of noise
2
should be investigated before deciding the axle is at
fault.
1
WARNING
To prevent personal injury and property
disk new =103mm disk worn
damage, be sure wheel blocks, blocking
out =100mm materials and lifting equipment are properly
Fig. 28 - Diff installation secured and of adequate capacity to do the job
safely.
SPECIAL TOOLS
The special tools referenced throughout this section True axle noises may be located by lifting or jacking
are available from your dealer. Refer to Section the machine up until all tyres are clear of the floor or
300-0070, SERVICE TOOLS, for part numbers of ground. Securely block the machine in this position.
general service tools and sealants required. Run power train at moderate speed. Be certain all tyres
are off the ground to prevent damage to the differential
For fabricated tools, refer to the end of this section for and make sure that there is no brake drag.
dimensions.
10 SM 2494 03-07
Front Axle Group - Axle Group (Hub)
Section 140-0020
FABRICATED TOOLS
The following tools are necessary to aid in removal /
assembly of the axle group.
Sm 3670
97mm 45mm
20mm
Ø30mm
Ø10mm
35mm 8mm
120mm
72mm
80mm Ø17mm
Sm 3671
Ø1" UNC
12
3" SQ
305
152
90
Ø60
Ø28 Ø80
22
Ø38
SM 2494 03-07 11
THIS PAGE IS INTENTIONALLY BLANK
Front Axle Group - Diff Lock Controls
Section 140-0020
SM - 3713
6
2
4
3
5
1 - Port 'P' 4 - Port 'T' (Tank return)
2 - Port 'B' 5 - Solenoid (CT1)
3 - Port 'A' (Plugged) 6 - Valve Block
SM - 3713
installed. In any case the cross axle differential lock
works in the same way. Diff-lock apply pressure is 42bar
(609 lbf/in²).
HI
The purpose of the valve is to, when actuated, allow
hydraulic pressure to flow to each axle to activate the
cross axle differential locks. This is achieved by the
operator requesting the differential lock via the foot
mounted switch (Fig. 2).
SM 2473 06-06 1
Front Axle Group - Diff Lock Controls
Section 140-0020
SM - 3714
SM - 3715
AXLE MANIFOLD
DIFF-LOCK PLATE
T
CT1 A B CT2
P
DL
P T T1
CT3
TRANSMISSION
FROM
PORT BR
DIAGNOSTIC
DL PLATE
TRANS. RETARDER
Fig. 4 - Diff Lock Schematic (non-retarder) Fig. 5 - Diff Lock Schematic (retarder)
T
CT2
WARNINGS P
To prevent personal injury and property DL
damage, be sure wheel blocks, blocking T1
safely.
BR
DIAGNOSTIC
PLATE
damage, the procedure for removing tyre and Fig. 6 - Diff Lock Schematic (Retarder Applied)
rim assembly described in Section 160-0050,
WHEEL, RIM AND TYRE, must be strictly
followed. SM - 3717
DL
3. Block the appropriate road wheels, place the T1
2 SM 2473 06-06
Front Axle Group - Diff Lock Controls
Section 140-0020
5. Ensure all hoses are capped and valve ports are MAINTENANCE
plugged.
Limited maintenance of the valve block is available.
Ensure pressures are set correctly periodically and in
6. Note orientation of valve on the vehicle and the
guidance with those listed.
corresponding hose / elbow connections to aid in
installation. SPECIAL TOOLS
The special tools referenced throughout this section
7. Thoroughly clean all parts with a suitable solvent
are available from your dealer. Refer to Section
and dry with compressed air. Inspect all parts for
300-0070, SERVICE TOOLS, for part numbers of
damage or excessive wear and replace where
general service tools and sealants required.
necessary.
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.
SM 2473 06-06 3
THIS PAGE IS INTENTIONALLY LEFT BLANK
CENTRE AXLE - Differential Drive Head
Section 150-0020
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container from the oil drain
plug (62)on the differential.
SM - 3675
2 Sm 2469 05-06
Centre Axle - Differential Drive Head
Section 150-0020
Sm 2469 05-06 3
Centre Axle - Differential Drive Head
Section 150-0020
DISASSEMBLY 16. If not already done so, remove nut (56) to allow
pinion (19) and elements to be removed from the
Numbers in parentheses refer to Fig. 1, unless
differential housing (35). All components should be
otherwise specified.
retained for inspection / replacement where necessary.
1. Remove bolt (56) to allow for removal of flange (72)
17. Through shaft (16) can be removed from the axle
from the end of the countercase (60).
housing (1). Along with all other elements.
2. If not done so previously, remove bolts (61) which
attach countershaft case (60) to differential housing INSPECTION
(35) and lift off the countershaft case assembly.
The importance of careful and thorough inspection
cannot be overstressed. Thorough inspection and
3. Remove bolts (70) and cover (69). As necessary
necessary replacement of parts now may eliminate
remove washer (68), seal (67), radial seal (66), disc
costly and avoidable trouble later.
(65) and centering ring (64) from the assembled unit.
1. Clean all parts in petroleum base solvent.
4. Using suitable lifting equipment remove complete
differential assembly from the axle housing (1).
2. Immediately after cleaning, dry all parts, except
bearings, with compressed air, or with a soft, clean lint
5. Index mark bearing cap (36) and differential housing
free wiping cloth. Compressed air has a corrosive
(35). Remove bushing (37), and bolts from the bearing
effect on bearings, therefore, they must be wiped dry
cap (36).
with a cloth.
6. Remove disc lock assembly, items 77 to 100
3. Coat cleaned, dried parts immediately with light oil to
inclusive from the end of diff housing (15).
prevent corrosion. If parts are not to be assembled
immediately, treat them with a good rust preventive
6. Remove tapered bearing (74), seal (73) and spur
and wrap them with treated paper or other suitable
gear (75) from the assembly.
material designed to prevent corrosion.
7. Remove bolt (32) and locking plate (33) from the nut
4. Before installing the differential assembly to the
(34).
machine, clean the inside and outside of the axle
housing to remove any foreign material.
8. Remove differential assembly from the differential
housing (35).
5. Inspect all gears, pinions, and splines for cracked or
broken teeth, excessive wear, and pitted or scored
9. Remove snap ring (28) from the differential
surfaces. Repair or replace as necessary.
assembly.
Note: If either ring gear or pinion gear is defective, both
10. Remove shim (31), washer (30) and bearing (26)
gears must be replaced, because they are serviced
from housing (15).
only as a matched set. Make sure the ring gear and
pinion gear have the same mating numbers.
11. Similarly remove bearing (14) from housing (15) on
the opposite end.
6. Check for pitted, scored or worn thrust surfaces of
differential case halves.
12. Remove bolts (16) and washers (17) . Now
separtate both halfs of housing (15) to allow for
disassembly of gears.
14. Fully disassemble pinion and side gears (24 & 20)
from the spider axle.
4 Sm 2469 05-06
Centre Axle - Differential Drive Head
Section 150-0020
ASSEMBLY SM - 3678
Se = L2 - Le - Lr - L1
where,
Sm 2469 05-06 5
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3680 SM - 3681
Fig. 6 - Measurement
Fig. 8 - Spacer orientation
Pinion bearing assembly and washer selection Selection of adjusting washer for crown wheel
backlash.
5. Assemble pinion (19) and put it in the measuring
device to determine thickness of the adjusting washer 10. The following measurement should be made:
(48). On pinion head surface the distance from the
SM - 3684
middle of the differential cage to the pinion head is
egraved. Refer to Figs. 6 & 7.
SM - 3682
6. Insert selected adjusting washer (48) with chamfer Fig. 9 - Crown Wheel Backlash Measurement
side (colour marked) down against the housing (35).
Ensure it is flat in the bore. Refer to Fig. 8.
6 Sm 2469 05-06
Section 150-0020
SM - 3685 14. Lift assembly into the differential housing (35).
Refer to Fig. 12.
SM - 3687
SM - 3686
Sm 2469 05-06 7
Centre Axle - Differential Drive Head
Section 150-0020
17. Using a suitable dial gauge indicator, inspect gear SM - 3694
backlash and contact pattern. Backlash should be 0.15
- 0.25mm. Refer to Fig. 15 & 16.
SM - 3691
18. Assemble oil seal, spur gear and tapered roller
bearing. Refer to Fig. 20.
Fig. 20 - Spur Gear Assembly
8 Sm 2469 05-06
Centre Axle - Differential Drive Head
Section 150-0020
SM - 3696 SM - 3699
23. Insert adjusting washer and mount top cover and oil
seals. Refer to Fig. 24.
Sm 2469 05-06 9
Centre Axle - Differential Drive Head
Section 150-0020
27. Taking axle housing (1), using a suitable fixture, MAINTENANCE
secure the axle in place. Refer to Fig. 26.
Proper lubrication of the differential assembly is
SM - 3701 essential if the differentials are to deliver the service
intended. Section 300-0020, LUBRICATION SYSTEM
gives full information on the proper lubrication intervals
and the lubricant which should be used.
SPECIAL TOOLS
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and sealants required.
28. Take axle housing (1) and position to allow for final
assembly stages.
29. The unit must be evenly pulled onto the two dowel
pins (27) and one shear sleeve using threaded bolts
and nuts.
SM - 3704
10 Sm 2469 05-06
Section 150-0020
DIFFERENTIAL DIAGNOSIS
Noises and vibrations originating in the tyres, WARNING
transmission, planetaries and drivelines are easily
To prevent personal injury and property
transmitted and may be erroneously attributed to the
damage, be sure wheel blocks, blocking
differential. Therefore, all possible sources of noise
materials and lifting equipment are properly
should be investigated before the differential is taken
secured and of adequate capacity to do the job
apart.
safely.
Whenever noises such as a grating or rattle are heard WARNING
coming from the differential, stop the unit immediately.
Removing the axle shafts or drivelines will
One tooth from a gear can cause damage to all gears
and bearings. When the differential is definitely at fault,
remove the axle shafts and disconnect the driveline
before moving the vehicle.
DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case
* * * *
Sm 2469 05-06 11
THIS PAGE IS INTENTIONALLY LEFT BLANK
REAR AXLE GROUP - Differential Drive Head
Section 160-0020
DESCRIPTION INSTALLATION
The differential assembly is mounted to the axle is the reversal of the 'Removal' procedure.
housing. It comprises of a differential for the normal
cross-axle drive function. Note: Use sealing compound between the axle housing
and differential housing mounting faces.
REMOVAL AND INSTALLATION Note: Tighten all fasteners to standard torques listed in
Numbers in parentheses refer to Fig. 1 unless Section 300-0080, AXLE BOLT AND NUT TORQUE
otherwise stated.. SPECIFICATIONS.
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container from the oil drain
plug (23)on the differential.
SM - 3709
DISASSEMBLY (19). Remove bushing (28), and bolts from the bearing
Numbers in parentheses refer to Fig. 1, unless cap.
otherwise specified.
3. Remove disc lock assembly (Fig. 2) items 46 to 71
Note: Procedure for disassembly is largely the same inclusive from the end of diff housing (19).
as that for the centre differential. If required refer to
section 150-0020 DIFFERENTIAL DRIVE HEAD for 4. Remove nut (45) flange (44) and cover (41).
additional information.
5. Remove Pinion gear (13) and constituent elements
Note: Arrow Fig. 1 shows location of Multi lock from the assembly.
assembly.
6. If necessary, disassemble the differential assembly
1. Remove bolt (30) and locking pin (29). as follows.
2. Index mark bearing cap, and differential housing 7. Remove Snap ring (1), washer (2), shim (3) and
SM - 3710
bearing (4) from the housing (5). 1. Clean all parts in petroleum base solvent.
8. Remove bearing (17) from housing (5). 2. Immediately after cleaning, dry all parts, except
9. Remove bolt (16) washers (15) which secures bearings, with compressed air, or with a soft, clean lint
Housing (5) and crown wheel (13). free wiping cloth. Compressed air has a corrosive
effect on bearings, therefore, they must be wiped dry
10. Remove screws (6) securing both housings (5). with a cloth.
11. Separate housings (5) to allow for removal of
pinion/ side gear assembly. 3. Coat cleaned, dried parts immediately with light oil to
prevent corrosion. If parts are not to be assembled
12. Remove remaining elements of assembly for immediately, treat them with a good rust preventive
inspection. and wrap them with treated paper or other suitable
material designed to prevent corrosion.
INSPECTION 4. Before installing the differential assembly to the
The importance of careful and thorough inspection machine, clean the inside and outside of the axle
cannot be over stressed. Thorough inspection and
necessary replacement of parts now may eliminate
costly and avoidable trouble later.
Note: During assembly and installation, make sure that Whenever noises such as a grating or rattle are heard
mated, punch marked, or otherwise identified parts are coming from the differential, stop the unit immediately.
returned to their original positions, if still serviceable. One tooth from a gear can cause damage to all gears
and bearings. When the differential is definitely at fault,
Assembly is the main is the reverse of disassembly. remove the axle shafts and disconnect the driveline
For specific measurements and steps required for shim before moving the vehicle.
selection. Refer to Section 150-0020 DIFFERENTIAL
DRIVE HEAD.
WARNING
To prevent personal injury and property
MAINTENANCE damage, be sure wheel blocks, blocking
Proper lubrication of the differential assembly is materials and lifting equipment are properly
essential if the differentials are to deliver the service secured and of adequate capacity to do the job
intended. Section 300-0020, LUBRICATION SYSTEM safely.
gives full information on the proper lubrication intervals
and the lubricant which should be used. WARNING
Removing the axle shafts or drivelines will
make the parking brake ineffective.
SPECIAL TOOLS
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and sealants required. Housing to remove any
foreign material.
DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case
* * * *
SM - 3736
SM - 3666
16. Prior to removal of slotted nut (19) it will be 18. Remove steel discs and inner discs (36 & 37) from
necessary to heat the nut to release the loctite bond. the assembly. Pins (35) can also be removed once the
Using a special tool (15503031) or suitable powered discs have been removed.
tool, remove slotted nut (19). Refer to Fig. 4 & 5.
16. Locate fabricated tool onto bolts (25) and screw 19. Seal ring (39) should be removed from the bore of
the wheel hub (41) as should o-ring (40).
SM - 3669
wheel hub (26) away from the wheel hub (41). Refer to
Fig. 6. Bearing (24) should come out during this step.
17. Cylinder (27), piston (29), seal ring (28), o-ring (34) ,
SM - 3661
WARNINGS
To prevent personal injury and property Fig. 9 - Hub Carrier Assembly - Brg
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 5. Grease o-ring (40) with a thin layer of grease to aid
secured and of adequate capacity to do the job installation. Fit o-ring (40) on hub carrier (50) as shown
safely. in Fig. 10.
SM - 3643
SM - 3641
Oil 'X'
Groove
Fig. 10 - Hub Carrier Assembly - O-ring
SM - 3644 SM - 3644
Hub Carrier
o-ring
Fig. 12 - Brg Outer Race Install SM - 3644 11. Assemble alternately; inner discs (37) with steel
discs (36). Ensure that all oil channel holes line up and
that one of the oil channels is in the top position. Refer
to Fig. 15
SM - 3648
Oil Channels
SM - 3645
Measuring Tangs
Hub Carrier
Opening
10. Fit o-ring (38) then locate pins (35) and dowel pins
(9) into mating holes on the hub carrier (50). Refer to
Fig. 14.
Fig. 16- Orientate Measuring Tang and Hole
SM - 3650
Coating
16. Assemble wheel hub (26) onto wheel hub (41) and
fit bearing (24) onto carrier (50). Ensure that punched
Fig. 17- Coating Hub assembly marks on outer diameter of both wheel hubs
(26 & 41) line up. Refer to Figs. 20 & 21.
13. Locate seal ring (30) to brake piston (29). Ensure
correct orientation of seal ring (30). SM - 3653
SM - 3651
Top
Oil Hole
Line Marks
SM - 3654
Preheated Bearing
Bleed Bore
17. Assemble ring gear and ring gear carrier (21 & 22), SM - 3658
18. Take ring gear assembly and locate over the hub
carrier (50). Refer to Fig. 22.
SPINDLE
"X1"
"X2"
Fig. 25 - Bearing Preload
Fig. 23 - Shim Measurement
26. Once the preload has been confirmed, re-install
22. The second measurement should be with the ring shim (20) and slotted nut (19) , coat engagement face
gear carrier (22) fixed in place. This should be noted as of nut with loctite 262.
dimension 'X2'
27. Taking special tool (15503031) torque slotted nut
23. Shim (20) thickness 'd' should fall within the (19) to a value of 2000 ± 120Nm (1475 ±88 Ibf ft).
following dimensions , refer to Fig 24. : Refer to Fig. 26 & 27.
'd' Max = X1 - X2 28. Once the slotted nut (19) has been secured. Mark
'd' Min = (X1 - X2) - 0.12 the position of the nut with a yellow colour point. Refer
to Fig. 25.
SM - 3660 32. Insert sun gear shaft (63) into the planetary cage
assembly. Refer to Fig. 29.
SM - 3662
Cover 24. Refit road wheels, securing with wheel nuts (64).
Remove stands or timber supports and lower the
machine to the ground. Fully tighten wheel nuts to a
Fig. 28 - Cover Detail torque of 600 Nm (442 lbf ft). Remove blocks from the
wheels.
2000 Hours
The multi-discs should be checked for wear. Refer to
Fig. 33 for detail. Should brake wear depth measured
be 77.5mm or less i.e. brake wear across disc set of
3mm or greater, then the discs should be replaced.
Brake wear should be measured with the brake applied.
Measurement is made by removing plug (1, Fig 31) and
inserting depth gauge through. Replace and torque plug
when measurement is completed.
Fig. 31 - View of Planetary Fill / Drain points SPECIAL TOOLS
The special tools referenced throughout this section
Numbers in parentheses refer to Fig. 32 unless
are available from your dealer. Refer to Section
otherwise stated.
300-0070, SERVICE TOOLS, for part numbers of
general service tools and sealants required.
2. Turn wheel hubs back by 90 deg. then remove oil fill
plug (2). Rest oil Drain plugs (1, Fig. 31 & 32) on back
For fabricated tools, refer to the end of this section for
dimensions.
FABRICATED TOOLS
The following tools are necessary to aid in removal /
assembly of the axle group.
Sm 3670
97mm 45mm
20mm
Ø30mm
Ø10mm
35mm 8mm
120mm
72mm
80mm Ø17mm
Sm 3671
DIMENSIONS IN mm UNLESS STATED OTHERWISE
508
425
1" UNC
Ø1" UNC
12
3" SQ
305
152
90
Ø60
Ø28 Ø80
22
Ø38
Fig. 35 - Bearing Puller
SM - 3603
7
6
8
9
3
1
2
DESCRIPTION AND OPERATION should be used to lift the tyre and rim: chain block and
The rim and wheel assembly are designed to allow the tackle, overhead crane, fork lift truck, boom truck, or
tyre and rim assembly to be replaced with a pre- tripod tyre changing tool.
assembled tyre and rim. The tyre and rim may be
removed from the machine as an assembly and
transported to a more suitable location for removing the PREPARATION FOR SERVICING
tyre from the rim.
SM 2449 03-06 1
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
SM - 3605
10
11
1
9
7
8 12
FROM MACHINE
Numbers in parentheses refer to Fig. 1.
WARNING SM - 206
2 SM 2449 03-06
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
4. Jack up the axle to the height required to allow 9. Pry lock ring (3) out in the same manner by starting
removal of the tyre and rim assembly. at prying notch in wheel rim (1) assembly, and work all
the way around wheel rim (1) with two pry bars.
5. Place safety blocks under the axle.
10. Remove and discard 'O' ring (5).
6. Support tyre and rim assembly with a suitable sling
and attach a suitable lifting device. 11. Remove lock ring (3).
7. Remove wheel nuts (9) and lock washers (8) securing 12. Breaking slots are provided inside the rims. The
wheel rim base assembly (1) to the wheel. inner bead may be broken as described in Steps 4
through 8. If the tyre and rim assembly is on the
8. With lifting device, remove tyre and rim assembly vehicle, the following procedure may be used for
from the wheel and lift clear of the vehicle. breaking the inner bead.
See Fig. 4. A pipe over the straight end of the pry bar Rim Assembly
will increase leverage.
Overloading, improper tyre inflation, rough terrain, high
6. A second pry bar may be inserted in the space speed, accidents, dirt accumulation, and corrosion all
between lockring (3) and flange (2). Twist the second tend to reduce the service life of rims and rim
pry bar to maintain the space gained by the first pry bar. components. It is recommended that rims be
inspected, as below, not less often than at every tyre
7. Move the first pry bar around wheel rim (1), twisting change and that, as the warranty limit approaches,
and following with the second pry bar, until the outer consideration be given to periodic replacement.
tyre bead is loose.
The rim and its components are designed with built-in
safety factors, to prevent the components from flying
off with killing force during inflation. Check components
SM 2449 03-06 3
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
SM - 207
for cracks, bends, distortion, or other damage. If
damage is found, the component must be replaced.
WARNING
Never mix components of one manufacturer's
rims with those of another. Using the rim base
of one manufacturer with the lock ring of
another or vice versa is dangerous. The lock
ring of one may not fully engage with the lock
ring groove of the other. Always consult the rim
manufacturer for proper matching and
assembly instructions.
MOUNTING TYRE ON RIM 8. Make sure all rim components are correctly
Numbers in parentheses refer to Fig. 2, unless assembled.
otherwise specified.
11. Lift the tyre upwards to effect a seal between
For mounting a tyre with rim on or off machine, the flange (2) and 'O' ring (5). In some cases the tyre will
procedure is basically the same. automatically spring out, making this step
unnecessary.
4 SM 2449 03-06
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
SM 2449 03-06 5
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
SM - 208 All machines whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on the body or
frame.
WARNINGS
Fig. 6 - Typical Safety Cage DO NOT USE charging assembly, Part No.
9359489, for tyre inflation because this
assembly does not include a pressure
Inflation regulator, safety relief valve, and adequate
Note: Always use tyre inflation equipment with an air pressure gauging which is mandatory for tyre
filter that removes moisture from the air supply, when inflation purposes. Tyre volume is as much as
available, to prevent moisture corrosion of internal rim 90 times greater than the average accumulator
parts. volume and hence it takes very much longer to
inflate a tyre - up to 40 minutes or more for very
1. Inflate tyre to 1 bar (15 lbf/in²) initially to seat large tyres.
components and tap lock ring lightly to ensure correct
seating. Visually check that all components are in Nitrogen gas cylinders used to inflate
place, then continue inflation observing all safety tyres are generally charged to approximately
precautions. (See Step 2). 152 bar (2 200 lbf/in2). A tyre blowout and/or rim
failure could occur if inflation equipment is not
2. If the tyre is off the machine, place it in a safety properly used. Proper nitrogen charging
cage after initially inflating to 1 bar (15 lbf/in²) to seat equipment and personnel training for its use is
components. See Fig. 6. a must to avoid over inflation.
3. Inflate tyres to 5.2 bar (75 lbf/in²) to seat beads and 1. A nitrogen tyre inflation kit is available from your
seal the 'O' ring, then adjust to the recommended dealer and consists of the following. Refer to Fig. 7.
inflation pressure.
a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with
4. For recommended operating air pressure, refer to the two dual pressure gauges.
'Tyre Inflation Pressures' table.
b. Safety relief valve, 8.6 bar (125 lbf/in²), that will
assure an upper limit to the pressure available for tyre
NITROGEN TYRE INFLATION inflation.
Note: All Warnings and procedures under 'Tyre
Inflation' will apply, except for differences covered by c. A 15.2 m (50 ft) length of flexible hose with
this passage. interconnecting fittings. On the tyre end of the hose is
a large bore quick connect/disconnect clip-on chuck.
In certain environments it is recommended that tyres
be inflated with dry nitrogen gas, and that the resulting 2. The pressure regulator is connected to a nitrogen
oxygen content of the inflation does not exceed 5%. compressed gas cylinder available from local suppliers.
6 SM 2449 03-06
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
d. Connect clip-on chuck to the tyre valve. The tyre will WARNING
now inflate. Tyre pressure can be monitored by Whenever a machines tyre(s) is (are) exposed to
observing the gauge at the pressure regulator. STAY excessive heat such as a machine fire or
AWAY FROM THE TYRE. extremely hot brakes the hazard of a
subsequent violent tyre explosion must be
e. When desired inflation pressure has been achieved, recognized. All persons must avoid
back off the regulator or close the valve on the approaching the machine so as not to be
compressed gas cylinder. physically endangered in the event of an
explosion of the tyre and rim parts.
f. Remove the clip-on chuck and adjust the tyre
pressure with the tyre gauge in the usual manner.
SM 2449 03-06 7
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
SM - 1041
WARNING (cont.)
The machine should be moved to a remote AT LEAST AT LEAST
15 m (50 ft) 460 m (1 500 lbf ft)
area, but only when this can be done with
complete safety to the operator operating or
towing the machine. All other persons should
stay clear of the machine. The fire or
overheated brakes, wheel, etc. should be
extinguished or cooled from a safe distance. Do
not attempt to extinguish the fire or cool the
machine by use of hand-held fire extinguishers.
8 SM 2449 03-06
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
Punctures 13 mm (0.50 in) or larger, large cuts, or Inspect Tyres Regularly
bruise breaks require sectional or reinforced vulcanized
A systematic plan for tyre inspection will more than
repair. Cover the repair patch with a layer of cushion
pay for itself in lowered tyre costs per hour of
gum after application to the tubeless tyre to ensure an
operation. All tyres should be checked regularly for
airtight repair. Any cords of the inside ply that are
cuts, bruises, ply material breaks, excessive or uneven
exposed in buffing and are not covered with repair patch
wear, embedded foreign matter, and any other damage
must be coated with cushion gum to prevent air leakage
which can be repaired. A considerable increase in tyre
into the carcass plies on tubeless tyres.
service can be realized if tyre injuries are repaired
before they have progressed to the irreparable stage.
Recapping and Retreading
The rim mounting nuts should also be checked
There are two general methods employed in restoring
periodically and tightened to the torque specified.
the tread surface of off-the-highway tyres: recapping
and retreading.
Prevent Overloading
A recapped tyre has a new tread cured right over the old
Off-highway machines are designed to carry a
tread surface.
maximum allowable payload. Excessive loading will
overstress both the machine and tyres and shorten the
A retreaded tyre has the old tread removed entirely and
life of both.
a new tread cured directly onto the body of the tyre. A
tyre can be recapped or retreaded if the cord body is
free of cuts, bruises and separation, and is thoroughly Prevent Contact with Oil
sound, including previous repairs.
Prevent tyre contact with petroleum products. Rubber
that is exposed to oil, gasoline, or grease becomes
TYRE CARE soft and spongy and deteriorates rapidly. Always avoid
driving machine through a puddle of gasoline, fuel oil,
To obtain maximum service from off-highway tyres, the
lubricating oil, or grease. Never let a tyre stand in an oil
following common-sense precautions should be
or grease spot overnight.
followed.
WARNING
Do not attempt repair of wheel components.
Twisted or damaged 'O' ring Replace 'O' ring (lubricate)
Tyre cuts and snags Repair tyre damage
Bead area awl holes Repair inner liner (preferred)
Leakage between tyre bead trim With tyre removed from rim:
Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5 degree tapered bead seat band and the rim base in the bead
seating area to determine if the transverse weld trims are flat or concave.
Replace defective part(s).
Note: Weld trim should follow rim contour.
Mount tyre using a lubricant such as Murphy's Tyre and tube Mounting
Compound, or equivalent, on tyre beads and rim bead seat area.
10 SM 2449 03-06
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
TYRE PRESSURES
Tyre pressures on this pages apply to the truck serial number range specified only, Gross Vehicle Weight
(G.V.W.) and axle weights may vary between truck derivatives. Tyre pressure should be recalculated if not shown
for a particular truck. Contact TEREX for assistance.
The tyre inflation pressures listed are manufacturers recommendations for G.V.W. travelling at maximum speed.
TEREX Advise that operators check tyre inflation pressures with tyre manufactures to ensure correct setting for
each particular application.
**
SM 2449 03-06 11
PARKING BRAKE - Parking Brake and Mounting
Section 170-0010
SM - 3498
1 - Actuator
1 2 - Calliper
3 - Bolt
2 4 - Hardened Washer
5 - Nut
6 - Brake Disc
7 - Lever / Slack adjuster
8 - Bracket Assembly
7
9 - Bolt
3 3
10 - Washer
11 - Nut
4
4
5
5
6 REF. LH
FRAME RAIL 9
8
9
10
11
REF. RH
FRAME RAIL
SM 2409 08-05 1
Parking Brake - Parking Brake and Mounting
Section 170-0010
REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 2, unless Numbers in parentheses refer to Fig. 2.
otherwise specified.
1. Remove cap plug (8), and insert a 3/8" hex socket
onto the shaft and rotate in the opposite direction of
WARNINGS actuation until you feel a positive stop. Do not over
To prevent personal injury and property torque.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 2. Remove retaining ring (9) and lever (10) from slack
secured and of adequate capacity to do the job adjuster (12) rotor end.
safely.
3. Remove 4-off bolts (11) and arm (20).
Hydraulic fluid pressure will remain
within the braking system after engine shut 4. Slack adjuster (12) can now be removed from the
down. Operate the treadle pedal continuously calliper (17) mounting face .
until the pressure has dissipated before
carrying out any work on the braking system or 5. 'O'-ring (13), piston (14) and seal (15) should be
serious injury could result. removed when removing calliper (17).
1. Position the vehicle on a level surface, apply the Note: Ensure piston (14) and seal (15) are pushed
parking brake, block all road wheels and place the through the calliper at removal, i.e. away from slack
steering lock bar in the 'Locked' position. adjuster end.
2. Raise the body and install body safety prop to 4. Remove seal (15), piston (14) and 'O'-ring (13) from
secure in partially raised position. the slack adjuster (12) and calliper (17) bore.
3. Pull out push control to release the parking brake. 5. Ensure calliper housing (17) is held in place.
Remove mounting pins (19), this should enable the
4. Remove 4-off cotter pins (18) from mounting pins calliper (17) to be removed from the chassis frame.
(19).
6. Should it be necessary to aid in the removal of the
5. Calliper (17) and constituent parts should be held in calliper (17), remove bolts (9, Fig. 1), washers (10, Fig.
place by bracket (8, Fig. 1) which mounting pins (19) 1) and nuts (11, Fig. 1) securing bracket (8, Fig. 1) to
are located through. the frame rail. Remove bracket (8, Fig. 1) and calliper
(17).
7. Disconnect the clevis rod (3) end from the lever (10)
by removing cotter pin (5) and clevis pin (4).
INSPECTION
8. Push park brake button in, releasing hydraulic Numbers in parentheses refer to Fig. 2.
pressure. This should cause the clevis rod (3) and
clevis pin (4) end to retract away from the lever (10). Note: Polish any discoloured or stained areas with
crocus cloth only. Use finger pressure and rotate the
Note: On engine shutdown the parking brake will crocus cloth in the bore. Do not use any other kind of
automatically apply. Ensure there is sufficient abrasive cloth.
clearance for actuator rod travel.
1. Examine all parts carefully. Parts showing signs of
8. Switch off the engine and place the battery master excessive wear, damage or corrosion should be
switch in the 'Off' position. replaced.
9. Disconnect and plug hydraulic line from actuator (1). 2. Clean all parts with denatured alcohol and either
Cap actuator (1) to prevent ingress of dirt. wipe dry with a clean lint free cloth or blow dry with an
air hose.
10. Remove nuts (7) and washers (6) securing actuator
(1) to arm (20).
SM - 3498
18
19
18 18
1
19
17 18
4
5
20 15
14
16
13
6
7 12
10
9
8 11
3. Inspect Calliper housing (17) bore for scoring, pitting (10) while it is mated to the rotor end of slack adjuster
or corrosion. According to severity of wear / damage, (12), in the direction of actuation. The coloured shaft
light scores and stains may be removed. For more that is extending through the spring cup should rotate
severe damage replace as necessary. and extend whilst the rotor is turning.
4. Similarly inspect items whose surfaces may be 9. If the coloured shaft rotated and extended out while
considered 'critical' i.e. piston (14) outer diameter and the rotor was rotated, it should not rotate but only
mating elements. Any such components whose retract inwards when the rotor is rotated back to its
damage will affect operational performance or integrity home position.
of the system should be replaced where applicable.
Repeat this procedure several times will show the
5. Check to see that the brake disc (9, Fig. 1) is not coloured shaft properly adjusting outwards simulating
bent of misshapen. adjustment due to pad wear.
6. Inspect lever (10) for wear and replace if necessary. 10. To return the sub-assembly back to its original
starting position, remove the plastic cap plug (8) from
7. Check to make sure that mounting pins (19) slide the rotor end of the slack adjuster (12) , and insert a
freely through the mating holes of the calliper (17). 3/8" socket into the rotor until it seats on the shaft.
Turn the socket the opposite direction of the brake unit
8. Check to make sure that the slack adjuster (12) is (Counter clockwise for a CW unit, or clockwise for a
still functioning properly. To do this, rotate the lever CCW unit), until you feel a positive stop. Do not over
torque.
SM 2409 08-05 3
Parking Brake - Parking Brake and Mounting
Section 170-0010
11. Inspect the actuator (1) and bracket (20) for INSTALLATION
damage or cracks. Replace the entire actuator (1), if
Numbers in parentheses refer to Fig. 2, unless
the outer housing, pull rod or hydraulic fitting is
otherwise specified.
damaged or if there is any leaking from the unit.
ASSEMBLY WARNING
To prevent personal injury and property
Numbers in parentheses refer to Fig. 2.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
1. Taking actuator (1) assembly, which includes clevis
secured and of adequate capacity to do the job
rod (3) and pin end. Secure in place to mating surface
safely.
of arm (20), using 4-off washers (6) and nuts (7).
Note: Ensure all parts are clean and are suitable for
WARNING
use prior to assembly. When reinstalling the piston
Do not pressurize actuator until the following
(14), ensure it is fitted from the slack adjuster (12)
instruction has been carried out. Pressurizing
mounting face end of the calliper (17).
the actuator beforehand can result in serious
brake damage.
2. Coat bore of calliper (17) with silicon grease.
1. Examine brake pads (16) for wear or damage. If pad
3. Insert new seal (15) into calliper (17) bore. Make
thickness is less than 1/32" (0.79mm), new pads
sure seal is not damaged or torn during this process.
should be fitted. If the pads are within limit, they can
be reused.
Note: Care should be exercised when inserting piston
(14), so as not to damage piston or other components
2. Ensure pads are installed in their original position.
during this assembly stage.
Note: The thinner pad should be orientated nearest the
4. Install piston (14) into the bore from the same end
actuator side of the calliper. This maintains the thicker
as the seal. Push the piston (14) through the seal (15)
pad on the carrier side of the calliper. which is
until the seal (15) is seated fully into the piston (14)
necessary for wear reasons, in operation.
groove.
3. Ensure any new pads have the same friction
5. Lubricate and install 'O'-ring (13) into the groove end
material type as the old ones as determined by the
cover.
code stamped on the pads.
6. Install slack adjuster (12) sub assembly into the
4. Should the bracket assembly (8, Fig. 1) have been
calliper (17) and place the arm (20), with actuator (1)
removed. Reinstall to frame rail, securing in place
attached into the rotor end of the slack adjuster (12).
using bolts, washers and nuts (9,10 & 11 Fig. 1).
7. Secure in place using 4-off bolts (11). Torque bolts
5. Remount the calliper (17) and brake pads (16) in
(11) to a value of 40 - 60 Ibf ft (54 - 81 Nm).
place, by locating mounting pin (19) through the
bracket (8, Fig. 1) and the calliper (17).
8. Place lever (10) on spline of rotor end of slack
adjuster (12) in the correct orientation and install
6. Secure calliper (17) in place between bracket (8, Fig.
retaining ring (9) into groove.
1) support arms by inserting 4-off cotter pins (18) into
the mounting pins (19).
9. Insert a new cap plug (8) into end of slack adjuster
(12) rotor.
7. Remove cap fitted to actuator (1) to prevent dirt
ingress at removal.
4 SM 2409 08-05
Parking Brake - Parking Brake and Mounting
Section 170-0010
9. Install clevis pin (4) through clevis (rod (3) and lever Brake Pad Replacement
(10). If pin does not assemble freely, push the park
brake button in, thus releasing oil pressure from the WARNING
actuator. At this stage, readjust the clevis rod (3) using
To replace brake pads it is necessary to release
the jam nut.
the park brake by applying hydraulic pressure
to the actuator chamber and rotating the
10. Reapply oil pressure to the actuator (1), by pulling
actuator shaft in the opposite direction that the
the park brake button out.
lever is actuated. Replace brake pads in pairs
only!
11. Repeat steps 8 to 10 until the pin (4) can be freely
assembled. Install cotter pin (5) and torque clevis jam
nut (2) hand tighten plus 1/4 turn without causing clevis
to turn and bind clevis pin (4) in lever (10). WARNING
To prevent personal injury and property
12. Actuate brake several times to allow slack adjuster
damage, be sure wheel blocks, blocking
(12) to fully adjust the brake to proper pad gap 0.025"-
materials and lifting equipment are properly
0.030" (0.635 - 0.762mm)
secured and of adequate capacity to do the job
safely.
13. Remove wheel blocks and place the steering lock
bar in the 'Stowed' position.
1. Position the vehicle on a level surface, apply the
parking brake, block all road wheels and place the
steering lock bar in the 'Locked' position.
MAINTENANCE
2. Raise the body and install body safety prop to
Every 250 hours secure in partially raised position.
Test park brake for proper operation. Check brake pads
3. Pull out park brake button to release the parking
and disc for wear.
brake.
* * * *
6 SM 2409 08-05
SUSPENSION SYSTEM - Front Suspension
Section 180-0020
SM - 2803
18
18
4
5 30
29
12
13
14 15
8 2
27 9,10,11 31 16 31 16
6
16 7
2
7 9,10,11
8
15
19
20 12,13,14
20 19
21
17 16 6
17
22
1
26 25 3 29
23 27
28
24
SM 2182 11-02 1
Suspension System - Front Suspension
Section 180-0020
2. Block rear road wheels, place the steering lock bar 16. Remove bolts (12 - 14) and washers (15) securing
in the 'Locked' position and place the battery master outer bushes (8) to front frame. Remove inner bushes
switch in the 'Off' position. (7), outer bushes (8) and shims (9 - 11).
3. Whilst the front road wheels are still on the ground, 17. Carefully lower suspension frame (1) assembly
loosen the wheel nuts. onto the trolley and remove from under the vehicle.
9. Support driveline and remove bolts securing driveline 3. If required, remove bolts (17), spacer (22), washers
to front axle. Refer to Section 130-0010, FRONT AND and nuts (3) securing link assembly (21) to front frame.
REAR DRIVELINES.
ASSEMBLY
10. Remove thread caps and mounting hardware
securing shock absorbers (27) to suspension frame (1). Numbers in parentheses refer to Fig. 1.
2 SM 2182 11-02
Suspension System - Front Suspension
Section 180-0020
Note: Tighten all fasteners without special torques SM - 2804
based lubricant.
1 - Suspension Frame 12 - Bolt
2 - Spherilastic Bush 13 - Bolt
b. Using press tool and power press (See Special
5 - Bolt 14 - Bolt
Tools), install spherilastic bushes (2) in suspension 6 - Locknut 15 - Washer
frame (1). 7 - Inner Bush 16 - Hardened Washer
8 - Outer Bush 19 - Stop Screw
9 - Shim 20 - Locknut
2. Using suitable lifting equipment, position front axle 10 - Shim 33 - Loctite Primer T
assembly on suspension frame (1). Position axle 11 - Shim 34 - Loctite 648
plates (4 & 5) and secure with bolts (28), hardened
washers (29) and locknuts (30). Tighten locknuts (30) Fig. 2 - Sectional View of Suspension Pivot
to a torque of 680 Nm (501 lbf ft).
4. Position suspension frame (1) completely to one
3. If removed, install link assembly (21) to front frame side and take a measurement of the gap between boss
using bolts (17), spacer (22), washers and nuts (3). on front frame and inside face of outer bush (8). Half
this size to obtain the thickness of shim (9 - 11) pack
INSTALLATION required for Gap 'A' (Fig. 2) at both sides.
Numbers in parentheses refer to Figs. 1 & 2. Note: Do not overshim, it is important to leave some
clearance.
WARNING 5. Remove outer bushes (8) and shim Gap 'A' at both
To prevent personal injury and property sides with shims (9 - 11) calculated at Step 4.
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job 6. Reinstall outer bushes (8), bolts (12 - 14) and
safely. washers (15). Hand tighten bolts at this stage.
1. Position suspension frame (1) assembly and trolley 7. Install rubber suspension mounts (18) between axle
under the front frame with spherilastic bushes (2) to the plates (4 & 5) and front frame.
rear.
8. Mount two hydraulic jacks (see Special Tools) below
2. Using suitable lifting equipment, lift suspension suspension frame. Using hydraulic pump to operate
frame (1) assembly and locate inner bushes (7) and hydraulic jacks, compress rubber suspension mounts
outer bushes (8) in front frame. (18) to 300mm (11.8").
3. Install bolts (31), hardened washers (16) and nuts (6) 9. Using torque multiplier (see Special Tools), tighten
through spherilastic bearings (2). Hand tighten nuts (6) nuts (6) to a torque of 1 835 Nm (1 325 lbf ft).
at this stage.
10. Remove bolts (12 - 14) and washers (15). Apply
SM 2182 11-02 3
Suspension System - Front Suspension
Section 180-0020
Loctite Primer T (33) and Loctite 648 (34) to threads of 18. Reconnect hydraulic brake line at tee on front axle
bolts and reinstall bolts (12 - 14) and washers (15). assembly. Reconnect differential breather line. Cap
Tighten bolts (12 - 14) to a torque of 170 Nm (125 lbf lines and fittings to prevent ingress of dirt.
ft).
19. Using suitable lifting equipment, position one tyre
11. Connect chain and shackle assemblies (23) and rim assembly on a front wheel and secure with
between link assembly (21) and suspension frame (1) wheel nuts. Tighten locknuts to a torque of 590 Nm
and secure with bolts (24), lockwashers (25) and nuts (435 lbf ft).
(26).
20. Using suitable lifting equipment, position opposite
12. Install shock absorbers (27) to the front frame and tyre and rim assembly on the opposite front wheel and
secure with locknuts. Tighten upper locknuts to a secure with wheel nuts.
torque of 103 Nm (74 lbf ft). Refit thread caps.
21. Using suitable lifting equipment, raise front frame
13. Align bottom of shock absorbers (27) with mounting sufficiently to remove stands and blocking from the
holes on suspension frame (1) and secure with front frame and articulation pivot. Lower vehicle to the
locknuts. Tighten lower locknuts to a torque of 103 Nm ground and remove lifting equipment. Tighten all wheel
(74 lbf ft). Refit thread caps. nuts to a torque of 590 Nm (435 lbf ft).
14. Install and adjust stop screw (19) to achieve 0.75 - 22. Remove wheel blocks from rear road wheels and
1.25 mm clearance (Fig. 2) between suspension frame place the steering lock bar in the 'Stowed' position.
(1) and stop screw (19).
23. Bleed all air from hydraulic brake lines. Refer to
15. Once clearance is obtained, install and tighten Section 165-0010, BRAKE PARTS - REAR.
locknut (20).
* * * *
4 SM 2182 11-02
SUSPENSION SYSTEM - Front Suspension
Section 180-0020
SM - 3751
WHEEL PLANETARY
SEC. 140-0030 26
26 6
2
DIFFERENTIAL
SEC. 140-0060
1
23, 24
22
21
26 3
19
17,18
29
20
5
12
8 13
30 14
15 31
16
11 9
10 2
DESCRIPTION
Numbers in parentheses refer to Fig. 1 unless
otherwise stated.
The front axle assembly is mounted to the front linked to lower wishbones (4 & 5) and are secured at
chassis frame, through the top plate of the front axle their tops to the front frame through spring mounts
housing (1). The complete unit is pivoted through the (26). Bumpstops (17) are provided to limit the travel of
front frame. Suspension is provided by four spring and the suspension assemblies during fully loaded
damper assemblies (25) (2-off each side) which are conditions.
SM 2365 04-07 1
Suspension System - Front Suspension
Section 180-0020
5. Using suitable lifting equipment, raise the machine Fig. 2: Front Axle on Assembly Rig
until both front tyres are off the ground. Support the 14. Remove locknuts (20), washers (17), bump stops
vehicle with suitable stands and blocking at the tractor (18) and bump stop caps (19) from chassis frame.
frame and articulation pivot area.
6. Support one tyre and rim assembly with suitable Braking System Removal
lifting equipment and remove wheel nuts securing the Number in parenthesis refer to Fig. 3.
rim to the axle. Remove tyre and rim assembly.
1. Remove brake pipes (1) from the wheel ends.
7. Repeat step 5 for the opposite tyre and rim
SM-3753
assembly.
Grease System Removal 4. Replace lower spring mount half caps on spring
assemblies to prevent damage.
Number in parenthesis refer to Fig. 4.
1. Remove the 20 grease pipes from the pivot points. Drive Shafts Removal
SM-3754 Numbers in parenthesis refer to Fig. 6.
SM-3756
1
3
2
B
4
3
2
1 A D
A
C
B
B Fig. 7: Endcap, Shim , O-Ring and Washer Removal
A
2. From each outboard pivot remove the M16 fastener,
Fig. 5: Suspension Assembly Removal end cap, o-ring, shim and thrust washer. Keep each set
of components from each pivot in a correspondingly
2. Remove 4 M12 fasteners attaching each of the rear
numbered bag.
lower spring mounts half caps to lower wishbone.
SM 2365 04-07 3
Suspension System - Front Suspension
Section 180-0020
1
2
Fig 10: Lower Wishbone Removal
5. Replace pivot block half cap (1) to prevent damage Axle Disassembly
to machined faces.
Numbers in parenthesis refer to Fig. 11.
4 SM 2365 04-07
Suspension System - Front Suspension
Section 180-0020
SM-3761 retaining bolts (4) with Loctite Superclean and apply
Loctite Elastic adhesive sealant 5062.
11 18
Half shaft Disassembly
2
Numbers in parenthesis refer to Fig. 12.
17 3
10 4
1. Use special tool (15503497) to remove half shaft (1)
1
locknut, remove tab washer (5).
6
2 SM-3762
Fig. 11: Axle Exploded View 3
4
5
Axle Assembly 6
Numbers in parenthesis refer to Fig. 11 7
6. Position breather splash cover (7). Clean the Fig. 12: Half Shaft Exploded View
SM 2365 04-07 5
Suspension System - Front Suspension
Section 180-0020
2. Use special tool (15503492) to remove half shaft Lower Wishbone Assembly
bearing (2).
Numbers in parenthesis refer to Fig. 13
3. Pull bearing retainer (2) from half shaft (1).
1. Check to ensure that all core plugs (5,8) are in
position, if required, tap a core plug into position until
4. Prise half shaft seal (4) from bearing retainer (2).
fully seated.
5. It should not be necessary to remove seal flinger (7)
2. Replace bushes (3,4) and o-rings with new parts and
from half shaft (1).
insert o-rings (7) into bushes.
Half shaft Assembly 3. Assemble into wishbone (1) with special tools
(15503501, 15503502) in alphabetical order as detailed
Numbers in parenthesis refer to Fig. 12
below.
1. If required apply loctite 603 to mating faces of seal
4. Two sets of tool (15503501) can be used with a long
flinger (7) and half shaft (1). Using special tool
M16 nut and bolt to insert the bush (3).
(15503495) press seal flinger (7) onto half shaft (1).
SM-3763
2. Apply a film of SAE 80W 90 LS oil to the outside
diameter of a new seal (4) and using special tool 5
8
4
5. Slide new locking washer (5) into position against 3 1
the bearing. 7
D
2
6. Tighten locknut (6) with special tool (15503497),
Torque to 175Nm and bend tab washer (5) to prevent 5 A
loosening. C
B
Lower Wishbone Disassembly
Numbers in parenthesis refer to Fig. 13
Fig.13: Lower Wishbone Exploded View
1. Use Special tool (15503491) to remove the bushes
(3,4). Upper Wishbone Disassembly
Numbers in parenthesis refer to Fig. 14
2. It should not be required to remove the core plugs
(5,8).
1. If required removed 2 x M12 fasteners (6) retaining
bumpstops mounting plate (5).
3. It is not possible to remove pivot pins(2,6).
2. It should not be required to remove the core plugs
(4).
6 SM 2365 04-07
Section 180-0020
3. Remove the dust cap, nut, metal washer and upper
SM-3764
6 3 rubber washer from damper (4).
4
5
4. If required use special tool (15503498) to extend the
2
damper (4).
4 5. Place upper spring mount (1) over spring (6) and set
parallel to the C/L of the lower spring mount.
1
6. Replace damper washers apply lubricant safteze to
threads and torque nut to 165Nm.
2 2
7. Slide pin (8) into position and hand tighten half cap
4
4 bolts.
Upper Wishbone Assembly 9. Place plastic protective cap (7) over exposed
damper thread.
Numbers in parenthesis refer to Fig. 14
10. Identify assemblies as A or B (see Bottom View).
1. Check to ensure that all core plugs are in position, if
required, tap a core plug into position until fully seated. SM-3765
Spring Disassembly
6
Numbers in parenthesis refer to Fig. 15
4
1. Remove protective thread cover (7).
3
Spring Assembly
Numbers in parenthesis refer to Fig. 15
SM 2365 04-07 7
Suspension System - Front Suspension
Section 180-0020
5
Pivot Block Seal Assembly
Numbers in parenthesis refer to Fig. 18.
4
3
9 1. Press new seals (2) into seal retainer (1) with special
2 tool (15503499) taking care to ensure that springs are
6 on the inside against shoulder in seal ring.
7
2. Completely pack seal assembly with Texaco
Multifax EP2 grease.
8 SM 2365 04-07
Section 180-0020
3. Attach special tool (15503491) and remove dowel with new parts to the recommended specification.
(5), repeat for second dowel.
4. Clean M20 x120 (30) retaining bolts with Loctite
4. Lift knuckle(1) clear of wheel end (2). Superclean, apply Loctite 243 and with special tool
(part number) torque to 522Nm.
Knuckle and Wheel End Assembly
5. Shim (See shimming procedure).
1. Position wheel end (2) on bench with input flange 6. Replace M16 x 40 end cap bolts (11) and M16
uppermost. washers (10) with new parts to the recommended
specification.
2. Lift knuckle assembly (1) into position and rotate
until all 19 holes are aligned. 7. Clean M16 x 40 end cap bolts (11) with Loctite
Superclean, apply Loctite 243 and torque to 266Nm.
3. Replace 17 x M16 fasteners (3) and washers (4) with
new parts to te recommended specification. 8. Repeat steps 1-7 for opposite wishbone.
5. Tap dowels (5) into position with tapped hole pointing 1. Remove end cap (9), o-ring (16), shims (15) and
outwards,dowels are fully home when flush with thrust washer (4) from the inboard upper pivot blocks.
knuckle (1).
2. Ensure dowels are in position in the axle housing
6. Torque fasteners (3) to 310 - 330Nm. and attach the upper wishbone to the axle housing
using two inner pivot block assemblies.
ASSEMBLY AND INSTALLATION
3. Replace M20 x 120 (30) socket head cap screws
Numbers in parentheses refer to Fig. 1 unless with new parts to the recommended specification.
otherwise stated.
4. Clean M20 x120 (30) retaining bolts with Loctite
Note: Tighten all fasteners without special torques Superclean, apply Loctite 243 and with special tool
specified to standard torques listed in Section (part number) torque to 522Nm.
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 5. Shim (See shimming procedure).
SM 2365 04-07 9
Suspension System - Front Suspension
Section 180-0020
2. Ensure that both the face of the pivot block and the
end face of the pin are clean and free of grease. Also
ensure that the end of the wish bone bush is behing the
end face of the pin.
4. Move the wishbone until the values of dimension X 10. Once the correct overall thickness has been
are within 1mm on both sides. achieved insert the assembly into the pivot block
taking care to ensure the shims are between the
endcaps and the bearing block washer.
5. Record the dimension of X to two decimal places.
11. Replace M16 x40 hex bolts with new parts to the
SM3771 recommended specification.
10 SM 2365 04-07
Section 180-0020
4. Position the wheel end assembly (2) against the 3. Attach each protection tube to the lower wishbone
lower wishbone (5) and attach the lower pivot knuckle with 2 x M6 fasteners, clean fasteners with Loctite
half cap (31). Clean the retaining bolts with Loctite Superclean, apply Loctite 243 and torque to 11Nm.
Superclean, apply Loctite 243 and with special tool
(15503500) fasten to torque 522Nm 4. Attach grease pipes to each of the 20 lubrication
points.
Note: When tool (15503500) is used the torque wrench
must be set lower than 522Nm.
Braking System Installation
5. Repeat steps 1-4 to attach knuckle to upper 1. Torque the end of the brake hose which attaches to
wishbone (7). the 90 O bend with special tool (15503489, 15503490)
6. Pepeat steps 1-5 for opposite wheel assembly. 2. Torque 90 O bend to tee piece with special tool
(15503489, 15503490).
Spring Assemblies Installation 6. Insert the brake pipe tee into its bracket and tighten
securely.
1. Remove half caps and lower spring pins from the
lower spring mounts. 7. Ensure the o-ring is correctly positioned on the
wheel end connector, screw the connector into the
2. Insert lower spring pivot pin into lower wishbone (5), wheelend and torque to 45Nm.
position spring assembly (26) with chamfer on upper
spring mount pointing towards the wheel and reattach 8. Attach the brake pipes to the wheel end connector
lower spring mounting half caps. and using special tool (15503489) torque to 34Nm.
SM 2365 04-07 11
Suspension System - Front Suspension
Section 180-0020
15 12
WARNING
To prevent personal injury and property
damage, be sure lifting equipment are properly
secured and of adequate capacity to do the job
safely.
6. Fasten 16 bolts to retain the suspension assemblies Fig. 22 Sequence to secure housing to chassis
to the chassis.
14. Re-install the cab to the machine. Refer to Section
7. Torque the 20 bolts in the correct order to 1000Nm. 260-0010 CAB AND MOUNTING.
8. Lower and remove the assembly rig.
15. Remove wheel blocks from rear road wheels and
9. Re-connect the brake line. place the steering lock bar in the "Stowed" position.
10. Pump grease into the grease line until you can see 16. Bleed air from the hydraulic brake line. Refer to
it escape form the 20 pivot points. Then re- attach the Section 165-0010 BRAKE PARTS.
grease line to the chassis.
MAINTENANCE
11. If required, fill differential housing with oil by Proper maintenance of the axle / differential and wheel
removing plug and filling to the level of this plug with hub elements of the front suspension assembly is
SAE grade 80W-90LS oil. The volume of oil required to essential if the unit is to function properly. Section 300-
fill the differential housing should be 21litres. 0020, LUBRICATION SYSTEM gives full information
on the proper lubrication intervals and lubricants which
12. Using suitable lift equipment, position one tyre and should be used. The relevant section within the manual
rim assemblt on a front wheel and secure with wheel should be referred to should greater detail on individual
nuts. Tighten locknuts to a torque of 540Nm. Repeat element service requirements be necessary.
for the opposite front wheel.
12 SM 2365 04-07
Section 180-0020
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools, special tools and
sealants which may be required during routine
maintenance. Fabricated tools (Fig. 13) which are
shown may need to be created to aid in the overhaul
procedure of the unit.
SM 2365 04-07 13
Suspension System - Front Suspension
Section 180-0020
14 SM 2365 04-07
SUSPENSION SYSTEM - Rear Suspension
Section 180-0040
SM - 3308
33 26 31 24
34 R.H.S. 25 30 11
27 9
27
28 28 46
L.H.S. 45 43 44
7 6 47 38
23 8 48
FR 23
ON 19 DETAIL C
T B
18
2
32
17 30
3,4 24
A 32
22
16 A 25
23 A C
26
1
17 32
3,4 27
5
A 28
6 3,4
8
7
24 2
30 A
25 29 A 35 40
25 A 41
5 3,4 37
9 21 32 39 35
26 11 37
C 22 35 42,49
27 1 13
10 32 23
28 A 12 39
15 46 37
14 A 30 16 17 45
A 47
B 32
3,4 17 36 36
32
31 26 35
44 35
29 38
B 2 48
23 27
27 43 2
20 3,4 A
28 A 28
DETAIL A DETAIL B DETAIL D
DESCRIPTION
Numbers in parentheses refer to Fig. 1. laminated interleaf mounts (30) located between the
axles and beam ends providing the cushioning
Each axle is coupled to the chassis by three rubber medium.
bushed control links (3) which provide longitudinal
location and control torque reactions. Lateral location is The rear suspension system requires minimal
by means of two Panhard rod links (16). The centre maintenance due to the use of rubber bushings (4)
and rear axles are linked by longitudinal equaliser being used in control links (3). Lubrication of Spherical
beams (6) which pivot on either side of the chassis. bearings (17) in Panhard rods (16) is through lube
fittings (41), similarly lubrication of bushings (7) in
Loads which act on the axles are balanced by equaliser beams (6) is through lube fittings (13).
equaliser beams (6), with bonded rubber/metal
1. Position the vehicle in a level work area, raise the 14. Remove bolts (12) and lockwashers (10) securing
body and install the body safety prop to secure the retainer (9) to spindle on the frame. Remove retainer (9).
body in the partially raised position.
15. Using suitable lifting equipment, support equaliser
2. Apply the parking brake and switch off the engine. beam (6) and withdraw from spindle on the frame.
Turn steering wheel several times to relieve any
pressure in the steering system. 16. Remove and discard 'V' seal (8) from bushing (7). If
required, remove bushing (7) from spindle on the frame.
3. Block the front road wheels, place the steering lock
bar and oscillation lock pin in the 'Locked' position and 17. Repeat steps 13 through 16 to remove the opposite
the battery master switch in the 'Off' position. equaliser beam (6).
4. Using suitable blocking equipment, block equaliser 18. Remove locknuts (19), hardened washers (23) and
beams (6) to prevent movement when raising the trailer bolts (18) securing centre control links (3) to cross
frame. shaft mounting brackets.
5. Whilst the rear road wheels are still on the ground, 19. Remove locknuts (29), hardened washers (23) and
loosen the wheel nuts. bolts (20) securing centre control links (3) to
suspension link brackets (5). Remove centre control
6. Using suitable lifting equipment, raise the trailer links (3).
frame until the rear wheels are off the ground. Support
the vehicle with suitable stands and blocking 20. Remove locknuts (29), hardened washers (23) and
equipment at the trailer frame, articulation pivot area bolts (20) securing control link (3) to bracket assembly
and centre and rear axles. (2) on the rear axle and the LH frame mounting bracket.
Remove control link (3).
7. Support one tyre and rim assembly with suitable
lifting equipment and remove wheel nuts and 21. Remove locknuts (29), hardened washers (23) and
lockwashers securing the rim to the axle. Remove tyre bolts (20) securing control link (3) to bracket assembly
and rim assembly. (1) on the centre axle and the LH frame mounting
bracket. Remove control link (3).
8. Repeat step 7 for the remaining rear tyre and rim
assemblies. 22. Remove locknuts (29), hardened washers (23) and
bolts (20) securing control link (3) to bracket assembly
9. With a suitable container in position, disconnect (1) on the rear axle and the RH frame mounting
hydraulic brake lines from the tee pieces at the centre bracket. Remove control link (3).
29. Remove V-ring seals (46 & 47), Spacers (45) and 3. Install suspension link bracket (2) on RH side of the
Panhard rods (16) from suspension link brackets (2) centre axle. Apply Loctite 243 to bolts (26 & 31) and
and frame assembly. secure suspension link bracket (2) to centre axle with
bolts (26 & 31), hardened washers (27) and locknuts
30. Remove locknuts (28), hardened washers (27) and (28). Tighten bolts (26 & 31) to a torque of 671 Nm (495
bolts (26 & 31) securing suspension link bracket (2) on lbf ft).
the rear axle. Remove suspension link bracket (2).
4. Install suspension link bracket (1) on LH side of the
31. Remove locknuts (28), hardened washers (27) and centre axle. Apply Loctite 243 to bolts (26) and secure
bolts (26) securing suspension link bracket (1) on the suspension link bracket (1) to centre axle with bolts
rear axle. Remove suspension link bracket (1). SM - 1425
9 7
32. Remove bolts (22) and hardened washers (23) 12,10
securing suspension link bracket (5) on the rear axle.
Remove suspension link bracket (5).
11
33. Remove locknuts (28), hardened washers (27) and
bolts (26) securing suspension link bracket (1) on the
centre axle. Remove suspension link bracket (1).
11. Install new 'V' seals (8) over bushings (7) with the 18. Install control links (3) between rear and centre axle
lip to the outside, as shown in Fig. 2. suspension link brackets (1 & 2) and frame mounting
brackets and secure with bolts (20), hardened washers
12. Clean bores on equalising beams (6) and, using (23) and locknuts (29). Tighten bolts (20) to a torque of
suitable lifting equipment, install beams onto bushings 556 Nm (410 lbf ft).
(7). Apply Loctite 243 to bolts (12) and secure retainers
(9) to spindles with bolts (12) and lockwashers (10). 19. Pre-assemble Panhard rods (16), spherical
Tighten bolts (12) to a torque of 150 Nm (110 lbf ft). bearings (17) and retainers (32).
13. Apply Loctite 243 to bolts (14) and Loctite 574 20. Refer to Details B: Install both LH and RH Panhard
gasket eliminator to mounting face of end caps (11). rod assemblies (16) between suspension link brackets
23. Fit elbows (35) and grease nipples (41) to manifold 34. Remove wheel blocks from the front road wheels
bracket (40), now fit elbows (35) to panhard rods (16). and place the steering lock bar and oscillation lock pin
in the 'Stowed' position.
24. Fit hose assemblies (36) to elbows (35) and run
hoses using p-clips (37)and bolts (39) to secure in
place. MAINTENANCE
Numbers in parentheses refer to Fig. 1.
25. If removed install lube fittings (41) in bracket (40).
Lubricate with grease specified in Section 300-0020, Pre-Starting Inspection: Visually check condition and
LUBRICATION SYSTEM, until excess lube is seen. mounting of equaliser beams (6), interleaf mounts (30)
and control links (3 & 16).
26. Remove caps and connect hydraulic brake lines to
the tee pieces at the centre and rear axle assemblies. Every 50 Hours: Lubricate spherical bearings (17) in
Clip brake lines with clips removed during removal. panhard rods (16) through remote lube fittings (41), with
grease specified in Section 300-0020, LUBRICATION
27. Connect brake line guards (33 & 34) to axles and SYSTEM, until excess lube is seen.
secure with mounting hardware removed during
removal. Every 250 Hours: Lubricate bushings (7) in equaliser
beams (6) through lube fittings (13), with grease
28. Using suitable blocking equipment, block equaliser specified in Section 300-0020, LUBRICATION
beams (6) to prevent movement when installing the SYSTEM, until excess lube is seen.
rear tyre and rim assemblies.
29. Using suitable lifting equipment, position one tyre SERVICE TOOLS
and rim assembly on one rear wheel and secure with There are no special tools required for the procedures
wheel nuts and lockwashers. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
30. Repeat step 26 for remaining tyre and rim tools and adhesives required during the removal and
assemblies. installation of the rear suspension. These tools and
adhesives are available from your dealer.
* * * *
COMPONENT DESIGNATIONS
A4 - 12V Radio/Cassette K27 - Difflock Relay S49 - Acc Press Switch (Trailer)
A5 - Radio/Cassette Speaker K32 - Engine Brake Relay S57 - Steering Press Switch
K34 - Horn Relay S60 - Difflock Request Switch
B7 - Coolant Level Sensor K47 - Intermittent Wipe Relay S68 - Eng Diag/Request Switch
B8 - Fuel Level Sender K50 - Brake Lights Control Relay S69 - Accel Idle Validation Switch
B13 - Rotational Speed Sensor K52 - Body Proximity Switch Relay S74 - Kickdown Switch
B19 - Throttle Position Sensor K57 - Sound Power Body UpRelay S78 - Body Lower Emergency
B21 - Trans Oil Temp Sender K58 - Sound Power 1st/Rev Gear Switch
B35 - Trans Oil Cooler Fan Temp Relay S79 - Heated Mirror Switch
Sender S81 - Eng Brake 1st Stage
L3 - Reverse Alarm Retardation Request Swt
E3 - Interior Light L4 - Warning Buzzer S82 - Eng Brake 2nd Stage
E5 - Reverse Light L5 - Electric Horn Retardation Request Swt
E11 - Side Marker Light, L L7 - Reverse Camera Monitor S106 - Brake Pedal Position Switch
E12 - Taillight, L S107 - Cross Axle Diff Lock
E13 - Side Marker Light, R M1 - Starter Motor Request Switch
E14 - Taillight, R M4 - Washer Motor, F
E15 - High/Low Beam H'lamp, L M5 - Wiper Motor, F Y4 - Emerg/Park Brake Solenoid
E16 - High/Low Beam H'lamp, R M6 - Wiper Motor, B Y7 - Difflock Solenoid (mid-axle)
E19 - Rear Fog Lamp M7 - Washer Motor, B Y26 - Body Raise Solenoid
E21 - Rotating Beacon M13 - Air Seat Compressor Y27 - Body Lower Solenoid
E23 - Work Light Y32 - Trans radiator fan solenoid
E26 - High Beam H'lamp, L N3 - Voltage Convertor 24V/12V Y33 - System Hyd Unloader Valve
E27 - High Beam H'lamp, R Y34 - System Hyd Float Valve
E35 - Heated Mirror R10 - Rkr Switch 'Locating' LED Y36 - Trans oil cooler fan isolation
R11 - Rkr Switch 'Function' LED solenoid
G1 - Generator/Alternator R12 - 12V Work Socket
G2 - Battery R11 - 24V Work Socket Wire Colours
B - Black
H6 - Direction Indicator; F, L S1 - Battery Master Switch N - Brown
H7 - Direction Indicator; B, L S2 - Starter Keyswitch U - Blue
H8 - Direction Indicator; F, R S7 - Emerg/Park Brake Switch R - Red
H9 - Direction Indicator; B, R S9 - Washer Switch, F G - Green
H10 - Brake Light, L S10 - Wiper Switch, F L - Light Green
H11 - Brake Light, R S11 - Rear Wash/Wipe Switch O - Orange
H29 - Work Socket Illumination S13 - Horn Button Y - Yellow
S14 - Hazard w/l Switch P - Purple
K1 - Starter Relay S15 - Direction Ind Switch W - White
K4 - Indicator Flasher Unit S18 - Lights Switch S - Slate
K5 - A/C Comp Clutch/Relay S19 - Dipswitch K - Pink
K14 - Start Interlock Relay S20 - Headlamp Flash Switch
K15 - Headlamp Relay S22 - Body Proximity Switch
K17 - Reverse Relay S31 - Park Brake w/l Switch
K21 - Trans Shift Clutch S37 - Axle Difflock Swt (Unused)
K22 - Lockup Clutch S41 - Auxiliary Lights Switch
K23 - Ignition Sensed Relay S48 - Acc Press Switch (Tractor)
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552
L - LEFT, R - RIGHT, F - FRONT, B - BACK
TRAILER
CONNECTION
FUSES
Location Fuse No. Circuit Current Rating
1 Ignition Sensed Equipment 20A
2 Keyswitch 15A
3 Hazard Warning Lights 7.5A
4 Rear Wash/Wipe 10A
5 Horn Relay Coil, Front Wash/Wipe 10A
Fuse/Relay 6 Air Seat Compressor 10A
Box 7 Dipped Beam Lights Supply 10A
8 Main Beam/Flash 10A
9 Wiper Park Front 7.5A
10 Transmission TCU Battery 7.5A
11 Transmission TCU Ignition 10A
12 Reverse System 7.5A
13 TOC8 Controler Ignition 30A
14 Interior Light 5A
15 Direction Indicators 5A
16 Emergency/Park Brake 3A
17 Instrument Cluster/CPU Ignition 7.5A
Fuse/Relay 18 Heated Mirrors 15A
Box 19 Ignition Sensed Relays 3A
20 24V Work Socket Battery 15A
21 Neutral Start 3A
22 Front Washer Pump 3A
23 Rear Washer Pump 3A
24 Horns 10A
25 Ignition Sensed Equipment 30A
26 Air Cond/Heater/Ventilation System 15A
27 Reverse Camera 10A
28 Front Working Lights 15A
29 Rear Working Lights 15A
Fuse/Relay 30 Rotating Beacon 5A
Box 31 Engine ECU Ignition 5A
32 Engine ECU Battery 10A
33 Proximity Switch 10A
34 Sound Power Relay Supply 3A
35 Brake Pedals Control 5A
36 12V Work Socket 15A
Fuse/Relay FL Engine ECU Battery 10A
Box FM Instrument Panel/CPU Battery Supply 15A
RELAYS
Location Relay Circuit
Fuse/Relay Box K58 Sound Power 1st / Rev Gear
Column A K57 Sound Power Body Up
K23 Ignition Sensed - A/C / Heater / Hyd. ECU Ignition
Fuse/Relay Box K23 Wiper Ignition
Column B K34 Horns
K15 Headlights
Fuse/Relay Box K17 Reverse Alarm / Lights
Column C K14 Neutral Start
K50 Brake Lights Control
Fuse/Relay Box - K23 Ignition Sensed - Engine ECU Ignition
Column D K5 A/C Compressor Clutch
K4 Indicator Flasher Unit
K32 Engine Brake
Fuse/Relay Box - K52 Body Proximity Switch
Column E K27 Differential Lock
K23 Ignition Sensed - Radio
SM - 3725
12 24 36 A B C D E
References
A Harness interface - Dash Harness and Main Chassis Harness (48 way connector)
B
Harness interface - Dash Harness and Main Chassis Harrness (102 way connector)
C Harness interface - Main Chassis Harness and Engine Harness (21 way socket housing on
main chassis section)
D Harness interface - Main Chassis Harness and Engine Harness (21 way pin housing on main
chassis section)
E Harness interface - Main Chassis Harness and Transmission Interface Harness
F Harness interface - Main Chassis Harness and Hydraulic Valve Harness
G Harness interface - Main Chassis Harness and Rear Frame Harness
H Harness Auxilliary Components Connection
All stated dash Harness splices are located in the controls area underneath the instructor seat
SM - 2858
SM - 3733
DESCRIPTION
The hydraulic electronic control unit (ECU) (Fig. 1) is a
stand alone control which controls the machines
hydraulic systems, including body hoist and
transmission oil cooler fan drive. The IQAN-TOC8
ECU communicates with a variety of input and output
devices. It utilises analog/digital inputs, proportional
current outputs and digital outputs.
WARNING
ECU Inputs
Before any welding is done on a machine
Refer to Figs. 3 & 4 and Section 190-0000, CIRCUIT
equipped with an IQAN-TOC8 hydraulic
DIAGRAMS.
system, disconnect the following in this order:
Battery earth cable, battery supply cable,
Ignition Switch - connected to the starter keyswitch,
alternator earth cables, alternator supply
rendering the circuit energised or de-energised.
cables and electrical connections at the engine
ECM, transmission ECU, body control lever,
Starter Motor Relay - when starter motor relay is
hydraulics ECU and cab bulkhead to avoid
activated, a digital signal is fed to the ECU.
damage to electrical components. Turn off
battery master switch to isolate the batteries
Body Control Lever - three position lever sends
before disconnecting any components.
analog signals to ECU.
After welding connect all of the above in the
Transmission Cooler Fan Drive Temperature
reverse order.
Sensor - sensor at transmission sends analog signal
to ECU.
SM - 2859
1 5
PROPORTIONAL
3 4
2 CONTROL VALVE
(RAISE) 33
8 9
6 7
13
10 11 FLOAT
12 44
SOLENOID
30
16
14 COLD START
IQAN-TOC8 SOLENOID
17
45
18
ECU 32
31 31
15
19 21 22
46
20
25
BODY CONTROL
24
LEVER 23
26
PROPORTIONAL
27
CONTROL VALVE 29
(LOWER)
BODY-UP
+ PROXIMITY
SWITCH ON
2nd GEAR RESTRICTION CHASSIS
TRANSMISSION
COOLER FAN DRIVE
OUTPUT INPUT
TEMPERATURE SENSOR
Body Up Proximity Switch - sends a digital signal to on ECU. For lower proportional control valve, measure
the ECU through relay K52 depending on the position across pins 31 and 32. When the body proximity
of the body. When the body is lowered the proxy switch switch is closed circuit (body lowered) the lower signal
is made. When the body is in a raised position the is inhibited.
proxy switch is open circuit.
Transmission Oil Cooler Fan Drive Proportional
Body Lower Emergency Switch - located in the cab, Solenoid - the transmission cooler fan drive
the switch sends a positive battery supply directly to temperature sensor feeds back to the ECU, which
the float solenoid when pressed. This is used to lower outputs a signal to the fan drive proportional solenoid
the body in the event of system failure. (typically 150 - 210 mA measured across pins 19 and
20, resulting in a delivery between 38 - 83 bar (551 -
1204 lbf/in2)). This causes the fan speed to increase
ECU Outputs proportionally. Refer to Section 215-0050, MAIN
Cold Start Solenoid - when ECU receives input from HYDRAULIC VALVE ASSEMBLY.
starter motor relay, the ECU sends an ouput signal to
activate cold start solenoid. This prevents the engine Transmission Oil Cooler Fan Drive Isolation
starting under hydraulic load. Solenoid - the transmission cooler fan drive
temperature sensor feeds back to the ECU, which
Body Raise/Lower - when ECU receives signals from outputs a signal to the fan drive isolation solenoid.
body control lever, ECU sends output signals to the Refer to Section 210-0060, TRANSMISSION OIL
raise and lower proportional control valves to shift the COOLER.
main control valve spool accordingly. Typical output
from ECU is 250 - 800 mA, providing a delivery Body-Up Warning Light - the body-up proximity
pressure between 4 - 25 bar (58 - 363 lbf/in2) at main switch sends a signal to the ECU through relay K52,
control valve spool. For raise proportional control and depending on the body position, the ECU sends a
valve, measure current output across pins 17 and 18
2 SM 2200 Rev1 02-07
Electrical System - Hydraulic System ECU
Section 190-0085
SM - 2860
A C1:21/22
Power
B C1:35/36
C1.15 -BAT
C1:28 +BAT
C C1:23/24
C1:4 -VREF-A
Power In C1:2 +VREF-A
C1:13 -VREF-B
C1:11 +VREF-B
C1:29 -BAT2
C1:42 +BAT2
RS-232
C1:25 RX
C1:26 TX
Communication Port C1:39 DSR
C1:40 RES
C1:38 GND
42 29
28 15
14 1
signal to illuminate the warning light in the cab. This prevents pressure being trapped in the hoist side
of cylinders when travelling, ensuring body is resting on
Body Float Solenoid - the body lower emergency the chassis. If body is not resting on the chassis when
switch sends a positive battery supply to energise the travelling, hinge points and cylinders may be damaged,
body float solenoid. This ensures that the hoist side of especially when body is laden.
the body cylinders are vented to tank, allowing body to
lower onto chassis under it's own weight in the event of Check the body float solenoid across pin 23 on ECU
system failure. and vehicle ground. Solenoid is rated at 15 W, 0.6 A,
42 ohms.
The body float solenoid is always energised when the
body-up proximity switch is open circuit (body lowered). Body Control Lever Detent - when the body control
SM - 2862
2 Input errors
3 VREF error
4 Supply voltage
error
5 Temp critical or
checksum error
6 Fatal software
error
System Safety If there are no errors, the bottom LED flashes yellow
Input/Output Protection - all inputs to the ECU are to indicate normal status. Some errors will cause the
designed to withstand the maximum specified supply ECU to stop operating or at least shut down the
voltage. The outputs are protected against short outputs to increase safety. The green LED indicates
circuit. Additionally, an error on one input/output will power on.
not influence other inputs/outputs. External fuse (10A),
located in the battery box, will blow if supply exceeds
35 V. WARNING
Do not use the machine if an error code is
Current Check - for the current outputs, a current present. Shutdown the machine until the
check is performed. The ECU compares the return problem is resolved.
current with the output's set-value. If current deviation
occurs, the user will be notified through an appropriate Refer to table of error codes for corrective action. The
error code on the unit's LED. ECU has a RS232 interface under theinstructor seat
which plugs directly into a laptop. This allows
If the ECU detects a short circuit to battery supply, the communication with the ECU using IQANdevelop
unit will shut off the outputs in order to increase safety. software, and gain more information about the ECU's
status.
* * * *
SM - 3732
HYD.
2 VALVE
3 9 ACC2S
HEADER TANK 10
FUEL
TANK
1 ACC1S
6
BOTTOM P1S
ELBOW AT
RETARDER
PBS
12
11
15
7
TRANS RETARDER
HOUSING LHS
HYDRAULIC TANK
4 13
IN
25
20 5 14
15
10
7
16
FRONT FRAME RAIL ON AIR CLEANER REAR FRAME RAIL AT FOOT PEDAL
1 - Engine Coolant Temperature Sender 7 - Trans Oil Cooler Fan Temp Sensor 12 - Steering System Pressure Switch
2 - Engine Coolant Level Sensor 8 - Retarder Oil Temperature Sensor 13 - Body Up Proximity Switch
3 - Fuel Level Sender 9 - Rear Brake Pressure Switch 14 - Hydraulic Filter Restriction Gauge
4 - Starter Relay 10 - Front Brake Pressure Switch 15 - Oil Filter Restriction Switch
5 - Air Cleaner Restriction Gauge 11 - Park Brake Pressure Switch 16 - Cross Axle Differential Lock Switch
6 - Transmission Oil Temp Sender
7 8 SM - 3706
4 5 6 9 10 11
3 12
2 13
2 STOP P
1
20 30 15
19
40 10 20
30 50
20 mph 60
10 40 r / min x100
km/h 5 25
10 70
80
0 0000000 50 30
0000 0
18 1 16 17 15 14
Tachometer (13, Fig. 2) - Driven from the engine Transmission Oil Temperature Sender (6) - The
ECU, the tachometer indicates the number of engine sender, located on the elbow at the retarder housing,
crankshaft revolutions per minute. The needle shows sends a signal to indicate transmission converter oil
the variations in engine operating speed. Never temperature on the bar graph gauge displayed on the
accelerate the engine to speeds indicated by the red VDU (3, Fig. 4).
zone on the dial face.
Transmission Oil Cooler Fan Temperature Sensor
Hourmeter (6, Fig. 4) - Driven from the engine (7) - Located in the retarder housing, the sensor sends
alternator, the hourmeter records the total number of a signal to the hydraulics ECU to operate the
engine hours. transmission oil cooler fan drive at a speed
proportional to transmission oil temperature.
Starter Relay (4) - Mounted on the tractor frame rail,
the starter relay powers up the starter motor when the Trans. Sump Oil Temperature Sensor (8) - The
keyswitch is turned. temperature sensor is located at the retarder housing
and records both the retarder and converter oil
temperature, which is supplied to the transmission
Transmission ECU. When either reaches a out of range condition
Refer to Section 120-0010, TRANSMISSION AND this will cause the tranmission oil temp high warning
MOUNTING, for further information on switches and symbol (2, Fig.3) to be displayed on the VDU.
sensors fitted to the transmission.
Oil Filter Restriction Switch (15) - The restriction
Speedometer (1, Fig. 2) - Driven by a signal from the switch sends a signal to the Transmission TCU to
transmission ECU, the speedometer indicates travel indicate that the Oil filter is restricted, which will in turn
speed in kilometres per hour and miles per hour. send a signal to the check transmission lamp (10, Fig.
2) indicating the need to check for a fault.
Steering System
Fig. 3 - Warning Symbol Screen Steering System Pressure Switch (12) - The
normally closed (NC) pressure switch is located in port
P1S of the main hydraulic valve. The pressure switch
SM - 3707 closes and sends a signal to illuminate 'Red'
emergency steering warning light (22, Fig. 2) when
Fuel Level
steering pressure drops to 5 bar (70 lbf/in2) or lower.
1 An audible buzzer also sounds.
0 25 50 75 100
Voltmeter
2 8 12 16 20 24 28 32 Hydraulic System
Trans Converter Temp
Hydraulic Filter Restriction Gauge (14) - The
3 50 75 100 125 150
hydraulic filter restriction gauge is located on top of
00000 N hydraulic tank. After 1 000 hours or when the needle
moves into the red zone, whichever comes first, the
hydraulic filter should be changed.
6 4 5 7
Air Cleaner
1 - Fuel Level Air Cleaner Restriction Gauge (5) - Mounted on the
2 - System Voltage air cleaner, the restriction gauge indicates the degree
3 - Transmission Converter Oil Temp.
4 - Transmission Retarder of air cleaner element restriction as the red panel rises
5 - Engine Brake in the gauge window. The filter element(s) should be
6 - Engine Hours Counter replaced if the red band locks in place when the
7 - Transmission Gear selected engine is shut down. Reset the gauge by pressing the
button on the gauge with the engine running.
Fuel Tank Note: Never move the vehicle until body up warning
light (5, Fig. 3) goes out, indicating that the body is
Fuel Level Sender (3) - Located at the rear of the fuel
fully lowered onto the trailer frame.
tank, the fuel level sender sends a signal to VDU
display which displays fuel level as a graph (1, Fig. 4)
Note: The proximity switch prevents the body being
to indicate the amount of fuel left in the tank.
fully powered down onto the frame. When the
proximity switch makes contact, the body control lever
Body detent is de-energised and float solenoid at main
hydraulic valve is energised.
Body Up Proximity Switch (13) - Mounted off 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 body up warning symbol on the VDU
panel (5, Fig. 3).
* * * *
SM - 2814
18
17 8
15
97 6
16 7
14
19
1
10
5 3 13
4
3
2 11
12
DESCRIPTION
Numbers in parentheses refer to Fig. 1. The electronic unit injector (15) is a lightweight,
compact unit that injects diesel fuel directly into the
The fuel system consists of the Quantum Celect Plus combustion chamber. The amount of fuel injected and
electronic fuel system controls, fuel filter (12), fuel the beginning of injection timing is determined by the
pump (19), ECM cooling plate (14), electronic unit electronic control module (ECM). The ECM sends a
injectors (15), fuel tank (1) and the necessary command pulse which activates the injector solenoid.
connecting fuel lines.
The EUI (15) performs four functions:
The fuel filter (12) is mounted inside the battery box,
alongside the oil filter. a - Creates the high fuel pressure required for efficient
injection.
Fuel pump (19) is attached to a drive assembly b - Meters and injects the exact amount of fuel required
mounted on the rear side of the gear case at the front to handle the load.
LH side of the engine and transfers fuel from fuel tank c - Atomizes the fuel for mixing with the air in the
(1), via fuel filter (12), to the electronic unit injectors combustion chamber.
(15). d - Permits continuous fuel flow for component cooling.
SM 2186 12-02 1
Fuel System - Fuel System
Section 200-0040
SM - 2815
11
12
10 19,20,21,22,23
14 17
13 16 18
17
2,3
4
19,20,21,22,23
17
18 15
17
5
9
8
6
2 SM 2186 12-02
Fuel System - Fuel System
Section 200-0040
3. Secure the inside of fuel tank (1) assembly to the To prevent personal injury or even death,
front frame rail with bolts (16), hardened washers (17), welding of the fuel tank is strictly prohibited at
shims (19 - 23) and nuts (18). Use shims (19 - 23) as all times, due to the hazardous flammable
necessary to improve longitudinal alignment of fuel liquids and vapours present inside the tank,
tank (1) assembly. even when empty.
11. Install transmission oil cooler to vehicle. Refer to From time to time, remove fuel sender guard and
Section 210-0060, TRANSMISSION OIL COOLER. check condition of electrical connections at fuel level
sender.
12. Place the battery master switch in the 'On' position,
start the engine and run for a few minutes to ensure Fuel Filter/Water Separator (12) - Drain the water and
fuel is being supplied to the engine. Check for leaks at sediment from the separator daily.
fuel lines (10, 11 & 13, Fig. 1) and tighten if required.
Position the vehicle on a level work area, apply the
13. Remove wheel blocks from all road wheels. parking brake, shut off the engine and, with a suitable
container below the drain valve to catch spillage, open
the drain valve by hand. Turn the valve anticlockwise
MAINTENANCE approximately 1.5 to 2 turns until draining occurs. Drain
Numbers in parentheses refer to Fig. 1. the filter sump until clear fuel is visible. Turn the valve
clockwise to close the drain valve.
4 SM 2186 12-02
Fuel System - Fuel System
Section 200-0040
Position the vehicle on a level work area, apply the Check for loose, faulty or improper fuel line
parking brake and switch off the engine. Using a strap connectors. Presence of an air leak may be detected
type filter wrench, remove the fuel filter/water separator by following the procedures under 'Checking Fuel Flow'.
and discard the thread adaptor sealing ring. Clean the
gasket surface of the filter head.
Checking Fuel Flow
Install the new thread adaptor sealing ring (supplied 1. Disconnect the fuel return line from the fitting at the
with new filter) and apply a film of clean engine oil to fuel tank and hold the open end in a suitable container.
lubricate the filter seal. Fill the new fuel filter/water
separator with clean fuel specified in Section 2. Start and run the engine at maximum rev/min and
300-0020, LUBRICATION SYSTEM. immerse the end of the fuel return line in the fuel. Air
bubbles rising to the surface of the fuel will indicate air
Install new fuel filter/water separator on the filter head being drawn into the fuel system on the suction side of
and tighten by hand until the gasket contacts the filter the pump. If air is present, tighten all fuel lines
head surface. Tighten fuel filter/water separator per connections between the fuel tank and fuel pump.
filter manufacturer's instructions.
3. If the fuel flow is insufficient for satisfactory engine
Note: Mechanical tightening of the filter is not performance then proceed as follows:
recommended and may result in seal and/or cartridge
damage. Tighten filter by hand only. a. Replace the fuel filter/water separator, as described
under 'Maintenance'. Start the engine and run it at
Fuel Filler Cap maximum rev/min and recheck for the presence of air.
Remove filler cap (2, Fig. 2) from filler neck. With the If fuel flow is still unsatisfactory, perform step 'b'.
handle in the up and rotated position, remove the two
screws securing the filter assembly (3, Fig. 2) to the b. Check the fuel lines for restrictions due to pinching,
cap. Discard 'O' rings. Clean top of filler cap and valve kinking or other damage. If no problem is found,
cavity. Install new filter assembly to filler cap using substitute another fuel pump that is known to be
new screws and 'O' rings (supplied with new filter). operating correctly and recheck the fuel flow. When
Tighten screws to 10 - 13 in lbs. changing the fuel pump, inspect the fuel pump drive.
Clean all fuel lines with compressed air and be sure all
fuel connections are tight.
Diesel Fuel Oil
The sulphur content of diesel fuel oil should be as low c. Disconnect the fuel lines from the ECM cooling
as possible to avoid premature wear of piston rings plate and, using a suitable connector, connect the two
and line, excessive deposit formation, and minimise fuel lines, bypassing the cooling plate. Run the engine
sulphur dioxide exhausted into the atmosphere. at maximum rev/min and recheck the fuel flow. If the
Limited amounts can be tolerated, but the amount of fuel flow with the cooling plate bypassed is normal, the
sulphur in the fuel and engine operating conditions can cooling plate should be replaced.
influence corrosion and deposit formation tendencies.
The use of diesel fuel oil with a MAXIMUM sulphur
content of 0.5% is recommended for use. Refer to
Section 300-0020, LUBRICATION SYSTEM.
SM 2186 12-02 5
Fuel System - Fuel System
Section 200-0040
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.
* * * *
6 SM 2186 12-02
FUEL SYSTEM - Electronic Foot Pedal
Section 200-0051
SM - 3711
4
3
2
DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
The pedal incorporates an idle validation switch (5) 1. Position the vehicle in a level work area, ensure the
which informs the engine ECM that the pedal is in the body is fully lowered, apply the parking brake and
idle position. Kickdown switch(4) , which can be used switch off the engine.
when automatic range is selected, allows for the
possibility of selecting a lower gear by pressing down 2. Block all road wheels and place the battery master
fully on pedal and holding (see Fig. 2). This can be switch in the 'Off' position.
used to provide a downshift on demand provided that
the vehicle speed is within the range allowable. That is, 3. Disconnect electrical harness from dash harness.
the vehicle is not travelling at a speed that would result
in the engine overspeeding in the lower gear. To 4. Remove bolts (2) and washers (3) securing pedal
disengage the transmission kickdown, release the assembly to cab wall. Remove pedal assembly.
pedal and allow it to return to a light throttle position.
Refer to Section 120-0010, TRANSMISSION AND
MOUNTING.
SM 2472 06-06 1
Fuel System - Electronic Foot Pedal
Section 200-0051
SM - 2798
Note: With the pedal at idle position, the diagnostic
reader should show 0%.
* * * *
2 SM 2472 06-06
COOLING SYSTEM - Cooling System
Section 210-0000
SM - 3606
16 2
15
4
1
14
13 5
12 7
11
8
6
9 10
1 - Header Tank 5 - Charge Air Inlet Pipe 9 - Radiator Outlet Pipe 13 - Deaeration Line
2 - Radiator Assembly 6 - Engine Oil Cooler 10 - Radiator Inlet Pipe 14 - Filter Outlet Line
3 - Engine Water Pump 7 - Thermostat Housing 11 - Deaeration Line 15 - Filter Inlet Line
4 - Coolant Filter 8 - Make-up Line 12 - Deaeration Line 16 - Charge Air Outlet Pipe
SM 2455 03-06 1
Cooling System - Cooling System
Section 210-0000
Note: Engine coolant thermostats start to open at SM - 3276
82° C (180° F) and are fully open at 93° C (199° F). 3
2 SM 2455 03-06
Cooling System - Cooling System
Section 210-0000
Note: Fuel oil, kerosene or gasoline should not be used 3. Clean the filter adaptor with a clean, lint free cloth.
to clean fins.
4. Lightly coat new coolant filter seal with clean engine
Note: It may be necessary to clean radiator and oil as specified in Section 300-0020, LUBRICATION
air-to-air charge cooler fins more frequently if the SYSTEM.
vehicle is being operated in extremely dusty or dirty
areas. 5. Start coolant filter on the filter adaptor and tighten it
by hand until the seal touches the adaptor filter head.
Tighten an additional 1/2 to 3/4 of a turn after contact,
WARNING or as specified by the filter manufacturer.
To prevent possible injury when using
compressed air, wear adequate eye protection Note: Mechanical tightening of coolant filter is not
and do not exceed 2.75 bar (40 lbf/in²). necessary and will distort or crack the adaptor. Tighten
Every 500 Hours coolant filter by hand only.
Check and replenish the DCA4 concentrations as 6. Open shut off valves at coolant filter inlet and outlet
described under 'Coolant Recommendations' in this lines, and install pressure cap on header tank.
section.
7. Start the engine and check for leaks. If any leaks are
The DCA4 coolant filter must be replaced. When noted, have them corrected. Add recommended coolant
testing the DCA4 concentration, the level of DCA4 as required.
determines which coolant should be installed. Refer to
instructions under 'Coolant Recommendations' in this Note: Any time a significant amount of coolant is added,
section. the coolant concentration MUST be checked.
4. Operate the engine at normal operating temperature, Heavy duty diesel engines installed in these vehicles
at least 85° C (185° F) for 1 - 1.5 hours. require a heavy duty coolant for optimum performance.
Heavy duty coolant is defined as a correct mixture of
good quality water, low silicate
WARNING antifreeze and supplemental coolant additives (SCA's).
Do not remove the filler cap from the radiator
header tank or attempt to drain the coolant until Water quality is important for cooling system
the engine has cooled to below 50° C (120° F). performance. Excessive levels of calcium and
magnesium contribute to scaling problems, and
5. Shut off the engine and drain the cooling system. excessive levels of chlorides and sulphates cause
cooling system corrosion.
6. Fill the cooling system with clean water and operate It is recommended to use a low silicate antifreeze
the engine at high idle for 5 minutes with the coolant concentrate that meets ASTM D4985 specifications
temperature above 85° C (185° F). (less than 0.1% silicate). Low silicate antifreeze must
4 SM 2455 03-06
Cooling System - Cooling System
Section 210-0000
be mixed with quality water at a 50/50 ratio (40 to 60% 2. After every 250 hours of operation.
working range). A 50/50 mixture of antifreeze and water
gives a -37° C (-34° F) freeze point and a boiling point 3. If the concentration is known to be above the high
of 109° C (228° F). The actual lowest freeze point of limit of 0.8 units per litre. Test at each subsequent oil
ethylene glycol antifreeze is at 68%. Using higher change until the concentration decreases below the
concentrations of antifreeze will raise the freeze point high limit.
of the solution and increase the possibility of a silicate Note: Do not use the test kit to omit or extend the
gel problem. A refractometer must be used to service intervals unless the concentration is above
accurately measure the freeze point of the coolant. 0.8 units per litre.
Refer to 'Special Tool and Test Kit'.
The test strip container is marked with an expiration
Supplemental coolant additives (DCA4), or equivalent, date and the plastic container must be securely
are used in conjunction with water and antifreeze to tightened to protect the moisture sensitive strips.
prevent liner pitting, corrosion and scale deposits in the Discard the strips if there is any doubt about the test
cooling system. The cooling system must be strip quality.
precharged with the correct concentration of DCA4.
Refer to the relevant 'Precharge Chart' in this section.
When coolant is replaced in the field, it must be
Test Instructions
replaced with heavy duty coolant precharged with 1. Collect coolant sample from the radiator or petcock.
DCA4. In addition, a service coolant filter must be DO NOT collect from the coolant recovery or overflow
installed. Together, this will result in a total precharge system. Coolant must be between 10° C and 54° C
of approximately 0.33 DCA4 units per litre of coolant. when tested.
Proper blending of heavy duty coolant is achieved as 2. Remove one strip from the bottle and replace cap
follows: immediately. DO NOT touch the pads on the end of the
strip.
a. Pour water into a suitable clean container.
Note: Discard kit if unused strips have turned light
b. Add the same quantity of low silicate antifreeze to brown or pink.
the water.
3. Dip strip in coolant sample for one second, remove,
c. Add the correct quantity of DCA4 liquid for the and shake strip briskly to remove excess liquid.
cooling system capacity required. Refer to the relevant
'Precharge Chart' in this section for DCA4 quantities. 4. 45 seconds after dipping strip compare and record
Refer to Section 300-0020, LUBRICATION SYSTEM results in the following order:
for cooling system capacity.
a. Compare Freeze Point (end pad) to colour chart and
d. Thoroughly blend all components. record the result.
Note: Following the correct order for mixing the heavy b. Next, compare Sodium Molybdate (middle pad) to
duty coolant will prevent additive dropout during the colour chart and record the result.
mixing process. c. Finally, compare Sodium Nitrate test to colour chart
and record the result.
Note: The cooling system must be clean before adding
DCA4 liquid. 5. All three readings must be completed no later than
75 seconds after dipping the strip.
Note: Do not use soluble oils in the cooling system.
The use of soluble oils will lead to cylinder lining 6. It is okay to estimate a value between colour blocks,
pitting, corrode brass and copper, damage heat transfer but if uncertain about the colour match, pick the lower
surfaces and damage seals and hoses. numbered block.
7. Determine where the Sodium Molybdate level
DCA4 Test Kit intersects the Sodium Nitrite level on the chart. The
The test kit must be used: amount of SCA units per litre in the cooling system is
given where the Sodium Molybdate row intersects the
1. When excessive coolant loss occurs. Sodium Nitrite column.
SM 2455 03-06 5
Cooling System - Cooling System
Section 210-0000
Note: For best results follow test times carefully. Use a Between 0.3 and 0.8 units per litre - Add the normal
stopwatch or clock with a sweep second hand. amount of DCA4 liquid as specified in the respective
Comparing the test strip to the colour chart too soon 'Service Chart'. Replace the DCA4 coolant filter.
before, or too late after, the required test time will result Above 0.8 units per litre - Do not replace the DCA4
in incorrect readings and improper treatment, and could filter or add liquid DCA4 until the concentration drops
result in liner pitting and engine damage. below 0.8 units per litre. The concentration must be
tested at every subsequent 250 hour service interval
8. All readings should be recorded on the truck until concentration decreases below 0.8 units per litre.
maintenance record for future reference.
SPECIAL TOOL AND TEST KIT
Treatment Instructions Refer to Section 300-0070, SERVICE TOOLS, for part
If the concentration is: numbers of the refractometer and coolant test kit
referenced in this section. These items are available
Below 0.3 units per litre - Add both the normal from your dealer.
amount of DCA4 liquid as specified in the respective
SPECIAL TOOLS
service chart' and the amount specified in the
respective 'Precharge Chart'. Replace the DCA4 Refer to Section 300-0070, SERVICE TOOLS, for part
coolant filter. numbers of the coolant test strips and general service
tools required. These strips and tools are available
from your dealer.
* * * *
6 SM 2455 03-06
COOLING SYSTEM - Radiator and Mounting
Section 210-0040
36 SM - 3604
42 41 46
1
37 45 47
37 2
43
38 44 48 8
3
39
33 4 49
32 7 50
5 51
35
6
28
35 67
34
68
30
67
66 31 27 29 12
65 26 29 9
25
24 52
14 53
60 20 54
64 15
61
55
62 59 57 56
63
58 21
14 22
23
17 19 14
15 10
14 13
18 14
40
15
14 11
17 16
SM - 3296
13
5
1
11
10
6
12
9
7 2
REMOVAL
WARNING
Numbers in parentheses refer to Fig. 1, unless To prevent personal injury and property
otherwise specified. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
WARNING safely.
Do not remove the pressure control cap from
the radiator header tank or attempt to drain the 1. Position the vehicle in a level work area, apply the
coolant until the engine has cooled. Once the parking brake and switch off the engine.
engine has cooled, use extreme caution when
removing the cap. Remove cap slowly as the 2. Block all road wheels and place the battery master
sudden release of pressure from a heated switch in the 'Off' position.
cooling system can result in a loss of coolant
and possible personal injury (scalding) from 3. Pull on handle to release hood catch mechanism
the hot liquid. and raise hood.
10. Ensure air conditioning lines from condenser 1 - Charge Air Cooler 3 - Outlet Pipe
mounted on front of charge air cooler (1, Fig. 2), and 2 - Inlet Pipe 4 - Inlet Pipe
from receiver drier mounted at rear left hand side of
radiator assembly are identified for ease of installation. Fig. 3 - Air-To-Air Charge Cooler Piping
Disconnect air conditioning lines. Fit blanking caps to
open lines and ports.
16. Remove nut, washers and clamp securing air outlet
Note: Refer to Section 260-0130, AIR CONDITIONING pipe (3, Fig. 3).
before disturbing the air conditioning circuit.
17. Slacken clamps securing cooler hoses to air outlet
11. Ensure hydraulic lines connected to hydraulic oil pipe (3, Fig. 3) and remove air outlet pipe (3, Fig. 3)
cooler mounted on front of radiator (2, Fig. 2) are from charge air cooler (1, Fig. 3) and inlet pipe (4, Fig.
identified for ease of installation and with suitable 3).
containers available to catch leakage, disconnect
hydraulic lines. Fit blanking caps to open lines and 18. Slacken clamps (14) and remove coolant inlet pipe
ports. (19), hoses (15) and clamps (14) from radiator
assembly and engine thermostat housing.
12. Disconnect deaeration line (28) from connector (9)
in radiator and deaeration lines (30 & 34 ) from elbows 19. Slacken clamps (14 & 17) and remove coolant
(29) in engine and pipe (19). Identify lines for ease of outlet pipe (16), hoses (15 & 18) and clamps (14 & 17)
installation and cap open lines and elbows. from bottom of radiator assembly and engine water
pump inlet.
13. Disconnect all clips and clamps securing air
conditioning lines, hydraulic lines and deaeration lines 20. Install two eye bolts in lifting bosses on side of
to radiator assembly. Move all lines away from radiator radiator assembly. Using suitable lifting equipment
assembly to prevent fouling on removal of radiator support radiator assembly.
assembly.
21. Remove bolts (11), washers (10), snubbing
14. Remove bolts, washers and nuts securing fan washers (40) and mounts (13) securing radiator
guards (7 & 8, Fig. 2) to radiator assembly. Remove assembly to the frame.
fan guards (7 & 8, Fig. 2) from radiator assembly.
22. Remove radiator assembly from the vehicle to a
15. Slacken clamps securing cooler hoses to air inlet clean area for disassembly. Support radiator standing
pipe (2, Fig. 3) and remove air inlet pipe from charge air upright to allow access to front and rear of radiator.
cooler (1, Fig. 3) and engine turbocharger.
Note: If Header Tank (32) requires to be removed,
follow steps 23 through 28.
24. With a suitable container available to catch 7. Remove remaining bolts and washers securing top
leakage, remove drain plug from radiator header tank column (3), LH column (5), RH column (6) and bottom
(32) and drain coolant. Apply Loctite 225 to drain plug column (4) to charge air cooler core (1) and radiator
and reinstall in header tank. core (2).
Note: Take care not to damage charge air cooler core 1. Fit RH column (6) and LH column (5) to charge air
(1), radiator core (2), condenser core and hydraulic oil cooler core (1) and radiator core (2) using fasteners
cooler core during disassembly. removed during 'Disassembly'. If baffle plates (11 & 12)
were removed during disassembly; refit accordingly.
1. Remove nut (58), bolt (52) and clip (59) from bracket
(53) allowing removal of drain cock assembly (12, 20 & 2. Secure mounts (7) to bottom column (4) with bolts
23, Fig. 1) from bottom of radiator core (2). Remove removed during 'Disassembly'.
connector (9, Fig. 1) from radiator core (2).
3. Fit top column (3) and bottom column (4) to radiator
2. Remove receiver drier and mounting from rear of assembly using fasteners removed during
radiator assembly. 'Disassembly'.
3. Remove mounting hardware securing hydraulic oil 4. Position fan cowl assembly (10) to radiator
cooler to radiator assembly. Remove hydraulic oil assembly and secure with fasteners removed during
cooler from radiator assembly. 'Disassembly'.
4. Remove mounting hardware securing air conditioning 5. Position fan plate assembly (9) to radiator assembly
condenser to radiator assembly. Remove condenser and secure with fasteners removed during
from radiator assembly. 'Disassembly'.
5. Remove bolts, washers and nuts securing fan plate Note: When installing radiator, ensure clearance around
assembly (9) to radiator assembly. Remove fan plate cooling fan tips to plate assembly is of equal
assembly (9) from radiator assembly. dimension all round.
8. Fit drain cock assembly (12, 20 & 23, Fig. 1) to 9. Feed electrical harness from engine cooling fan
bottom of radiator core (2). Secure in place using clip through hole in fan plate assembly (9, Fig. 2). Fit
(59), bolts (52) nut (58) located on plate (53). grommet if previously removed.
9. Install receiver drier to rear of radiator assembly 10. Connect engine cooling fan electrical harness to
picking up mounting locations and hardware as main electrical harness.
identified at 'Disassembly'.
11. Install LH and RH fan guards (7 & 8, Fig. 2) to
radiator assembly with bolts, washers and nuts
INSTALLATION removed during 'Removal'.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified. 12. Remove blanking caps from deaeration lines
(28 , 30 & 34) and connect deaeration line (28) to
Note: Tighten all fasteners without special torques connector (9) in radiator assembly, deaeration line (30)
specified to standard torques listed in Section to connector (29) in engine and deaeration line (34) to
300-0020, STANDARD BOLT AND NUT TORQUE pipe (19). Do not clip lines at this point.
SPECIFICATIONS.
13. Remove blanking caps from hydraulic oil cooler
lines and fittings. Connect all hydraulic lines to
WARNING hydraulic oil cooler as identified at removal.
To prevent personal injury and property
damage, be sure lifting equipment is properly 14. Remove blanking caps from air conditioning lines
secured and of adequate capacity to do the job and fittings. Connect air conditioning lines to condenser
safely. and receiver drier. Refer to Section 260-0130, AIR
CONDITIONING for procedure on charging the system.
1. Using suitable lifting equipment, position radiator
assembly on the frame and secure with bolts (11), 15. Secure all lines with clips and clamps as removed
washers (10), mounts (13) and snubbing washers (40). during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
2. Position support bracket (8) on mounting brackets at evident.
top of radiator assembly and secure in place with bolts
(1), washers (2) and nuts (3). 16. Ensure fittings, lines and pipes are securely
tightened to prevent leaks at initial fill and start up.
3. Secure support bracket (8) to engine bracket with
bolt (4), snubbing washer (5), rubber mounts (6) and nut Note: If Header Tank (32) was removed and has not
(7). yet been installed, proceed from step 17, however, if
header tank (32) was not removed or has been
4. Install coolant outlet pipe (16) between radiator outlet reinstalled, proceed from step 24.
port and engine water pump inlet, and secure with
hoses (15 & 18) and clamps (14 & 17). 17. Fit header tank (32) to goalpost and secure using
bolts (36), nuts (38) and washers (37).
5. Install coolant inlet pipe (19) between radiator inlet
port and engine thermostat housing, and secure with 18. Following installation instructions in Section
hoses (15) and clamps (14). 100-0040, HOOD AND MOUNTING, install header tank
(32) and goalpost assembly on the vehicle.
6. Install air outlet pipe (3, Fig. 3) between engine inlet
pipe (4, Fig. 3) and charge air cooler (1, Fig. 3) and 19. Remove blanking from make-up line (31) and
secure with hoses and clamps. connect to header tank (32). Secure with clamp (27).
* * * *
SM - 2821
12,
13,14
6
16
TRANS. RETARDER 21
HOUSING 5
7
19
12,
13,14
16
8,9,10,11 3 TRANSMISSION
OIL COOLER
15
2 8,9,10,11
15 20
1 17
18
TO HYDRAULIC TO HYDRAULIC
TANK OIL COOLER
TRANSMISSION OIL
TEMP. SENDER
FROM MAIN
HYDRAULIC
VALVE
DESCRIPTION AND OPERATION The fan motor (21) is proportionally controlled by the
Numbers in parentheses refer to Fig. 1, unless hydraulic ECU. The higher the transmission
otherwise stated. temperature, the more hydraulic oil is supplied to the
fan motor (21) through hose (18). Refer to Section 215-
The transmission oil cooler (1, Fig. 2) is mounted on 0050, MAIN HYDRAULIC VALVE. Hydraulic oil leaving
the right hand side of the tractor, on top of the fuel the fan motor (21) returns through hose (20) to the
tank. The transmission oil cooler is an air blast cooler, hydraulic tank via the hydraulic oil cooler.
using hydraulic oil from the main hydraulic circuit to
supply the fan motor (21). An isolation solenoid valve also controls flow to the fan
motor (21), preventing hydraulic oil being supplied to
Transmission oil to be cooled exits from the bottom the motor (21) until the transmission oil temperature
port of transmission retarder housing and flows through increases to 90° C (194° F). This prevents the
hose (17) and tube assembly (5) into bottom of cooler transmission oil being overcooled. Refer to Section
(1, Fig. 2). Transmission oil flows through the crossflow 215-0050, MAIN HYDRAULIC VALVE.
core and is cooled by air flow produced by the rotation
of fan (4, Fig. 2), which is driven by motor (21). Cooled The isolation solenoid valve, mounted on the right hand
transmission oil then exits the top of cooler (1, Fig. 2) fender, is failsafe i.e. if the solenoid fails, the valve will
and flows through tube assembly (4) and hose (3) and default to an open position, allowing hydraulic oil to the
into the top port of transmission retarder housing. motor (21). The solenoid valve is controlled by the
hydraulic ECU (refer to Section 190-0085, HYDRAULIC
SYSTEM ECU).
SM - 3283
24
23
25 1
21
9 8
10
13
11 26 14
31 12 15
30 16
29
4
20 6
18 19
28
9 5
8
17
3
25
24
27
2 22
7
23
25
20
19
18
1. Position the vehicle in a level work area, apply the 6. Remove bracket from rear of cooler. It may be
parking brake and switch off the engine. Turn steering possible to remove bracket without disturbing hoses.
wheel several times to relieve any pressure in the
steering circuit. Operate brake pedal continuously to 7. With a suitable container available to catch leakage,
relieve pressure in the braking system. disconnect supply hose (18, Fig. 1), case drain hose
(19, Fig. 1) and return hose (20, Fig. 1) from fan motor
2. Block all road wheels and place the battery master (21, Fig. 1) and secure clear of transmission oil cooler.
SM - 2823
7 4
10
1
9
6
3 2
8
11
5 12
9. Support transmission oil cooler assembly with 1. Remove clamp (6, Fig. 1) and mounting hardware
suitable lifting equipment. (12 - 14, Fig. 1) securing tube assembly (4, Fig. 1) to
cooler (1).
10. Remove nuts (11), bolts (1), hardened washers (8 &
9), isolators (5) and washers (10) from cooler brackets 2. Disconnect tube assembly (4, Fig. 1) from elbow
(2) and support plate (6). (16, Fig. 1) and remove. Remove elbow (16, Fig. 1)
from cooler (1), noting orientation.
11. Using suitable lifting equipment, remove
transmission oil cooler from machine to a clean area 3. Remove clamp (7, Fig. 1) and mounting hardware
for disassembly. (12 - 14, Fig. 1) securing tube assembly (5, Fig. 1) to
cooler (1).
SM - 2824
1
8
16
13
9
4 1
6
8
5
4 1
12 10
11
9
5 8
7 10 9
3 11 15
5
14
2
10 7
11 3
4. Disconnect tube assembly (5, Fig. 1) from elbow 9. Remove bolts (8) and washers (9) securing motor (3)
(16, Fig. 1) and remove. Remove elbow (16, Fig. 1) to mounting (6), and remove motor (3).
from cooler (1), noting orientation.
10. Remove nuts (16), lockwashers (15) and washers
5. Remove bolts (18), lockwashers (19) and washers (14) securing fan ring assembly (2) to cooler (1).
(20) securing fan guard (17) to fan ring assembly (2), Remove fan ring assembly (2) from cooler (1).
and remove fan guard (17).
11. Remove bolts (23) and washers (24) securing
6. Remove bolts (18), lockwashers (19) and washers brackets (21 & 22) to cooler (1).
(20) securing mounting (6) to cooler (1). Remove
mounting (6) complete with motor (3), fan (4) and 12. Remove mounting hardware securing cowl
adaptor (5). assembly (6, Fig. 3) to cooler (1), and remove cowl
assembly (6, Fig. 3).
7. Remove nut (13), toothed washer (11) and washer
(12) securing fan (4) and adaptor (5) to motor (3) shaft. 13. Remove mounting hardware securing end columns
Pull fan (4) and adaptor (5) from motor (3) shaft. (7 & 8, Fig. 3) to top and bottom channels (4 & 5, Fig.
3).
8. Remove bolts (8), washers (9) and nuts (10)
securing fan (4) to adaptor (5). 14. Remove remaining mounting hardware to allow end
15. Remove mounting hardware securing top and 13. Fit bracket (6, Fig. 1) to cooler. Fit tube assembly
bottom channels (4 & 5, Fig. 3) to cooler core (1, Fig. (4, Fig. 1) to top elbow (16, Fig.1) and secure with
3), and remove channels (4 & 5, Fig. 3). clamp (12, Fig. 1), plate (13, Fig. 1) and screws (14,
Fig. 1).
ASSEMBLY 14. Fit bracket (7, Fig. 1) to cooler. Fit tube assembly
Numbers in parentheses refer to Fig. 2, unless (5, Fig. 1) to bottom elbow (16, Fig.1) and secure with
otherwise stated. clamp (12, Fig. 1), plate (13, Fig. 1) and screws (14,
Fig. 1).
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. INSTALLATION
Numbers in parentheses refer to Fig. 4, unless
1. Secure top and bottom channels (4 & 5, Fig. 3) to otherwise specified.
cooler core (1, Fig. 3) using mounting hardware
removed previously. Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
2. Fit end columns (7 & 8, Fig. 3), side columns (2 & 3, TORQUE SPECIFICATIONS.
Fig. 3) and baffles (9 - 11, Fig. 3) to cooler core (1,
Fig. 3) and secure using mounting hardware removed
previously. WARNING
To prevent personal injury and property
3. Secure cowl assembly (6, Fig. 3) to cooler (1) using damage, be sure lifting equipment is properly
mounting hardware removed previously. secured and of adequate capacity to do the job
safely.
4. Secure brackets (21 & 22) to cooler (1) using bolts
(23) and washers (24). 1. Using suitable lifting equipment, position
transmission oil cooler assembly on machine and
5. Secure fan ring assembly (2) to cooler (1) using nuts secure to cooler brackets (2) and support plate (6) with
(16), lockwashers (15) and washers (14). nuts (11), bolts (1), hardened washers (8 & 9), isolators
(5) and washers (10).
6. Fit motor (3) to mounting (6) using bolts (8) and
washers (9). 2. Connect transmission hoses (3 & 17, Fig. 1) to tube
assemblies (4 & 5, Fig. 1).
7. Assemble fan (4) to adaptor (5) using bolts (8),
washers (9) and nuts (10). 3. Fit bracket to rear of cooler, using fasteners
removed previously.
8. Press fan (4) and adaptor (5) onto motor (3) shaft,
ensuring key is fitted. 4. Connect supply hose (18, Fig. 1), case drain hose
(19, Fig. 1) and return hose (20, Fig. 1) to fan motor
9. Secure fan (4) and adaptor (5) using washer (12), (21, Fig. 1).
toothed washer (11) and nut (13).
5. Following installation instructions in Section
10. Install mounting (6) complete with motor (3), fan (4) 100-0040, HOOD AND MOUNTING, install hood
and adaptor (5) to cooler (1). assembly on the vehicle.
Note: When installing mounting, ensure clearance 6. Fill transmission oil cooler with transmission oil
around fan (4) tips to fan ring assembly (2) is of equal specified in Section 300-0020, LUBRICATION
dimension all round. SYSTEM. Refer to Section 120-0010,
TRANSMISSION AND MOUNTING, for filling
11. Secure fan guard (17) to fan ring assembly (2) procedure and level check.
using bolts (18), lockwashers (19) and washers (20).
7. Top up hydraulic tank as necessary with hydraulic
CLEANING
MAINTENANCE
External Cleaning
Motor Overhaul
Numbers in parentheses refer to Fig. 2.
Internal parts of the motor are lubricated by the
operating fluid itself; therefore preventive maintenance Note: If a build up of dirt is apparent during routine
is limited to keeping the fluid in the system clean. Dirt inspection, the following cleaning procedure should be
should not be allowed to accumulate on the motor or adopted.
around the shaft seal. Check frequently that all fittings
and bolts are tight.
WARNING
Every 10 Hours To prevent possible injury when using
compressed air or steam jet, wear adequate eye
Check cooling fan for cracks and damage. Check fan
protection and do not exceed pressure values
mounting and tighten if required. Replace cooling fan if
stated.
damaged.
1. Direct a steam jet at 100 - 300 kN/m², or
Check lines and components for leaks and damage.
compressed air at 500 - 700 kN/m² on to the faces of
the cooler core (1).
Check the fan and motor for debris or damage. Clean
or replace as required.
2. Liberally brush a liquid detergent on to those
surfaces which were not satisfactorily cleaned at
Note: The fan is a non-serviceable component. step 1. Leave to soak for at least 1 hour.
However, the following instructions must be strictly
adhered to:
3. Apply a high pressure steam jet at 100 - 300 kN/m²,
or compressed air at 500 - 700 kN/m² on to the treated
1. DO NOT clean around fan drive with steam or high surfaces, forcing the fouling material out from the
pressure jet. cooler core (1).
2. DO NOT add any fluids or lubricants to the drive.
Note: In the case of grossly fouled surfaces which are
not cleaned adequately in steps 1 through 3, the
3. DO NOT restrict fan rotation during engine operation following procedure may be used.
for ANY reason.
4. Ensure that the cooler core (1) is dry.
4. DO NOT operate a machine with a damaged fan
assembly. Replace a damaged fan as soon as the 5. Liberally brush on to both sides of the cooler core (1)
fault is noted. an emulsifying cleaner such as 'Gunk', or equivalent,
and leave to soak for at least 1 hour.
5. IMMEDIATELY investigate and correct ANY
operator complaint involving drive or cooling
6. Apply a high pressure steam jet at 100 - 300 kN/m²,
performance.
or compressed air at 500 - 700 kN/m² on to the treated
surfaces, from several different angles, forcing the
* * * *
SM - 3314
17
11
16
10
3
15 5
16 4
TANK RETURN
TUBE ASSY.
18 5
6
1
14 2 8
13 9
7 5
12 6
5
4 8
10 11
CLEANING AND INSPECTION 4. Fill hydraulic tank with oil. Refer to Section
230-0040, HYDRAULIC TANK, for correct fill level and
1. Inspect fins on hydraulic oil cooler carefully, for Section 300-0020, LUBRICATION SYSTEM for
trapped debris and damage. If hydraulic oil cooler fins specifications of oil to be used.
show signs of leakage or are excessively damaged, it
must be replaced as an assembly. 5. Place the battery master switch in the 'On' position,
start engine and operate the body hydraulics several
2. Check connectors in hydraulic oil cooler ports for times to circulate the oil. Check hydraulic oil cooler (1)
damaged threads. Replace if required. and lines for leaks. Tighten fittings as required.
3. After hydraulic oil cooler is completely drained, 6. Install front grille assembly to the hood with
circulate a solution of Agmasol PS40 through the mounting hardware, as removed at 'Removal'.
cooler tubes.
7. Remove wheel blocks from all road wheels.
4. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through the hydraulic oil cooler, in
the reverse direction to normal flow, for approximately MAINTENANCE
15 minutes. The duration of circulation depends on Check and clean hydraulic oil cooler every 4 000
how badly clogged the cooler tubes are. Flush hours, or more frequently, if required. Debris in the
thoroughly with clean hot water. cooling fins can restrict the flow of air through the
cooler which significantly reduces the cooling effect.
INSTALLATION
Note: In the event of a hydraulic failure, hydraulic oil
Numbers in parentheses refer to Fig. 1. cooler should be removed and cleaned to prevent
clogging.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. SERVICE TOOLS
There are no special tools required for procedures
Note: Tighten all hydraulic lines fitted with ORFS outlined in this section. Refer to Section 300-0070,
connections, as described in Section 220-0000, SERVICE TOOLS, for part numbers of general service
STEERING SYSTEM SCHEMATIC. Renew all tools and adhesives required. These tools are available
'O' rings where used. from your dealer.
* * * *
Valves that control all the above functions are Emergency Steering
integrated into the Main Hydraulic Valve Assembly and Refer to Section 220-0000, STEERING SYSTEM.
are identified in Figs. 2 through 7.
The emergency valve (19) forms part of the emergency
steering system. It is connected to the main output line
System Relief of the wheel driven Emergency Steering Pump
The system relief valve (14) protects the main mounted on the transmission.
hydraulic valve assembly components against
pressure spikes. This system relief valve is pre-set at
265 bar (3850 lbf/in2 )and is non-adjustable. Brake Charging Function
Refer to Section 250-0000, BRAKE SYSTEM.
Priority Function Brake charge valve (8) and brake pressure reducer
This function automatically ensures that the steering valve (7) are integral valves that form part of the brake
and brake charging circuits are given preference over charging function. Brake charge valve (8) ensures that
the fan and body tipping functions. there is sufficient load sense pressure to the main
pump to allow the charge pressure to be generated.
When the pump is not running, the priority valve (15) is Brake pressure reducer valve (7) maintains a safe
Section 215-0050
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
1 5
3 4
2
47
8 9 33
6 7
13
10 11
12 44 30
16
14
17
45
15 18 32
31 31
19 21 22
46
20
25
24
23
26
29
27
1 - Orifice 10 - Check Valve 19 - Emergency Steer Valve 29 - Proportional Pressure Control Valve
2 - Bleed Down Sequence Valve 11 - Orifice 20 - Orifice 30 - Body Control Spoo
3 - Check Valve 12 - Orifice 21 - Shuttle Valve 31 - Load Sense Copy Spoolsl
4 - Check Valve 13 - Float Solenoid 22 - Shuttle Valve 32 - Load Sense Dump Valve
5 - Proportional Pressure Control Valve 14 - Relief Valve 23 - Check Valve 33 - Make Up Check Valve
SM 2192 Rev3 02-07
SM2918
Fig. 2 Main Hydraulic Valve Assembly Schematic - Based on Engine Shutdown
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
operating pressure within the front and rear brake transmission oil temperature reaches 90°C (195°F).
accumulators.
The hydraulic ECU receives an electrical signal from
the transmission cooler fan drive temperature switch,
Park/Emergency Brake Function mounted on the transmission retarder housing. Once
Refer to Section 250-0000, BRAKE SYSTEM. an electrical signal reflecting a transmission oil
temperature of 90°C (195°F) has been received, the
Park/Emergency brake solenoid (6) is the integral valve hydraulic ECU sends a signal to de-energise the fan
that controls hydraulic pressure to the park and drive solenoid valve, allowing actuation pressure to
emergency brake function of the truck. access the fan drive circuit. This fan drive solenoid
valve is a fail safe system. If power or connection is
lost the fan drive solenoid valve will de-fault to the
Body Control Function open (de-energised) condition.
Refer to Section 230-0000, BODY SYSTEM
The hydraulic ECU (Refer to Section 190-0085) sends
Proportional pressure control valve (5) is the integral an electrical signal from Pin C1:24 to the fan drive
valve that controls the body tipping function. This valve solenoid valve. This signal de-energises the fan drive
is operated via the body control lever located in the solenoid, opening the transmission cooler fan drive
operators cab. The body control lever sends an circuit.
electrical signal to the hydraulic ECU. (Refer to Section
190-0085). The hydraulic ECU processes this signal The transmission cooler fan speed pressure is
and delivers an actuating electrical signal to the controlled by the Electro-Hydraulic Proportional Control
proportional pressure control valve (5). The proportional Valve (17). A varying current input into this valve of
pressure control valve (5) converts this electrical signal between 150 to 210 mA controls the pressure between
into a pilot pressure, that then is allowed to stroke the 34 bar (490 psi) and 87 bar (1260 psi). This pressure
body control spool to the lift position. then acts upon the Shuttle Valve (22) and onto the
main pump load sense connection via Shuttle Valve
Proportional pressure control valve (29) is the integral (25). This pressure acts upon the spring chamber of
valve that controls the body lower function. This valve the Logic Valve (18) that controls the pressure at the
is operated via the body control lever located in the fan.
operators cab. The body control lever sends an SM2829
1
electrical signal to the hydraulic ECU (Refer to Section
190-0085). The hydraulic ECU processes this signal
and delivers an actuating electrical signal to the
proportional pressure control valve (29). The
proportional pressure control valve (29) converts this
electrical signal into a pilot pressure, that then is
allowed to stroke the body control spool to the lower 2
position.
3
Transmission Cooler Fan Drive
The transmission cooler fan speed is modulated by
proportionally controlling the pressure at the fan motor.
Fan speed is a function of the pressure at the fan RHS
motor. 1 - Transmission Oil Temp. Sender
2 - Trans. Cooler Fan Drive Temp. Switch
On a cold start, the transmission cooler fan will not 3 - Retarder Oil Temperature Switch
rotate. A fan drive solenoid valve, mounted on the right
hand fender next to the transmission cooler, will remain Fig. 3 - Trans. Cooler Fan Drive Temperature Switch
closed, blocking actuating pressure until the
SM 2192 Rev3 02-07 3
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
Trans. Cooler Fan Drive Temperature Switch - Typical Analog Outputs (Mv) Vs' Oil Temperature (°C)
The hydraulic ECU receives an analog input from the Cold start solenoid (16) energises when starter motor
Transmission Cooler Fan Drive Temperature Switch at signal is high, this dumps all load sense pressure from
Pin C1:3. The temperature sensor output is calibrated the main hydraulic pump, rendering the pump off-load.
against actual temperature within the hydraulic ECU. This reduces parasitic losses during engine cranking
The hydraulic ECU converts the analog signal into a procedure.
varying current output. This varying current output,
from Pin C1:19, controls Electro-Hydraulic Proportional There is about a 2 second delay before de-energising
Control Valve (17) increasing and decreasing pressure cold start solenoid (16) (starter motor signal low). This
at the fan motor. The fan speed increases and de- function prevents brake charging during engine start
creases proportionally between transmission oil up, which is particularly important in cold climates.
temperatures of 90 to 140°C (195 to 285°F).
A starter motor high signal is received by the hydraulic
The Fan Drive Solenoid will remain de-energised until ECU at Pin C1:9. The hydraulic ECU converts this high
the transmission oil temperature falls to 87°C (188°F). signal into digital output signal at Pin C1:22, energising
At this point the oil flow to the transmission cooling fan the cold start solenoid (16). The signal to energise the
will stop. cold start solenoid (16) will remain on until a starter
motor low signal is received by the hydraulic E.C.U. at
Refer to troubleshooting charts. Pin C1:9, this will negate the digital output signal from
Pin C1:22.
(Refer to section 190-0085 for full Hydraulic E.C.U.
Cold Start Function detail.)
Cold Start Solenoid (16) is the integral valve that
controls the cold start function of the Main hydraulic
valve assembly
SM2833
16
18
Fig. 4 - Main Hydraulic Valve Assembly - Transmission Cooler Fan Valves/Cold Start Solenoid
25
15 15 - Priority Valve
21 - Shuttle Valve
25 - Shuttle Valve
21
Fan drive solenoid, located on right (a) Check signal from hydraulic
hand fender remains closed. E.C.U. - Pin C1:24. Should be
low signal.
(b) Check electrical connections.
(c) Replace fan drive solenoid.
Check for output fault at hydraulic Ref. Output from Pin C1:19. Ref.
E.C.U. Section 190-0085 Hydraulic E.C.U.
Fan control logic valve (18) sticking in Replace fan control logic valve (18).
the open position.
Contamination or Air in Load Sense Disconnect the fan and plug port
Drillings or Shuttle Valves (22 & 25) DF. Raise and lower the body
several times to flush out the
system. If this does not work
change the whole manifold block.
Fan unstable over the speed range Orifices(44 or 45) Blocked. Clean Orifices
when another function is selected.
Fan Proportional Pressure Solenoid Replace Valve(17)
(17) Faulty.
WARNING ASSEMBLY
Accumulators are charged with Nitrogen. The
All integral valves must be re-installed into correct
service pressure is 95 bar (1380 lbf/in²) at 20° C
locations on the main hydraulic valve assembly. All
(68o F). To prevent personal injury and property
integral valves must be torqued to correct value.
damage do not attempt to remove any valves or
fittings until all nitrogen pressure is completely
1. Re-install O.R.F.S. connectors into correct ports.
relieved.
Replace o-rings and seals. Ref. Fig. 6
SM - 1335
2. Block all road wheels and place battery master
switch in the 'Off' position. FITTING NUT
TUBE
3. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose on
remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
hose and reinstall blanking cap.
5. Clean outer area of the main hydraulic valve 3. Manoeuvre main hydraulic valve assembly into
assembly with a suitable cleaning solvent. Ensure all position and secure to vehicle with mounting hardware.
hydraulic lines connected to the main hydraulic valve
assembly are identified for ease of installation. With 4. Remove blanking caps from all hydraulic lines and
suitable containers catch any oil leakage when fittings. Re-connect hydraulic lines to correct fittings
disconnecting hydraulic lines. Install blanking caps to astagged at removal.
all open lines and fittings.
5. Lower operator cab and secure. Ref. Section 260-
6. Install M10 eye bolt into clamp mounting hole at port 0010, CAB AND MOUNTING.
'T' located on top of main hydraulic valve assembly.
Support main hydraulic valve assembly with suitable 6. Fill hydraulic tank with hydraulic oil as described in
lifting equipment, using eye bolt. Section 300-0020, LUBRICATION SYSTEM. Ensure
3 Check Valve 1 30
4 Check Valve 1 30
10 Check Valve 1 30
11 M6 Orifice Screw 1 3
12 M6 Orifice Screw 1 3
24 Volt Coil 1 3
Coil Nut 1 3
24 Volt Coil 1 3
Coil Nut 1 3
CoilNut 1 3.5
21 Shuttle Valve 1 10
22 Shuttle Valve 1 10
25 Shuttle Valve 1 10
31 Plug – G1/8” 3 15
32 Plug – G1/4” 1 30
33 Plug – G3/8” 3 45
35 Plug – G1/4” 1 30
40 Nut – M12 3 80
44 M6 Orifice Screw 1 3
45 M6 Orifice Screw 1 3
46 M6 Orifice Screw 1 3
47 Relief Valve 1 80
SM2919
1 - Orifice 4 32 26 7
9
2 - Bleed Down Sequence Valve
3 - Check Valve 24
4 - Check Valve 3
5 - Proportional Pressure Control Valve 11
6 - Park/Emergency Brake Solenoid
7 - Pressure Reducing Valve
8 - Brake Charge Valve
9 - Pressure Reducing Valve
10 - Check Valve
11 - Orifice 16
12 - Orifice 13 10/12
13 - Float Solenoid
14 - Relief Valve 2
15 - Priority Valve
16 - Cold Start Solenoid 34
17 - Hydraulic Proportional Control Valve 20
18 - Pressure Compensating Valve
19 - Emergency Steer Valve
20 - Orifice 6
21 - Shuttle Valve
22 - Shuttle Valve
23 - Check Valve
24 - Check Valve 29
44
25 - Shuttle Valve
26 - Body System Relief Valve
27 - Emergency Steer Relief Valve
45
29 - Proportional Pressure Control Valve
5 22/46
44 - Orifice
45 - Orifice
47 - Relief Valve 17
18
31 8
19 27
33
23
35 14
25
15
21
47
T LS P
14
15
19 21
20
25
24
23
27
Steering Orbitrol Valve (1) The steering valve is of a closed centre design,
Refer to Section 220-0090, STEERING VALVE indicating oil is dead headed at the valve until it is
operated.
Mounted off the underside of the cab floor, the steering
SM 2197 2-03 1
STEERING SYSTEM - Steering System Schematic
Section 220-0000
Load Sense (LS) pressure is set 25 bar (360 lbf/in2) The pressure demanded by the steering is fed back to
below steering system pressure, i.e. at maximum the main pump (4) & the priority valve (15) via shuttle
setting LS pressure will be 215 bar (3120 lbf/in2).
2 SM 2197 2-03
STEERING SYSTEM - Steering System Schematic
Section 220-0000
valve (21). The priority valve (15) will close & the main Check valve (24) prevents the emergency steer flow
pump will increase its displacement to make sure there going towards the main pump (4), which may already
is enough flow & pressure available to meet that have failed.
demanded by the steering.
The steering load sense orifice (20) feeds oil from the STEERING PRESSURE SETTING
main pump supply, to boost the load sense pressure
back to the main pump during the steering operation. WARNING
This is to make sure an adequate flow is always Machine has to fully articulate to set steering
available from the main pump (4) to meet that pressure, therefore steering lock bar cannot be
demanded by the steering. This is commonly known as 'Locked'. To prevent personal injury and
a dynamic load sense system. property damage, exercise extreme caution
while working around articulation and
Note: The maximum steer pressure is set by the oscillation pivot area.
pressure cut off (compensator) on the main hydraulic
pump (240 bar (3500 lbf/in2)). Refer to Section 230- The maximum steer pressure is set by the pressure
0050 MAIN HYDRAULIC PUMP. cut off (compensator) on the main pump (240 bar (3500
lbf/in2)). Refer to Section 230-0050, MAIN HYDRAULIC
PUMP.
EMERGENCY STEERING
The emergency steering ground driven pump (3) Steering pressure can be checked at the diagnostic
provides flow to the steering circuit in the event that check point located inside the battery box (refer to Fig.
the main pump (4) can no longer function effectively. 2). Install pressure gauge capable of reading at least
240 bar (3500 lbf/in2) to correct diagnostic check point.
Engine failure, transmission failure or internal failure of
the main pump (4) could cause ineffective Steer truck over relief (against steering stops) to
performance. observe maximum cut-off pressure of 240 bar (3500
lbf/in2). Adjust pressure cut-off screw on main pump (4)
The emergency steering pump (3) will also assist with if necessary. Refer to Section 230-0050, MAIN
flow from the main pump to articulate the vehicle if the HYDRAULIC PUMP.
main pump cannot deliver the flow required by the SM - 2849
steering circuit. This can happen at low engine speed
when the vehicle is moving and the operator attempts
to articulate the vehicle rapidly.
SM 2197 2-03 3
STEERING SYSTEM - Steering System Schematic
Section 220-0000
24
20
19 27
23
14
25
15
14 - Relief Valve
15 - Priority Valve 21
19 - Emergency Steer Valve
20 - Steering Load Sense Orifice
23 - Check Valve
24 - Check Valve
25 - Shuttle Valve
27 - Emergency Steering Relief Valve
4 SM 2197 2-03
STEERING SYSTEM - Steering System Schematic
Section 220-0000
a. Ensure 'O' ring/seal is in place and that the joining b. When the oil in the tank is clear (not cloudy or
surfaces are clean. If necessary, retain 'O' ring/seal in creamy), the system is free of air.
place with a light coating of grease or vaseline.
Note: Slight creep or drift of the steering wheel is
b. Initially, the nuts should be tightened by hand. normal.
c. Where a hose is fitted, ensure that it is not twisted c. Fill hydraulic tank to the recommended level and
or kinked when the nuts are tightened so that it is install the filler cap.
allowed to adopt a natural position.
Hydraulic Oil
d. Where a tube is fitted, ensure that the connection is
aligned correctly. The steering system should be kept filled with
hydraulic oil as listed in Section 300-0020,
e. Tighten the nut a further 1/4 to 1/2 a turn using the LUBRICATION SYSTEM.
correct size spanner (wrench).
MAINTENANCE
f. Check that a satisfactory hose or tube routing has
been achieved. Maintenance instructions, intervals and warnings, in
the individual steering and body hydraulic component
SM - 1335 sections of this manual, should be adhered to at all
times.
FITTING NUT
TUBE
SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, SERVICE
SLEEVE TOOLS, for part numbers of these tools.
'O' RING 'O' RING
SM 2197 2-03 5
STEERING SYSTEM - Steering System Schematic
Section 220-0000
simply aim, pull the trigger, and read the temperature. O' Ring Face Seals (ORFS) - Seal Kit
Since there is no need to touch what you are
The steering system utilizes 'O' Ring Face Seal
measuring, temperatures of hard-to-reach or moving
(ORFS) connectors. An ORFS kit, 15271082, is
components can be taken without getting burned or
available. This kit contains a minimum stock
shocked.
requirement of all sizes of ORFS type seal.
Heavy steering due to not enough Fault with main pump or standby Refer to Section 230-0050, MAIN
flow being available at the steering pressure incorrectly set HYDRAULIC PUMP
valve but differential pressure
between the main pump outlet and Faulty steer valve Refer to Section 220-0090,
the load sense port is between 15 - STEERING VALVE
22 bar (218 - 319 lbf/in2)
Priority valve (15) - sticking open or Replace valve (15)
wrong spring setting
No steering flow available whilst the Ground driven pump faulty Replace ground driven pump at
vehicle is still travelling and engine is transmission.
switched off
Emergency steer valve (19) sticking Replace valve (19)
open
With no functions operated pressure Emergency steer valve (19) spool Replace valve (19)
at ground driven pump too high. sticking closed.
6 SM 2197 2-03
STEERING SYSTEM - Steering Valve
Section 220-0090
SM - 2016
12 11 10 8 16 7 6 5 4
1
15
19
2
17
18 14
20 13 9 3
SM 2193 1-03 1
Steering System - Steering Valve
Section 220-0090
Turning action of the steering wheel is transmitted SM - 282
through the steering column to sleeve (8) and
POCKETS
driveshaft (6), which is fastened to the sleeve with
centring pin (10). Rotation of driveshaft (6) causes
gerotor gear (19) to rotate in gerotor housing (4).
When gerotor gear (19) rotates, oil in gerotor housing
(4) pockets (see Fig. 2) is forced out and flows through
spool (16) and sleeve (8) to the steering cylinder port.
When the operator turns the steering wheel a certain RIGHT LEFT
number of degrees for either a left or right hand turn, SYSTEM TURN TURN
the movement is transmitted through the steering PRESSURE FEED FEED
column to spool (16). After a minimum rotation of 2.5 METER TO
PORTS TANK
degrees, the ports in spool (16) start to align with ports
in sleeve (8). When the steering wheel is rotated to a
maximum of 10 degrees the ports are fully aligned
allowing full oil flow. After 10 degrees of travel in either
direction the spool and sleeve rotate as an assembly
through centring pin (10).
Oil from the priority valve flows into valve housing (7)
at port 'P' and is channelled through sleeve (8) and
spool (16) to gerotor housing (4). Porting in gerotor
housing (4) permits oil to flow into pockets formed by Fig. 3 - Porting of Spool and Sleeve
gerotor housing (4) and gerotor gear (19). As spool
(16) rotates, driveshaft (6) also rotates which, in turn, REMOVAL
rotates gerotor gear (19) to which it is splined. When
gerotor gear (19) rotates it progressively forces oil out Numbers in parentheses refer to Fig. 4.
of the pockets (see Fig. 2) of gerotor housing (4). The
oil is channelled through sleeve (8) and spool (16) and
exits valve housing (7) through port 'R' for a right hand WARNING
turn, or port 'L' for a left hand turn. Oil then travels To prevent personal injury and property
through steering lines to the steering cylinders. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
As the steering cylinder pistons move, oil forced out of secured and of adequate capacity to do the job
the steering cylinders returns to valve housing (7). The safely.
return oil passes through valve sleeve (8) and spool
(16) and exits through port 'T' to tank. 1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering
When the steering effort is released, centring spring wheel several times to relieve any pressure in the
(11) which was put under tension by the rotation of steering circuit. Operate brake pedal continuously to
spool (16), forces sleeve (8) to rotate back to its relieve pressure in the braking system.
original position. This puts the ports out of alignment
and stops pump oil flow to the steering cylinders. The 2. Block all road wheels and place the battery master
vehicle stops turning further but will hold the present switch in the 'Off' position.
turning radius until spool (16) is rotated past the 2.5
degree minimum. 3. Remove hydraulic tank remote drain plug and drain
2 SM 2193 1-03
Steering System - Steering Valve
Section 220-0090
SM - 2827
12 22
20 21
13
14
18
19
12
7
6 9 16
5
10
4 11 17
2 8
1 15
hydraulic oil into a suitable container. Reinstall drain 6. Slide bellows (13) over steering shaft (14) to gain
plug in hydraulic tank remote drain fitting. access to bottom joint (12) and loosen bolt which
tightens joint (12) onto stub shaft (8).
4. Pull floor mat back to allow access to bolts (7).
Raise cab and secure with prop. Refer to Section 260- 7. Support steering valve (1) and remove bolts (7),
0010, CAB AND MOUNTING. locknuts (2) and washers (3 & 6) securing mounting
plate (5) to cab floor. Remove steering valve (1) and
5. Clean outer area of steering valve (1) with a suitable mounting plate (5) to a clean area for disassembly.
solvent. Ensure all hydraulic lines connected to Remove nitrile seal (9) and discard rubber mounts (4),
steering valve (1) are identified for ease of installation if damaged.
and with suitable containers available to catch
leakage, disconnect hydraulic lines. Cap all lines and
plug all ports to prevent entry of dirt.
SM 2193 1-03 3
Steering System - Steering Valve
Section 220-0090
SM - 2017
9 11 13 12 13
16 20 14 17 18 15
3 4 19 21 5
1
22
6
8
10
24
23
DISASSEMBLY SM - 2018
4 SM 2193 1-03
Steering System - Steering Valve
Section 220-0090
13. Remove pin (10) and slide drive shaft (6) from
spool (16) and sleeve (8) assembly. Refer to Fig. 9.
SM 2193 1-03 5
Steering System - Steering Valve
Section 220-0090
SM - 2022 vice and tilt until roll pins (23) and ball valves (24) slide
PORT FACE through the straws and out of the valve housing (7).
Refer to Fig. 10.
16. Remove and discard 'O' ring (14), seal (17) and
backup ring (18) from valve housing (7).
PORT
FACE
17. Using a thin blade screwdriver, pry dust seal (15)
from valve housing (7). Take care not to damage dust
seal seat.
TOP
VIEW
24
INSPECTION
Anti-Cavitation Valves -
Insert Soda Straws (2), 1. Clean all metal parts in a suitable solvent and blow
one into each of these dry with compressed air. Do not wipe dry with cloth or
two threaded holes. 23 paper towel as lint or other matter may get into the
hydraulic system and cause damage.
TILT 2. Check all mating surfaces and replace any parts that
HOUSING have scratches or burrs that could cause leakage.
SODA STRAW 3. Do not use course grit or try to file any metal parts.
Note: Replace all 'O' rings and seals with new 'O' rings
23 - Roll Pin
24 - Ball Valve
and seals at 'Assembly'. Lubricate all 'O' rings and
seals with a petroleum jelly.
Fig. 10 - Removing Ball Valves
ASSEMBLY
SM - 2023
PORT FACE Numbers in parentheses refer to Fig. 5, unless
otherwise specified.
23
6 SM 2193 1-03
Steering System - Steering Valve
Section 220-0090
SM - 2024 SM - 2027
6 8 11 13
6 8
16
10
6 - Drive Shaft
8 - Sleeve
9 - Ball Check
10 - Pin 9 9 10 16
16 - Spool
9
Fig. 12 - Installing Spool and Ball Checks
SM - 2025
17
6 16
18
6 - Drive Shaft
20
8 - Sleeve
9 - Ball Check 12 14
8 10 10 - Pin
11 - Centring Springs 16 - Spool
12 - Needle Bearing 17 - Seal
6 - Drive Shaft 10 - Pin 13 - Bearing Race 18 - Backup Ring
8 - Sleeve 16 - Spool 14 - 'O' Ring 20 - Retainer
Fig. 13 - Installing Centring Pin and Drive Shaft Fig. 15 - Sectional View of Seals and Bearings
SM 2193 1-03 7
Steering System - Steering Valve
Section 220-0090
SM - 2028 SM - 2029
Fig. 16 - Compressing Centering Spring Fig. 17 - Installing Spool and Sleeve Assembly
SM - 2030
7
3 4 19 21 5
1
22
8. Using a cloth to protect the hand, place gerotor gear valve housing (7). Align bolt holes in spacer plate (5) with
(19) over end of drive shaft (6). Insert special tool tapped holes in valve housing (7). Refer to Fig. 18.
through valve housing (7) and engage with splined
end of spool (16) and sleeve (8) assembly. Twist tool 13. Lubricate and install new 'O' ring (21) in groove in
to compress centering spring (11) radially CW or spacer plate (5). Refer to Fig. 18.
CCW. Refer to Fig. 16.
14. Install gerotor housing (4) on valve housing (7).
9. Keep centering spring (11) compressed and Align bolt holes in gerotor housing (4) with tapped
carefully insert assembled parts into valve housing (7), holes in valve housing (7). Refer to Fig. 18.
as shown in Fig. 17.
15. Align gerotor gear (19) on driveshaft (6) and
10. Release tension on centering spring (11) and gerotor housing (4), as shown in Fig. 18.
remove special tool and gerotor gear (19).
16. Lubricate and install new 'O' ring (3) in groove in
11. Lubricate and install new 'O' ring (22) in groove in gerotor housing (4).
valve housing (7). Refer to Fig. 18.
17. Install end cap (2) on gerotor housing (4), as
12. Install spacer plate (5) with the 'O' ring groove up, on shown in Fig. 18.
8 SM 2193 1-03
Steering System - Steering Valve
Section 220-0090
WARNING
To prevent personal injury and property WARNING
damage, be sure wheel blocks, blocking Do not operate the vehicle until all air is bled
materials and lifting equipment are properly from the oil.
secured and of adequate capacity to do the job
safely. b. When the oil in the tank is clear (not cloudy or
creamy), the system is free of air.
1. Make certain area of installation is clean.
Note: Slight creep or drift of the steering wheel is normal.
2. Install rubber mounts (4) if removed, and secure
steering valve (1) and mounting plate (5) to cab floor c. Fill hydraulic tank with hydraulic oil specified in
with bolts (7), washers (3 & 6) and locknuts (2). Section 300-0020, LUBRICATION SYSTEM. Refer to
Section 230-0040, HYDRAULIC TANK, for correct fill
3. Install nitrile seal (9) to steering shaft (14). level. Install filler cap on tank.
SM 2193 1-03 9
Steering System - Steering Valve
Section 220-0090
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for
details of the centring spring installation tool
referenced in this section. This tool is available from
your dealer.
* * * *
10 SM 2193 1-03
STEERING SYSTEM - Steering Cylinder
Section 220-0120
SM - 3372
14
13
10 11 9
1 11 12
7 15,16 5
3 6
14
13
4 4
20 2 8
18
19 18 20
19
PART OF
FRAME PART OF
17 FRAME
17
ORIENTATION OF
CUSHION SLEEVE
21
21
22
23
REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
WARNINGS WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure lifting equipment is properly
materials and lifting equipment are properly secured and of adequate capacity to do the job
secured and of adequate capacity to do the job safely.
safely.
1. Ensure clean working conditions, remove any port
Hydraulic fluid pressure will remain plugs thus allowing easy entry of air into the cylinder,
within the system after engine shutdown. preventing a vacuum when parts are withdrawn from
Operate the treadle pedal continuously until the cylinder body (1).
pressure has dissipated before carrying out any
work on the hydraulic system or serious injury 2. Remove circlips (14) from base end of cylinder body
could result. (1) and piston rod (2) end. Press out spherical
bearings (13).
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering 3. Using special tool which can be fabricated as shown
wheel several times to relieve any pressure in the in Fig. 2, unscrew end cap (3) until thread is
steering circuit. Operate brake pedal continuously to disengaged from cylinder body (1).
relieve pressure in the braking system.
4. Pull end cap (3) and piston rod (2) out of cylinder
2. Place steering lock bar in the 'Locked' position. body (1) as an assembly.
Block all road wheels and place the battery master
switch in the 'Off' position. 5. Place piston rod (2) on supports which will not
damage the chrome piston rod diameter.
3. Identify, tag and with a suitable container in position
to catch the spillage, disconnect all hydraulic lines on 6. Remove and discard piston seal (12) and wear rings
one steering cylinder. Cap all lines and fittings to (11) from piston (9).
prevent ingress of dirt.
7. Remove grub screw (10) from wear ring groove in
4. Support steering cylinder with a suitable lifting piston (9).
device.
8. Provide an anti-torsion device through piston rod (2)
5. Remove bolt (20), lockwasher (19) and hardened eye to allow unscrewing of piston (9). Using special
washer (18) securing pin (17) at base end of the tool which can be fabricated as shown in Fig. 3,
cylinder. Remove pin (17) securing base end to the unscrew piston (9) from piston rod (2).
front frame.
9. Remove and discard 'O' ring (5) from piston (9).
6. Remove bolt (20), lockwasher (19) and hardened Remove and retain cushion sleeve (8) from piston rod
washer (18) securing pin (17) at piston rod (2) end of (2).
the cylinder. Remove pin (17) securing piston rod (2)
end to the articulation and oscillation pivot. 10. Pull end cap (3) assembly off piston rod (2).
Remove and discard back up ring (15) and 'O' ring (16)
7. Remove cylinder assembly from the machine. from end cap (3) outer grooves. Remove and discard
Spacers (22 & 21) will come free at this time. wiper (7) and rod seal (6) from end cap (3) inner
grooves.
8. Remove cylinder assembly to a clean area for
disassembly. Drain oil from cylinder assembly into a 11. If damaged, remove lube fittings (4) from cylinder
suitable container. body (1) and piston rod (2).
SM - 407
DRILL
RAD
DEEP
RAD TYP
BURN OUT
SQUARE
Dimensions in mm (inches)
Fig. 2 - End Cap Torque Tool
SM - 633
SILVER STEEL
SQUARE
Dimensions in mm (inches)
Fig. 3 - Piston Torque Tool
* * * *
18
LOWER
ACC3
RAISE
1
DL
5
PPA
PP B A
1
9 33 47
T
13
30
R
15 32
P1
31 31
L
LSM
21 22
46
25
PP
26
PPB
29
T LSP T
The body hydraulic system enables the operator to lift The body control lever is mounted on the right hand
and lower the body in a safe manner with an electric side dash panel inside the operators cab. The body
output from the body control lever. control lever is manually operated to control the lift and
lower function of the body assembly.
A brief description of the individual components used in
the body hydraulic system are listed below. Detailed
SM 2199 Rev 1 6-03 1
BODY SYSTEM - Body System Schematic
Section 230-0000
Body Cylinders (1) Valves 5, 9, 13, 15, 21, 22, 25, 26, 29, 30, 31,
Refer to Section 230-0130, BODY CYLINDER. 32, 33, 46 & 47
These valves form part of the brake cuircuit and are an
There are two single stage, double acting body hoist intregal part of the main hydraulic valve assembly,
cylinders, cushioned at both ends of the stroke, on the mounted on the left hand side of the tractor frame.
vehicle. The cylinder base end is connected to the Refer to Section 215-0050, MAIN HYDRAULIC VALVE
trailer frame and piston rod eye end is connected at the ASSEMBLY.
body. Single stage double acting means that the piston
rod can have oil applied to either end, extending or
retracting the piston rod. OPERATION
The cushioning effect when the cylinder is being
extended is obtained by a tapered spear on the piston LIFTING THE BODY
rod passing through a cushioned sleeve. This gradually Refer also to Sections 190-0000 CIRCUIT DIAGRAMS
slows the piston which in turn helps to control and 215-0050 MAIN HYDRAULIC VALVE ASSEMBLY.
destructive shock effects when the piston reaches the
full extent of its travel. When the operator pulls back on the body control lever
a voltage between 0 and 5 volts is sent to the hydraulic
The cushioning effect when the cylinder is being ECU, Pin C1:8. The hydraulic ECU converts this signal
retracted is obtained by a tapered spear at the base to an output current at Pin C1:17 to between 250 & 800
end of the cylinder body entering a cavity in the piston mA dependent upon how far the lever is selected. This
rod through a cushioning ring. This gradually slows the current is delivered to the Electro-Hydraulic
piston which in turn helps to control destructive shock Proportional Pressure Control Valve (5) which converts
effects when the piston bottoms. this current into a pilot pressure.
Cylinder mounting is by pins, spacers and spherical The primary accumulator (18) pressure is reduced to a
bearings secured in place by circlips. Spherical 35 bar (508 lbf/in2) pilot control pressure by pressure
bearings permit a limited amount of cylinder reducing valve (9). This pilot control pressure acts
misalignment. upon the poportional pressure control valve (5) which
reduces the pilot pressure to between 4 bar (58 lbf/in2)
and 25 bar (363 lbf/in2), depending on the current output
Accumulators (18) fom the hydraulic ECU. This pilot pressure then selects
Refer to Section 250-0060, ACCUMULATOR. the main spool (30) in the lift valve section of the main
hydraulic valve assembly to the raise position.
The primary accumulators mounted inside the battery
box located on the front left hand side of the tractor. When the main spool (30) has been stroked to the raise
The primary accumulator supports the service brake position, oil from the main pump flows through the
system and the body pilot pressure system. The control spool (30) out of port 'A' on the main hydraulic
primary accumulator is of the piston type and valve, onto the tip cylinders (1).
precharged with nitrogen to 95 bar (1 380 lbf/in²). It
consists of a charging valve assembly, cylinder When oil from the main pump flows through control
assembly and piston. The charging valve is equipped spool (30), a pressure is created at the head of copy
with a locking feature which, when opened, will allow spool (31). The copy spool (31) strokes down allowing
precharge to be checked or accumulator charged. a load sense pressure to be fed back to the load sense
port of the main pump via shuttle valves (22 & 25). The
The piston acts as a separator dividing the cylinder main pump then increases its displacement and flow
assembly into two sections. The section nearest the passes to port 'A' lifting the body. Returning flow from
charging valve contains the nitrogen precharge. the tipping cylinders (1) passes to Port 'B', through the
Hydraulic oil from the accumulator charge valve flows control spool (30) back to tank.
through accumulator check valves in the brake
manifold valve and into the other section of the The load sense pressure created by copy spool (31) is
accumulator. controlled to a maximum of 195 bar (2830 lbf/in2) by
relief valve (26). This will result in a maximum main
Accumulator pressure is monitored by pressure pump delivery pressure for the body raise circuit of 220
switches in the brake lines (Ref. Section 250-0000, bar (3200 lbf/in2). This is a result of the 195 bar (2830
BRAKING SYSTEM). lbf/in2) maximum load sense pressure, plus the 25 bar
SM - 2867 When the main spool (30) has been stroked to the
lower position, oil from the main pump flows through
the control spool (30) out of port 'B' on the main
hydraulic valve, onto the tip cylinders (1).
SM - 2920
15
Valve (5 & 29) Coil Rating
Ohms Amps Watts
21 1.1 25
Voltage: 24V
PORT 'B'
PORT 'A'
26 47
9 32 PORT 'T'
13
29
5 22/46
6. A hydraulic pressure of 35 bar (500 lbf/in2) should f. Check that a satisfactory hose or tube routing has
be observed on the pressure gauge. been achieved.
11. Remove wheel blocks, place the steering lock bar SERVICE TOOLS
in the 'Stowed' position, start the engine and check the It is recommended that the following service tools are
body system for proper operation. used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
'O' RING FACE SEALS (ORFS) from your dealer. Refer to Section 300-0070, SERVICE
Where hydraulic lines are fitted with ORFS TOOLS, for part numbers of these tools.
connections, the following procedure should be carried
out during 'Installation'. Refer to Fig. 6.
Control lever in the cab faulty Check output from lever. Refer to
Sections190-0085 HYDRAULIC
ECU and 230-0081, BODY
CONTROL LEVER
Main control spool (30) in the lift Replace lift section of the main
section of the main hydraulic valve hydraulic valve assembly
assembly sticking
Lift function too slow. Proportional control valve (5) current Check output from body control
not high enough lever. Refer to Sections190-0085
HYDRAULIC ECU and 230-0081,
BODY CONTROL LEVER
Main control spool (30) not fully Replace lift section of main
selecting. hydraulic valve assembly.
Body will not lower. Supply fuse to hydraulic ECU blown. Check that green LED on the
hydraulic ECU is illuminated.
Replace fuse F48 located inside
fuse box. Refer to Section190-0000
CIRCUIT DIAGRAMS
Control lever in the cab faulty. Check for output from control lever.
Refer to Sections 190-0085
HYDRAULIC ECU and 230-0081
BODY CONTROL LEVER
Body lowers too slow. Not enough electric current at the Check output from body control
proportional control valve (29) lever. Refer to Sections 190-0085
HYDRAULIC ECU and 230-0081
BODY CONTROL LEVER
Main control spool (30) sticking. Replace lift section of the main
hydraulic valve assembly.
Oil by-pass body lift cylinders (1) Repair lift cylinders (1)
Control spool (30) not centering Check that there is zero pilot
pressure at both ends of control
spool (30). Either of proportional
control valves (5/29) could remain
active
Power down available when body is Faulty proximity switch on chassis Check connections. Replace
on the chassis proximity switch. Refer to Section
190-0085 HYDRAULIC ECU, for
check tool
Body fails too slow down when Faulty proximity switch on chassis Check gap between body plate and
reaching the proximity switch on the proximity switch. Max. gap 15mm.
chassis Replace proximity switch
Body fails too go into float and stops No voltage at the float solenoid valve Check connections at valve (13)
before it reaches the chassis (13) and hydraulic ECU. Refer to
Section 190-0085 HYDRAULIC
ECU
* * * *
SM - 3316
25 24 14 13 12
6
19 18
19 17
11 9
10
5
2,3,4
15
23
22
20 27
21 28
16
26
18
8
7
DESCRIPTION cover (21). Located on top of the tank is filler cap (12),
breather (17) and filter restriction gauge (14).
Numbers in parentheses refer to Fig. 1.
The hydraulic tank (1) is the common reservoir for the OPERATION
steering, braking, body hoist and transmission oil Numbers in parentheses refer to Fig. 2.
cooler fan drive systems. It is mounted off the frame at
the rear right hand side of the tractor. Oil is added to the hydraulic tank (4) through filter
assembly (2). The hydraulic oil is drawn from hydraulic
Integral with hydraulic tank (1) assembly are filter tank (4) by main hydraulic pump (1) and pumped to the
assembly (2), oil level sight gauge (5) and access main hydraulic valve to supply the various hydraulic
SM 2350 10-04 1
Body System - Hydraulic Tank
Section 230-0040
SM - 2864
EMERGENCY
SUPPLY TO
SUPPLY TO MAIN
MAIN HYDRAULIC RETURN
HYDRAULIC
VALVE TO TANK
VALVE
1 3
2
5 5
2 SM 2350 10-04
Body System - Hydraulic Tank
Section 230-0040
steering circuit. Operate treadle valve continuously to directions several times to relieve any pressure in the
discharge accumulators. steering circuit. Operate treadle valve continuously to
discharge accumulators.
3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in 2. Block all road wheels, place the steering lock bar in
the 'Off' position. the 'Locked' position and the battery master switch in
the 'Off' position.
4. Check oil level and add if low. Oil should at least
reach the minimum level in the sight gauge (5). If oil is 3. Remove blanking cap from remote drain valve (7) on
required, remove filler cap (12) from hydraulic tank (1) the bottom of hydraulic tank (1). Install a hose adaptor
and fill hydraulic tank with hydraulic oil specified in (15) on remote drain fitting, open drain cock and drain
Section 300-0020, LUBRICATION SYSTEM. Install hydraulic oil into a suitable container. Close drain cock,
filler cap (12) on hydraulic tank (1) and tighten. remove hose and reinstall blanking cap on remote drain
valve (7).
Replacing Hydraulic Oil 4. Remove bolts (6 & 18) and washers (19) securing
Hydraulic oil should be changed every 2 000 hours. guard (25) and cover plate (11) to top of hydraulic tank
Refer to Section 300-0020, LUBRICATION SYSTEM, (1). Remove guard (25), cover plates (11) and gasket
for hydraulic oil used in the system. (10) from hydraulic tank (1). Discard gasket (10).
Note: When replacing the hydraulic oil due to a 5. Remove filter assembly (2) from hydraulic tank (1).
hydraulic failure, or at recommended change interval,
element (3) must be replaced and hydraulic tank (1) 6. Remove and discard element (3) from filter
cleaned thoroughly using a suitable solvent. assembly (2). Discard 'O' ring (4).
2. Block all road wheels, place the steering lock bar in 9. Install new element (3) in filter assembly (2).
the 'Locked' position and the battery master switch in
the 'Off' position. 10. Install filter assembly (2) in tank (1), complete with
new 'O' ring (4).
3. Unscrew breather (17) and remove from tank (1).
Discard 'O' ring (9). 11. Place new gasket (10), cover plate (11) and guard
(25) on hydraulic tank (1). Secure with bolts (6 & 18)
4. Install new 'O' ring (9) and breather (17) to tank (1). and washers (19).
12. Install new 'O' ring (20) and secure access cover
Replacing Filter Element plate (21) on hydraulic tank (1) with bolts (18) and
Every 2 000 hours of operation or when filter restriction lockwashers (16).
gauge (14) shows red, whichever comes first, clean
filter assembly (2) and install new element (3). 13. Remove filler cap (12) from hydraulic tank (1) and
fill hydraulic tank with hydraulic oil specified in Section
1. Position the vehicle in a level work area, ensure the 300-0020, LUBRICATION SYSTEM. Install filler cap
body is fully lowered, apply the parking brake and (12) on hydraulic tank (1) and tighten.
switch off the engine. Turn steering wheel in both
SM 2350 10-04 3
Body System - Hydraulic Tank
Section 230-0040
14. Place the battery master switch in the 'On' position Inspection
and the steering lock bar in the 'Stowed' position,
Numbers in parentheses refer to Fig. 1.
remove all wheel blocks, start the engine and operate
the steering, braking and body hoist systems to
circulate the oil. WARNING
Splashing liquid. Wear a suitable face shield
15. Switch off the engine, check for leaks and check
when using compressed air to dry hydraulic
oil level as described under 'Checking Oil Level'.
tank and components.
4 SM 2350 10-04
Body System - Hydraulic Tank
Section 230-0040
5. Place the battery master switch in the 'On' position SPECIAL TOOLS
and the steering lock bar in the 'Stowed' position,
There are no special tools required for the procedures
remove all wheel blocks, start the engine and operate
outlined in this section. Refer to Section 300-0070,
the steering, braking and body hoist systems to
SERVICE TOOLS, for part numbers of general service
circulate the oil.
tools required. These tools are available from your
dealer.
6. Switch off the engine, check for leaks and check oil
level as described under 'Checking Oil Level'.
* * * *
SM 2350 10-04 5
THIS PAGE IS INTENTIONALLY LEFT BLANK
BODY SYSTEM - Main Hydraulic Pump
Section 230-0050
SM - 2837
59
70 71 69 48 66 72 61 60 58
68
72
3
75 4
76
5
51 62
50
64 1
83
82
79
81
80
54
55
78
77
84
49 47 45 44 46 52 43 41 65 2 40
53
1 - Valve Cover 47 - Shoe Plate 60 - 'O' Ring 75 - 'O' Ring
2 - Bolt 48 - Tilting Bush 61 - Servo Piston 76 - Plug
3 - Bolt 49 - Swash Plate 62 - 'O' Ring 77 - Snap Ring
4 - Nut 50 - Swash Plate Support 64 - Pin 78 - Bearing Spacer
5 - Set Screw 51 - Pump Casing 65 - Pin 79 - Roller Bearing
40 - Needle Bearing 52 - 'O' Ring 66 - Tilting Pin 80 - Driveshaft
41 - Valve Plate 53 - Plug 68 - Eye Bolt 81 - Oil Seal
43 - Cylinder Spring 54 - 'O' Ring 69 - Spring Seat 82 - 'O' Ring
44 - Spherical Bush 55 - Plug 70 - Outer Spring 83 - Seal Cover
45 - Set Plate 58 - Stopper 71 - Inner Spring 84 - Bolt
46 - Piston & Shoe 59 - Back-up Ring 72 - Plug
SM 2196 2-03 1
Body System - Main Hydraulic Pump
Section 230-0050
SM - 2845
A - Outlet Port
B - Outlet Kidney Slot 41 - Valve Plate 47 - Shoe Plate
C - Inlet Port 42 - Cylinder Block 80 - Driveshaft
D - Inlet Kidney Slot 46 - Piston & Shoe
SM - 603
MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
VIEW A VIEW B VIEW C
Fig. 3 - Variable Displacement Action
rate. Consists of swash plate (49), shoe plate (47), block (42) being spline coupled to the shaft will also
swash plate support (50), tilting bush (48), tilting pin rotate. If the swash plate (49) has been tilted, the
(66), servo piston (61) and servo assist springs (70 & pistons and shoes (46) arranged in the cylinder block
71). (42) due to the shoes being retained on the shoe plate
(47) will both rotate with the cylinder block and
Valving Cover Group - Provides the switching of oil reciprocate once per revolution.
between suction and delivery ports. Consists of valve
cover (1), valve plate (41) and valve plate pin (65). Paying attention to one such piston, then it will move
away from the valve plate (41) for half a rotation
(suction stroke), and move towards the valve plate (41)
OPERATION for the second half of rotation (delivery stroke). The
Numbers in parentheses refer to Figs. 1, 2 & 7. Refer larger the tilt angle of the swash plate (49), the longer
to Figs. 4 - 6 for hydraulic schematics of pump. the piston (46) stroke and the higher the pump's
displacement. As the swash plate (49) tilting angle
When the pump's driveshaft (80) rotates, the cylinder approaches zero, the piston (46) does not stroke and
2 SM 2196 2-03
Body System - Main Hydraulic Pump
Section 230-0050
LS LINE FROM MAIN HYDRAULIC VALVE SM - 2844A therefore delivers minimum displacement. (Refer to
Pl
Fig. 3).
Pressure Regulator
DIFFERENTIAL
PRESSURE SPOOL
Numbers in parentheses refer to Figs. 1 & 7.
DELIVERY LINE
SM 2196 2-03 3
Body System - Main Hydraulic Pump
Section 230-0050
overcoming spring (70 & 71) force and reducing swash 5. Support pump assembly with suitable lifting
plate (49) angle to zero. equipment. It is possible to set up a sling arrangement
using exhaust cradle. Remove bolts (56) and
The pump also has a pressure limiting function, used lockwashers (57) securing pump to transmission.
for example when steering cylinder reaches the end of Remove pump from transmission.
it's stroke. In this condition the delivery pressure will
rise, and the load sense control will try to raise delivery 6. Remove 'O' ring from pump. Wash the outside of
pressure above the now 'dead head' pressure. This pump thoroughly with a suitable solvent and move to a
causes differential pressure spool (23) to shift to the clean work area for disassembly. Discard 'O' ring.
extreme left, allowing oil pressure to pass through cut-
off pressure spool (24) and reach the large side of
servo piston (61), overcoming spring (70 & 71) force DISASSEMBLY
and reducing swash plate (49) angle to zero. Numbers in parentheses refer to Figs. 1 & 7.
1. Position the vehicle in a level work area, apply the 5. If necessary remove needle bearing (40) and valve
parking brake, switch off the engine and turn steering plate (41) from valve cover (1). Only remove needle
wheel in both directions several times to relieve any bearing (40) if it is nearing the end of its life. Do not
pressure in the steering circuit. loosen nut (4) as this will affect delivery flow rate.
2. Operate the treadle valve continuously to relieve 6. Pull cylinder block (42) out from pump casing (51)
pressure in the braking system. Block all road wheels straight over driveshaft (80). Pull out pistons and
and place battery master switch in the 'Off' position. shoes (46), set plate (45), spherical bush (44) and
Place steering lock bar in the 'Locked' position. cylinder springs (43) at the same time. Be careful not
to damage sliding surfaces of components.
3. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose on 7. Cover splined end of shaft with plastic tape to
remote drain fitting, open drain cock and drain hydraulic prevent oil seal (81) being damaged. Remove bolts (84)
oil into a suitable container. Close drain cock, remove and seal cover (83), ensuring oil seal (81) is not
hose and reinstall blanking cap. damaged.
4. Clean pump housing and surrounding area with a 8. Hold front of driveshaft (80) and using a plastic
suitable solvent. Ensure all hydraulic lines connected hammer, tap driveshaft (80) out of pump casing (51).
to pump are identified for ease of installation and, with Do not remove roller bearing (79) unless it is
suitable containers available to catch leakage, considered to be near the end of its expected life.
disconnect hydraulic lines. Fit blanking caps to all open
lines and fittings. 9. Push down servo piston (61), and remove shoe
4 SM 2196 2-03
Body System - Main Hydraulic Pump
Section 230-0050
SM - 2836
58
59
60
69 66 61
70 63 62
71 63
68 63
72 64
73
74
75
76
51 50
79
52
78 53
77 54
80 78 55
81 56
82 57
83
84
28 30 31 33
32 34 4
26 27 29
5
72
35
21 23
17 19 37 36
13 15
12 25 38
9 3
24
8
20 22
16 18 39
7 11 14
10 6 40
8 41
42 2
1
43 65
44
45
46
48 47
49
SM 2196 2-03 5
Body System - Main Hydraulic Pump
Section 230-0050
plate (47) and swash plate (49). a) Ensure that all damaged parts are fixed or replaced
before assembly.
10. Remove swash plate support (50) from pump
casing (51). b) Before assembly wash each part with clean oil and
dry with compressed air. Assemble pump in a clean
11. If necessary, remove servo piston (61), tilting pin work area to prevent contamination.
(66), outer spring (70), inner spring (71), spring seat
(69) and plug (76). Ensure servo piston (61) and tilting c) When assembling apply clean oil on the sliding
pin (66) are not damaged when being removed. surfaces and bearings.
4. If necessary, remove plugs (27, 31, 34 & 36) and 3. Push down servo piston (61) and insert tilting pin
orifice (28 & 35). (66) into tilting bush (48) of swash plate (49). Install
swash plate (49) and shoe plate (47) into groove of
swash plate support (50) correctly.
ASSEMBLY
Numbers in parentheses refer to Figs. 1 & 7. 4. Insert driveshaft (80) into pump casing (51), tapping
driveshaft (80) lightly so that the end of roller bearing
This is largely the reverse sequence to disassembly, (79) is slightly above the surface of pump casing (51).
but note the following:- This prevents the swash plate support (50) being
displaced.
6 SM 2196 2-03
Body System - Main Hydraulic Pump
Section 230-0050
5. Cover the splined end of the driveshaft (80) with INSTALLATION
plastic tape. Apply grease on lip of oil seal (81)
Numbers in parentheses refer to Figs. 1 & 7.
installed in seal cover (83). Insert seal cover (83)
slightly into pump casing (51). Tighten bolts (84)
Note: Tighten all hydraulic lines fitted with ORFS
uniformly to locate seal cover (83), then tighten bolts to
connections, as described in Section 250-0000,
standard torque.
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
6. Sub-assemble cylinder block (42), pistons and
shoes (46), spherical bush (44), set plate (45) and
cylinder springs (43).
WARNING
To prevent personal injury and property
7. Place pump casing (51) horizontally with surface of
damage, be sure lifting equipment is properly
regulator downward. Install piston-cylinder sub-
secured and of adequate capacity to do the job
assembly into pump casing (51).
safely.
8. Install valve plate (41) on valve cover (1). When
1. Install new 'O' ring to pump.
installing valve plate (41), ensure that pin (65) enters
into the slit of valve plate (41). If stopper (58), max flow
2. Push pump inward to engage with coupling in
set screw (5) and max flow set screw lock nut (4) have
transmission. Secure pump assembly to transmission
been removed, reinstall these parts on valve plate (41)
with bolts (56) and lockwashers (57). Tighten bolts (56)
beforehand.
to a torque of 230 Nm (170 lbf ft).
9. Install valve cover (1) on pump casing (51) and
3. Remove caps and connect outlet, inlet and load
secure using bolts (2 & 3).
sense lines to pump. Before connecting case drain
line, fill pump casing through drain port with clean
10. Install regulator casing (25) to pump casing (51)
hydraulic oil as used in the hydraulic tank. Connect the
and secure with bolts (26).
case drain line to pump. Fill hydraulic tank with oil
specified in Section 300-0020, LUBRICATION
Pressure Regulator SYSTEM.
1. If removed, install plugs (27, 31, 34 & 36) and orifice
Note: It is very important that pump casing is
(28 & 35) into regulator casing (25).
completely filled with hydraulic oil. This will ensure
proper lubrication of the internal parts of pump when it
2. Install plug (33) and insert spools (23 & 24). When
is initially operated. Fill the pump casing through the
inserting spools, care should be taken not to damage
drain port. Filling only the suction line is totally
the sliding surface of the spools.
insufficient.
3. If removed, install nut (8), set screw (7) and stopper
4. Refer to 'PUMP STARTING PROCEDURE' for
(13). Insert springs (17 & 19) and spring seat (21) into
proper start-up procedure.
plug (9).
4. Install plug (9) into regulator casing (25). PUMP STARTING PROCEDURE
1. Be sure the pump case drain line is free from
5. If removed, install nut (8), set screw (7) and stopper obstructions that restrict the pump case drain flow
(14). Insert springs (18 & 20) and spring seat (22) into back to tank and cause high case drain pressure which
plug (10). can lead to an early pump failure.
6. Install plug (10) into regulator casing (25). 2. Ensure that all hydraulic controls are set to a neutral
position, the steering lock bar is in the 'Locked' position
7. Ensure 'O' rings (38) are in place and install regulator and place the battery master switch in the 'On' position.
casing (25) on pump casing (51) using bolts (26). Start the engine and allow the pump to run unloaded for
a period to ensure that all residual air within the system
is released.
PRESSURE CHECKS
To check pump delivery pressure (cut-off pressure) the
1
steering should be operated full lock against the stops.
The pump is checked against the steering system as 2
P
this is the highest pressure requirement in the hydraulic FB 3
circuit. RB 4
5
6
WARNING
7
Machine has to fully articulate to check pump
8
pressures, therefore steering lock bar cannot be
'Locked'. To prevent personal injury and 9
property damage, exercise extreme caution
while working around articulation and
oscillation pivot area.
1 - LS VAL (Load Sense Pressure)
Delivery Pressure (cut-off pressure) 5 - STR (Steering Pressure)
Install a pressure gauge capable of at least 240 bar (3
500 lbf/in2) into STR diagnostic checkpoint in battery Fig. 8 - Diagnostic Test Points
box (5, Fig. 8). When steering against stops, pressure
should be 240 bar (3 500 lbf/in2). completely filled with hydraulic oil before pump is
operated. Fill the pump casing through the drain port.
Differential Pressure (load sense pressure) Filling only the suction line is totally insufficient.
Install a pressure gauge capable of at least 240 bar (3
500 lbf/in2) into STR diagnostic checkpoint in battery
box (5, Fig. 8). Install a pressure gauge capable of at
Differential Pressure Setting
least 240 bar (3 500 lbf/in2) into LS VAL diagnostic Numbers in parentheses refer to Figs. 1 & 7, unless
checkpoint in battery box (1, Fig. 8). With steering in otherwise stated.
neutral position, pressure at STR gauge should be 25
bar (360 lbf/in2) greater than pressure at LS VAL gauge. 1. Install a pressure gauge capable of at least 240 bar
(3 500 lbf/in2) into STR diagnostic checkpoint in battery
If these pressures are not observed, then pump may box (5, Fig. 8) to measure pump delivery pressure (cut-
need to be reset (refer to Troubleshooting). off pressure) (Gauge A).
8 SM 2196 2-03
Body System - Main Hydraulic Pump
Section 230-0050
WARNING
Machine has to fully articulate to set pump,
Fig. 9 - Pump Adjustment At Pressure Regulator therefore steering lock bar cannot be 'Locked'.
To prevent personal injury and property
the ∆P pressure differs from 25 bar (360 lbf/in2), then damage, exercise extreme caution while
carry out steps 5 through 9. working around articulation and oscillation
pivot area.
Note: Typical readings -
STR = 34 - 38 bar (500 - 550 lbf/in2) There should be no requirement to adjust the set screw
LS Val = 11 - 13 bar (160 - 180 lbf/in2) (7) at delivery pressure (cut-off pressure) port (see Fig.
9) as this is factory set. The cut-off pressure sets the
Note: If the pump delivery pressure (Gauge A) is less pump delivery pressure. If the set screw (7) or nut (8)
than 25 bar (360 lbf/in2), disconnect transmission oil has been moved, to reset the pump delivery pressure
cooler fan solenoid, causing solenoid valve to default follow the procedure below:
to an open position, allowing hydraulic oil to the fan
motor. This will place a demand on the pump, causing 1. Install a pressure gauge capable of at least 240 bar
pump delivery pressure to increase. (3 500 lbf/in2) into STR diagnostic checkpoint in battery
box to measure pump delivery pressure (cut-off
5. At differential pressure (load sense) port (see Fig. 9), pressure).
unlock nut (8) and turn set screw (7) clockwise (looking
straight at set screw) to increase ∆P pressure, or 2. Start the engine and run at full throttle. Steer full
counter-clockwise to decrease ∆P pressure. lock against the stops. Observe pressure on gauge.
This cut-off pressure should be 240 bar (3 500 lbf/in2).
Note: Adjustment of ∆P pressure = 5 bar (70 lbf/in2) If the pressure reading differs or the steering is
increase per quarter turn of set screw (7). This is a excessively heavy, then carry out steps 3 through 8.
result of an increase of 7 bar (100 lbf/in2) on the pump
delivery pressure and an increase of 2 bar (30 lbf/in2) Note: Steering has to be operated over relief (against
on the LS pressure. stops) as this is the maximum pressure the pump must
deliver. Setting pump against any other operation would
Note: Pressure should always be adjusted on the result in the pump being set at a lower maximum
increase. Hence if ∆P pressure is too high, set screw delivery pressure.
(7) should be turned counter-clockwise approximately 2
turns, then turn set screw (7) clockwise to attain 25 bar 3. At delivery pressure (cut-off pressure) port (see Fig.
(360 lbf/in2). 9), unlock nut (8) and turn set screw (7) clockwise to
increase cut-off pressure, or counter-clockwise to
SM 2196 2-03 9
Body System - Main Hydraulic Pump
Section 230-0050
decrease cut-off pressure (adjustment 90 bar (1 305 lbf/ Note: If there are still problems with the pump
in2) per turn). pressures after completing the 'Pump Setting
Procedure', ensure set screw (5) has not been
Note: Pressure should always be adjusted on the adjusted. As a dimensional check, the distance
increase. Hence if cut-off pressure is too high, set between the end of set screw (5) to the face of nut (4)
screw (7) should be turned counter-clockwise to should be 16 mm (0.63 ").
decrease cut-off pressure below 240 bar (3 500 lbf/in2),
then turn set screw (7) clockwise to attain 240 bar (3
500 lbf/in2). LUBRICATION
Refer to Section 300-0020, LUBRICATION SYSTEM,
4. Once correct cut-off pressure has been attained, for recommended periodic oil change periods and oil
revert steering to neutral position, then steer full lock specifications.
against the stops. Observe gauge to confirm cut-off
pressure is set to 240 bar (3 500 lbf/in2). All pump parts are lubricated by the hydraulic oil
therefore the oil must be kept clean to minimize pump
Note: A change in pump tone should be heard when wear. Whenever there is a hydraulic system failure, the
cut-off pressure is reached, as pump de-strokes to oil should be drained, the entire system flushed, oil
standby condition. filter replaced and clean hydraulic oil added to
eliminate all metal particles or foreign matter.
5. If no change in pump tone is heard, cut-off pressure
is too high. Return to step 3 of procedure. If problem
persists, refer to Section 220-0000, STEERING PUMP WEAR LIMITS
SYSTEM SCHEMATIC. Before reassembling the pump after disassembly, the
Pump Wear Limits table should be consulted to
6. Tighten nut (8) at cut-off pressure port to 16 Nm (12 establish which components should be replaced.
lbf ft).
Note: The body must remain lowered with lever in the 2. Operate the treadle valve continuously to relieve
'NEUTRAL' position until it is necessary to operate the pressure in the hydraulic system.
body again. Failure to comply to this could result in
overheating the hydraulic oil and failure of the hydraulic 3. Block all road wheels, place the steering lock bar in
system components. the 'Locked' position and the battery master switch in
the 'Off' position.
* * * *
SM - 2468
20 21 23 7 22,6 17,18 9 4 5 11 14 13 14 18 19 23 21 20
3 10 1 16 12 15
DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
Cylinder mounting is by pins (24 & 29), spacers (25) Hydraulic fluid pressure will remain
and spherical bearings (20) secured in place with within the body hoist system after engine
circlips (21). Spherical bearings (20) permit a limited shutdown. Operate the treadle pedal
amount of cylinder misalignment. continuously until the pressure has dissipated
before carrying out any work on the hydraulic
system or serious injury could result.
SM 2207 9-05 1
Body System - Body Cylinder
Section 230-0130
DISASSEMBLY
WARNING Numbers in parentheses refer to Fig. 1.
Exercise extreme caution when lowering
the cylinders from the body. The cylinders will
swing out sharply as they leave their WARNING
mountings. To prevent personal injury and property
damage, be sure lifting equipment is properly
1. Position the vehicle in a level work area, ensure the secured and of adequate capacity to do the job
body is fully lowered, apply the parking brake and safely.
switch off the engine.
1. Ensure clean working conditions, remove any port
2. Press and hold down body hoist bleed down switch plugs thus allowing easy entry of air into cylinder body
and operate the body control joystick continually to (1), preventing a vacuum when parts are withdrawn
relieve pressure in the body hoist system. from cylinder body (1).
3. Block all road wheels, place the steering lock bar in 2. Remove circlips (21) from base end of cylinder body
the 'Locked' position and the battery master switch in (1) and piston rod (2) end. Press out spherical bearings
the 'Off' position. (20).
4. Install a suitable strap around the cylinder and 3. Remove lock ring (10) from end cap (3).
attach to a lifting device.
4. Using special tool which can be fabricated as shown
5. Position a suitable container at the base end of one in Fig. 2, unscrew end cap (3) until thread is
cylinder. Identify and remove the hydraulic lines. Cap disengaged from cylinder body (1).
hydraulic lines and cylinder ports to prevent entry of
dirt. 5. Support piston rod (2) at the rod eye and withdraw
piston rod (2) from cylinder body (1). Ensure centre
6. Remove bolt (26), lockwasher (27), washer (28) and lines of piston rod (2) and cylinder body (1) remain
upper pin (24) connecting piston rod (2) end of the coincidental during removal of piston rod (2).
cylinder to the body. If due to lack of maintenance the
upper pin can not be removed from the front, there is 6. Place piston rod (2) on supports which will not
plate on the inside of the body that can be removed to damage the piston rod diameter.
allow access to the rear of the pin to ease removal.
This plate is tack welded in place so a grinder is 7. Remove and discard piston seals (13) and wear
required to remove it. rings (14) from piston (12).
7. Lower cylinder slowly and remove spacers (25). 8. Remove grub screw (15) from wear ring (14) groove
in piston (12).
Note: Cylinder will swing out sharply as it leaves its
mounting. 9. Provide an anti-torsion device through piston rod (2)
eye to allow unscrewing of piston (12). Using special
8. Remove bolt (26), lockwasher (27), washer (28) and tool which can be fabricated as shown in Fig. 3,
lower pin (29) connecting base end of the cylinder to unscrew piston (12) from piston rod (2).
the frame.
10. Remove cushion spear (11) and 'O' rings (16) from
9. Remove spacers (25) and remove cylinder assembly piston rod (2). Discard 'O' rings (16).
to a clean area for disassembly.
11. Remove cylinder end cap (3) from piston rod (2).
10. Repeat steps 4 through 9 for opposite cylinder. Remove and discard cushion sleeve (4), circlip (5), rod
seal (6), nylon ring (22), wiper (7), 'O' rings (8 & 9) and
back up ring (17).
2 SM 2207 9-05
Body System - Body Cylinder
Section 230-0130
1. Clean all parts of the cylinder with a suitable solvent 7. Insert new piston seal (13) and new wear rings (14)
and dry with clean, lint-free cloths. Clean all grooves in piston (12).
carefully to remove any foreign material.
8. Fully grease piston (12) OD and 'O' rings (8 & 9) in
2. Check cylinder body (1) and outer diameter of piston end cap (3).
(12) for scratches, cracks or other defects. Remove
ridges, nicks and scratches with a fine stone and re- 9. Sling assembled piston rod (2) in a manner to allow
clean. Replace any components which cannot be careful leading of the assembled piston rod into
repaired. cylinder body (1). Take care not to damage piston seal
(13) on cylinder body (1) threads.
3. Inspect piston rod (2) for distortion, cracks or other
defects. Replace piston rod if defective area is 10. After piston (12) is inserted in cylinder body (1), push
irreparable. the piston rod assembly into cylinder body (1) maintaining
coincidental centre lines of piston rod and cylinder body.
4. Check spherical bearing (20) for wear and replace if
necessary. 11. Before piston rod (2) is fully home and, with slings
still taking some of piston rod (2) weight, engage end
cap (3) thread and screw home.
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 12. Push piston rod (2) to the fully retracted position and
tighten end cap (3) to a torque of 237 Nm (175 lbf ft).
WARNING 13. Re-drill end cap (3) for lock ring (10), 3 x 12 mm
To prevent personal injury and property (0.125 x 0.50 in) deep, if necessary. Insert lock ring
damage, be sure lifting equipment is properly (10) in end cap (3).
secured and of adequate capacity to do the job
safely.
INSTALLATION
1. Press spherical bearing (20) in base end of cylinder Numbers in parentheses refer to Fig. 1.
body (1) and piston rod (2) end. Secure spherical
bearings (20) with circlips (21). Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY
2. Install new cushion sleeve (4), circlip (5), rod seals (6), SYSTEM SCHEMATIC. Renew all 'O' rings where used.
nylon ring (22), 'O' rings (8 & 9) and back up (17) in end cap
(3). Load end cap (3) over piston rod (2) thread, taking care
not to damage rod seal (6) on the thread. WARNING
To prevent personal injury and property
3. Install new 'O' rings (16) on piston rod (2) and damage, be sure lifting equipment is properly
replace cushion spear (11). secured and of adequate capacity to do the job
safely.
4. Apply Loctite 243 to first two threads of piston (12).
Using special tool which can be fabricated as shown in 1. Install a suitable strap around the cylinder and
Fig. 3, screw on piston (12) and tighten to a torque of position cylinder on unit with base end of cylinder ready
1 356 Nm (1 000 lbf ft). for mounting.
5. Insert piston grub screw (15) through wear ring (14) 2. Install spacers (25) in base end of cylinder and
groove in piston (12) and into groove machined in insert lower pin (23) through mounting bores, spacers
piston rod (2). Tighten grub screw (15) to a torque of 49 (25) and cylinder. Secure lower pin (23) with washer
Nm (36 lbf ft). Ensure the extreme of grub screw (15) is (28), lockwasher (27) and bolt (26). Tighten bolt (26) to
below the level of wear ring (14) groove. a torque of 66 Nm (49 lbf ft).
SM 2207 9-05 3
Body System - Body Cylinder
Section 230-0130
3. Install spacers (25) in rod end of cylinder, align start the engine, operate the body and check cylinder lines
spherical bearing with bores in body and install upper for leaks. Tighten lines and fittings as required.
pin (24) through mounting bores, spacers (25) and
cylinder. Secure upper pin (24) with washer (28), 8. Remove wheel blocks from road wheels.
lockwasher (27) and bolt (26). Tighten bolt (26) to a
torque of 66 Nm (49 lbf ft).
MAINTENANCE
4. Connect the hydraulic oil lines to the cylinder ports Every 250 hours: Lubricate cylinder pins as described
as tagged during removal. in Section 300-0020, LUBRICATION SYSTEM. Inspect
cylinders for leaks, if leaks are found, replace seals
5. Lubricate pins at lube fittings (22) with lubricant as with seals contained in the Service Repair Kit, as
specified in Section 300-0020, LUBRICATION SYSTEM. specified in the parts book.
SM - 2469
50 25
160 (6.299) (1.9680) (0.984)
10
90 (3.54) DRILL 13 (0.51) 11
(0.394)
RAD X 25 (0.984) (0.433)
DEEP
10 (0.394)
RAD TYP
150 (5.90) DIA
(3.154 - 0.000 )
(4.724 - 0.005 )
+0.002
120.00 - 0.13
(1.9680)
80.10 - 0.00
+0.05
94 (3.7)
+
50
19 (0.75)
SQUARE
4 SM 2207 9-05
Body System - Body Cylinder
Section 230-0130
SM - 2470
89 (3.5)
38.1 (1.5)
(0.375)
9.525
DIA
(0.470)
11.938
124.45 - 0.000 (4.899 - 0.000 )
+0.005
DIA
90 - 0.05 (3.543 - 0.002 )
SILVER STEEL
136 (5.35)
+
25.4 (1.0)
SQUARE
+0.13
+
(0.500)
12.7
EN3B
DIA
MILD STEEL
Dimensions in mm (in)
Fig. 3 - Piston Torque Tool
* * * *
SM 2207 9-05 5
THIS PAGE IS INTENTIONALLY LEFT BLANK
BRAKING SYSTEM - Braking System Schematic
Section 250-0000
SM - 2848
9 TO PARKING 17 17 18
PP BRAKE
FROM
TRANSMISSION
P1
A 13 13
TO FRONT
SERVICE BRAKES T1
ACC2
ACC1
ACC1
ACC2
ACC3
PBP
PB
TS
1
P2
A
TO REAR 3 4
SERVICE BRAKES 2
T2
14
8
6 7
10 11
12
19 16
15
P1
21
25
5
LSP T
1 - Orifice 6 - Park Brake Solenoid Valve 11 - Orifice 16 - Cold Start Solenoid Valve
2 - Directional Control Valve 7 - Brake System Relief Valve 12 - Orifice 17 - Brake Accumulators
3 - Check valve 8 - Brake System Charge Valve 13 - Pressure Switch 18 - Primary Accumulator
4 - Check Valve 9 - Brake Treadle Valve 14 - Pressure Switch 19 - Pressure Switch
5 - Main Hydraulic Pump 10 - Check Valve 15 - Priority Valve 21 - Shuttle Valve
25 - Shuttle Valve
Fig. 1 - Brake System Schematic
The hydraulic braking system is of closed centre The service brakes are of the oil immersed multi disc-
design wherein constant pressure is stored in type. The service piston is designed for use with
accumulators and is regulated as required to retard or hydraulic oil as specified in Section 300-0020,
stop the machine. LUBRICATION SYSTEM. DO NOT USE BRAKE
FLUID (J 1703).
A brief description of the individual components used
in the braking system are listed below. Detailed The brake head is bolted to a mounting plate on the
service and operating instructions can be found in the axle housing. There are 2 brake heads at each of the
relevant component sections of this manual. six road wheels.
A push control on the right hand dash panel activates Brake Circuit Pressure Switches (13)
the park brake solenoid valve (6) on the main hydraulic Front and rear brake circuit pressure switches are both
valve assembly, controlling oil pressure from the rear located on the main hydraulic valve assembly. The
brake circuit accumulator to the actuator. Application of pressure switches sense pressure in the front and rear
the push control releases oil from the actuator allowing brake circuits and sends a signal to warning lights on
internal springs in the actuator to apply the parking the dash (a buzzer also sounds) when the pressure
brake. Pulling out the push control directs oil pressure drops below 122 bar (1 770 lbf/in²). The warning lights
from the rear brake circuit accumulator to the actuator, will remain illuminated until the pressure rises above
compressing internal springs, to release the parking 135 bar (1 960 lbf/in2).
brake.
(F)
Accumulators (17) are charged from accumulator (18)
13 via brake system relief valve (7), to limit the pressure
in these accumulators to 155 bar (2248 lbf/in2) and then
via check valves (3 & 4) respectively.
13
14
(R) If the pressure in accumulator (18) is below the lower
charge limit of 165 bar (2390 lbf/in2) the brake system
charge valve (8) spring closes the brake system
charge valve (8). The pressure then builds up in the
load sense line from brake system charge valve (8) to
the shuttle valve (21) and onto the priority valve (15)
spring chamber where it helps this valve to close,
ensuring flow priority is to the brake charging. At the
same time it also acts upon the main hydraulic pump
load sense line via shuttle valve (25) to supply enough
flow to charge the accumulators.
1 - Microswitch
Brake Apply
The minimum pressure required at the brake treadle
valve is 117 bar (1 696 lbf/in2) and the accumulator pre-
charge pressure is 90% of this at 105 bar (1522 lbf/in2).
1 13 25
Fig. 4 - Brake Treadle microswitch
Fig. 3 - Fuse Box Layout (Operators Cab) (Advanced engine brake)
SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, SERVICE
TOOLS, for part numbers of these tools.
Multi-Gauge
The multi-gauge, 15269784, is basically four pressure
gauges in one. Continuous system pressure readings
are indicated on one of three simultaneously reading
gauges through a pressure range of 30 in of vacuum to
5 000 lbf/in².
The following items should be added to the multi-gauge
to enable the gauge to be used on the diagnostic
pressure check points;
15018226 Diagnostic Coupling
SM - 2834/2854
4 7
3
11
10/12
25
1 - Orifice
2 - Directional Control Valve
3 - Check valve
4 - Check Valve
6 - Park/Emergency Solenoid Valve
7 - Brake System Relief Valve
8 - Brake System Charge Valve
10 - Check Valve
11 - Orifice 21
12 - Orifice
15 - Priority Valve
21 - Shuttle Valve
25 - Shuttle Valve
Front and Rear Brake Accumulators Check Valves (3) or (4) leaking Replace Check Valves (3) or (4)
(17) do not hold their charge pressure
Pre-charge gas pressure in the Check Pre-charge gas pressure in
accumulator not at the correct level the accumulator. Refer to Section
250-0060, ACCUMULATOR
Brake Charging System Fails to Cold Start Solenoid Valve (16) Replace Valve (16). Refer to
charge at initial engine start up remains open Section 215-0050, MAIN
HYDRAULIC VALVE ASSEMBLY
Air or contamination in the Load Lift the body of the truck up and
Sense System, especially when first down several times to purge the
running the truck after new main system.
hydraulic valve is fitted.
Primary Accumulator (18) does not Front and Rear Brake Accumulators See previous symptoms.
hold its charge pressure. (17) are not holding their charge.
Leakage across the Valves (10, 9, 5 Replace each valve one at a time
or 29) is too high. (in order stated) until the fault is
found.
Park Brake Solenoid Valve (6) not Check if there is hydraulic pressure
functioning. Sticking in the selected at the Park Brake port. If there is
position pressure present, replace Valve(6).
Park Brake fails to release. No voltage at Park Brake Solenoid Check park/emergency switch in
Valve (6) when the switch is activated operators cab.
in the cab.
Check wiring between park/
emergency switch and park brake
solenoid (6).
Service brakes fail to come on when Faulty Brake Treadle Valve. Spool not Refer to Section 250-0070,
Parking Brake is selected when the stroking when pressure at port 'PP'. TREADLE VALVE.
engine is running.
No transmission pressure at Port TS Check piping and see instructions
on main hydraulic valve assembly. for the transmission.
Service Brakes come on when Directional Control Valve (2) sticking Replace Valve (2)
Parking Brake is selected and Engine in the selected position.
is not running.
* * * *
Blank Page
SM - 3277
18 19
17 20
16
15
14 21
25 28 13
24 27 12
11
26 10
Charge Valve Assembly
23 22
9
7
6
5
4
8
3
2
1
DESCRIPTION OPERATION
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
The accumulators can be identified as items 17 and Piston (9) acts as a separator dividing cylinder (8) into
18, and the pressure switches as items 13 in Section two sections. The bottom section nearest charging
250-0000, BRAKING SYSTEM SCHEMATIC. valve (3) contains the nitrogen precharge. Hydraulic oil
from the main hydraulic pump flows through check
There are three accumulators mounted inside the valves in the main hydraulic valve and into the top
battery box located on the front left hand side of the section of the accumulators.
tractor; one for the front brake system and one for the
rear. The front and rear brake accumulators are Accumulator pressure is monitored by pressure
supplemented by a third (primary) accumulator. Refer switches located in the main hydraulic valve, which
to Fig. 2. The primary accumulator supports the send a signal to illuminate warning lights in the dash
service brake system and the body pilot pressure panel when the pressure drops below 122 bar (1 769
system. All three accumulators are of the piston type lbf/in²). The warning lights will remain illuminated until
and are precharged with nitrogen to 96 bar (1 392 lbf/ the pressure rises above 135 bar (1 958 lbf/in²).
in²). Each accumulator consists of a charging valve
assembly (3), end cap (17), cylinder (8) and piston (9).
Charging valve (3) is equipped with a locking feature.
Loosening locknut (26) will open the valve so that the
precharge can be checked or the accumulator charged.
SM 2326 07-04 1
Braking System - Accumulator
Section 250-0060
SM - 2872 SM - 1273
P
FB
RB
TESTING 2. Remove cap (24) from charging valve (3) and loosen
locknut (26). Coat open end of charging valve (3) with
WARNING soapy water. Bubbles indicate leaky valve core (25).
To prevent personal injury and property
damage, be sure wheel blocks are properly 3. Attempt to reseat the valve core by depressing and
secured and of adequate capacity to do the job releasing it quickly once or twice. Recheck for leakage.
safely. If leakage continues, discharge the accumulator as
described under 'Discharging Nitrogen' in this section.
WARNINGS
Accumulators are charged with Nitrogen. 4. Replace valve core (25). Tighten locknut (26) to
The service pressure is 95 bar (1 380 lbf/in²) at 11 Nm (100 lbf in) and replace valve cap (24) finger
20° C (68o F). To prevent personal injury and tight.
property damage do not attempt to remove any
valves or fittings until all nitrogen pressure is Testing Precharge Pressure
completely relieved.
Numbers in parentheses refer to Fig. 3, unless
otherwise specified.
Hydraulic fluid pressure will remain
within the system after engine shut down. Note: The nitrogen pressure in an accumulator is
Operate the treadle pedal continuously until the directly affected by changes in nitrogen temperature.
pressure has dissipated before carrying out any The cylinder pressure will increase or decrease
work on the braking system or serious injury proportionally with temperature changes. An
could result. accumulator pressure reading can vary about 4.3 bar
(62 lbf/in²) with 22° C (72° F) temperature change.
Such temperature changes could easily occur between
Testing Charging Valve For Leakage noon and midnight of the same day. Refer to the table
Numbers in parentheses refer to Fig. 1. at the end of this section for nitrogen pressures at
ambient temperatures of other than
1. Remove cover plate from bottom of battery box. 20° C (68° F).
2 SM 2326 07-04
Braking System - Accumulator
Section 250-0060
To test accumulator precharge pressure or to charge CHARGING THE ACCUMULATOR
the accumulator, a charging assembly kit can be used.
Numbers in parentheses refer to Fig. 3, unless
Refer to Fig. 3.
otherwise specified.
1. Position the vehicle in a level work area, apply the
Note: Either oil or water pumped nitrogen can be used
parking brake, switch off the engine and turn steering
to charge the accumulator. Both types are readily
wheel in both directions several times to relieve any
available from a local compressed gas dealer.
pressure in the steering circuit.
SM 2326 07-04 3
Braking System - Accumulator
Section 250-0060
7. Rotate 'T' handle of valve chuck (2) anticlockwise 5. Disconnect hydraulic lines from top of accumulators
until it stops, tighten locknut (26, Fig. 1) to 11 Nm (100 and plug accumulators to prevent oil spillage. Cap open
lbf in), loosen the swivel nut and remove gauging head. lines and fittings to prevent entry of dirt.
8. Check charging valve (3, Fig. 1) for leakage using 6. Support accumulators with an adequate sling and
soapy water. Reinstall valve cap (24, Fig. 1) and lifting device. Remove bolts, nuts, washers and
tighten finger tight. clamps. Remove accumulators and drain oil from top
section into a suitable container.
DISCHARGING NITROGEN 7. Remove accumulators to a clean area for
Numbers in parentheses refer to Fig. 1. disassembly.
Do not remove charging valve (3) until all the gas has WARNING
been completely evacuated. Accumulators are charged with Nitrogen. The
service pressure is 96 bar (1 392 lbf/in²) at 20° C
(68o F). To prevent personal injury and
WARNING property damage do not attempt to remove any
Do not try to discharge the accumulator by valves or fittings until all nitrogen pressure is
depressing charging valve core (25). completely relieved.
Accumulators are charged with Nitrogen. 4. Install pins in three equally spaced holes in end cap
The service pressure is 96 bar (1 392 lbf/in²) at (17), then use a long bar working against the pins to
20° C (68o F). To prevent personal injury and remove end cap from cylinder (8). Remove and discard
property damage do not attempt to remove any Backup ring (6) and 'O' ring (7).
valves or fittings until all nitrogen pressure is
completely relieved. 5. Grip cast web of piston (9) with pliers and, while
rotating, pull piston from cylinder (8). Remove and
1. Position the vehicle in a level work area, apply the discard Seal rings (10 & 14), Washers (11 & 13) and
parking brake, switch off the engine and turn steering 'O'-Ring (12).
wheel in both directions several times to relieve any
pressure in the steering circuit.
INSPECTION
2. Operate the treadle valve continuously to relieve Numbers in parentheses refer to Fig. 1.
pressure in the braking system. Block all road wheels
and place battery master switch in the 'Off' position. 1. Wash metal components with a suitable solvent and
thoroughly air dry.
3. Remove cover plate from bottom of battery box.
2. Inspect piston (9) for cracks or burrs. Replace piston
4. Discharge nitrogen from the accumulators as (9) if excessively scored or worn.
described under 'Discharging Nitrogen'. 3. Use an inspection lamp to check the bore of
accumulator cylinder (8) for scratches or scoring.
4 SM 2326 07-04
Braking System - Accumulator
Section 250-0060
Minor nicks, scratches or light scoring of the bore can be Note: Tighten all hydraulic lines fitted with ORFS
removed by using crocus cloth. Dress the bore until all connections, as described in Section 250-0000,
apparent imperfections have been removed. Replace BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
complete accumulator assembly if the inside of cylinder where used.
(8) is excessively scored or worn.
3. Install End cap (17) on cylinder body (8). 4. Charge the accumulator with Nitrogen gas as
described under 'Charging the Accumulator' in this
4. Install new Seal rings (10 & 14), Washers (11 & 13) section.
and 'O'-Ring (12) on grooves of Piston (9).
5. Install cover to bottom of battery box.
5. Insert Piston (9) into bore of Cylinder body (8) with
the cupped end facing the open end of the cylinder 6. Check oil level in hydraulic tank and add oil as
body (8). Taking care not to damage any components required. Refer to Section 230-0040, HYDRAULIC
on the threadfs of the Cylinder body (8) on insertion. TANK, for correct fill level and Section 300-0020,
Use a hammer and wood block to carefully tap the LUBRICATION SYSTEM, for oil specification.
Piston (9) into place until the Piston (9) is 50.8mm (2.0
in) below the beginning of the honed bore. Keep 7. Place the battery master switch in the 'On' position,
pressure against the Piston (9) while tapping into place start the engine and check for leaks. Tighten lines and
to ensure the Piston (9) does not resist movement and fittings as required. Remove wheel blocks.
force its way back.
6. Install 'O'-ring (7) and Backup ring (6) onto the MAINTENANCE
Cylinder cap (5) and install the Cylinder cap into the Inspect accumulator assembly for leaks. If leaks are
bore of the Cylinder body (8). Tighten the Cap so that it found, disassemble and replace all 'O' rings and seals.
is flush with the end of the Cylinder body (8), within Inspect hydraulic lines for wear and leaks. Replace/
1.6-2.4mm (0.062 - 0.094in) above or below. tighten lines as required.
SM 2326 07-04 5
Braking System - Accumulator
Section 250-0060
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft lbf in
1 1D
26 Locknut 11 - 100
WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the vehicle or cylinders by any method while
cylinders are charged. For shipment, contact the appropriate agency in the country involved. Consult
your dealer for further permit information.
* * * *
6 SM 2326 07-04
BRAKING SYSTEM - Treadle Valve
Section 250-0070
SM - 3731
3
4 14
5 15
11
6
23
7
16 24
8
25
9 26 35
27
17
10 28
18 29
19
11
20 30
12
21 31
13 32 1
22
33
34
DESCRIPTION
Refer to Section 215-0050, MAIN HYDRAULIC VALVE
Numbers in parentheses refer to Fig. 1. ASSEMBLY.
Note: The treadle valve can be identified as item 9 in In the normal position, brake pedal assembly (1) is in
Section 250-0000, BRAKING SYSTEM SCHEMATIC. the up position. In this condition the regulated pressure
outlet ports of the valve 'A1' and 'A2' are directly linked
The tandem circuit modulating treadle valve is a closed to the hydraulic tank ports 'T1' and 'T2'. While the pedal
centre controller which controls the level of hydraulic oil is in this position the brakes are released.
pressure applied to the front and rear brakes and the
maximum pressure available to these circuits. It is Mounted on the brake treadle valve is a microswitch
operated by a foot pedal in the operators cab and with (35) that sends a signal to activate the rear brake
the engine running, is automatically applied by the park lights and the engine brake when the treadle valve is
brake solenoid valve within the main hydraulic valve. depressed.
SM 2486 Rev1 02-07 1
Braking System - Treadle Valve
Section 250-0070
SM - 2875 SM - 2876
9 9
PP PP
SUPPLY SUPPLY
FROM FROM
P1 P1
TO FRONT A1 MAIN HYDRAULIC FROM FRONT A1 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC1 BRAKES VALVE, PORT ACC1
T1 T1
SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC2 BRAKES VALVE, PORT ACC2
T2 T2
Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release
SM - 2877 SM - 2878
9 9
SUPPLY
FROM TO TANK VIA
PP PP MAIN HYDRAULIC
MAIN HYDRAULIC
VALVE, PORT PBP VALVE, PORT PBP
SUPPLY
SUPPLY FROM
P1 P1
TO FRONT A1 FROM FROM FRONT A1 MAIN HYDRAULIC
BRAKES MAIN HYDRAULIC BRAKES VALVE, PORT ACC1
T1 VALVE, PORT ACC1 T1
SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC2 BRAKES VALVE, PORT ACC2
T2 T2
REBUILD CRITERIA
Inspect the valve regularly for any signs of leakage or
damage and replace components if necessary.
REMOVAL SM - 2879
A
WARNINGS P2
P
To prevent personal injury and property
A2
T T2
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job P1
P
safely.
T T1
A1
Hydraulic oil pressure will remain A
within the system after engine shut down.
Operate the treadle pedal continuously until the PP
pressure has dissipated before carrying out any
work on the braking system or serious injury PP
could result.
12. Remove spacer (15), sleeves (9 & 12) and spools 10. Install new 'O' ring (17) on valve housing (16).
(10 & 13) assembly from housing bore. This assembly
must be removed through end plug (5) end of housing 11. Install retainer assembly (18) in housing. Note:
(16). Note: Be careful not to scratch housing bore. Depress retainer (18) until it bottoms on spacer (15).
Spools (10 & 13) and retainer (18) should return when
13. Separate spacer (15) and spools (10 & 13) from released. If the spools and retainer do not return when
sleeves (9 & 12). Note: Excessive wear on either released, the bore of sleeves (9 & 12) were possibly
spools (10 & 13) or sleeves (9 & 12) may require damaged when installed.
replacement. Spool (10)/sleeve (9) and spool (13)/
sleeve (12) are matched sets and MUST be replaced 12. Install shims (18), springs (20, 21 & 22) and piston
as matched sets - DO NOT intermix. (24) in valve housing bore. Note: For proper brake
pressure setting, install the same number of shims and
14. Remove 'O' ring (11) and cup (14) from spacer (15). spacer that were removed during disassembly. If
Remove other 'O' rings (11) from sleeve (12) and 'O' spools (10 & 13), sleeves (9 & 12), or spring (22) were
rings from sleeve (8). Note: Be careful not to damage replaced, shim adjustment may be required.
cup and 'O' ring grooves and bores.
13. Install new 'O' rings (26 & 28) and new back-up
rings (25 & 29) on piston (27). Note order of back-up
ASSEMBLY rings and 'O' rings.
Numbers in parentheses refer to Fig. 1.
14. Lubricate piston (27) with clean hydraulic oil and
Lubricate all new rubber components with clean insert into pilot housing (30) through valve housing (16)
hydraulic oil used in the braking system. Refer to end. Be sure to install piston (27) as far as it will go
Section 300-0020, LUBRICATION SYSTEM. into pilot housing bore.
1. Clean all parts thoroughly before assembly. 15. Carefully attach pilot housing (30) to valve housing
(16) using screws (31). Torque screws to 24 - 30 Nm
2. Install new cup (14) in spacer (15) and one new 'O' (18 - 22 lbf ft).
ring (11) on spacer (15). Note direction of cup.
16. Install spring (32) and push rod (33) into pilot
3. Install other new 'O' rings (11) on sleeve (12) and housing (30) bore.
MAINTENANCE
General
Check all hydraulic brake lines and fittings at treadle
valve for leaks and damage. Tighten/replace as
required.
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 and adhesives required. These tools and
adhesives are available from your dealer.
Brakes will not release Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
completely BRAKE PARTS
Inoperative brakes Check brakes. Refer to Section 165-0010,
BRAKE PARTS
Pedal angle out of adjustment Check for proper pedal angle
Air in system Bleed air from system. Refer to Section
165-0010, BRAKE PARTS
Inoperative treadle valve. Replace treadle valve
Piston (24) sticking, spring
(7) broken
Back pressure on return line Remove restriction
excessive
No brakes No oil in hydraulic system Add oil to tank
Broken/damaged hydraulic line Replace broken/damaged line
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
BRAKE PARTS
No accumulator Check accumulator pre-charge pressure.
pre-charge pressure Refer to Section 250-0060,
ACCUMULATOR
No pump pressure Check pump operation
Worn brakes Replace brake pads and discs
Inoperative treadle valve. Replace treadle valve
Piston (24) binding, broken
spring (21)
Pedal kickback when brakes Air in system Bleed air from system. Refer to Section
are applied 165-0010, BRAKE PARTS
* * * *
SM - 3571
11 20,21
12
13
19
14,18 13
12
11
20,21
15
3, 35, 36, 37
16
17
CAB -
R.H.S.
23, 24
LH 25, 26 RH
31
R H - HINGED LH
32 22
34
38 1 6
33 4
5 40
27
41
29
5 28
2 39
10
LH
29
39 39
39
30 9 7 8
RH 30
SM 2493 02-07 1
Operators Compartment - Cab and Mounting
Section 260-0010
SM - 2882
11
9
8 CAB BRACKET
10 5
13
3 9 12
6
BRACKET IN 11
1 BATTERY BOX
FRAME BRACKET
12 13
16
2
15
14
2 SM 2493 02-07
Operators Compartment - Cab and Mounting
Section 260-0010
4. Disconnect the electrical cables in the following Disconnect earth strap at rear right hand cab support
order to prevent damage to the electrical components: (40).
a. Battery earth cable. 11. Lower cab safety prop (7) and place in the stowed
b. Battery supply cable. position, then using lifting equipment, slowly lower cab
c. Alternator earth cables. until horizontal.
d. Alternator supply cables.
e. Electrical harnesses at cab bulkhead. 12. Remove spring pins (5) to allow right hand pins (2)
to be driven out using a suitable driver.
9. Attach suitable slings to the cab lifting points and 5. Install and connect steering valve hoses as noted on
raise lifting equipment to take up the slack. Disconnect removal. Connect earth strap at rear right hand cab
cab raise cylinder (7, Fig. 2) from cab floor by removing support.
bolt (11, Fig. 2), washer (12, Fig. 2) and nut (13, Fig.
2). 6. Connect and secure any other harnesses and hoses
that were previously removed.
10. Tag and disconnect any other harnesses and
hoses that may be affected by cab removal. 7. Place cab safety prop (7) in the stowed position.
SM 2493 02-07 3
Operators Compartment - Cab and Mounting
Section 260-0010
Using hand pump (1, Fig. 2) to control lowering of cab, SM - 3572
gently lower cab until cab brackets align with cab
supports (40). Install pins (1) and secure with bushes
(4) and bolts (6).
TILTING THE CAB 5. Using hand pump (1), charge the cab raise cylinder
Numbers in parentheses refer to Fig. 2, unless (7) sufficiently to allow left hand pins (1, Fig. 1) to be
otherwise stated. removed. Hold cylinder (7) in this position by locking
hand valve on hand pump (1).
WARNINGS 6. Remove bolts and bushes (6 & 4 Fig. 1), then drive
To prevent damage, always ensure hood is out pins (1, Fig. 1). Carefully raise or lower the cab as
raised before tilting or lowering the cab. necessary to facilitate removal of pins (1, Fig. 1).
Never work near or under an unblocked 7. Once pins (1, Fig. 1) have been safely removed,
or unsupported cab. Always use the cab safety continue to raise the cab using hand pump (1) until the
prop. cab safety prop (1, Fig. 3) can be fitted.
1. Position the vehicle in a level work area, apply the 8. Remove pin assembly (8, Fig. 1) to allow cab safety
parking brake and switch off the engine. prop (1, Fig. 3) to swing down to a vertical position on
top of the front left hand cab leg.
2. Operate the brake pedal continuously to relieve
pressure in the hydraulic system. 9. Lock the cab safety prop (1, Fig. 3) in position using
pin assembly (8, Fig. 1), locating through holes on
3. Block all road wheels, place the battery master bracket at front left hand cab leg.
switch in the 'Off' position and lift the hood assembly.
10. Lock off hand valve on hand pump (1). Remove
4 SM 2493 02-07
Operators Compartment - Cab and Mounting
Section 260-0010
lever (6) from pump (1) and place in the stowed (17), hardened washers (15) and springs (16) securing
position. mirror arm assembly to mounting brackets.
WARNINGS
To prevent damage, always ensure hood is MIRROR ARMS
raised before tilting or lowering the cab.
Installation
Never work near or under an unblocked Numbers in parentheses refer to Fig. 1.
or unsupported cab. Always use the cab safety
prop. Note: Tighten all fasteners without special torques
specified to standard torques listed in
1. Remove pin assembly (8, Fig. 1) from bracket at Section 300-0080, STANDARD BOLT AND NUT
front left hand cab leg. Place cab safety prop (1, Fig. 3) TORQUE SPECIFICATIONS.
in stowed position by locating pin assembly (8, Fig. 1)
in bracket under cab.
WARNING
2. Slowly open hand valve on hand pump (1) to allow To prevent personal injury and property
cab to gently lower. Rate of descent is controlled by damage, be sure blocking materials and lifting
the hand valve on pump (1). equipment are properly secured and of
adequate capacity to do the job safely.
3. Lower cab until holes in cab brackets line up with
holes in cab supports (2, Fig. 3). Hold cylinder (7) in 1. Coat ball bearings (14) with grease (18) and locate in
this position by locking hand valve on hand pump (1). mounting brackets.
4. Install pins (1, Fig. 1) through cab brackets and cab 2. Locate mirror arm bracket (11) to mounting brackets
supports (2, Fig. 3). Secure pins in position with bush and install hardened washers (15), springs (16) and
(4, Fig. 1) and bolts (6, Fig. 1). locknuts (17) as shown in Fig. 1.
5. Lower the hood and place the battery master switch 3. Set mirror bracket spring (16) pressure as follows;
in the 'On' position before closing the battery box. a. rotate mirror arm (11) until ball bearings (14) are
out of their detent.
6. Ensure parking brake is applied and remove wheel b. tighten locknut (17) until spring (16) is almost
blocks from all road wheels. completely compressed (typical two places).
c. swing arm until it seats in detent.
d. check the other two detent positions
MIRROR ARMS
4. Repeat steps 1, 2 and 3 for other mirror arm bracket
Removal (11).
Numbers in parentheses refer to Fig. 1.
REPLACING GLASS
WARNING Note: When replacing broken glass, it is the user’s
To prevent personal injury and property responsibility to ensure that the replacement glass
damage, be sure blocking materials and lifting meets the required specifications. Replacement glass
equipment are properly secured and of can be purchased from your dealer.
adequate capacity to do the job safely.
The rear glass, left and right hand side glasses and
1. Support mirror arm bracket (11) and remove locknuts front windscreen are held in place by a bonding
adhesive.
To replace a glass assembly, proceed as follows:
SM 2493 02-07 5
Operators Compartment - Cab and Mounting
Section 260-0010
the sealing adhesive to set properly.
Note: Ensure the glass is supported adequately before
starting to cut the adhesive seal. 9. Clean off any excess adhesive using a suitable
solvent.
1. Using a pointed tool, pierce a hole in the adhesive
seal, it is advisable to start at the top edge of the
glass. Unscrew one handle of the special tool and feed Water Leaks
the wire through the opening. Pierce a second hole in Test for leaks by directing a stream of water along the
the adhesive on the side directly opposite the first. adhesive seal, while an assistant marks the spot of
leakage inside the cab. Care should be taken to note
2. From inside the cab pull the wire through and feed it whether the leak is between adhesive and glass. Then
back out through the second hole. apply a sealing compound from the outside. Start from
a point near the leak and continue applying the sealer
3. Re-fit the handle on the special tool. Pull both until well beyond the suspected point of entry.
handles outwards until wire is taut.
This should stop the leak immediately, but since some
4. Manoeuvre the special tool around the edge of the sealing compounds should be allowed to set before
glass, keeping the wire taut, to cut the adhesive seal. getting wet, wait a few minutes before testing.
Ensure the glass is supported adequately before
completing the cut.
MAINTENANCE
5. Clean the remains of the adhesive from the edge of
the panel opening using a suitable solvent.
General
Ensure that hand pump hydraulic tank (2, Fig. 2) is
6. Coat the edge of the replacement glass with primer filled with clean hydraulic oil as specified in Section
and apply adhesive around the lip of the window 300-0020, LUBRICATION SYSTEM. Capacity is 0.75
aperture, as per the manufacturers recommendations. litre (0.2 US gallon).
* * * *
6 SM 2493 02-07
OPERATORS COMPARTMENT - Driver Seat and Mounting
Section 260-0090
SM - 2884
DESCRIPTION pan (10). Seat pan (10) is attached to a cab seat base
by means of a suspension assembly (14). The air seat
Numbers in parentheses refer to Fig. 1.
only reacts when the driver sits on the seat. When
WARNING unoccupied, the seat sinks to the lowest position to
allow easier access.
By Law, seat belts must be provided. Always
wear seat belts when travelling in the vehicle.
A retractable seat belt (4) is secured to the seat
assembly using nuts and spacers. A push button
The seat assembly consists of a seat cushion (3) and
allows quick release of seat belt (4).
backrest cushion (2) mounted to backrest (8) and seat
SM 2210 4-03 1
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
SM - 2885 the seat position in now engaged properly.
34 - Bolt (x4)
35 - Washer (x4)
36 - Lock Washer (x4)
6 3. Pull up horizontal adjustment handle (2) and move
37 - Nut (x4) seat forwards or backwards, release handle when
required position is achieved.
OPERATION REMOVAL
To achieve the most comfortable driving position, Numbers in parentheses refer to Fig. 2.
adjust the seat as follows;
WARNINGS
1. Sit in seat. To prevent personal injury and property
damage, be sure wheel chocks, blocking
2. Pull up and release height and weight adjustment (1) materials and lifting equipment are properly
handle - this will reset the seat to the predetermined secured and of adequate capacity to do the job
height setting - 'bounce' lightly until a 'click' is heard, safely.
2 SM 2210 4-03
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
1. Position the vehicle in a level work area, apply the Horizontal Shock Absorber
parking brake and switch off the engine.
Numbers in parentheses refer to Fig. 3.
2. Block all road wheels and place the battery master
Note: Remove seat assembly as described in
switch in the 'Off' position.
'Disassembly'
3. Disconnect harness connector at the rear of the
1. Remove pop-out buttons (1) and remove access
seat.
cover (2) to allow access to suspension assembly.
4. Push down height and weight adjustment (1) handle
2. Unclip hooked end of shock absorber (4) from
to release the air from the seat air suspension system.
horizontal spring assembly.
5. Remove bolts (34), washers (35), lock washers (36)
3. Remove circlip (3) and lever out shock absorber (4)
and nuts (37) securing complete seat assembly to the
from rocker shaft and slide off of mounting pin.
cab seat base. Remove seat assembly from vehicle
using suitable lifting equipment.
4. Remove spacer (5) from mounting pin.
SM 2210 4-03 3
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
Note: Inscription must face upwards when assembling 3. Remove pressurised airline (5) from compressor (6).
shock absorber (7).
4. Identify and tag and disconnect electrical plug
SM - 2488 connections (7 & 8). Unfasten cable tie on the rocker.
SM - 2489 SM - 2490
Fig. 5 - Exploded View of Compressor and Mounting Fig. 6- Exploded View of Level Controller and Mounting
Note: Remove seat assembly as described in Note: Remove seat assembly as described in
'Disassembly' 'Disassembly'
1. Remove pop-out buttons (1) and remove access 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly. cover (2) to allow access to suspension assembly.
2. Remove pop-out buttons (3) and push down 2. Remove pop-out buttons (3) and push down
suspension skirt (4) to allow further access to suspension skirt (4) to allow further access to
suspension assembly. suspension assembly.
4 SM 2210 4-03
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
3. Pull suspension assembly up to its highest position slide seat assembly rearwards. Hold captive nuts using
and block securely. a suitable spanner and install front allen screws.
Tighten allen screws to a torque of 25 Nm (18 lbf ft).
4. Unhook bowden wires (5 & 6) from level controller (7).
3. Install seat cushion (3) to seat frame (1) and secure
5. Identify and tag and disconnect electrical plug using screws.
connections (8 & 9).
4. Install backrest cushion (2) to seat frame (1) and
6. Identify and tag and disconnect pressurised airlines secure using screws.
(10) from air suspension unit (11). Unfasten cable tie on
the rocker. 5. Refit headrest (5) to seat frame (1).
7. Remove screw (12), push out pin (13) and release 6. Position lap belt (4) to seat assembly and secure
roll up belt (17). using nuts and spacers as removed at 'Disassembly'.
Tighten nuts to a torque of 50 Nm (36 lbf ft). Refit
8. Remove nuts (14) and manoeuvre level controller (7) covers (6 & 7).
until studs are free from mounting holes.
10. Remove level controller (7) from suspension base. Note: Tighten all fasteners without special torques
specified to torques listed in Section 300-0080,
11. Reassembly is done in the reverse order. STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Note: Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).
WARNINGS
INSPECTION To prevent personal injury and property
Numbers in parentheses refer to Fig. 1. damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
1. Inspect air lines, shock absorbers (15 & 26), secured and of adequate capacity to do the job
compressor (21), level controller (28) and air spring safely.
(30) for leaks and damage and replace if required.
2. Check all brackets and frame for cracks and/or 1. Using suitable lifting equipment, position seat
damage. Repair or replace as necessary. assembly on the cab seat base and secure using bolts
(34), washers (35), nuts (37) and lock washers (36).
3. Check springs for fatigue or damage and replace as
required. 2. Reconnect harness at the rear of the seat.
Note: Tighten all fasteners without special torques 4. Remove wheel chocks from road wheels.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
SM 2210 4-03 5
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
MAINTENANCE
Numbers in parentheses refer to Fig. 1.
* * * *
6 SM 2210 4-03
OPERATORS COMPARTMENT - Air Conditioning
Section 260-0130
SM - 2430
1 3 IN
D
S OUT
4
5
2 SM 2211 4-03
Operators Compartment - Air Conditioning
Section 260-0130
SM 2211 4-03 3
Operators Compartment - Air Conditioning
Section 260-0130
SM - 2886
10
CAB 9
FIREWALL
12
11
12
1
26
5 8 6 26
25
11 27 20
3 22
26 23
24
21
28
18
2 13
19
10
10 10
7
17
16 4
15 14
18. Support compressor (1) and remove bolts (25), 21. If required, remove bolts (24), lockwashers (23),
washers (26) and nuts (27) securing compressor (1) to washers (22) and bracket (19).
bracket (2). Remove compressor (1) from the vehicle.
Note: If fitted, coolant filter will have to be removed.
Note: If drive belt (3) does not require replacement do
not remove from engine pulley. If drive belt (3) requires 22. If required, disconnect all clamps and clips
replacement, proceed with steps 19 and 20. securing refrigerant hoses and harnesses to the
vehicle. Remove hoses and harnesses from the
19. If required, remove mounting hardware securing vehicle.
fan guard assembly to radiator assembly. Refer to
Section 210-0040, RADIATOR AND MOUNTING.
INSTALLATION
20. If required, remove bolts (28), lockwashers (18), Numbers in parentheses refer to Fig. 2, unless
washers (13) and bracket (2) from engine. otherwise stated.
4 SM 2211 4-03
Operators Compartment - Air Conditioning
Section 260-0130
SM - 2887
SM 2211 4-03 5
Operators Compartment - Air Conditioning
Section 260-0130
Note: Tighten all fasteners to standard torques and ports on receiver/drier (4) and connect hoses to
specified in Section 300-0080, STANDARD BOLT AND ports as tagged at removal.
NUT TORQUE SPECIFICATIONS.
9. If removed, install condenser (5) to radiator
Note: Renew all 'O' rings where necessary (10, 11 & assembly and secure with bolts (15), lockwashers (16)
12). and washers (17).
3. Reconnect heater hoses to front of cab and connect Note: If fan guard and compressor drive belt (3) were
to water inlet hose (24, Fig. 3) and water outlet hose removed, proceed with steps 14 & 15.
(23, Fig. 3), as identified at removal.
14. Install new drive belt (3) onto engine pulley and fit
4. Once all necessary connections have been made, to groove on compressor (1).
secure front cover (36, Fig. 3) and end plate (19, Fig. 3)
to main weldment (18, Fig. 3) using fasteners 15. Adjust tension of compressor drive belt with nut
previously removed. (21) on adjuster bolt (20) until there is approximately an
inward deflection of 10 mm (0.4 in) at the centre of
5. Remove caps from end of refrigerant hoses (8 & 9) drive belt (3). Fully tighten all mounting hardware.
and ports at front of cab and connect hoses to ports as
tagged at removal. 16. Remove caps from end of refrigerant hoses (6 & 9)
and ports on compressor (1) and connect hoses to
6. Route refrigerant hoses (8 & 9) along the LH side of ports as tagged at removal.
the engine securing with clamps removed during
removal. 17. Connect electrical connection to compressor (1)
clutch.
7. If removed, install receiver/drier (4) to mounting
bracket (14) and secure with clamps. 18. Secure all lines with clips and clamps as removed
during removal. Ensure no lines are chaffing on sharp
8. Remove caps from end of refrigerant hoses (7 & 8) edges or resting against areas where heat will be
6 SM 2211 4-03
Operators Compartment - Air Conditioning
Section 260-0130
evident. is engaged in this situation, there should be very few
bubbles visible in the receiver-drier sight glass.
19. Charge the air conditioning system as described
under 'Charging Procedure'. Note: Unit can operate with some bubbles visible, but
not milky looking.
20. Switch the battery master switch to the 'On'
position, start up the engine and check for correct 4. Ensure all hoses and hose clamps are free from
operation of the air conditioning system. contact with sharp metal, moving parts or near to
manifolds.
21. Lower hood and remove wheel blocks from all road
wheels. 5. Inspect condensation drain lines for debris, sharp
bends or breaks.
MAINTENANCE 6. Inspect the clutch wire from the thermostat for bare
spots.
1. Periodically clean the condenser coil of debris and - The ideal tension is the lowest tension at which the
dirt using water or air pressure. A partially blocked belt will not slip under peak load conditions.
condenser coil can reduce the life of the compressor - Check belt tension frequently during the first 24 - 48
belt and/or clutch. hours of run-in operation.
- Initial belt tension should be 533 N (120 lbf)
2. If the system has a heater in the same location as dropping to 422 N (95 lbf) after the first 48 hours.
the air conditioning evaporator core, heater valves - There should be a freeplay of 10 mm in the belt.
should be closed. - Do not over tension belts.
- Keep belts free from foreign material that may
3. To check the refrigerant level, run the engine at cause slippage.
1 200 rev/min with fans on high speed and thermostat - Inspect the drive periodically. Re-tension belts if
fully open for a minimum of five minutes. If the clutch they are slipping.
SM 2211 4-03 7
Operators Compartment - Air Conditioning
Section 260-0130
- Maintain sheave alignment with a strong straight The oil should be added to the oil filling port of the
edge tool while tensioning belts. compressor before the evacuation procedure is started
or by using an oil injector when the system is being
4. Never attempt to correct belt slippage by using a charged, observing the following good practises:
belt dressing. The dressing may cause softening and
deterioration. a. Only pour the amount required from the container
straight into a CLEAN measuring jug and
5. If belt slips, even when properly tensioned, check for immediately pour the oil into the compressor.
overload, worn sheave grooves or oil or grease on the b. Re-cap container tightly as soon as the required
belts. amount has been taken (never leave an oil container
open).
6. Never pry a drive belt or force it into the sheave c. Do not mix different oils.
groove. Loosen the drive belt tightener prior to
installation. Only new oil should be used, because oil that has
been exposed to the air will have absorbed water
7. A belt that has operated while rolled over in the (hygroscopic).
sheave groove may be damaged - replace it.
Use only refrigerant oil as specified in Section
8. Store belts in a cool, dry place. If stored on a 300-0020, LUBRICATION SYSTEM.
machine, relieve all belt tension by loosening the
drive belt tightener.
System Leak Testing
9. Never attempt to check or adjust belts while they are Recommended Equipment Required:
running. Electronic Leak Detector
8 SM 2211 4-03
Operators Compartment - Air Conditioning
Section 260-0130
10. Tighten down (turn clockwise) both high and low
WARNING side valves on the gauge manifold to the closed
The vehicle must not be running during this position, remove the service hose (yellow) from the
procedure. Be sure to have adequate ventilation vacuum connection (6) on vacuum pump and switch
during this operation. Do not discharge the pump 'Off'.
refrigerant near an open flame.
11. Connect the service hose (yellow) to the R-134a
Numbers and letters in parentheses refer to Fig. 4. cylinder. Open the cylinder valve and then purge air
from the hose at the manifold connection.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. 12. Open the low side hand valve on the manifold
slowly, until low pressure gauge (B) is at bottle
2. Block all road wheels and place the battery master pressure. Watch the high side manifold gauge (C) rise
switch in the 'Off' position. to ensure that no blockage is present. Close the
manifold valve and cylinder, then disconnect the hose
3. Pull on handle to release hood catch and raise the from the cylinder.
hood.
13. Connect the service hose (yellow) to the Nitrogen
4. Connect the service hose (yellow) to the centre cylinder. Open the neck valve on the cylinder and set
access port on the manifold gauge and to the vacuum the regulator pressure such that it is higher than the
connection (6) on vacuum pump. Ensure that the system pressure then purge the hose. Open the low
system is empty before connecting the vacuum so that side hand valve on the manifold, as the pressure
refrigerant does not enter the pump. rises open the high side hand valve on the manifold
and allow a system pressure of 10 bar (150 psig) to
5. Tighten down (turn clockwise) both high and low side be reached. Close all the valves. Using a suitable
valves on the gauge manifold to the closed position. electronic leak detector, check all joints in the air
Remove protective caps from the service ports on the conditioning system for leaks. Tighten any loose
compressor. joints and re-test if necessary.
6. Connect both service hoses from the two fittings (2 14. Vent the refrigerant mix to atmosphere by
& 3) in the bottom of the manifold to the two service removing the service hose (yellow) from the Nitrogen
ports on the compressor. High side (red) to compressor cylinder and opening the low side hand valve on the
discharge valve, low side (blue) to compressor suction manifold. Re-evacuate the system to below 6 mb
valve. (steps 7 to 10).
7. Switch vacuum pump on, open vacuum pressure 15. Lower hood assembly and remove wheel blocks.
valve (1) until less than 6 mb is reached on vacuum
gauge (A). The vacuum gauge (A) should remain at CHARGING THE SYSTEM
this value when vacuum pressure valve (1) is closed
to indicate that there are no leaks. Note: Refer to all WARNINGS listed under
'Maintenance' prior to charging the system.
8. Open the low side hand valve on the manifold and
vacuum pressure valve (1) and watch that the Recommended Equipment Required:
gauges start to register that a vacuum is being drawn. Portable High Vacuum Charging Station
If the gauges do not register the vacuum thena Electronic Leak Detector
blockage is present. Open the high side and pump or Standard Service Manifold (Refer to Fig. 4)
down until a vacuum of 10 mb is achieved.
For New Or Completely Empty System
9. After 10 - 15 minutes close vacuum pressure valve
(1) and allow the system to settle, vacuum gauge (A) Note: The charging procedure must be done in ambient
should not alter. If the vacuum is held, no leaks or temperatures above 15.5° C (60° F) with the R-134a
refrigerant contaminated oil is present. If not, open the canister temperature equal to the outside ambient
vacuum pressure valve (1) and continue pumping, temperature.
checking at regular intervals. If there is a leak, check
all fittings and tighten if necessary.
SM 2211 4-03 9
Operators Compartment - Air Conditioning
Section 260-0130
1. Shut off engine and block all road wheels. Ideal gauge readings should be 29.92 inches of
mercury. The pressure will vary with altitude; it will be
2. Pull on handle to release hood catch and raise the approximately 0.03 bar (0.5 lbf/in²) less for each 305 m
hood. (1 000 ft) of elevation.
3. Remove protective caps from 'quick coupler' valves 10. Before disconnecting power supply from vacuum
on rear of compressor. pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
4. Connect low pressure gauge hose (blue hose and R-134a source.
gauge) to suction side or low side fitting on
compressor. The suction side can be identified by the 11. Open R-134a source. Loosen, but do not remove,
size of the hose connected to the fitting. This will be yellow supply hose at manifold on gauges to remove all
the largest diameter hose of the system. air in the yellow supply hose, replacing the air with R-
134a. This is done in a few seconds. Tighten yellow
5. Connect the high pressure gauge hose (red hose and supply hose.
gauge) to discharge or high side fitting on compressor.
12. Open low side of R-134a gauges slowly. When
6. Connect yellow supply hose to suction port on gauge reads zero open both sides completely. Vacuum
vacuum pump. in the system will draw R-134a gas into the system.
Hold until both gauge readings equalize.
7. Open both sides of gauges, low and high, completely.
Note: Never charge with liquid R-134a. Charge on
8. Start vacuum pump to evacuate the complete air the low pressure side only.
conditioning system.
9. Run vacuum pump for approximately 30 minutes. Final Charging Of The System
1. Start the engine and run at engine idle speed.
SM - 2424
2. Turn the air conditioning system on with the
B C D
thermostat set on maximum cooling and fan on high
speed.
10 SM 2211 4-03
Operators Compartment - Air Conditioning
Section 260-0130
The system is completely charged when; 4. Check the cab fresh air inlet filter for blockage.
a. the suction pressure on the gauge is approx. 5. Check that, with the ignition switch on (engine not
20 - 30 psig at 25° C ambient. running), the blower operates over whole speed range
b. the correct weight of refrigerant has been added i.e.
1.1 kg (2.43 lbs). 6. Check that, with the ignition switch on (engine not
c. the correct sub-cooling can be measured at the running), the blower and air conditioning switched on,
condenser, approx. 5 - 7° C. the compressor clutch engages.
SM 2211 4-03 11
Operators Compartment - Air Conditioning
Section 260-0130
2. Vibration/Noise in Compressor
area
3. Noise - Evaporator
12 SM 2211 4-03
Operators Compartment - Air Conditioning
Section 260-0130
5. Electrical Trouble
Blower motor or condenser fan Defective circuit breaker or bad Replace. Clean and tighten
motor inoperable wiring connections connections
SM 2211 4-03 13
Operators Compartment - Air Conditioning
Section 260-0130
* * * *
14 SM 2211 4-03
BODY - Body and Mounting
Section 270-0010
SM - 2883
10
7
1
6
15
5
13
4
7 A A
8
A
14
17
BODY
18 1
19 3
21
16
8
17
18
11
20 2
22 12 9
L.H. FRAME RAIL
DESCRIPTION OPERATION
The standard body is an all welded construction with The body control lever, mounted on the right hand dash
all wear plates fabricated from high hardness panel, controls the main hydraulic valve assembly.
(min. 360 BHN) 1 000 MPa (145 000 lbf/in2) yield
strength steel. Angled lower body sides reduce body When the body control lever is operated, a voltage is
impacts when loading and a tailshute angle of 25° sent to the hydraulic ECU, which converts voltage to
provides good retention when travelling without a current. This current controls the body raise and lower
tailgate. Refer to Section 000-0000, GENERAL proportional pressure control valves, producing a pilot
INFORMATION for body capacities. pressure to shift the control spool in the main hydraulic
valve. This allows the flow of oil to reach the body
The body is pivoted at the rear of the trailer frame and cylinders, to either raise or lower the body. Refer to
is operated by two single stage, double acting hoist Section 230-0000, BODY SYSTEM SCHEMATIC and
cylinders which are cushioned at both ends of the Section 215-0050, MAIN HYDRAULIC VALVE.
stroke to reduce impact shocks. The hoist cylinders
raise the body to a tipping angle of 65° in The three operating positions of the joystick from front
12 seconds and powerdown the body in 7.5 seconds. to rear are as follows:
SM 2212 4-03 1
Body - Body and Mounting
Section 270-0010
lever fully forward will engage the electric detent. When
the body reaches the body proximity switch, the lever
REMOVAL
springs back to 'NEUTRAL' and power down is ramped Numbers in parentheses refer to Fig. 1.
back to allow the body to float down onto the chassis.
A body lower emergency switch in the cab is 1. Position the vehicle in a level work area, ensure the
connected directly to the float solenoid, within the main body is fully lowered, apply the parking brake and
hydraulic valve, to enable the lowering of the body in switch off the engine.
the event of an engine, hydraulic or hydraulic ECU
failure. The cause of the failure must be investigated 2. Relieve stored hydraulic pressure in accumulators
and corrected. (x3), by pressing and releasing brake treadle valve
continuously, until all accumulator pressure is relieved.
Note: The body must remain lowered with lever in the
'NEUTRAL' position until it is necessary to operate the 3. Block all road wheels, place the steering lock bar in
body again. Failure to comply to this could result in the 'Locked' position and the battery master switch in
overheating the hydraulic oil and failure of the hydraulic the 'Off' position.
system components.
4. Remove upper pins securing the body cylinders to
Note: A proximity sensor prevents the body being fully body (1) assembly and secure body cylinders clear of
powered down onto the chassis. At a predetermined the body. Refer to Section 230-0130, BODY
height, the sensor automatically energises the float CYLINDER.
solenoid on the main hydraulic valve assembly.
Note: Body lifting lugs can be fabricated as shown in
Note: If an electrical failure occurs, the main hydraulic Fig. 2.
valve assembly will automatically default to the 'HOLD'
condition. The cause of the electrical fault must be 5. Secure lifting lugs to body (1) using suitable bolts.
investigated and corrected. Using appropriate lifting equipment, sling body (1)
assembly at the four lifting points and take an initial
strain.
WARNING
Never work under or near an unblocked or Note: Approximate weight of body (1) assembly is
unsupported raised body. Always use the body 4 400 kg (9 700 lb).
safety prop. The body safety prop must only be
used when the body is empty. 6. Remove bolts (15) and washers (13) securing hinge
pins (3) in place. Remove hinge pins (3) and shims (9)
from body (1).
2 SM 2212 4-03
Body - Body and Mounting
Section 270-0010
7. Remove body (1) assembly from the vehicle. BODY SHIMMING PROCEDURE
Numbers in parentheses refer to Fig. 1.
8. Remove bushing (2) from body hinge bores.
Note: Tighten all fasteners to standard torques listed in
INSTALLATION Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
Numbers in parentheses refer to Fig. 1.
Note: When it becomes necessary, body pads (4)
Note: Tighten all fasteners to standard torques listed in
should be replaced as a set to maintain load
Section 300-0080, STANDARD BOLT AND NUT
distribution along the frame. Existing body pads will
TORQUE SPECIFICATIONS.
have taken a compression 'set' and a new pad,
shimmed to match existing pads, will not carry its
share of the load, resulting in uneven load distribution
WARNING
along the frame.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
1. Raise body (1) clear of the trailer frame and lay
materials and lifting equipment are properly
body pads (4) (metal face down) roughly in position on
secured and of adequate capacity to do the job
the frame.
safely.
2. Lower body (1) assembly onto body pads (4).
1. Inspect bushing (2) for damage and replace if
necessary. Install bushing (2) in body hinge bores.
3. Centralise body (1) assembly to the frame and
place shims (5 & 6) under the front two body pads (4)
Note: Body lifting lugs can be fabricated as shown in
until all other pads are clear of body (1) assembly.
Fig. 2.
4. Slide shims (5 & 6) under remaining body pads (4)
2. Secure lifting lugs to body (1) using suitable bolts.
until they just make contact with body (1) assembly.
Using appropriate lifting equipment, sling body (1)
assembly and position over the trailer frame.
5. Raise body (1) assembly and install body pads (4)
and shim packs (5 & 6) to their relative brackets on
Note: Approximate weight of body (1) assembly is
body (1) assembly securing with bolts (8), washers (7)
4 400 kg (9 700 lb).
and locknuts (10).
3. Align hinge pin bores in body (1) assembly with bores
6. Lower body (1) assembly to the frame and check the
in the trailer frame. Install hinge pins (3) and shims (9) and
shimming.
secure with bolts (15) and washers (17).
7. Install body guide plates (12) with spacers (11) to
4. Secure body cylinders to body (1) assembly with
mounting brackets on body (1) assembly. Set gap
pins and mounting hardware removed during removal.
between plates (12) and the frame at 5 - 10 mm
Refer to Section 230-0130, BODY CYLINDER for
(0.2 - 0.4 in). Secure plates (12) and spacers (11) to
instructions.
mounting brackets with bolts (8).
5. Lubricate hinge pins (3) through lube fitting (14) with
lubricant specified in Section 300-0020, LUBRICATION
SYSTEM. Lubricate slowly until excess lube is seen.
SM 2212 4-03 3
Body - Body and Mounting
Section 270-0010
MAINTENANCE SM - 1630
Lubricate the body hinge pins and body cylinder pins at 64 DIA HOLE
the intervals stated and with lubricant specified in BURN
Section 300-0020, LUBRICATION SYSTEM. Lubricate 8
R4
slowly until excess lube is seen.
SPECIAL TOOLS
Special tools can be fabricated as shown in Fig. 2.
96
Refer to Section 300-0070, SERVICE TOOLS, for part
19.5
numbers of the general service tools required. These 6 6
0
2 PLACES 2 PLACES
10
tools are available from your dealer.
40˚
114
R 20
71
31
48 16
* * * *
4 SM 2212 4-03
MISCELLANEOUS - Lubrication System
Section 300-0020
When working on or around exhaust components, Small circles on the following illustration represent
remember that the components may be hot and can points at which lubrication and/or servicing must take
cause burns to unprotected skin. place, at the intervals indicated on the left hand side of
the lubrication and service chart.
Always deflate the tyre before trying to remove any
embedded objects or removing the tyre and rim The numbered circles on the illustration contain
assembly from the vehicle. reference numbers which correspond to the reference
numbers in the 'Ref. Points' column of the lubrication
Always use a self-attaching chuck with a long airline, and service chart.
and stand to one side while inflating the tyre. Refer to
Section 160-0050, WHEEL RIM AND TYRE.
SM - 2871
19 31 19 19
5 18 1 32 4 30 15 20 10 23 3 23 10 11 22 15 11 12 20 15 13
33 17 14 16 34 6 7 23 15 10 29 2 28 35 25 11 9 21 27 23 20 15 23 12 15 13
19 19 19
Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and
'Miscellaneous Servicing' contained on the following pages.
Notes on Lubrication and Service Chart Note 6 - Independent Front Suspension (IFS) grease
points(2). Remove excess grease from
Note - Capacities given are approximate - work to
lower wishbone inner pivot block grease
dipstick, sight gauges or level plugs.
holes.
Note 1 - Lubricate slowly until excess lube is seen.
Lube Left Hand IFS grease manifold until
Note 2 - Capacity of front and rear differentials is
excess is observed exiting through grease
21 litres (5.5 US gal). Capacity of centre
hole in pivot block.
differential is 23.0 litres (7.5 US gal).
Lube Right Hand IFS grease manifold until
Note 3 - Clean radiator and cooler fins more often
excess is observed exiting through grease
when operating under extremely dusty
hole in pivot block.
conditions.
Note 4 - Remove plug from port on underside of EO - Engine Oil. Refer to 'Recommended
oscillation hub. Plug is removed to drain the Lubricants' and 'Engine Oil Drain Intervals'.
cavity of any oil that enters the cavity when HO - Hydraulic Transmission Oil. Refer to
filling. Remove grommet and level plug on 'Recommended Lubricants'.
side of oscillation hub. Add oil if required. EPL - Extreme Pressure Gear Lubricant spec.
Refit all plugs. MIL-L-2105D.
Note 5 - Change safety element after every third EP, NLGI- Extreme Pressure Lithium No. 2 Grease
primary element service. (without 'Molybdenum').
PAG Oil - Polyalklene Glycol (PAG) Compressor
Lubricating Oil - Low Viscosity (ISO46).
SM 2360 Rev3 05-07 3
Miscellaneous - Lubrication System
Section 300-0020
Engine Air Cleaner - Change air cleaner element only Oil Can Points - Oil working parts with engine oil.
when air restriction gauge locks up in the red. Service
vacuator valves daily. Inspect and remove any General Inspection - Check entire dumptruck for
obstructions from the vacuator valve lips which should leaks, loose bolts and nuts or damaged parts. Examine
be open and pliablewith the engine stopped. the dumptruck, particularly the chassis, for cracks or
Note: Service air cleaners more often when operating broken welds. Repair where necessary.
under extremely dusty conditions.
Engine Air Intake - Check air intake system for wear
Engine Crankcase - Check oil level and add oil if low. points or damage to piping, loose clamps and leaks.
With the engine off, the oil should be between the lower
and upper marks on the dipstick, up to the upper mark Service Brakes - Check pads and discs for wear and
is preferable. adjust or replace where necessary. Test for proper
function.
Transmission - Check oil level and add oil if low. Note: This service interval applies to normal driving.
Refer to Section 120-0010, TRANSMISSION AND Check the pads more frequently under more severe
MOUNTING, for correct oil level check procedure. conditions. Thickness of pad friction material should
never be allowed to wear below 3 mm (0.12 in).
Hydraulic Tank - Check oil level and add oil if low.
With the engine off and the body down the oil should be Parking Brake - Check pads and disc for wear. Adjust
visible in the sight gauge. or replace if required. Test for proper function. Friction
material thickness should never be allowed to wear
Radiator Header Tank - Check coolant level when cold below 3 mm (0.12 in).
and add if low. Fill the radiator header tank with coolant
until coolant reaches the bottom of the filler neck and
EVERY 500 HOURS OF OPERATION (3
holds that level.
Note: Any time a significant amount of coolant is MONTHS)
added, the coolant concentration MUST be checked. Differentials - Check Oil level and add if low.The
Failure to use recommended coolant and to maintain correct oil level is up to the rim of the oil filler and level-
mixture at sufficient concentration levels can result in check hole. Refer to relevant Differential section within
damage to the cooling system and its related the service manual for specific details.
components. Always maintain concentrations at
recommended levels. Refer to 'Recommended
Coolants'. Section 210-0000, COOLING SYSTEM.
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE
Engine Crankcase Engine Oil with 1.00% 41 litre CH-4 15W-40
(Including Filters) sulphated ash limit is (10.8 US gal) (See Note 1)
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission Engine Oil with 1.85% 63 litre (See Note 2) CH-4 15W-40
(Including cooler) max. sulphated ash limit (16.6 US gal) See Trans.
Oil Table.
Transmission Engine Oil with 1.85% 8.25 litre (See Note 2) CH-4 15W-40
Cooler max. sulphated ash limit (2.18 US gal) See Trans.
Oil Table.
Hydraulic System Hydraulic Transmission Oil 202 litre See Hydraulic Oil Table
(Including Lines) (53.4 US gal) (See Note 3)
Cooling System Anti-freeze, Ethylene Glycol 54 litre
(14.3 US gal)
Differential Extreme Pressure 21 litre each MIL-L-2105 B GL-5 85W-90 HLS
(Front & Rear) Gear Lubricant (5.5 US gal) (See Note 4)
Differential Extreme Pressure 23.0 litre MIL-L-2105 B GL-5 85W-90 HLS
(Centre) Gear Lubricant (6.07 US gal) (See Note 4)
Planetaries Extreme Pressure 11.0 litre each MIL-L-2105 D GL-5 80W-90
(Front) Gear Lubricant (2.9 US gal) (See Note 6 & 7)
Planetaries Extreme Pressure 7.5 litre each MIL-L-2105 D GL-5 80W-90
(Centre & Rear) Gear Lubricant (2.0 US gal) (See Note 6 & 7)
Fuel Tank Diesel Fuel Oil with 390 litre DIN EN590
max. sulphur 0.5% (103 US gal)
Grease Nipples Extreme Pressure No.2
Lithium Grease Consistency
Driveshaft through Extreme Pressure (See Note 4 - Pag e 3) MIL-L-2105 D GL-5 80W-90
Bearings Gear Lubricant
Articulation Extreme Pressure No.2
Bearings Lithium Grease Consistency
Air Conditioning Polyalklene Glycol (PAG) 0.125 litre ISO46
Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10
Low Viscosity
Note 1 - The use of low viscosity oils, such as 10W-30 or Note 5 - Automatic Transmission Fluids (ATF) may only be
5W-30, can be used to aid in starting the engine and used when the ambient temperature is less than -10° C
providing sufficient oil flow at low ambient temperatures. (14° F). Should the temperature increase, it is necessary to
Continuous use of low viscosity oils can decrease engine switch to engine oil.
life due to wear.
Note 6 - 1.5% of Lubrizol (TEREX Part No. 15250489),
Note 2 - Operation below the minimum temperatures listed must be added to planetary capacity to prevent brake
for the oil used without proper preheat or warm-up results squeal
in greatly reduced transmission life. Proper warm-up
requires 20 minutes minimum operation in neutral (with Warning: Any increase in the stated volume of
engine at part throttle) before operating the transmission in Lubrizol will result in a decrease inbrake performance.
gear.
Note 7 - Volume of Lubrizol to each planetary is as follows:
Note 3 - Hydraulic Transmission Oil meeting Specification
EMS19058 is suitable for use in the hydraulic system. Front: 1.5% = 165ml (5.57 oz)
Centre & Rear: 1.5% = 110ml (3.71 oz)
Note 4 - Axles have limited slip differentials. If use of
standard SAE 90 oil results in very loud noise and jerking
of the wheels when driving slowly round sharp corners, an
EP oil with limited slip additives should be used.
API
SAE CODE MIL-SPEC
1 - - MIL-H-5606A
2 DEXRON Auto Trans. Fluid
3 10W CC/CD MIL-L-2104 B/C
4 20W/20 CC/CD MIL-L-2104 B/C
5 30 CC/CD MIL-L-2104 B/C
SM - 639
TRANSMISSION OIL
ENGINE OIL
(See Note 5)
Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.
* * * *
TYRE PRESSURES
Tyre pressures on this pages apply to the truck serial number range specified only, Gross Vehicle Weight
(G.V.W.) and axle weights may vary between truck derivatives. Tyre pressure should be recalculated if not shown
for a particular truck. Contact TEREX for assistance.
The tyre inflation pressures listed are manufacturers recommendations for G.V.W. travelling at maximum speed.
TEREX Advise that operators check tyre inflation pressures with tyre manufactures to ensure correct setting for
each particular application.
**
MISCELLANEOUS - Service Tools
Section 300-0070
SM - 407
DRILL
RAD
DEEP
RAD TYP
BURN OUT
SQUARE
Dimensions in mm (inches)
Fig. 2 - End Cap Torque Tool (Section 220-0120, STEERING CYLINDER)
SM - 633
SILVER STEEL
SQUARE
Dimensions in mm (inches)
Fig. 3 - Piston Torque Tool (Section 220-0120, STEERING CYLINDER)
SM - 2469
50 25
160 (6.299) (1.9680) (0.984)
10
90 (3.54) DRILL 13 (0.51) 11
RAD (0.394)
X 25 (0.984) (0.433)
DEEP
10 (0.394)
RAD TYP
(3.154 - 0.000 )
(4.724 - 0.005 )
+0.002
120.00 - 0.13
(1.9680)
80.10 - 0.00
+0.05
94 (3.7)
+
50
+
19 (0.75)
SQUARE
Dimensions in mm (in)
Fig. 4 - End Cap Torque Tool (Section 230-0130, BODY CYLINDER)
SM - 2470
89 (3.5)
38.1 (1.5)
(0.375)
9.525
DIA
(0.470)
11.938
124.45 - 0.000 (4.899 - 0.000 )
+0.005
DIA
90 - 0.05 (3.543 - 0.002 )
SILVER STEEL
136 (5.35)
+
25.4 (1.0)
SQUARE
+0.13
+
(0.500)
12.7
EN3B
DIA
MILD STEEL
Dimensions in mm (in)
Fig. 5 - Piston Torque Tool (Section 230-0130, BODY CYLINDER)
SM - 1630
64 DIA HOLE
BURN
8
R4
96
19.5
6 6
2 PLACES 2 PLACES 0
10
40˚
114
R 20
71
31
48 16
SM - 3785
Fig. 7 - Assembly Rig Drawing (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3786
15503485
Fig. 8 - Assembly Support Drawing (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3787
15503485
15503486
Fig. 9- Assembly Stand Drawing (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3774
Fig. 10- 1/2 Shaft Assy Removal Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3775
Fig. 11- 1/2 Shaft Seal Insertion Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3776
Fig. 12- 1/2 Shaft Seal Insertion Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3777
Fig. 13- 1/2 Shaft Seal FlingerTool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3778
Fig. 14- 1/2 Shaft Locknut Assembly Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3779
Fig. 15- Damper Extention Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3780
Fig. 16-Pivot Block Seal Insertion Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3781
Fig. 17- Socket Head Bolt Tightening Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3782
Fig. 18- LWB Bush Insertion Tool 1(Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3783
Fig. 19- LWB Bush Insertion tool 2(Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM - 3784
Fig. 20 - Knuckle Dowel Removal Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)
SM 1521 10-98 1
Miscellaneous - Axle Bolt and Nut Torque Specifications
Section 300-0080
Friction coefficient total 0.14 for screws and nuts
without after treatment as well as for phosphated
nuts.
Tighten by hand!
* * * *
2 SM 1521 10-98
MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
Section 300-0080
SM 1238 2-98 1
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
Note: Where materials other than GM Standards are used, refer to the conversion table below.
Types of Steel Rockwell Hardness Range Applicable Torque Values SAE Bolt Head Symbols
2 SM 1238 2-98
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
SM 1238 2-98 3
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080
Lockscrews Locknuts
SAE Grade 5 & 8
and ASTM A-574 SAE Grade 5 SAE Grade 8
Size Nm lbf in Nm lbf in Nm lbf in
0.25 - 20 0.3 3 0.4 3.5 0.5 4.5
0.25 - 28 0.3 3 0.4 3.5 0.5 4.5
0.31 - 18 0.6 5 0.6 5.5 0.9 7.5
0.31 - 24 0.6 5 0.6 5.5 0.9 7.5
0.38 - 16 1.0 9 1.0 8.5 1.3 11.5
0.38 - 24 1.0 9 1.0 8.5 1.3 11.5
0.44 - 14 1.4 12 1.4 12 1.8 16
0.44 - 20 1.4 12 1.4 12 1.8 16
0.50 - 13 1.8 16 1.7 15 2.3 20
0.50 - 20 1.8 16 1.7 15 2.3 20
0.56 - 12 2.5 22 2.4 21 3.2 28
0.56 - 18 2.5 22 2.4 21 3.2 28
0.62 - 11 3.4 30 3.1 27 4.1 36
0.62 - 18 3.4 30 3.1 27 4.1 36
0.75 - 10 5.1 45 4.6 41 6.1 54
0.75 - 16 5.1 45 4.6 41 6.1 54
0.88 - 9 7.3 65 7.0 62 9.3 82
0.88 - 14 7.3 65 7.0 62 9.3 82
1.00 - 8 9.6 85 9.5 84 12.7 112
1.00 - 12 9.6 85 9.5 84 12.7 112
1.00 - 14 - - 9.5 84 12.7 112
* * * *
4 SM 1238 2-98
MISCELLANEOUS - Unit Storage
Section 300-0090
5. RUST PREVENTION - Remove all evidence of rust 8. TRANSMISSION - Consult the relevant
from the machine and repaint. In addition, cover all Transmission Maintenance Manual for storage data
exposed machine surfaces with a good rust involving periods longer than 30 days.
preventive.
9. ENGINE - Consult the relevant Engine Maintenance
6. SUPPLY TANKS - Fill fuel and hydraulic tanks to Manual for storage data involving periods longer than
prevent moisture condensation within the tanks. 30 days.
7. TYRES - Inflate all tyres to correct pressure. During 10. VENTS AND BREATHERS - Remove all vents
storage, check inflation pressure approximately once and breathers and plug openings with pipe plugs. If it
every two weeks. is not possible to do this, seal vents and breathers with
waterproof tape.
SM 1239 2-98 1
Miscellaneous - Unit Storage
Section 300-0090
EXTENDED STORAGE - Over Six Months 2. BATTERIES - Install batteries and check for a full
When a machine is to be stored for a period over SIX charge. Charge batteries as required.
MONTHS, the following procedure must be followed:
3. TYRES - Inflate tyres to the proper pressures. Refer
Note: These steps are in addition to those given to Section 140-0040, WHEEL RIM AND TYRE, of this
previously under 'Extended Storage - Under Six manual.
Months'.
4. FUEL AND HYDRAULIC TANKS - Drain off
1. LUBRICATION - Completely lubricate the machine condensation and fill tanks to proper level, remove
according to the instructions contained in Section breather covers and install air breathers. Be sure
300-0020, LUBRICATION SYSTEM of this manual. breathers are clean before installation.
2. WHEEL BEARING - Remove, clean, inspect and 5. VENTS AND BREATHERS - Remove seals and
repack all wheel bearings. plugs from all breather openings, then install all
breathers and vents.
Note: The above steps must be repeated for every Six
Month period the machine is in storage. 6. ENGINES - Consult the relevant Engine
Maintenance Manual for instructions on removing an
engine from storage.
REMOVAL FROM EXTENDED STORAGE
7. PAINT - Check machine for rust. Remove all rust
General spots and repaint rusted areas.
1. LUBRICATION - Completely lubricate the machine
according to the instructions in Section 300-0020, 8. TRANSMISSION - Consult the relevant
LUBRICATION SYSTEM of this manual. Transmission Maintenance Manual for instructions on
removing from storage.
* * * *
2 SM 1239 2-98