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Articulated Dumptruck Maintenance Manual: Click Here For of Contents
Articulated Dumptruck Maintenance Manual: Click Here For of Contents
TABLE
OF CONTENTS
Articulated Dumptruck
Maintenance Manual
MODEL: General
PURPOSE:
DETAIL:
It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces a
highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315° C.
The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.
We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.
c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.
d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by washing
thoroughly with Limewater (Calcium Hydroxide solution).
f. Any cloths, residue and gloves used MUST be safely discarded after use.
Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.
Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.
It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the possible
hazardous consequences of each way. Consequently, no such broad evaluation has been undertaken.
Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must first satisfy
themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the service
method he/she selects.
Two types of heading are used in this manual to attract your attention.
1. WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly
followed could result in personal injury or loss of life. Look for this symbol to point out important safety
precautions. It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.
WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardize
the integrity of the machine and could result in property damage or serious personal injury.
* * * *
2 685
Max. (8-10)
Body 1 445
Depth (4-9) 2 895
(9-6)
45˚
6 110
65˚ (20-0)
SAE Turning Radius 8 470mm (27-9)
Clearing Radius 8 950mm (29-4)
5 010
(16-5)
4 920
(16-2)
3 450
(11-3)
3 420
(11-2)
3 325 2 895
(10-10) (9-6)
2 175
(7-0)
405 725
(1-6) (2-3)
1 580
(5-3)
2 200 2 400 1 310 2 945 1 690 1 410
(7-2) (7-9) (4-4) (9-8) (5-6) (4-9)
2 895 9 755
(9-6) (32-0)
Fig. 1 - Machine Dimensions
ENGINE
overspeed. Blocked filter indicator and filter bypass system
Make/Model .............................................. Cummins QSM11 provide valve block with additional protection from unfiltered
Type .............. Four cycle diesel, turbocharged with air-to-air oil.
charge cooling, water-cooled. Electronic management.
Pressures:
Gross power at 2 100 rev/min ....... 261 kW (350 hp, 355 PS) Main ........................................ 16 + 2 bar (232 + 30 lbf/in²)
Net power at 2 100 rev/min ........... 248 kW (333 hp, 338 PS) 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 II and EU NRMM
Converter Relief Valve ........................ 8.5 bar (123 lbf/in²)
(non-road mobile machinery) Tier II directive.
Retarder ................................................. 5.5 bar (80 lbf/in²)
Maximum Torque .... 1 776 Nm (1 310 lbf ft) at 1 400 rev/min Temperatures:
Number of cylinders/configuration ........................... 6, in line Normal ................................... 80° - 110° C (176° - 230° F)
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in) Maximum (Retarder Mode) ....................... 145° C (293° F)
Piston Displacement ............................... 10.8 litres (660 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 2169 Rev 5 08-05 1
General Information - Technical Data
Section 000-0000
AXLES HYDRAULIC SYSTEM
Three axles in permanent all-wheel drive with differential Braking, steering and body hoist systems are controlled by
coupling between each axle to prevent driveline wind-up. a main hydraulic valve mounted on frame. Systems are
Heavy duty axles with fully-floating axle shafts and outboard supplied with oil from a common tank by the main hydraulic
planetary reduction gearing. pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
Automatic limited slip differentials in each axle. Centre axle line.
incorporates a through-drive differential to transmit drive to
the rear axle. Locking of this differential is actuated Pump:
simultaneously with the transmission output differential lock. Type ......................................................................... Piston
Capacity at 2 100 rev/min ....... 4.9 litre/s (77.4 US gal/min)
Ratios:
Differential ............................................................... 3.44:1 Brakes
Planetary ................................................................. 6.35:1
Total Reduction ..................................................... 21.85:1 All hydraulic braking system with dry disc on each wheel
with two heavy-duty callipers per disc. Independent circuits
for front and rear brake systems. Warning lights and audible
SUSPENSION alarm indicate low brake system pressure. Brake system
Front: Axle is carried on the leading arms of a sub-frame conforms to ISO 3450, SAE J1473.
which pivots on the main frame. Suspension is by rubber
elements with four heavy duty hydraulic dampers. Actuating Pressure ............................. 103 bar (1 500 lbf/in²)
Rear: Each axle is coupled to the frame by three rubber-
Discs:
bushed links with lateral restraint by a transverse link.
Diameter ................................................. 477 mm (18.8 in)
Pivoting inter-axle balance beams equalise load on each
Thickness ................................................. 16 mm (0.63 in)
axle. Suspension movement is cushioned by rubber/metal
laminated compression units between each axle and
Parking: Spring-applied, hydraulic-released disc on
underside of balance beam ends. Pivot points on rear
rear driveline.
suspension linkages are rubber-bushed and maintenance-
free.
Emergency: Automatic application of driveline brake
WHEELS AND TYRES should pressure fall in main brake hydraulic
system. Service brakes may also be applied
Wheels: ............ 5-piece earthmover rims with 12 stud fixing using the parking-emergency brake control.
Size:
Standard ....................... 25 x 19.50 in for 23.5 R25** tyres Retardation: Hydraulic retarder integral with transmission,
Optional .................... 25 x 22.00 in for 750/65 R25** tyres or optional engine brake.
Tyres:
Standard ........................................................... 23.5 R25** Steering
Optional ........................................................ 750/65 R25**
Hydrostatic power steering by two single-stage, double-
Inflation Pressures (Bridgestone): acting, cushioned steering cylinders. Emergency steering
Front Rear pressure is provided by a ground driven pump mounted on
23.5 R25** ...... 4.75 bar (69 lbf/in²) 4.75 bar (69 lbf/in²) the rear of the transmission. An audible alarm and warning
750/65 R25** .. 3.25 bar (47 lbf/in²) 3.25 bar (47 lbf/in²) light indicates should the emergency system activate.
Conforms to ISO 5010, SAE J53.
Inflation Pressures (Michelin):
Front Rear System Pressure ................................ 241 bar (3 500 lbf/in²)
23.5 R25** ........... 4 bar (58 lbf/in²) 4 bar (58 lbf/in²) Steering Angle to either side ............................................ 45°
750/65 R25** .... 3.0 bar (44 lbf/in²) 3.0 bar (44 lbf/in²) Lock to Lock Turns, steering wheel .................................... 4
Inflation Pressures (Continental): System Pressure ................................. 220 bar (3 200 lbf/in²)
Front Rear Control Valve ....................... Pilot Operated, Closed Centre
23.5 R25** ........ 5.0 bar (73 lbf/in²) 5.0 bar (73 lbf/in²) Body Raise Time (loaded) .......................................... 12 sec
Body Lower Time (power down) ................................ 7.5 sec
Inflation Pressures (Marangoni):
Front Rear ELECTRICAL SYSTEM
750/65 R25** .... 3.0 bar (43 lbf/in²) 3.0 bar (43 lbf/in²) Type .............................................. 24 volt, Negative Ground
Battery ......................................... Two, 12 Volt, 143 Ah each
Note: Tyre pressures should be regarded as nominal only. It Accessories ................................................................ 24 Volt
is recommended that for tyres both listed and unlisted, the Alternator .................................................................. 70 Amp
user should consult the tyre manufacturer and evaluate all
job conditions in order to make the proper selection.
* * * *
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
CHASSIS - Articulation and Oscillation Pivot
Section 100-0020
SM - 2784
29 25 60
16 30
59 59
28 61
19 5,6
7
14 20 62
17 63
59
DETAIL A
42 47 25
46
43
44,45
58
36-38
34,35,23
33
26,59 26,62
60,61 63,61 10,26
59
11
2,3,4 2,3,4 57
40,41 32 39 27 1
54,55,56
30 18
DETAIL A 13
15 8,9
30
17 31
19 19
28 28
45,52,53 50 48
16 16
49 31
8,9 29
29 15
36-38
34,35,23 21,22
51 14 24
12
25
45,46,49 48 44,45,58 10,26
1 - Pivot 17 - Front Yoke 33 - Retainer 49 - Retainer
2 - Nylon Bush 18 - Brake Yoke 34 - Bearing Cup 50 - Pin Assembly
3 - Loctite 648 19 - Nut 35 - Bearing Cone 51 - Retainer
4 - Loctite Primer 20 - Washer 36 - Shim 52 - Bolt
5 - Gasket 21 - Hardened Washer 37 - Shim 53 - Washer
6 - Cover Plate 22 - Bolt 38 - Shim 54 - Adaptor
7 - Bolt 23 - EMS19057 Grease 39 - Pin Assembly 55 - Connector
8 - Bearing Cone 24 - EMS19003 EP Oil 40 - Bolt 56 - Elbow
9 - Bearing Cup 25 - Plug 41 - Hardened Washer 57 - Pipe Assembly
10 - 'V' Ring Seal 26 - EMS19014 Grease 42 - 'O' Ring 58 - Loctite 243
11 - Thrust Nut 27 - Lube Fitting 43 - Retainer 59 - Elbow
12 - Lockplate 28 - Lockwasher 44 - Bolt 60 - Hose Assy
13 - Antiseize Compound 29 - 'O' Ring 45 - Lockwasher 61 - Lube Fitting
14 - Driveshaft 30 - 'O' Ring 46 - Spacer 62 - Hose Assy
15 - Seal 31 - Retaining Ring 47 - Lock Nut 63 - Connector
16 - Thrust Washer 32 - 'O' Ring 48 - 'O' Ring
DESCRIPTION AND OPERATION connecting the drive between the front and rear
The articulation and oscillation pivot allows the front frames.
and rear frames to rotate horizontally (articulation) and
tilt laterally (oscillation) with respect to each other. It is Articulation bearings, oscillation bushes, pivot
also the main load bearing coupling between the two driveshaft bearings and associated parts can be
frames. The pivot assembly houses the driveshaft removed, inspected and replaced or renewed by
SM 2171 11-02 1
Chassis - Articulation and Oscillation Pivot
Section 100-0020
following the procedures outlined in this section. 8. Place a suitable container under the front of the
pivot and pull front yoke (17) from driveshaft (14).
Note: The following procedures assume that only thru- 10. Release the parking brake by turning the hex-head
drive components require repair. on the parking brake slack adjuster fully anticlockwise.
When necessary to drive out or drive on 13. Remove mounting hardware securing parking
components during disassembly/assembly, be brake disc to brake yoke (18) and remove brake disc.
sure to use a soft drift to prevent property
damage and personal injury. 14. Withdraw driveshaft assembly (14) from housing
by pulling rearwards on parking brake disc/brake yoke
assembly (18). If necessary, tap front end of driveshaft
Removal and Disassembly (14) to ease removal, take care to avoid damaging
1. Position the vehicle on a level work area and apply threads. Place driveshaft (14) assembly on work
parking brake. bench for further disassembly.
2. Raise body and install body safety prop to secure 15. Prise out and discard seal (15) from front of the
body in partially raised position. housing.
3. Shut down engine and block all wheels securely. 16. Lift out front bearing assembly cup (9) from front of
the housing.
4. Identify the relationship of the driveline caps to the
transmission yoke and front yoke (17). Remove 17. If bearing replacement is required, use a suitable
capscrews and remove driveline from vehicle. Refer to puller to remove front and rear bearing assembly cups
Section 130-0010, FRONT AND REAR DRIVELINES. (9) from the housing.
Note: Take extra care when handling drivelines as any Note: If either bearing assembly cup or cone (9 or 8)
deformity on a rotating mass creates vibration and need replacing, they must be replaced as a set.
excessive wear during any operation.
18. If retaining rings (31) need replacing, use a
5. Remove wheel blocks, start engine and steer suitable drift or puller to remove them from the housing.
vehicle into a full left-hand lock. Shut down engine and
block all wheels securely. 19. Remove front nut (19) then temporarily install front
yoke (17) fully onto front of driveshaft (14) and suitably
6. Remove front nut (19), lockwasher (28) and thrust restrain to resist rotation.
washer (16) from driveshaft (14). Reinstall nut (19)
temporarily onto driveshaft (14) to protect the threads. 20. Remove rear nut (19), lockwasher (28), thrust
washer (16), and brake yoke (18) from driveshaft (14).
7. Remove and discard 'O' rings (29 & 30) from thrust Identify front and rear ends of driveshaft (14).
washer (16).
2 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
21. Remove and discard 'O' rings (29 & 30) from thrust 5. Remove nut (19), thrust washer (16) and brake
washer (16). yoke (18) from driveshaft (14). The distance from the
end of the bearing cone (8) to the end of the spline
22. Remove and discard seal (15) from driveshaft (14). should be 60mm.
23. If bearing replacement is required, use a suitable 6. Install driveshaft (14) through the housing from the
puller or drift to remove rear bearing assembly cone rear.
(8) from driveshaft (14).
7. Using a suitable driver, install front bearing
24. Reinstall nuts (19) on driveshaft (14) to protect the assembly cone (8) on driveshaft (14).
threads.
8. Using a suitable driver, install seals (15) into ends
of housing, ensuring that they butt hard against
Inspection abutment shoulders.
1. Clean all parts with a suitable solvent and let dry.
DO NOT spin bearings with compressed air. Place 9. Install brake yoke (18) on rear of driveshaft (14)
bearings on a clean surface, cover with a lint free cloth until it butts against bearing assembly cone (8).
and allow to dry.
10. Install 'O' rings (29 & 30) to thrust washer (16) and
2. Check bearing assemblies cups and cones (9 & 8) install assembly on rear of driveshaft (14).
for wear or damage. Renew as necessary.
11. Install rear nut (19) temporarily on rear of
Note: If either bearing assembly cup or cone (9 or 8) driveshaft (14) and tighten.
need replacing, they must be replaced as a set.
12. Install front yoke (17) on driveshaft (14) until it
3. Inspect splines of driveshaft (14) and yokes butts against bearing assembly cone (8).
(17 & 18) for nicks, burrs or excessive wear. Replace
if wear is excessive or splines are nicked. Burrs may 13. Install 'O' rings (29 & 30) to thrust washer (16) and
be removed with a fine file or medium India stone. install assembly on front of driveshaft (14).
4. Check yokes (17 & 18) for damage in region 14. Install nut (19) and lockwasher (28) to front
polished by oil seal lip; even slight damage in this area threads of driveshaft (14). Prevent driveshaft (14) from
can cause leakage. Very slight marks may be polished turning by restraining brake yoke (18).
out with fine emery cloth but it is essential that
polishing marks are parallel to the seal lip. 15. Tighten nut (19) and bend at least one lockwasher
(28) tab into nut (19). If required back off nut (19) until
5. Replace all seals and 'O' rings with new parts. the first available tab lines up with a slot in the nut
(19).
Assembly and Installation 16. Tighten nut (19) at rear of driveshaft (14) to a
1. If removed, use a suitable driver and install retaining torque of 250 Nm (180 lbf ft) to seat bearing cup and
rings (31) into housing, ensuring that they butt hard cone assemblies (9 & 8).
against abutment shoulders.
17. Chap driveshaft (14) at both ends with a hide-
2. Using a suitable driver, install front and rear bearing faced hammer. Re-torque nut (19) to 250 Nm (180 lbf
assembly cups (9) into housing, ensuring that they butt ft).
hard against abutment shoulders.
18. Back off nut (19) four flats, and chap rear end of
3. Lightly oil both bearing assembly cones (8) with driveshaft (14) with a hide-faced hammer to remove
EMS19003 E. P. gear oil (24). pre-load from bearing cup and cone assemblies (9 &
8).
4. Using a suitable driver, install rear bearing assembly
cone (8) on rear end of driveshaft (14). Temporarily install 19. Remove nut (19) from rear of driveshaft (14),
brake yoke (18), thrust washer (16) and nut (19) to install lockwasher (28) and reinstall nut (19).
driveshaft (14). Tighten nut (19) until the yoke (18)
bottoms out on the driveshaft (14). 20. Set up dial indicator with pointer positioned on rear
SM 2171 11-02 3
Chassis - Articulation and Oscillation Pivot
Section 100-0020
end face of driveshaft (14). Push and pull on parking pivot assembly (1) of any oil that entered while filling
brake disc to move driveshaft (14) backwards and the driveshaft bearing housing.
forwards, remembering to rotate shaft at the same
time to obtain an accurate reading. Note dial indicator 31. Install plug (25) into filler/level hole on pivot
reading. assembly (1). Install gasket (5) and cover plate (6) on
side of oscillation hub, secure with bolts (7) and
21. Tighten nut (19) until end play on driveshaft (14) washers (20).
can just be felt. Take dial indicator reading of end play.
Tighten nut (19) until end play on driveshaft (14) is 32. Install plug (25) into cavity drain port on underside
0.05 - 0.15 mm (0.002 - 0.006 in). of oscillation hub.
Note: One flat on nut (19) turned is equivalent to 33. Install parking brake disc protective guard (if fitted)
0.025 mm (0.001 in) axial movement. and secure with bolts, washers and nuts.
22. When correct end play is obtained, remove dial 34. Start engine, raise body, lower body safety prop
indicator and secure nut (19) by bending the first and lower body.
available lockwasher (28) tab into nut (19). Recheck
end play. 35. Remove wheel blocks.
29. Add EMS19003 E. P. gear oil (24) through filler/ Disconnecting Front and Rear Frames
level hole in pivot assembly (1) until the oil is level with Note: The front and rear frames can be separated
the bottom of filler/level hole. sufficiently to permit disassembly/assembly of the
articulation components without disconnecting
30. Remove plug (25) from underside of oscillation hydraulic lines or electrical wiring.
hub to drain the cavity between the oscillation hub and
4 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
1. Position the vehicle on a level work area and apply hydraulic and electrical connections could result.
parking brake.
13. Remove blocks from rear wheels and use lifting
2. Raise body and install body safety prop to secure equipment to pull pivot/rear frame assembly clear of
body in partially raised position. the front frame. After moving, block pivot/rear frame
assembly and block the wheels.
3. Shut down engine and block all wheels securely.
14. Remove spacer (46) noting orientation to ensure
4. Identify the relationship of the driveline caps to the correct installation.
transmission yoke and front yoke (17). Remove
capscrews and remove driveline from vehicle. Refer to
Section 130-0010, FRONT AND REAR DRIVELINES. Disassembly
1. Identify retainers (33, 43, 49 & 51) to ensure correct
5. Support tractor frame at front and rear with suitably location on assembly/installation.
placed stands or timbers so the frame will remain level
during and after pin removal. Note: Retainers (33, 43, 49 & 51) are not
interchangeable.
6. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of 2. Remove bolts (44), lockwashers (45), retainers (33,
pivot. Refer to Section 220-0120, STEERING 43, 49 & 51) and upper and lower shims (36, 37 & 38).
CYLINDER.
3. Prise out and discard 'O' rings (32, 42 & 48) from
7. Release the parking brake by turning the hex-head the retainers.
on the parking brake slack adjuster fully anticlockwise.
4. Remove and tag all bearing assemblies (34 & 35)
with spacers to ensure correct assembly/installation.
WARNING
Tensioned spring on adjuster. Note: Bearing assemblies (34 & 35) and spacers are a
matched set, never interchange cups, cones or
8. Attach suitable lifting equipment to pivot/rear frame spacers between sets.
assembly. Lifting equipment must prevent pivot from
oscillating after separation, and, be capable of pulling
pivot/rear frame assembly clear of front frame. Raise Inspection
lifting equipment to support pivot/rear frame assembly. 1. Clean all parts with a suitable solvent and let dry.
DO NOT spin bearings with compressed air. Place
9. Remove nut (47) securing upper pin (39). Remove bearings on a clean surface, cover with a lint free cloth
bolt (40) and washer (41) securing upper pin (39) to and allow to dry.
tractor frame.
2. Check bearing assemblies (34 & 35) and spacers,
10. Remove upper pin (39). If necessary tap upper pin and pins (39 & 50) for wear or damage. Renew as
(39) to ease removal taking care to avoid damaging necessary.
the threads.
Note: Bearing assemblies (34 & 35) and spacers must
Note: It may be necessary to relieve binding between be renewed as a matched set.
the pin and pin bores by raising or lowering the pivot/
rear frame assembly. 3. Replace all seals with new parts.
SM 2171 11-02 5
Chassis - Articulation and Oscillation Pivot
Section 100-0020
2. Using EMS19057 grease (23), pack bearing 4. Remove blocks from rear wheels and blocking from
assemblies (34 & 35), including end faces, and install pivot/rear frame assembly. Using lifting equipment, pull
bearings using a suitable driver. pivot/rear frame assembly to align pivot bearing bores
and front frame pin bores. Block wheels and block
3. Remove bolts (44) and retainers (33 & 51) from pivot/rear frame assembly to remain level and
pivot bores. stationary.
4. Temporarily install retainers (43 & 49) to pivot 5. Freeze upper and lower pins (39 & 50) to ease
bores. Ensure pressure relief hole is opposite the installation.
grease nipple (27). Install retainers (33 & 51) to pivot
bores and secure with bolts (44) and washers (45). 6. Smear upper pin (39) and bearing bores with
Tighten bolts (44) to a torque of 27 Nm (20 lbf ft). EMS19057 grease (23) and install through front frame
and bearing bores. Fit nut (47), with anti-seize
5. Using feeler gauges, as shown in Fig. 2, measure compound, and tighten to pull assembly into position.
the dimension between the top pivot faces and Tighten nut (47) to a torque of 1425 Nm (1050 lbf ft).
retainers (43 & 49). Measure at 3 positions equally
spaced around retainers and determine average Note: It may be necessary to relieve binding between
dimension, this is the size of shims (36 - 38) required. the pin and pin bores by raising or lowering pivot/rear
frame assembly.
6. Remove bolts (44), washers (45) and retainers (43
& 49). 7. Secure upper pin (39) with bolt (40) and hardened
washer (41).
7. Install shims (36 - 38) as calculated at Step 5,
reinstall retainers (43 & 49) and secure with bolts (44), 8. Smear lower pin (50) and bearing bores with
coated with sealant (58), and washers (45). Tighten EMS19057 grease (23) and install through front frame
bolts (44) to 106 - 116 Nm (78 - 86 lbf ft). and bearing bores.
8. Install seals (32, 42 & 48) into retainers (33, 43, 49 9. Secure lower pin (50) with bolt (52), lockwasher (45)
& 51). and washer (53).
2. Smear bearing and pin bores with EMS19057 2. Remove lifting equipment from pivot/rear frame
grease (23). assembly.
3. Attach suitable lifting equipment to pivot/rear frame 3. Remove stands or timbers from front frame.
assembly. Lifting equipment must prevent pivot from
oscillating and be capable of pulling pivot/rear frame 4. Apply Loctite 270 to the threads of capscrews used
assembly to align pivot bearing bores and front frame to mount driveline between transmission yoke and
pin bores. Raise lifting equipment to support pivot/rear front yoke (17). Align match marks and install
frame assembly. driveline. Tighten capscrews to a torque of 153 Nm
(113 lbf ft).
SM - 008
5. Align steering cylinder bores and mounting pin
bores on pivot, install pins and secure with bolts and
washers.
6 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
8. Remove wheel blocks. capscrews and remove driveline from vehicle. Refer to
Section 130-0010, FRONT AND REAR DRIVELINES.
OSCILLATION COMPONENTS 6. Support tractor frame at front and rear with suitably
Numbers in parentheses refer to Fig. 1. placed stands or timbers so the frame will remain level
during and after pin removal.
Note: The following procedure assumes that only
components associated with oscillation require repair. 7. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of
Note: It is necessary to disconnect the front and rear pivot. Refer to Section 220-0120, STEERING
frames at the articulation point to service the CYLINDER.
oscillation components.
8. Release the parking brake by turning the hex-head
Note: It is essential that the grease used for oscillation on the parking brake slack adjuster fully anticlockwise.
components is EMS19014 grease (26), as specified in
Section 300-0020, LUBRICATION SYSTEM.
WARNING
Note: Tighten all fasteners without special torques Tensioned spring on adjuster.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE 9. Attach suitable lifting equipment to pivot/rear frame
SPECIFICATIONS. assembly. Lifting equipment must prevent pivot from
oscillating after separation, and, be capable of pulling
pivot/rear frame assembly clear of front frame. Raise
WARNINGS lifting equipment to support pivot/rear frame assembly.
To prevent personal injury and property damage,
be sure wheel blocks, blocking materials and 10. Remove nut (47) securing upper pin (39). Remove
lifting equipment are properly secured and of bolt (40) and washer (41) securing upper pin (39) to
adequate capacity to do the job safely. tractor frame.
When necessary to drive out or drive on 11. Remove upper pin (39). If necessary tap upper pin
components during disassembly/assembly, be (39) to ease removal taking care to avoid damaging
sure to use a soft drift to prevent property the threads.
damage and personal injury.
Note: It may be necessary to relieve binding between
Hydraulic fluid pressure will remain the pin and pin bores by raising or lowering the pivot/
within the braking system after engine shut rear frame assembly.
down. Operate the treadle pedal continuously
until the pressure has dissipated before 12. Remove bolt (52), lockwasher (45) and washer
carrying out any work on the braking system (53) securing lower pin (50).
or serious injury could result.
13. Remove lower pin (50). If necessary tap lower pin
(50) to ease removal taking care to avoid damaging
Disconnecting Front and Rear Frames the pin.
1. Position the vehicle on a level work area and apply
parking brake. 14. Remove blocks from rear wheels and use lifting
equipment to pull pivot/rear frame assembly clear of
2. Raise body and install body safety prop to secure the front frame. After moving, block pivot/rear frame
body in partially raised position. assembly and block the wheels.
3. Shut down engine and block all wheels securely. 15. Remove spacer (46) noting orientation to ensure
correct installation.
4. Depress and release brake pedal continuously to
relieve the pressure in the braking system.
Disassembly
5. Identify the relationship of the driveline caps to the 1. Remove protective guard (if fitted) from beneath
transmission yoke and front yoke (17). Remove parking brake disc by removing mounting hardware
SM 2171 11-02 7
Chassis - Articulation and Oscillation Pivot
Section 100-0020
securing guard to the rear frame. Refer to SM - 038
Section 170-0010, PARKING BRAKE AND
MOUNTING.
8 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
1. Wipe bush housing clean using a suitable solvent 12. Install nut (19) at rear of driveshaft (14), and
and allow to dry. tighten to a torque of 250 Nm (180 lbf ft) to seat
bearing cup and cone assemblies (9 & 8).
2. Apply Loctite (3) and Loc Quick Primer (4) and align
new bushes (2) in rear frame with grease holes 13. Chap driveshaft (14) at both ends with a hide-
aligned vertically and identification 'PAINT DOT' at Top faced hammer. Re-torque nut (19) to 250 Nm (180 lbf
Dead Centre. Refer to Fig. 4. Drift bushes (2) into rear ft).
frame using hammer with soft packing for protection.
14. Back off nut (19) four flats, and chap rear end of
3. Install plug (25) in filler/level hole on pivot assembly driveshaft (14) with a hide-faced hammer to remove
(1). Install gasket (5) and cover plate (6) on side of pre-load from bearing cup and cone assemblies (9 &
oscillation hub and secure with bolts (7) and washers 8).
(20).
15. Remove nut (19) from rear of driveshaft (14),
4. Install plug (25) in cavity drain port on underside of install lockwasher (28) and reinstall nut (19).
oscillation hub.
16. Set up dial indicator with pointer positioned on rear
5. Lightly coat 'V' ring (10) and machined surfaces of end face of driveshaft (14). Push and pull on parking
pivot with EMS19014 grease (26) and, install 'V' ring brake disc to move driveshaft (14) backwards and
(10), with lip towards rear, on front of oscillation hub. forwards, remembering to rotate shaft at the same
time to obtain an accurate reading. Note dial indicator
6. Using suitable lifting equipment, and taking care to reading.
prevent damaging bushes (2) or pivot threads, install
pivot assembly (1) into rear frame. 17. Tighten nut (19) until end play on driveshaft (14)
can just be felt. Take dial indicator reading of end play.
7. Thread thrust nut (11) on pivot assembly (1) and Tighten nut (19) until end play on driveshaft (14) is
tighten as follows: 0.05 - 0.15 mm (0.002 - 0.006 in).
a) Restrain pivot assembly (1) to prevent it oscillating, Note: One flat on nut (19) turned is equivalent to
by placing a heavy bar between the steering cylinder 0.025 mm (0.001 in) axial movement.
mountings. Lock the bar in position using suitable
trestles or stands. See Fig. 3. 18. When correct end play is obtained, remove dial
indicator and secure nut (19) by bending the first
b) Secure a special tool, which can be manufactured available lockwasher (28) tab into nut (19). Recheck
as shown in Fig. 5, to pivot thrust nut (11) and tighten end play.
thrust nut (11) until there is no end float/ clearance at
thrust face of either bush. Slacken thrust nut (11) until
pin of the locking plate (12) can be inserted in the first Connecting Front and Rear Frames
available hole in the thrust nut (11). 1. Install spacer (46) in upper retainer (43), as noted
on removal.
c) Secure locking plate (12) with bolts (22) and
lockwashers (21). Torque tighten bolts (22) to 94 Nm 2. Smear bearing and pin bores with EMS19057
(69 lbf ft). grease (23).
8. Install adaptor (54), connector (55), elbow (56) and 3. Attach suitable lifting equipment to pivot/rear frame
pipe assembly (57) to oscillation hub. assembly. Lifting equipment must prevent pivot from
oscillating and be capable of pulling pivot/rear frame
9. Install brake yoke (18) on driveshaft (14) until it assembly to align pivot bearing bores and front frame
butts against bearing assembly cup and cone (9 & 8). pin bores. Raise lifting equipment to support pivot/rear
frame assembly.
10. Install parking brake disc on brake yoke (18) and
secure with bolts and washers. Tighten bolts to a 4. Remove blocks from rear wheels and blocking from
torque of 49 Nm (36 lbf ft). pivot/rear frame assembly. Using lifting equipment, pull
pivot/rear frame assembly to align pivot bearing bores
11. Install thrust washer (16) on rear of driveshaft (14). and front frame pin bores. Block wheels and block
pivot/rear frame assembly to remain level and
SM 2171 11-02 9
Chassis - Articulation and Oscillation Pivot
Section 100-0020
stationary. SM - 011
5. Freeze upper and lower pins (39 & 50) to ease PAINT DOT
installation.
8. Smear lower pin (50) and bearing bores with 8. Connect hydraulic lines and electrical wiring as
EMS19057 grease (23) and install through front frame noted on disassembly.
and bearing bores.
9. Remove bolts (7), washers (20), gasket (5) and
9. Secure lower pin (50) with bolt (52), lockwasher (45) cover plate (6) from side of oscillation hub to gain
and washer (53). access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).
Final Assembly 10. Add EMS19003 E. P. gear oil (24) through filler/
1. Install parking brake assembly to mounting brackets level hole in pivot assembly (1) until the oil is level with
and secure with bolts, washers and nuts. Tighten bolts the bottom of filler/level hole.
to a torque of 75 Nm (55 lbf ft).
11. Remove plug (25) from underside of oscillation hub
2. Apply parking brake by turning the hex-head on the to drain the cavity between the oscillation hub and
parking brake actuator fully clockwise. pivot assembly (1) of any oil that entered while filling
the driveshaft bearing housing.
3. Remove lifting equipment from pivot/rear frame
assembly. 12. Install plug (25) in filler/level hole on pivot
assembly (1). Install gasket (5) and cover plate (6) on
4. Remove stands or timbers from front frame. side of oscillation hub, secure with bolts (7) and
washers (20).
5. Apply Loctite 270 to the threads of capscrews used
to mount driveline between transmission yoke and 13. Install plug (25) in cavity drain port on underside of
front yoke (17). Align match marks and install oscillation hub.
driveline. Tighten capscrews to a torque of 153 Nm
(113 lbf ft). 14. Fill bearing housings with EMS19057 grease (23)
through lube fittings (27) until excess grease starts to
6. Align match marks and reconnect driveline to brake escape from retainers (43 & 49).
yoke (18). Tighten capscrews to a torque of
153 Nm (113 lbf ft). 15. Add EMS19014 grease (26) to oscillation bushing
lube fittings (61) on top of oscillation hub. Lube until
Note: Take extra care when handling drivelines as excess grease in seen.
chips, dents, burrs or deformity on any rotating mass
creates vibration and excessive wear during any 16. Install parking brake disc protective guard (if fitted)
operation. and secure with bolts, washers and nuts.
7. Align steering cylinder bores and mounting pin 17. Start engine to charge hydraulic systems, raise
bores on pivot, install pins and secure with bolts and body, lower body safety prop and lower the body.
10 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
18. Bleed the braking system as described in Section 2. Raise body and install body safety prop to secure
165-0010, BRAKE PARTS. body in partially raised position.
19. Remove wheel blocks. 3. Shut down engine and block all wheels securely.
Every 250 hours, oscillation bushes must be 5. Remove bolts (7), washers (20), gasket (5) and
lubricated. Add EMS19014 grease (26) to oscillation cover plate (6) from side of oscillation hub to gain
bushing lube fittings (61) on top of oscillation hub. access to filler/level plug (25) on pivot assembly (1).
Lube until excess grease in seen. Remove filler/level plug (25).
Every 1 000 hours (6 months), follow the procedure 11. Add EMS19014 grease (26) to oscillation bushing
given below to check the oil level in the driveshaft lube fittings (61) on top of oscillation hub. Lube until
bearing housing, and, lubricate the articulation and excess grease in seen.
oscillation bearings.
12. Install parking brake disc protective guard (if fitted)
Note: It is essential that the grease used for and secure with bolts, washers and nuts.
articulation and oscillation components is EMS19057
grease (23), as specified in Section 300-0020, 13. Start engine, raise body, lower body safety prop
LUBRICATION SYSTEM. and lower body.
1. Position the vehicle on a level work area and apply 14. Remove wheel blocks.
parking brake.
SM 2171 11-02 11
Chassis - Articulation and Oscillation Pivot
Section 100-0020
SM - 844
Dimensions in mm (in)
Fig. 5 - Fabrication Details of Thrust Nut Removal and Installation Tool
12 SM 2171 11-02
Chassis - Articulation and Oscillation Pivot
Section 100-0020
* * * *
SM 2171 11-02 13
CHASSIS - Hood and Mounting
Section 100-0040
SM - 2785
38
35
35 36 37 19
34 9,10,11
30 29 31 20
31
32
21
31
22
33
18
32
29 28 23
9
24
1 9
10 25
26
16
11
12 IN BATTERY BOX
27 12 15
39
7 14
8 13
6 17
7
4
5
2 3
HOOD 2. Block all road wheels and place the battery master
switch in the 'Off' position.
Removal
Numbers in parentheses refer to Fig. 1. 3. Remove bolts, washers, lockwashers and nuts
securing grille (27) to grille subframe. Secure grille
(27) clear of hood (1).
WARNING
To prevent personal injury and property 4. Pull cable assembly (16), handle inside battery box,
damage, be sure blocking materials and lifting to release hood catch and lift up hood (1). Secure
equipment are properly secured and of hood (1) in raised position using suitable lifting
adequate capacity to do the job safely. equipment.
1. Position the machine on a level surface, apply the 5. Carefully remove bolts, washers and nuts securing
parking brake and switch off the engine. hood retaining straps (14) and gas struts (15).
SM 2173 10-02 1
Chassis - Hood and Mounting
Section 100-0040
Remove fasteners, hood retaining straps (14) and gas GOALPOST SUPPORT ASSEMBLY
struts (15) from hood (1).
Removal
6. Remove bolts (39), washers (13) and nuts (17) Numbers in parentheses refer to Fig. 1.
securing hinge assemblies (2) to frame. Carefully lift
hood (1) assembly from the machine.
WARNING
7. If required, remove mounting hardware securing To prevent personal injury and property
grille subframe to hood (1). Secure grille subframe damage, be sure blocking materials and lifting
clear of hood (1). equipment are properly secured and of
adequate capacity to do the job safely.
8. If required, remove bolts (10) and washers (11)
securing handles (9) to hood (1). Secure handles (9) 1. Position the machine on a level surface, apply the
clear of hood (1). parking brake and switch off the engine.
Installation 2. Block all road wheels and place the battery master
switch in the off position.
Numbers in parentheses refer to Fig. 1.
3. Pull cable assembly (16), handle inside battery box,
Note: Tighten all fasteners to torques listed in to release hood catch and lift up hood (1). Secure
Section 300-0080, STANDARD BOLT AND NUT hood (1) in raised position.
TORQUE SPECIFICATIONS.
4. Remove mounting hardware securing washer bottle
to mounting bracket on the left hand side of goalpost
WARNING support assembly (18). Secure washer bottle clear of
To prevent personal injury and property goalpost support assembly (18).
damage, be sure blocking materials and lifting
equipment are properly secured and of 5. Remove plate and mounting hardware securing
adequate capacity to do the job safely. transmission oil cooler to goalpost support assembly
(18). If required, disconnect transmission oil cooler
1. If removed, secure handles (9) to hood (1) using hoses.
bolts (10) and washers (11).
6. Remove mounting hardware securing air cleaner
2. If removed, secure grille subframe to hood (1) using intake tube to goalpost support assembly (18).
mounting hardware as removed at 'Removal'.
7. With a suitable container available to catch leakage,
3. Using suitable lifting equipment, lift and position remove drain plug from radiator header tank and drain
hood (1) on the machine and align holes in hinge coolant. Apply Loctite 225 to drain plug and reinstall in
assemblies (2) with mounting holes on frame. Secure header tank.
hood (1) using bolts (39), washers (13) and nuts (17).
8. Ensure all cooling lines connected to header tank
4. Carefully install hood straps (14) and gas struts (15) are identified for ease of installation and with suitable
using mounting hardware as removed at 'Removal'. containers available to catch leakage, disconnect
cooling lines. Fit blanking caps to all open lines.
5. With lifting equipment still in place, lower hood (1) to
match with goalpost support assembly (18). Remove 9. Disconnect electrical harness from coolant level
lifting equipment. sensor in header tank. Note routing of all hoses and
harnesses attached to and through goalpost support
6. If required, adjust fitment of hood (1) to frame at assembly (18) and disconnect.
hinge assemblies (2) and adjustment rod (6).
10. Disconnect hood cable (16) ball joint from cam
7. Install grille (27) to hood (1) and secure using bolts, plate assembly (33) and secure cable (16) clear of
washers, lockwashers and nuts. hood catch mechanism.
8. Remove wheel blocks. 11. Check to make certain that all necessary line and
2 SM 2173 10-02
Chassis - Hood and Mounting
Section 100-0040
cable disconnections have been made, before lifting 6. Fit plate and mounting hardware securing
goalpost support assembly (18). transmission oil cooler to goalpost support assembly
(18) as removed during 'Removal'. If necessary,
12. Attach suitable lifting equipment to goalpost reconnect transmission oil cooler hoses. Ensure
support assembly (18). Remove bolts (23), washers transmission oil cooler contains sufficient oil. Refer to
(24 & 25) and locknuts (26) securing goalpost support Section 210-0060, TRANSMISSION OIL COOLER.
assembly (18) to its mounting. Lift goalpost support
assembly (18) from the machine. 7. Install washer bottle to mounting bracket on the left
hand side of goalpost support assembly (18) and
13. If required, remove locknuts (22), bolts (19), hood secure using mounting hardware as removed during
stops (20) and springs (21) from goalpost support 'Removal'.
assembly (18).
8. Secure air cleaner intake tube to goalpost support
14. If required, remove bolts (30), washers (31) and assembly (18) using mounting hardware as removed
nuts (29) securing hood catch mechanism (28 - 38) to during 'Removal'.
goalpost support assembly (18). Remove hood catch
mechanism (28 - 38). 9. Remove blanking caps from all cooling lines and
connect cooling lines to radiator header tank as tagged
at 'Removal'.
Installation
Numbers in parentheses refer to Fig. 1. 10. Connect electrical harness to coolant level sensor
in header tank. Secure all hoses and harnesses to and
Note: Tighten all fasteners to torques listed in through goalpost support assembly (18) following
Section 300-0080, STANDARD BOLT AND NUT routing as noted at 'Removal'.
TORQUE SPECIFICATIONS.
11. Fill radiator header tank with coolant as specified
in Section 210-0000, COOLING SYSTEM.
WARNING
To prevent personal injury and property 12. Lubricate hood catch mechanism. Use grease as
damage, be sure blocking materials and lifting specified in Section 300-0020, LUBRICATION
equipment are properly secured and of SYSTEM.
adequate capacity to do the job safely.
13. Lower hood assembly and check for correct
1. If removed, secure hood catch mechanism (28 - 38) alignment between hood (1) and goalpost support
to goalpost support assembly (18) with mounting assembly (18) and for operation of hood catch
hardware as removed at 'Removal'. mechanism.
2. If removed, secure hood stops (20) and springs (21) 14. Remove wheel blocks.
to goalpost support assembly (18) with bolts (19) and
locknuts (22).
MAINTENANCE
3. Using suitable lifting equipment, lift and position Periodically check bolts (39), washers (13) and
goalpost support assembly (18) on the machine. locknuts (17) and tighten when necessary.
Secure goalpost support assembly (18) to its mounting
with bolts (23), washers (24 & 25) and locknuts (26). Periodically check condition of hood catch mechanism
and adjust and lubricate when necessary.
4. Remove lifting equipment.
5. Connect hood cable (16) ball joint to cam plate SPECIAL TOOLS
assembly (33) and secure cable (16) using clips There are no special tools required for procedures
removed during 'Removal'. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
adhesives are available from your dealer.
* * * *
SM 2173 10-02 3
ENGINE - Engine and Mounting
Section 110-0030
SM - 3373
xx
31
1 39
20
30 29
23
18
19
27
28
21 19
6
2
16 10
9 12
13
16
15
xx
14 xx 14
25 22 xx
8 38
xx 12
17 7 xx xx
24 11 17
35
32
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.
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 - 2787
3 6 7
STOP
STOP
1 2 P
1,2
4
10 11
5. Electronic Foot Pedal - The electronic foot pedal 8. Diagnostic Test Point - Plug in connector for
provides an electrical signal to the engine's fuel control diagnostic data reader (DDR).
system in proportion to the degree of pedal actuation.
9. Maintenance Light - The maintenance light will
Note: The engine MUST be started with foot 'OFF' the illuminate when it is time to change the engine oil. The
electronic foot pedal. maintenance monitor continuously monitors the time
the engine has been operating and the amount of fuel
Do not place engine under full load at full speed burned to determine when it is time to change oil.
immediately after starting. Always allow the engine to
fully circulate lubricant and warm up gradually before Note: Whenever an electrical fault has occurred, the
operating at full speed and full load. Operate engine at maintenance monitor data can be inaccurate.
top rated speed when maximum power is needed for
the load. 10. Engine Diagnostic Switch - To check for active
codes:
6. Check Engine Light - When the 'Check Engine' light
comes on, the computer has detected a fault in the a - turn the ignition key switch to the 'OFF' ('0') position.
engine. The fault should be diagnosed and corrected at
b - press the diagnostic switch to the 'ON' position.
the earliest opportunity.
c - turn the ignition key switch to position '1'.
7. Stop Engine Light - When the 'Stop Engine' light
comes on, the computer has detected a major If no active codes are recorded, both the 'Stop' and
malfunction in the engine that requires immediate 'Check' lights will illuminate and stay on.
attention. It is the operators responsibility to shut down
the engine to avoid serious damage. If active codes are recorded the 'Stop' and 'Check'
Operation WARNING
Numbers in parentheses refer to Fig. 2. The operator of a Quantum-equipped vehicle
must not attempt to use or read a data reader of
When the 'Stop' light on the dash panel illuminates, the any kind while the vehicle is operating. Doing
ECM (1) has detected a major malfunction in the so can result in loss of control, which may
engine that requires immediate attention. It is the cause vehicle damage and may result in
operators responsibility to shut down the engine to personal injury.
avoid serious damage.
The operator can check for active faults by turning the
The machine is equipped with an engine protection ignition key switch to the 'OFF' position, switching the
derate system, which records fault codes and diagnostic switch (10) 'ON' and then turning the ignition
illuminates appropriate warning lights when an out-of- key switch to position '1'.
range condition associated with any of the following
sensors is found: If no active fault codes are recorded, both 'Stop' (7) and
• Coolant temperature 'Check' (6) lights will come on and stay on. If active
codes are recorded, both lights will come on
• Coolant level momentarily. The amber 'Check' (6) and red 'Stop' (7)
• Intake manifold temperature lights will begin to flash the code of the recorded fault.
• Oil pressure The fault codes flash in the following sequence: the
• Oil temperature amber light flashes once, then there is a pause where
both lights are off. Then the numbers of the recorded
The engine power and speed will be gradually reduced
fault code flash in red. There is a pause between each
depending on the level of severity of the out-of-range
number. When the number is done, the amber light
condition. The operator MUST shut down the engine to
flashes again. e.g. amber flashes once - pause - red
avoid serious damage.
flashes twice - pause - red flashes three times - pause
- red flashes five times - pause - amber flashes once,
The engine should not be restarted after it has been
indicates fault code 235. The number will repeat in the
shut down after activation of the engine protection
same sequence until the the system is advanced to
derate system unless the problem has been diagnosed
the next active fault code by diagnostic request switch
and corrected.
(11), or the diagnostic switch (10) is switched to the
'OFF' position. Refer to 'Electronic Fuel System
Whenever the 'Stop' (7) or 'Check' (6) light comes on,
Diagnostic Codes' table for fault code descriptions.
the Electronic Fuel System computer will determine
where the problem is and will store this information in
its memory. If the malfunction is intermittent, the lights
will come on and go off as the computer senses the
changing engine condition.
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 & 38) 8. Turn the adjusting screw (4, Fig. 3) anticlockwise to
and bolts (16) securing engine (1) to the frame through release tension. Remove alternator belt (2).
front mounting bracket (8) and rear mounting brackets
(7). 9. Remove alternator mounting capscrew (3, Fig. 3)
and adjustment link locking capscrew (2, Fig. 3).
25. Check to make certain that all necessary line and Remove alternator.
electrical disconnections have been made before lifting
engine (1). 10. Disconnect the electrical harness to fan clutch (27).
26. Carefully lift engine (1) clear of the frame, remove 11. Remove bolts (29) and washers (30) securing fan
to a suitable work area and mount securely on a work (28) and clutch (27) to engine (1) fan hub.
stand.
12. Remove both fan (28) and clutch (27) together from
the engine (1).
DISASSEMBLY
Numbers in parentheses refer to Fig. 1. 13. Loosen fan idler pulley shaft locknut. Loosen the
adjusting link to slacken the fan belt (6). Remove fan
1. Remove bolts (11 & 13) and washers (12) securing belt (6).
front mounting bracket (8) to engine (1). Remove front
mounting bracket (8). 14. Remove bracket supporting hoses from top of
flywheel housing.
2. Remove bolts (9) and washers (10) securing rear
mounts to engine (1). Remove mounts (7). 15. Remove bolts (21) and washers (19) securing
flywheel guard (20) to flywheel housing, then remove
flywheel guard (20) from engine (1).
SM - 2786
INSPECTION
1 - Locknut 3 - Capscrew Numbers in parentheses refer to Fig. 1.
2 - Capscrew 4 - Adjusting Screw
Fig. 3 - Alternator Mounting 1. Inspect rubber isolation mounts (14) for damage and
9. Install alternator on engine (1) and secure with 3. Connect driveline to the engine coupling (23). Install
adjustment link locking capscrew (2, Fig. 3) and guard to flywheel housing. Refer to Section 130-0010,
alternator mounting capscrew (3, Fig. 3). FRONT DRIVELINES.
10. Fit alternator belt (2) between alternator pulley and 4. Install radiator assembly on the vehicle. Refer to
accessory drive pulley. Turn adjusting screw (4, Fig. 3) Section 210-0040, RADIATOR AND MOUNTING.
clockwise to increase belt tension; anticlockwise to
decrease belt tension. Refer to Engine Operation and 5. Install air cooler pipes from engine turbocharger and
Maintenance Manual for correct alternator belt (2) engine inlet manifold to charge air cooler mounted on
tension. the radiator assembly. Refer to Section 210-0040,
6. Install air cleaner intake pipe and exhaust piping to 19. Fill the cooling system with coolant. Refer to
engine turbocharger. Section 210-0000, COOLING SYSTEM.
7. Remove caps from heater lines and fittings and 20. Fill the engine with lubricant through oil filler to the
connect heater lines to engine (1) as identified at top mark on dipstick. Refer to Section 300-0020,
removal. LUBRICATION SYSTEM for oil specification.
8. Remove caps from fuel lines and fittings and 21. Fill transmission oil cooler with oil. Refer to Section
connect fuel lines to engine (1) as identified at removal. 210-0060, TRANSMISSION OIL COOLER.
9. Connect all electrical harnesses and cables to 22. Check all line and pipe connections for leaks prior
engine (1) (with the exception of battery connections) to starting the vehicle. Tighten as required.
as identified at removal.
23. Install hood assembly on the vehicle. Refer to
10. Connect air conditioner lines at the compressor as Section 100-0040, HOOD AND MOUNTING.
identified at removal. On completion of engine
installation the air conditioning system will require to 24. Using hydraulic hand pump inside battery box,
be charged. Refer to Section 260-0130, AIR lower cab and secure. Refer to Section 260-0010, CAB
CONDITIONING. AND MOUNTING.
11. Install the goalpost and radiator header tank 25. Switch the battery master switch to the 'On'
assembly on the vehicle. Refer to Section 100-0040, position, start up the engine and check for leaks.
HOOD AND MOUNTING. Tighten lines, pipes and fittings and top up all systems
as required.
12. Ensure all cooling lines to radiator assembly,
engine (1) and radiator header tank are correctly 26. Using suitable lifting equipment position front guard
connected. Refer to Section 210-0040, RADIATOR plate under the engine and secure to the frame with
AND MOUNTING. mounting hardware removed during removal.
13. Remove covers from air cleaner intake pipe and 27. Using suitable lifting equipment position engine
rubber hose on the air cleaner inlet then slide air sump guard under the engine and secure to the frame
cleaner assembly towards the cab locating the rubber with mounting hardware removed during removal.
hose to the inlet pipe.
28. Remove wheel blocks from all road wheels.
14. Secure air cleaner assembly to the battery box,
rubber hose to the inlet pipe and intake tube to
goalpost assembly with mounting hardware removed MAINTENANCE
during removal. Numbers in parentheses refer to Fig. 1.
15. Install transmission oil cooler on the vehicle. Refer Note: Carry out the following maintenance procedures
to Section 210-0060, TRANSMISSION OIL COOLER. in conjunction with additional procedures listed in
Section 300-0020, LUBRICATION SYSTEM.
16. Connect battery positive connections to battery
terminals. Connect battery earth connections to battery
terminals. Every 10 Hours (Daily)
Engine (1) - Visually check engine for damage, loose
17. Ensure all lines, harnesses and cables are secured or frayed belts and listen for any unusual noises.
with clips and clamps as removed during removal. Check coolant level and air cleaner restriction. Check
Ensure no lines are chaffing on sharp edges or resting charge air piping for damage.
against areas where heat will be evident.
Engine (1) Oil Level Check - Position the vehicle on a
18. Ensure shut-off valve at the bottom of the radiator level work area, apply the parking brake, shut off the
assembly and any drain cocks on engine (1) water engine and wait at least five minutes (to allow oil to
jacket are securely closed. Ensure shut off cocks at drain to the oil pan) before checking the oil level. The
Engine (1) Crankcase Breather - Check and clean the Engine oil pressure must be indicated on the gauge
crankcase breather hose. Remove the breather hose within 15 seconds after starting engine. If oil pressure
and check internally for obstructions or sludge buildup. is not reached within 15 seconds, shut off the engine
Clean or replace breather hose as necessary, to immediately to avoid engine damage. Confirm the
prevent excess crankcase pressure buildup. correct oil level in the oil pan.
Install the new thread adaptor sealing ring (supplied 5. Start coolant filter (5) on the filter adaptor and tighten
with new filter) and apply a film of clean engine oil to it by hand until the seal touches the adaptor filter head.
lubricate the filter seal. Fill the new filter with clean fuel Tighten an additional 1/2 to 3/4 of a turn after contact,
specified in Section 300-0020, LUBRICATION or as specified by the filter manufacturer.
SYSTEM.
Note: Mechanical tightening of coolant filter (5) is not
Install new fuel filter (6) on the filter head and tighten necessary and will distort or crack the adaptor. Tighten
by hand until the gasket contacts the filter head coolant filter by hand only.
surface. Tighten fuel filter (6) per filter manufacturer's
instructions. 6. Open shut off valves at coolant filter (5) inlet and
outlet lines, and install pressure cap on header tank.
Note: Mechanical tightening of the filter is not
recommended and may result in seal and/or cartridge 7. Start the engine and check for leaks. If any leaks are
damage. Tighten filter by hand only. noted, have them corrected. Add coolant as required.
Refer to Section 210-0000, COOLING SYSTEM.
Coolant Filter (5) - Replace coolant filter (5) as
follows:
Every 2 000 Hours
Note: There is a shut off valve at the coolant inlet and Engine Mounting Bolts (16) - Check torque on engine
outlet lines of coolant filter (5). Closing these valves mounting bolts (16). If required, tighten to 298 Nm (220
will enable coolant filter (5) to be replaced without an lbf ft).
excessive loss of coolant.
Engine (1) - Steam clean.
1. Remove the cooling system pressure cap from Engine (1) Turbocharger Mounting Nuts - Tighten
header tank. nuts to 65 Nm (50 lbf ft).
* * * *
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
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 - 2793
5 11
3
4 17
16
15
14
10
1 6 8 12 LH
13 RH
8 9
7
16
22
10
21 19
20
18
15 - Lockwasher
1 - Sleeve 8 - Washer 16 - Isolation Mount
2 - Front Bracket 9 - Bolt 17 - Snubbing Washer
3 - Lockwasher 10 - Nut 18 - Dipstick Tube
4 - Bolt 11 - Bolt 19 - Gasket
5 - Front Plate 12 - LH Bracket 20 - Bolt
6 - Centre Bonded Mount 13 - RH Bracket 21 - Lockwasher
7 - Bolt 14 - Bolt 22 - Hardened Washer
SM 2177 11-02 1
Transmission - Transmission and Mounting
Section 120-0010
SM - 2794
1
2
10 4
11
RHS
8
1 - Oil Temperature Sender (Gauge)
2 - Main Control Valve 7
3 - Transmission Difflock Solenoid
4 - Lockup Solenoid
5 - Engine Speed Sensor
6 - Output Speed Sensor
7 - Central Gear Train Sensor
8 - Turbine Speed Sensor
9 - Trans. Cooler Fan Drive Temp. Sensor
10 - Breather
11 - Retarder Oil Temperature Sensor 3
2 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
SM - 1826
VALVE BLOCK
COVER
Y3 Y4
Y2 Y5 6
Y1 Y6
2 1
HOUSING
SYSTEM PRESSURE FROM
CONTROL UNIT BREATHER
Fig. 3 - Sectional View of Typical Control Unit with Lockup Clutch (Wk)
Lockup Clutch (Wk) clutches. These clutches are controlled via the six
The transmission lockup clutch is automatically proportional valves (6, Fig. 3). Each proportional valve
engaged. Engine speed is picked up by turbine speed (6, Fig. 3) is composed of a pressure regulator (Y1 to
sensor (8) which sends a signal to energise lockup Y6, Fig.3), follow-on slide (5, Fig. 3) and vibration
solenoid (3, Fig. 3) when turbine speed reaches a damper (7, Fig. 3).
predetermined level. Energising lockup solenoid
(3, Fig. 3) will move lockup valve (4, Fig. 3) across, The control pressure of 9 bar for the actuation of the
allowing oil to flow through the valve to engage lockup. follow-on slides (5, Fig. 3) is created by the pressure
reduction valve (2, Fig. 3). The pressure oil (16+2
bar) is directed via the follow-on slide (5, Fig. 3) to
Gear Selection the respective clutch.
The transmission can be engaged and disengaged
under load by means of hydraulically controlled multi- Due to the direct proportional control with separate
disc clutches. All gears run in antifriction bearings and pressure modulation for each clutch, the pressures to
are constantly meshed. The gears, bearings and the clutches, which are taking place in the gear
clutches are lubricated with cooled oil. change, are controlled. In this way, a hydraulic
intersection of the clutches to be engaged and
The transmission is equipped with six multi-disc disengaged becomes possible. This creates fast
SM 2177 11-02 3
Transmission - Transmission and Mounting
Section 120-0010
shiftings without traction force interruption. move when the vehicle speed is below 20 km/hr. Warning
light will illuminate when differential locks are selected,
NOT attained.
Speedometer Sensor
Speedometer sensor, within the ECU, sends a signal to Note: Before driving in soft or slippery conditions, stop
the speedometer, via the speedometer frequency and engage the differential locks. Spinning wheels can
divider, to indicate travel speed in kilometres per result in damage to the transmission and axle
hour and miles per hour. differentials.
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
4 SM 2177 11-02
SM 2177 11-02
2nd POWER TAKE-OFF
SCHEDULE OF MEASURING POINTS
CONVERTER
Measurements to be carried out with oil at normal operating 14
RETARDER WK
temperature of 80° C and operating at full speed. KV K1
MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE: 1st POWER TAKE-OFF
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
WITHOUT RETARDER = CONVERTER EXIT PRESSURE
= LUBRICATION
= RETURN TO SUMP
SM 2177 11-02
COARSE FILTER
LUBRICATION
33 34
RT OIL SUMP
Transmission - Transmission and Mounting
Section 120-0010
OPERATION
WARNING
EST-37 Automatic Shift Control Before any welding is done on a machine
The EST-37 transmission is equipped with an equipped with an EST-37 shift system,
electronic control unit (ECU) which continually monitors disconnect the following in this order: Battery
the transmission and shift system electrical earth cable, battery supply cable, alternator
components and warns the operator when a problem earth cables, alternator supply cables and
develops. It also takes action to prevent damage to the electrical connections at the engine ECM,
transmission, and provides the serviceman with transmission ECU, body control lever,
diagnostic capabilities so that problems can be hydraulics ECU and cab bulkhead to avoid
corrected quickly and easily. damage to electrical components. Turn off
battery master switch to isolate the batteries
When a fault occurs, a two digit error code will be before disconnecting any components.
displayed on the LCD display on the dash panel. The After welding connect all of the above in the
error code is also recorded in the transmission ECU, reverse order.
and can be accessed by the serviceman by plugging in
a data reader to extract information relating to the fault. VTS-3 Shift Controller - Operation: The shift
The error code recorded in the ECU memory will remain controller has 3 positions the lever can rest in,
until it is erased by a technician. Forward, Neutral and Reverse. Within each of these
positions, the gear can be changed by pushing the
If a major fault is detected, it is the operators lever to the right (+) to upshift or to the left (-) to
responsibility to shut down the machine as soon as it downshift. In the Neutral position, this can be used to
is safe to do so. The machine should not be restarted preselect the starting gear (the default being 2nd gear).
until the fault has been diagnosed and corrected.
The shift controller has a 'Function' button on the top of
Refer to 'EST-37 Trouble Shooting' table for a list of the lever which is used to switch between automatic
fault codes and checks. and manual modes. Press the function button from
'NEUTRAL' and move the lever forward to select
The EST-37 transmission control has been designed to automatic mode, when driving normal upshifting and
provide the driver with maximum operational flexibility downshifting will occur. If required, a gear can be held
by allowing the choice of automatic or manual gear in manual mode by pressing the function button once,
selection to optimize vehicle performance under all to resume full automatic mode the function button
operating conditions. should be pressed again. Manual gears can also be
selected by pushing the lever to the left for lower gears
The rotational pressure compensated (RPC) system or to the right for higher gears, again by pressing the
gives improved shift quality due to more accurate function button once automatic mode will be resumed.
clutch filling, in addition to reduced clutch filling time.
Note: The transmission will only allow gearshifting
The transmission provides six forward gears, three when the predetermined values have been reached.
reverse gears and a neutral position. The gear
positions are indicated on the LCD display located on Note: There is no shift inhibitor in the gear shift
the dash panel. The transmission will only operate in control, therefore, no resistance would be felt while
the gear selected by the operator in the manual moving through the gear ranges.
range, or, when the lever is in the automatic range,
shifts will occur automatically between 1st and 6th The gear lever housing sends a signal to the electronic
gear, depending on operating requirements. The control unit, which in turn will only allow the engine to
reverse gears 1st through 3rd are manual mode only. be started when the gear lever is in the 'NEUTRAL'
position. The gear shift lever must always be placed in
'NEUTRAL' and the parking brake applied when starting
the engine, or whenever the machine is left unattended.
SM 2177 11-02 7
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
the rear of the machine that reverse gear has been speed has increased sufficiently to allow this to
selected. happen, and that the shift lever is in the automatic
mode.
During reversing operations it is recommended to
reduce engine speed, use only 1st or 2nd gear and A dashboard display is provided which indicates gear
never exceed 10 km/h (6.2 mile/h). selected and driving direction as follows (See Fig. 9):
The electronic control system distinguishes between Manual Mode - When driving with shift selector in
the throttle position (or load ranges) depending on the manual range, the bars only are shown in position 1,
governor position (injection pump). On a light throttle and, driving direction and gear selected are indicated
opening, the transmission will give earlier upshifts and in positions 2 and 3.
later downshifts than when operating at full throttle.
Automatic Mode - When driving with shift selector in
A kickdown facility (See Fig. 8), which can be used automatic range, a full display of bars and arrows are
when automatic mode is selected, allows for the shown in position 1, and, driving direction and gear
possibility of selecting a lower gear by pressing down selected are indicated in positions 2 and 3.
fully on the throttle pedal and holding. This can be used
to provide a downshift on demand provided that the Under certain conditions the transmission may start
vehicle speed is within the range allowable. That is, the to 'hunt' between gears when in automatic mode. The
vehicle is not travelling at a speed that would result in transmission changes up and down between two
the engine overspeeding in the lower gear. gears at short intervals because there is not
When driving with kickdown, the transmission will give sufficient power to sustain driving in the higher gear,
earlier downshifts and later upshifts. To disengage the but is sufficient for upshifting from the lower gear. By
transmission kickdown, release the throttle pedal and using the shift display, it can be established which
allow it to return to a light throttle position. gears are involved and in these circumstances the
lower gear should be selected using the shift control
When operating in automatic range with the display lever. Automatic mode should be reselected at the
indicating that the transmission has downshifted to 2nd earliest opportunity.
gear, there are two options for providing a further
downshift as conditions indicate. During machine operation, watch for wide deviations
from normal readings on the transmission oil
1. 1st gear can be manually selected by pushing the temperature gauge. If the gauge shows the oil
shift lever to the left. temperature rising above 120° C (248° F) during normal
operation, or above 145° C (293° F) during retarder
2. Kickdown can be selected from 2nd automatic, when operation, the machine must be stopped and inspected
the transmission will downshift to 1st gear, depending for external oil leakage. If no leaks are found, shift to
upon vehicle speed. 'NEUTRAL' and operate the engine at 1 200 - 1 500 rev/
min. If the transmission oil temperature does not
When the kickdown is released the transmission will decrease into the normal zone within 2 or 3 minutes,
upshift to 2nd automatic, provided that the forward the cause of the overheating should be corrected
8 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
before the machine is operated further.
WARNINGS
Note: In cold weather, the transmission oil should be
Never allow the machine to coast with the
warmed up by running the engine at idle speed with the
transmission in 'NEUTRAL'.
gear selector in neutral, since the system will not
operate satisfactorily if the oil is too cold. When running down a gradient the engine
speed should not be allowed to drop below
When temporarily stopped, such as for yielding the 1 200 rev/min, at which point, lockup would
right-of-way to a loaded machine, the transmission disengage preventing retarder operation.
can be left in gear and the machine held stationary with
In the event of a loss of electric power to the
the service brakes.
gear shift control, the transmission will
automatically shift to 'NEUTRAL'. If this occurs,
When stopped for a more extended period with the
stop the machine using the service brakes and
engine left running, shift to 'NEUTRAL' to avoid
apply the parking brake. Do not operate until
unnecessary heat buildup, and apply the parking brake.
the fault has been repaired.
Always select 'NEUTRAL' and apply the parking
WARNING brake before leaving the operators seat.
Always select the correct drive direction and The retarder will automatically disengage when
gear before releasing the parking brake. the oil temperature reaches 150° C (302° F),
irrespective of engine speed.
SM 2177 11-02 9
Transmission - Transmission and Mounting
Section 120-0010
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.
10 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
15 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2 TCU shifts transmission •check cables from TCU Fault is taken back if
SHIFT LEVER to neutral if selector to shift lever 2 TCU detects a valid
TCU detected a wrong signal combination for the active •check signal neutral signal for the
direction OP-Mode: transmission combinations of shift lever direction at the shift
•cable from shift lever 2 to TCU is broken shutdown if selector positions F-N-R lever
•cable is defective and is contacted to battery active
voltage or vehicle ground
•shift lever is defective
16 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal •check cables from TCU
feedback axle connection measured by TCU to feedback axle
and output signal axle connection don't fit connection switch
•axle can't be connected/disconnected due to •check signals of the
mechanical problem feedback axle connection
•one of the cables from feedback axle connection -
switch to TCU is broken
SM 2177 11-02 11
Transmission - Transmission and Mounting
Section 120-0010
12 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
SM 2177 11-02 13
Transmission - Transmission and Mounting
Section 120-0010
14 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
•regulator has an internal defect OP-Mode: TCU shutdown •check internal wire
harness of the gearbox
74 S.C. TO BATTERY VOLTAGE AT CLUTCH K2 TCU shifts to neutral •check cable from TCU to 1)
see figure 10
the measured resistance value of the valve is out of OP-Mode: limp home gearbox
limit, the voltage at K2 valve is too high. if failure at another •check connectors from
•cable / connector is defective and has contact to clutch is pending gearbox to TCU
battery voltage TCU shifts to neutral •check regulator resistance 1)
•cable / connector is defective and has contact to OP-Mode: TCU shutdown •check internal wire
another regulator output of the TCU harness of the gearbox
•regulator has an internal defect
SM 2177 11-02 15
Transmission - Transmission and Mounting
Section 120-0010
16 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
SM 2177 11-02 17
Transmission - Transmission and Mounting
Section 120-0010
18 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
SM 2177 11-02 19
Transmission - Transmission and Mounting
Section 120-0010
20 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS see fault codes no. 21 •check cables and fault codes no. 21
TCU measures more than 6V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
•check power supply at
pin AU1 (should be
approx. 5V)
D2 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS see fault codes no. 21 •check cables and fault codes no. 21
TCU measures less than 4V at the pin AU1 to no. 2C connectors to sensors, to no. 2C may be
(5V sensor supply) which are supplied a reaction of this
from AU1 fault
•check power supply at
pin AU1 (should be
approx. 5V)
D3 LOW POWER AT BATTERY shift to neutral •check power supply
measured voltage at power supply is lower OP-Mode: TCU shutdown battery
than 18 V •check cables from
batteries to TCU
•check connectors from
batteries to TCU
D4 HIGH POWER AT BATTERY shift to neutral •check power supply
measured voltage at power supply is higher OP-Mode: TCU shutdown battery
than 32.5 V •check cables from
batteries to TCU
•check connectors from
batteries to TCU
SM 2177 11-02 21
Transmission - Transmission and Mounting
Section 120-0010
22 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
8.1 Actuator:
1
2
G
P (power supply)
TCU
1 2 Actuator / Sensor
C (chassis)
Gnd
SM 2177 11-02 23
Transmission - Transmission and Mounting
Section 120-0010
80° C (176° F) and 120° C (248° F). However, during 1. Position the vehicle in a level work area, ensure the
retarder operation the gauge may reach 145° C (293° body is fully lowered, apply the parking brake and
F). Provided the vehicle is not in an overspeed switch off the engine. Operate steering right and left
condition, the transmission 'Stop' warning light will several times to relieve any pressure in the steering
illuminate when the transmission oil temperature system.
reaches 140° C (284° F). The retarder will automatically
disengage when the oil temperature reaches 150° C 2. Operate the treadle valve continuously to discharge
(302° F) irrespective of engine speed. The speed must the accumulators, block all road wheels, place the
be reduced by using the service brakes so that the oil steering lock bar in the 'Locked' position and the
is cooled down. Reduce downgrade travel speed to battery master switch in the 'Off' position.
avoid the oil overheating and possible damage to the
transmission. 3. Disconnect the following cables and connectors in
the order given, to prevent serious damage to the
If the vehicle is approaching an overspeed condition, vehicles electrical components.
the transmission upshifts automatically through the
gears (to 6th) to decrease the engine speed, whether in a- Battery earth cables
manual or automatic mode. The service brakes should b- Battery supply cables
be applied to reduce travel speed. With the accelerator c- Alternator earth cables
pedal released, the retarder will automatically engage d- Alternator supply cables
when the engine speed reaches 2 000 rev/min and it e- Transmission ECU (Est-37) connector
will disengage at 1 850 rev/min to prevent engine f- Engine ECM connectors
overspeeding. g- Body control lever
h- Hydraulics ECU
With the accelerator pedal depressed, the retarder is
automatically engaged at 2 600 rev/min to decrease 4. Place a suitable container under the transmission
the engine speed. The retarder is disengaged at 2 450 drain port, remove drain plug and drain oil. After
rev/min. A fault code will be displayed and recorded by draining, reinstall drain plug and tighten securely.
the ECU. If the oil temperature reaches 150° C (302°F)
the retarder is disengaged and a fault code will be 5. Remove blanking cap from remote drain line at the
displayed and recorded by the ECU. bottom of the hydraulic tank. Install a length of hose on
remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
REMOVAL hose and reinstall blanking cap.
Numbers in parentheses refer to Fig. 1.
6. Remove cab from the machine. Refer to Section
Note: Tag all lines, cables and linkages disconnected 260-0010, CAB AND MOUNTING. Ensure all
during removal to aid in installation. connections and lines connected to cab are
disconnected.
24 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
SM - 2795
8
12
13
14
5
7 10 2
3
1 4
11 8
the cab assembly. hydraulic tank. Cap lines and ports to prevent entry of
dirt.
11. Identify and tag all hydraulic lines at the hydraulic
pump. Disconnect hydraulic lines and cap lines and 16. Identify and tag diagnostic hose assemblies (22 &
ports to prevent entry of dirt. 23, Fig. 12) to aid in installation. Disconnect hose
assemblies (22 & 23, Fig. 12) and cap open ends and
Note: The transmission can be removed from the tee (21, Fig. 12) and adaptor (26, Fig. 12) to prevent
vehicle without removing the hydraulic pump. entry of dirt.
12. Identify, tag and disconnect hydraulic lines at the 17. Identify, tag and disconnect all remaining lines and
main hydraulic valve. Cap lines and ports to prevent fixtures necessary to allow removal of the transmission
entry of dirt. from the vehicle.
13. Identify, tag and disconnect transmission oil cooler 18. Attach suitable lifting equipment to the lifting points
lines from the transmission. Cap lines and ports to on transmission and raise lifting equipment to take up
prevent entry of dirt. the slack.
14. Identify, tag and disconnect hydraulic lines (6, 7, 8, 19. Remove locknut (10), hardened washer (22), bolt
9 & 10, Fig. 12) at the diff-lock/retarder valve. Cap (11) and snubbing washer (17) securing LH bracket (12)
lines and ports to prevent entry of dirt. to frame mounts.
15. Identify, tag and disconnect hydraulic lines at the 20. Remove locknut (10), hardened washer (22), bolt
SM 2177 11-02 25
Transmission - Transmission and Mounting
Section 120-0010
SM - 2796
21 13
5
12
23
11 6
1
11
7
17 2
1
22 26
18 10
3,4
8 25
19 20
TO DIAGNOSTIC
MANIFOLD PLATE
TO 'TS' PORT
ON HYD. VALVE
9 TO AXLE DIFF-LOCK
24
27
15 16
MANIFOLD
(REAR OF FRONT FRAME)
MANIFOLD
14 (REAR FRAME)
26 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
(13) from the transmission. Remove isolation mount (16) Note: Tighten all fasteners without special torques
from RH bracket (13) and replace if required. specified to standard torques listed in Section 300-
0080, STANDARD BOLT AND NUT TORQUE
5. Remove bolts (4) and lockwashers (3) securing front SPECIFICATIONS.
bracket (2) and front plate (5) to transmission.
1. Install new gasket (19) on dipstick tube (18)
6. Remove mounting hardware securing front plate (5) assembly and secure assembly to the transmission
to front bracket (2). Press out centre bonded mount (6) with bolts (20) and lockwashers (21). Secure dipstick
from front plate (5) and remove sleeve (1). tube (18) to support bracket with fasteners previously
removed.
7. Remove mounting hardware securing hydraulic pump
to the transmission power takeoff. Refer to Section 2. If removed, install oil temperature sender (gauge) (1,
230-0050, HYDRAULIC PUMP. Fig. 2), transmission oil cooler fan drive temperature
switch (9, Fig. 2) and retarder oil temperature sender
8. If required, identify and tag electrical connections to (11, Fig. 2) in top of the transmission. Tighten electrical
engine speed sensor, output speed sensor, central connections securely.
gear train sensor and turbine speed sensor (5, 6, 7 & 8,
Fig. 2) and remove sensors from the transmission. 3. If removed, install engine speed sensor, output
speed sensor, central gear train sensor and turbine
9. If required, identify and tag electrical connections to speed sensor (5, 6, 7 & 8, Fig. 2) in the transmission
oil temperature sender (gauge) (1, Fig. 2), transmission as shown in Fig. 2. Tighten electrical connections
oil cooler fan drive temperature switch (9, Fig. 2) and securely.
retarder oil temperature sender (11, Fig. 2) and remove
from the top of the transmission. 4. Install hydraulic pump to the transmission power
takeoff and secure using mounting hardware removed
10. Remove fasteners securing dipstick tube (18) at Disassembly. Refer to Section 230-0050, MAIN
support bracket. Remove bolts (20), lockwashers (21), HYDRAULIC PUMP.
dipstick tube (18) assembly and gasket (19) from the
transmission. 5. Install centre bonded mount (6) and sleeve (1) to
front plate (5). Secure front plate assembly to front
11. Refer to transmission manufacturers service bracket (2) with bolt (7), washer (8) and nut. Tighten
manual if transmission service or repair is required. bolt (7) to 920 Nm (679 lbf ft).
Note: Clean, prime and seal joint using Loctite 7063
cleaner, Loctite T primer and Loctite 648 retaining
INSPECTION compound.
Numbers in parentheses refer to Fig. 1.
6. Secure front bracket assembly to transmission using
1. Check front bracket assembly (1, 2, 5 - 8), LH bolts (4) and lockwashers (3). Tighten bolts (4) to 225
bracket (12), RH bracket (13) and frame mounting Nm (166 lbf ft).
brackets for cracks and damage. Repair or replace as
required. 7. Secure LH bracket (12) and RH bracket (13) to the
transmission with bolts (14) and lockwashers (15).
2. Check general condition of transmission assembly Tighten bolts (14) to 410 Nm (302 lbf ft).
for wear and damage. Check for worn or damaged Note: Clean, prime and seal joint using Loctite 7063
driveline flanges and excessive wear on mounting cleaner, Loctite T primer and Loctite 648 retaining
holes and isolation mounts (16). compound.
3. Check condition of all electrical harnesses and 8. Secure diff-lock/retarder valve (1, Fig. 12) to bracket
connections and repair/replace as required. Check assembly (20, Fig. 12) with mounting hardware
condition of all hydraulic lines on the transmission removed during Disassembly.
and replace if damaged.
9. Mount bracket assembly (20, Fig. 12) and diff-lock/
retarder valve (1, Fig. 12) to transmission with
ASSEMBLY fasteners removed during Disassembly.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.
SM 2177 11-02 27
Transmission - Transmission and Mounting
Section 120-0010
4. Secure front bracket assembly to frame mounts with 18. Fill hydraulic tank with hydraulic oil specified in
bolts (9), washers (8) and locknuts (10). Tighten bolts Section 300-0020, LUBRICATION SYSTEM. Refer to
(9) to a torque of 920 Nm (679 lbf ft). Section 230-0040, HYDRAULIC TANK for fill level
and procedure.
5. Remove lifting equipment from lifting points on
transmission. 19. Fill transmission with engine oil specified in Section
300-0020, LUBRICATION SYSTEM. Check the oil
6. Remove blanking caps from hose assemblies level as described under 'Oil Level Check'.
(22 & 23, Fig. 12), tee (21, Fig. 12) and adaptor (26, Note: Transmission oil cooler should be primed when
Fig. 12) and connect hose assemby (22, Fig. 12) to refilling transmission. Refer to Section 210-0060,
adaptor (26, Fig. 12), and hose assembly (23, Fig. 12) TRANSMISSION OIL COOLER.
to tee (21, Fig. 12).
20. Connect the following cables and connectors in the
7. Remove blanking caps from hydraulic tank hose order given to prevent serious damage to the engines
assemblies and ports, and connect hose assemblies to electrical components.
the hydraulic tank.
a - Hydraulics ECU
8. Remove blanking caps from hose assemblies b - Body control lever
c - Engine ECM connectors
28 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
d- Transmission ECU (Est-37) connector SM - 2797
e- Alternator supply cables HOT COLD FILL
f- Alternator earth cables COLD FILL LEVEL
LEVEL LEVEL
BAND - MINIMUM -
g- Battery supply cables MINIMUM -
ENGINE OFF
ENGINE ENGINE
RUNNING RUNNING
h- Battery earth cables
MAX MIN
Oil Level Check 1. Position the vehicle on a level work area, apply the
parking brake and block all road wheels securely.
SM 2177 11-02 29
Transmission - Transmission and Mounting
Section 120-0010
Topping Up Oil with mineral spirits at each oil and filter change. Metal
particles in the oil (except for the minute particles
If transmission oil level has to be topped up, according
normally trapped in the oil filters) indicate damage has
to dipstick, oil should be added through the filler on the
occurred in the transmission. When these particles are
transmission oil cooler. Bleed plug on top of
found in the filters, the cause must be established and
transmission oil cooler should be opened while adding
rectified immediately to prevent damage to the
oil. Allow oil to drain into system then recheck level.
transmission.
Oil and Filter Change At each oil change, examine the used oil for evidence
of dirt or water. A normal amount of condensation will
emulsify in the oil during transmission operation.
However, if there is evidence of water or engine coolant
WARNING
in the oil, the cause must be established and rectified
When changing filter cartridges, it is imperative
immediately to prevent damage to the transmission. Oil
that new filter cartridges are the same part
should be added to transmission as described in
number and colour as the original cartridges.
'Topping Up Oil'.
The transmission oil and filter cartridges should be
changed every 1 000 hours, or sooner, depending on AEB Starter
operating conditions. Clean oil filter head when
The AEB Starter is an electronic tool used to calibrate
changing filter cartridges. Also, the oil must be
the transmission to ensure optimum shift comfort. It is
changed whenever there are traces of dirt or evidence
recommended to run the AEB Starter after the first 500
of high temperature indicated by discoloration or strong
hours of transmission operation. The AEB Starter
odour.
should also be run if shift quality deteriorates, or
whenever the transmission, electronic control unit
The internal filter and finger magnet at the lower front
(ECU) or shift lever are replaced. The procedure for
left hand of the sump should be removed and cleaned
30 SM 2177 11-02
Transmission - Transmission and Mounting
Section 120-0010
running the AEB Starter is detailed in the table on Lock-Up Solenoid
previous page. Refer to table on page 10 for typical The solenoid can be checked at plug X9, pins 7 & 8
codes displayed during AEB mode. (located below the right hand dash panel).
Resistance: 60 - 80 ohms
Note: Connect the AEB Starter to plug X25 located
below the right hand dash panel, adjacent to the ECU. Current: 0.25 - 0.35 A
Voltage: 24 V
Pressure can also be checked (see Fig. 6).
TROUBLESHOOTING
Numbers in parentheses refer to Fig. 2, unless
otherwise specified. Temperature Sensors
The sump temperature sensor, located in the main
control valve (2) can be checked at plug X8, pins 14 &
Transmission Sensor Checks 15. Resistance should be 1 000 - 1 500 ohms.
The engine (5), turbine (8), central gear train (7) and
output (6) speed sensors can be checked by The retarder temperature sensor (11) can be checked
measuring their resistance at plug X8 (located below at plug X9, pins 15 & 16. Resistance should be 800 - 1
the right hand dash panel). 500 ohms.
1. Engine speed sensor (5). Check across pins 1 & 2. The transmission oil cooler fan drive temperature
Resistance should be 945 - 1 155 ohms at a sensor (9) can be checked by measuring resistance
temperature of 20° C (68° F). across terminals:
At 20° C (68° F), resistance should be 1 020 - 1 280
2. Turbine speed sensor (8). Check across pins 3 & 4. ohms.
Resistance should be 945 - 1 155 ohms at a At 60° C (140° F), resistance should be 219 - 261
temperature of 20° C (68° F). ohms.
At 90° C (194° F), resistance should be 82 - 96 ohms.
3. Central gear train speed sensor (7). Check across At 120° C (248° F), resistance should be 36.3 - 40.7
pins 5 & 6. Resistance should be 945 - 1 155 ohms at ohms.
a temperature of 20° C (68° F).
4. Output speed sensor (6). Check across pins 21 & Shift Controller
22. Resistance should be 5 mega ohms. To troubleshoot the shift controller, continuity checks
can be easily done by removing plug X2, selecting
The installation of the speed sensors can also be position and measuring across following pins:
checked by measuring the gap between the sensor and Neutral - Pins 2 & 5
the gear tooth:
Forward - Pins 2 & 4
Engine speed sensor (5) and turbine speed sensor (8) - Reverse - Pins 2 & 6
gap should be 0.5 - 0.8 mm. Up - Pins 2 & 7
Down - Pins 2 & 8
Central gear train speed sensor (7) - gap should be 0.3 Button - Pins 2 & 10
+
/- 0.1 mm.
SM 2177 11-02 31
Transmission - Transmission and Mounting
Section 120-0010
* * * *
32 SM 2177 11-02
DRIVELINES - Front and Rear Drivelines
Section 130-0010
SM - 2799
15
13 14
12
15 2 3
ENGINE
TRANSMISSION
10
1
10
5 9 8
6
TO
TRAILER
FRONT AXLE
11 11 10 10
4 7
1 - Driveline Assembly 6 - Screw 11 - Capscrew
2 - Universal Joint 7 - Driveline Assembly 12 - Anti-flail Guard
3 - Screw 8 - Universal Joint 13 - Bolt
4 - Driveline Assembly 9 - Screw 14 - Washer
5 - Universal Joint 10 - Capscrew 15 - Bracket
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
CENTRE AXLE - Differential Drive Head
Section 150-0020
Note: Never engage or disengage the Differential 8. Support the weight of the thru-drive differential and
Lock when moving or when the wheels are spinning. countershaft case assembly with suitable lifting
equipment. Remove bolts (50 & 74) securing
countershaft case (49) to differential housing (73) and
REMOVAL AND INSTALLATION carefully remove countershaft case (49) assembly
Numbers in parentheses refer to Fig. 1. clear of differential housing (73).
2. Apply the parking brake and switch off the engine. Note: Use sealing compound between the axle
housing and differential housing mounting faces.
3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in Note: Tighten all fasteners to standard torques listed
the 'Off' position. in Section 300-0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container. Add gear oil of the type specified in Section 300-0020,
LUBRICATION SYSTEM, through the differential filler/
5. Remove the planetary assemblies and axle shafts level hole until the oil is level with the bottom of the
from the axle housing. Note from which side the long filler/level hole. Fill the planetary assemblies up to the
'Oil Level Check Line'.
SM - 250
SM - 252
3. Index mark cover (3, Fig. 2) and housing (11, Fig. 2).
Remove bolts (1, Fig. 2) and lockwashers (2, Fig. 2)
and lift off cover.
6. Remove the other side gear (8, Fig. 2), thrust ring SM - 1111
(7, Fig. 2), two internally splined discs (6, Fig. 2), two
externally splined discs (5, Fig. 2) and thrust washer
(4, Fig. 2) from housing (11, Fig. 2).
13. With a bearing puller, pull ball bearing (10) off the
bearing journal of differential case half (14).
SM - 1114 14. Index mark differential case halves (14 & 20).
Remove bolts (13) from differential case half (14) and
separate the differential case halves. Remove thrust
washer (15), side gear (16), thrust washers (17),
pinion gears (18) and spider (19). Refer to Fig. 8.
SM - 1115 15. Remove bolts (45) from shifter fork lock pins (44).
Push down on piston (36) and remove shifter fork lock
pins (44) with seal rings (46) from differential housing
(4) as shown in Fig. 9. Remove and discard seal rings
(46).
SM - 1116 16. Remove shifter fork (23) with thrust blocks (24),
piston (36) with centring ring (37) and spring (38) from
differential housing (4). Also remove shift collar (21).
Refer to Fig. 10.
21. Unlock and remove nut (54) from pinion gear (61)
shaft. With the press set shown in Fig. 15, press pinion
gear (61) out of countershaft case (49). Remove Fig. 12 - Removing Bolts
spacing ring (56) from the shaft end of pinion gear
(61).
SM - 1119
23. Press pinion gear (61) out of gear (57) and bearing
retaining bush (58) as shown in Fig. 16. Drive roller
bearing (60) out of the bearing retaining bush and
remove shim (59).
25. Remove seal retainer (78) and pull shaft seal (79)
from axle housing. Remove snap rings (80) and drive
ball bearing (81) from the axle housing.
SM - 1120 INSPECTION
The importance of careful and thorough inspection
cannot be overstressed. Thorough inspection and
necessary replacement of parts now may eliminate
costly and avoidable trouble later.
ASSEMBLY SM - 1133
Example:
Dimension 'A' 164.2 mm (6.40 in)
+ Dimension 'B' 25.75 mm (1.00 in)
= 189.95 mm (7.40 in)
- Bearing width 37.05 mm (1.45 in)
Dimension 'X' = 152.90 mm (5.95 in)
SM - 1162 10. Thread nut (54) on pinion gear (61) shaft. Tighten
nut (54) to a torque of 750 Nm (550 lbf ft). Refer to
Fig. 23.
SM - 1124 16. Thread slotted nut (86) onto the threaded end of
differential side gear (22). Tighten slotted nut (86) using
socket 15269943 to a torque of 550 Nm (400 lbf ft).
Refer to Fig. 29.
SM - 1125 18. Mesh shift collar (21) with differential side gear
(22) splines. Refer to Fig. 31.
SM - 1126 19. Assemble thrust blocks (24) to shifter fork (23) and
install in differential housing (4). Thrust blocks fit into
shift collar (21) groove. Refer to Fig. 32.
21. Place new seal rings (46) on the ends of shifter SM - 1128
fork lock pins (44) and insert them into differential
housing (4) bores. To facilitate assembly, push shifter
piston (36) down slightly. Bolt in place with bolts (45).
Tighten bolts (45) to a torque of 42 Nm (30 lbf ft).
Refer to Fig. 34.
22. If limit disc (33), filter element (32) and plug (31) SM - 1129
were removed from cover (34), reinstall them. Install
the cover on differential housing (4) and fasten with
bolts (29) and lockwashers (30). Tighten bolts (29) to a
torque of 42 Nm (30 lbf ft). Refer to Fig. 35.
SM - 1142 24. Place side gear (16) into differential case half (14).
Refer to Fig. 37.
SM - 1143 25. Install pinion gears (18) and thrust washers (17) on
spider (19) arms. Be sure the thrust washer notches
are properly positioned on the pinion gears. Install the
assembled spider in differential case half (14). Refer to
Fig. 38.
SM - 1144 26. With a dial indicator gauge, check pinion gear (18)
backlash as shown in Fig. 39. Backlash should be
between 0.15 - 0.2 mm (0.00585 - 0.0078 in).
SM - 1145 27. Align the index marks and place second differential
case half (20) on top of the assembled differential case
half (14). Bolt the two case halves together with bolts
(13). Tighten bolts (13) to a torque of 120 Nm
(90 lbf ft). Refer to Fig. 40.
Example:
SM - 1150 32. Using a seal driver, install shaft seal (6) in bearing
flange (8) with the seal lip facing down. Refer to Fig.
45.
SM - 1152 34. Measure the distance from bearing flange (8) face
to ball bearing (10) contact face as shown in Fig. 47.
This is dimension 'B'. e.g. 6.5 mm (0.240 in).
SM - 1153 35. Coat intermediate flange (12) bolt circle with sealing
compound, install the size shim (11) determined in
Steps 29 and 30 and install bearing flange (8). Bolt the
flanges together with bolts (7). Refer to Fig. 48.
36. Install dust cover (2) and seal ring (5) on the
splined end of drive flange (1). Align the drive flange
splines with the internal splines in differential case half
(14) and install the drive flange into the differential
case assembly. Thread castle nut (3) onto the
threaded end of differential case half (14). Tighten
castle nut (3) using socket 15269943 to a torque of 1
Fig. 48 - Installing Bearing Flange 200 Nm (885 lbf ft).
44. Install one side gear (8, Fig. 2) into thrust ring
(7, Fig. 2) and make sure the side gear splines into the
two internally splined discs (6, Fig. 2). Fig. 51 - Installing Shaft and Pinion Gears
46. Install other side gear (8, Fig. 2) and other thrust
ring (7, Fig. 2) flat side up. Refer to Figs. 52 & 53.
SM - 881 48. Determine the end play between the discs and the
housing as shown in Figs. 54 & 55.
52. Place the two outer races of tapered bearings (68) SM - 1160
on the inner races and install the differential assembly
into differential housing (73). Install bearing cap (62),
washers (64) and bolts (63). Tighten bolts (63) to a
torque of 245 Nm (180 lbf ft). Thread in adjusting nuts
(67) and displace the differential to obtain a backlash
of 0.25 - 0.35 mm (0.010 - 0.014 in). Refer to Fig. 59.
54. Tighten adjusting nut (67) opposite ring gear (71) two
notches in order to obtain the bearing pre-load of
3 - 4 Nm (115 - 155 lbf ft), then recheck the backlash.
Fig. 60 - Checking Backlash
57. After all adjustments are made and the gear tooth
pattern is correct, lock adjusting nuts (67) with cotter Fig. 61 - Coast Side (Concave)
pins (66). Lock bearing cap bolts (63) in place with
lockwire (65). SM - 894
60. Insert dust shield (77) over drive flange shaft (76)
and insert drive flange shaft through axle housing,
shaft seal (79) and ball bearing (81). Install shim (82)
over drive flange shaft (76) and retain with circlip (83).
SM - 896 SM - 899
SM - 897 SM - 900
Fig. 65 - Pinion Distance Must Be Decreased Fig. 68 - Pinion Distance Must Be Increased
SM - 898
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.
DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust
* * * *
SM - 849
SM 1969 4-00 1
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 850
1- Housing
2- Thrust Washers 5 - Thrust Ring 8 - Differential Axle
3- Externally Splined Discs 6 - Side Gears 9 - Cover
4- Internally Splined Discs 7 - Pinion Gears 10 - Bolts
2 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020
6. Identify the relationship of the driveline flange and Add gear oil of the type specified in Section 300-0020,
differential pinion flange with punch marks. LUBRICATION SYSTEM, through the differential filler/
level hole until the oil is level with the bottom of the
7. Disconnect the driveline from the differential drive filler/level hole. Fill the planetary assemblies up to the
flange. The driveline can be removed if it is convenient 'Oil Level Check Line'.
to do so.
SM 1969 4-00 3
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 851
4 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 852 DISASSEMBLY
Numbers in parentheses refer to Fig. 3.
SM - 855 4. Remove bolts (23) and lock plate (24) from bearing
caps (22) as shown in Fig. 7.
SM 1969 4-00 5
Rear Axle Group - Differential Drive Head
Section 160-0020
5. Punch mark bearing caps (22) and differential SM - 856
housing (14) as shown in Fig. 8. Loosen adjusting nuts
(10). Remove bolts (20), washers (19) and bearing
caps (22).
6 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 861 10. Punch mark cover (26) and housing (33) as shown
by the arrows in Fig. 13, then lift off the cover.
12. Remove four pinion gears (31) and axle (32) out of
housing (33).
13. Remove other side gear (30), thrust ring (35), two
internally splined plates (29), two externally splined
Fig. 13 - Removing Cover plates (28) and thrust washer (27) from housing (33).
15. Remove cotter pin (1), slotted nut (2), washer (3)
and drive flange (4) from pinion gear (17).
SM - 863 16. Remove and discard pinion shaft seal (7) from
differential housing (14) as shown in Fig. 15.
SM 1969 4-00 7
Rear Axle Group - Differential Drive Head
Section 160-0020
17. Press pinion gear (17) out of differential housing SM - 864
(14) as shown in Fig. 16. Remove spacing washer (15).
18. With the special tool shown in Fig. 17 pull the inner SM - 865
race of the bearing off the pinion drive end.
8 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 866
(Straight edge +
gauge blocks) = 90.0 mm (3.543 in)
- Measured Value = 43.9 mm (1.728 in)
SM 1969 4-00 9
Rear Axle Group - Differential Drive Head
Section 160-0020
3. The arrow in Fig. 21 is pointing to a dimension SM - 869
etched on the face of pinion gear (17). For example
159.90 mm (6.295 in).
Shim Thickness = 0.80 mm (0.032 in) Fig. 21 - Dimension on Drive Pinion Face
10 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 876 10. If dust shield (6) was removed from drive flange (4),
press it back on the drive flange. Spline drive flange
(4) to pinion (17). Install slotted nut (2) and tighten to a
torque of 600 Nm (443 lbf ft). Check the rolling
resistance as shown in Fig. 28. Rolling resistance
should be 1.1 - 2.3 Nm (0.81 -1.70 lbf ft).
SM 1969 4-00 11
Rear Axle Group - Differential Drive Head
Section 160-0020
11. Remove slotted nut (2), pull off drive flange (4) and SM - 877
remove pinion gear (17) from differential housing (14).
Remove and measure the measuring ring with a
micrometer. The thickness of the compressed
measuring ring will be the thickness of spacing washer
(9).
21. Install the other side gear (30) and the other thrust
ring (35), flat side up, as shown in Figs. 31 and 32.
12 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020
23. Determine the end play between the plates and the
housing as shown in Figs. 33 and 34.
SM 1969 4-00 13
Rear Axle Group - Differential Drive Head
Section 160-0020
27. Place outer races of roller bearings (11 & 12) on SM - 885
both differential ends. Using the special lifting tool
install ring gear (18) assembly into differential
housing (14), as shown in Fig. 37.
29. Align the index marks and install bearing caps (22) SM - 887
with washer (19) and bolts (20), as shown in Fig. 39.
Tighten bolts (20) to a torque of 295 Nm (218 lbf ft).
30. Thread both adjusting nuts (10) into bearing caps SM - 888
(22) as shown, until the yoke width is between
340 - 340.30 mm (13.386 - 13.400 in) diagonally
across the bearing cap lock pads, as shown in Fig. 40.
14 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 889 31. To check the backlash between ring gear (18) and
pinion gear (17), mount a dial indicator gauge at right
angles to the outer diameter of the ring gear tooth flank
as shown in Fig. 41. Rock the ring gear back and forth
being careful not to move the pinion gear. Backlash
should be 0.30 mm (0.012 in).
SM - 891 33. To check the tooth pattern of ring gear (18), coat
about twelve ring gear teeth with prussian blue, oiled
red lead or some other easily removed print or dye.
When the pinion is rotated, the paint is squeezed away
by the contact of the teeth, leaving bare areas the
exact size, shape and location of the contacts as
shown in Fig. 43.
SM - 892 34. After all adjustments and gear patterns are correct,
secure adjusting nut lock plates (24) in place with bolts
(23) and lockwire (21), as shown in Fig. 44.
SM 1969 4-00 15
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 893 SM - 896
SM - 894 SM - 897
16 SM 1969 4-00
Rear Axle Group - Differential Drive Head
Section 160-0020
SM - 898
SM - 899
SM - 900
SM 1969 4-00 17
Rear Axle Group - Differential Drive Head
Section 160-0020
DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth Replace damaged gear
Excessive run-out of pinion or flanged case Disassemble, correct or replace faulty
part
Continual noise Bearing worn Replace worn parts
Gears damaged or worn Replace gears
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Loose ring and pinion gear adjustment Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case
* * * *
18 SM 1969 4-00
REAR AXLE GROUP - Axle Group (Hub)
Section 160-0030
SM - 1781
30
10
31 7 8
5 33
32
35
34
13 12
6
9 11
22
28
2,3
1 4
38
21 37
17
15
14
24
23
27 25
29 26
18
36
20 19
16
1 - Hub Carrier 29 - Slotted Nut
2 - Capscrew 11 - Wheel Bolt 20 - Retainer Ring 30 - Axle Housing
3 - Capscrew 12 - Wheel Nut 21 - Thrust Washer 31 - Brake Disc
4 - Washer 13 - Lockwasher 22 - Bolt 32 - Capscrew
5 -Nut 14 - Locking Plate 23 - 'O' Ring 33 - Washer
6 - Roller Bearing 15 - Lock Screw 24 - Plug Screw 34 - Split Pin
7 - Bearing Inner Race 16 - Ring Gear 25 - Driver 35 - Split Pin
8 - Bearing Outer Race 17 - Sun Gear Shaft 26 - Thrust Washer 36 - Shim
9 - Shaft Seal 18 - Planet Carrier 27 - Grooved Pin 37 - 'O' Ring
10 - Hub 19 - Planet Gear 28 - Axle Shaft 38 - Plug
WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Fig. 2 - Jacking Planet Carrier Out Of Hub
secured and of adequate capacity to do the job
safely.
SM - 1027
5. Jack up the axle and support with suitably placed 11. Remove bearing inner race (7) from hub carrier (1).
stands or timbers.
12. Lift out sun gear shaft (17) from planet carrier
6. Support tyre and rim assembly with a suitable sling (18) assembly. Remove retainer rings (20) and pull
and lifting device. Remove wheel nuts (12) and planet gears (19) from planet carrier (18). Remove
remove tyre and rim assembly from the machine. thrust washer (21).
Remove opposite road wheel in the same way.
13. Remove driver (25) from axle shaft (28). Remove
7. Place suitable containers under the differential and thrust washer (26) from grooved pins (27) on hub
both hubs (10). Remove differential drain plug and carrier (1). Pull axle shaft (28) from axle housing
drain oil from the differential. (30).
8. Rotate hubs (10) until plug screws (24) are at their 14. Remove the brake calliper. Refer to Section
165-0010, BRAKE PARTS - REAR.
SM - 1028 18. Remove shaft seal (9), roller bearing (6) and
bearing outer race (8) from hub (10) as shown in Fig. 5.
SM - 1029
INSPECTION
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely.
Fig. 6 - Installing Wheel Bolts
1. Cover the mounting flange of axle housing (30)
with Loctite 574 sealing compound and line up the
15. Remove two lock screws (15) and locking plate (14) index mark on hub carrier (1) with the mark on axle
from ring gear (16). Remove slotted nut (29) from hub housing (30). Secure hub carrier (1) to axle housing
carrier (1) with the special tool (15269943, socket) as (30) with capscrews (2 & 3), washers (4), nuts (5)
shown in Fig. 4. Remove shims (36) from hub carrier and slot pins (34 & 35). Tighten capscrews (2 & 3) to
(1). a torque of 460 Nm (340 lbf ft).
16. Using suitable lifting equipment, remove ring gear 2. If removed, install new wheel bolts (11) on hub
(16), then hub (10) assembly from hub carrier (1). (10) using the special tool shown in Fig. 6.
17. If necessary, remove capscrews (32), washers 3. Place brake disc (31) on hub (10) and secure with
(33) and brake disc (31) from hub (10). capscrews (32) and washers (33). Tighten
capscrews (32) to a torque of 295 Nm (220 lbf ft).
Where:
F
F = Pull in N (lbf)
T = Rolling resistance Nm (lbf ft)
R = Radius of hub m (ft)
SM - 2831
a. Position the assembled planet carrier (18) as
shown in Fig. 12. Place a straight edge along top of
HUB planetary gears and measure the dimensions to carrier
mounting face (dimension 'X') and thrust washer (21)
(dimension 'Y'). Note the difference and record this as
dimension 'A'.
Example:
Dimension 'X' = 100.00 mm (3.937 in)
B Dimension 'Y' = 85.40 mm (3.362 in)
SUN GEAR SHAFT
Dimension 'A' = 14.60 mm (0.575 in)
Fig. 13 - Measuring Dimension 'B'
b. Slide sun gear shaft (17) fully into driver (25).
Place a straight edge across the mounting surface of
12. Using Loctite 243, coat the threads of hub carrier hub (10) and measure the distance from the mounting
(1) and slotted nut (29). Thread slotted nut (29) on hub surface of hub (10) to the end of sun gear shaft (17) as
carrier (1) threads and, using the special tool shown in shown in Fig. 13. Record this as dimension 'B'.
Fig. 9, tighten slotted nut (29) to a torque of
1 000 Nm (738 lbf ft). Example:
Dimension 'B' = 14.90 mm (0.587 in)
13. Install locking plate (14) and secure with lock
screws (15). Tighten lock screws (15) to a torque of Example:
79 Nm (58 lbf ft). Dimension 'A' = 14.60 mm (0.575 in)
Dimension 'B' = 14.90 mm (0.587 in)
14. Re-check the rolling resistance of hub (10). The Difference (End play) = 0.30 mm (0.012 in)
rolling resistance (T) should be 12 - 18 Nm
(9 - 13 lbf ft) for new bearings, or 6 - 9 Nm
* * * *
SM - 1038
1 - Flanges
2 - 'O' Ring 5 - Wheel Rim 8 - Driver (if used)
3 - Bead Seat Band 6 - Valve Assembly 9 - Lock Washer
4 - Lock Ring 7 - Valve Cap 10 - Wheel Nut
FROM MACHINE
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
4. Insert flat hooked end of pry bar into breaking slots INSPECTION
between bead seat band (3) and outer flange (1). See
Tyre
Fig. 4. A pipe over the straight end of the pry bar will
increase leverage. Check the interior surface of the tyre to determine its
condition. Inspect for cuts or fabric breaks that have
5. Twist pry bar toward tyre to break bead. penetrated the tyre body. The casing should be
inspected closely for any sharp , pointed object that
6. A second pry bar may be inserted in the space may have penetrated the tyre body but is invisible from
between bead seat band (3) and outer flange (1). Twist the outside. All dust, dirt, water or other foreign matter
the second pry bar to maintain the space gained by the should be cleaned from the inside of tyre.
first pry bar.
Rim Assembly
7. Move the first pry bar around wheel rim (5), twisting
and following with the second pry bar, until the outer Overloading, improper tyre inflation, rough terrain, high
tyre bead is loose. speed, accidents, dirt accumulation, and corrosion all
tend to reduce the service life of rims and rim
8. Pry bead seat band (3) away from lock ring (4) by components. It is recommended that rims be
placing hooked end of pry bar in the groove of wheel inspected, as below, not less often than at every tyre
rim (5), between ends of lock ring (4), and prying up change and that, as the warranty limit approaches,
with the pry bar. Using two pry bars, as in Step 7, work consideration be given to periodic replacement.
completely around wheel rim (5).
The rim and its components are designed with built-in
9. Pry lock ring (4) out in the same manner by starting safety factors, to prevent the components from flying
at prying notch in wheel rim (5) assembly, and work all off with killing force during inflation. Check
the way around wheel rim (5) with two pry bars. components for cracks, bends, distortion, or other
damage. If damage is found, the component must be
10. Remove and discard 'O' ring (2, Fig. 1). replaced.
11. Remove lock ring (4) then pry out and remove bead
seat band (3). WARNING
Never mix components of one manufacturer's
12. Breaking slots are provided inside the rims. The rims with those of another. Using the rim base
inner bead may be broken as described in Steps 4 of one manufacturer with the lock ring of
through 8. If the tyre and rim assembly is on the another or vice versa is dangerous. The lock
vehicle, the following procedure may be used for ring of one may not fully engage with the lock
breaking the inner bead. ring groove of the other. Always consult the
rim manufacturer for proper matching and
13. Place jack between inner flange (6) and vehicle assembly instructions.
frame. Extend jack until tyre bead is broken. Continue
around the rim until tyre bead is broken at all points.
SM 2179 Rev2 08-05 3
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
SM - 207
WARNING (cont.)
Also, use and servicing of damaged, worn out,
or improperly assembled rim assemblies is a
very dangerous practice. Failure to comply
with the above warnings could result in
explosions from tyre pressure causing serious
personal injury and property damage.
Clean all rust and dirt from the rim parts and wheel
and apply a coat of good grade primer paint. Allow the
paint to dry thoroughly before remounting tyre.
D.
WARNING Do not charge batteries, either in or out of a
To prevent personal injury and property machine, near the air inlet of a compressor
damage, the tyre and rim assembly should be used for inflating tyres. Charging batteries
placed in a safety cage before inflating. If no produces highly explosive hydrogen gas
safety cage is available or tyre is on the which can be readily drawn into a nearby
machine, the tyre and rim assembly should be compressor inlet and pumped into the tyre.
wrapped with safety chains or with lash cables
before inflating. E.
Never exceed the specified concentration of
Even with these precautions remember that alcohol when adjusting the alcohol vaporizer,
air-blast is a potential hazard. Tyre inflation or adding alcohol to the auxiliary air tank,
should be carried out away from busy working used on machine air systems to prevent
areas. freezing or moisture condensate in below-
freezing temperatures. Excessive alcohol,
WARNING added to the machines air tanks in this
To avoid personal injury and property damage, manner can produce flammable vapours that
never stand or sit in front of a mounted tyre will be pumped into a tyre when this air
during tyre inflation. Use a clip-on air chuck supply is used for tyre inflation if the tyre
with a long hose and stand to one side while inflation kit is not equipped with a moisture
the tyre is being inflated. filter. Alcohol added to machine air systems
in recommended concentration to prevent
WARNING condensate freezing are below hazardous
To prevent personal injury and property levels for tyre inflation.
damage, always prevent flammable vapours
that could produce tyre explosions, from being F.
pumped into tyres during inflation, by Another source of hazardous flammable
observing the following precautions: vapours in tyres is the tyre bead lubricant.
Always use bead lubricants that do not
introduce flammable vapours into the tyre.
SM - 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
1. Inflate tyre to 1 bar (15 lbf/in²) initially to seat very large tyres.
components and tap lock ring lightly to ensure correct
seating. Visually check that all components are in Nitrogen gas cylinders used to inflate
place, then continue inflation observing all safety tyres are generally charged to approximately
precautions. (See Step 2). 152 bar (2 200 lbf/in2). A tyre blowout and/or
rim failure could occur if inflation equipment is
2. If the tyre is off the machine, place it in a safety not properly used. Proper nitrogen charging
cage after initially inflating to 1 bar (15 lbf/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 two dual pressure gauges.
the '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.
d. Connect clip-on chuck to the tyre valve. The tyre will WARNING
now inflate. Tyre pressure can be monitored by Whenever a machines tyre(s) is (are) exposed
observing the gauge at the pressure regulator. STAY to excessive heat such as a machine fire or
AWAY FROM THE TYRE. extremely hot brakes the hazard of a
subsequent violent tyre explosion must be
e. When desired inflation pressure has been achieved, recognized. All persons must avoid
back off the regulator or close the valve on the approaching the machine so as not to be
compressed gas cylinder. physically endangered in the event of an
explosion of the tyre and rim parts.
f. Remove the clip-on chuck and adjust the tyre
pressure with the tyre gauge in the usual manner.
SM - 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.
A recapped tyre has a new tread cured right over the Prevent Overloading
old tread surface. Off-highway machines are designed to carry a
maximum allowable payload. Excessive loading will
A retreaded tyre has the old tread removed entirely and overstress both the machine and tyres and shorten the
a new tread cured directly onto the body of the tyre. A life of both.
tyre can be recapped or retreaded if the cord body is
free of cuts, bruises and separation, and is thoroughly
sound, including previous repairs. Prevent Contact with Oil
Prevent tyre contact with petroleum products. Rubber
that is exposed to oil, gasoline, or grease becomes
TYRE CARE soft and spongy and deteriorates rapidly. Always avoid
To obtain maximum service from off-highway tyres, the driving machine through a puddle of gasoline, fuel oil,
following common-sense precautions should be lubricating oil, or grease. Never let a tyre stand in an
followed. oil or grease spot overnight.
Although it takes time and effort to maintain good haul The beads of tubeless tyres must be protected from
roads, the delay and cost of tyres and machine damage or a faulty air seal will result. Do not use
breakdowns caused by poor haul roads is many times hooks, cables, or chains in contact with the tyre beads
greater.
SM 2179 Rev2 08-05 9
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
when lifting these tyres. If forklift trucks are used for 'O' rings are seals and should be carefully stored in a
handling, they should be equipped with broad, well- cool, dry place where they will not be injured or
rounded arms to distribute the load and prevent damaged.
damage to the tyre bead. When handling tyres with the
fork truck do not scrape the fork across the bead. Valve cores should also be stored in a cool, dry and
clean place.
Tubeless tyre rims perform an important function as
part of the assembly air seal. Proper care, therefore,
must be taken not to distort or mutilate the rim parts MAINTENANCE
because they must mate properly to form part of the Check tyre pressures daily, preferably before the
basic air chamber. Since the rim base and bead seat machine is placed in operation. Refer to 'Tyre Inflation
band are mating surfaces, distortion may prevent easy Pressures' table.
assembly as well as possibly resulting in no seal.
Every 50 hours of operation (weekly), torque tighten
Never drop, tumble, or roll rim parts. wheel rim nuts to 590 Nm (435 lbf ft).
If rim parts are stored outdoors, they should be given a Check tyres regularly and replace or repair if required.
protective coat of a good commercial primer.
WARNING
Do not attempt repair of wheel components.
Twisted or damaged 'O' ring Replace 'O' ring (lubricate)
Tyre cuts and snags Repair tyre damage
Bead area awl holes Repair inner liner (preferred)
Leakage between tyre bead trim With tyre removed from rim:
Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5 degree tapered bead seat band and the rim base in the bead
seating area to determine if the transverse weld trims are flat or concave.
Replace defective part(s).
Note: Weld trim should follow rim contour.
Mount tyre using a lubricant such as Murphy's Tyre and tube Mounting
Compound, or equivalent, on tyre beads and rim bead seat area.
* * * *
SM - 2477
1,5
4,5
4,5
1,5
are two brake heads and one brake disc at each wheel.
WARNINGS
Use only hydraulic oils meeting specifications Each calliper brake head assembly consists of a
outlined in Section 300-0020, LUBRICATION torque plate, two brake pads (one on each side of the
SYSTEM. Do Not use Brake Fluid (J1703). Use brake disc) and four brake pistons, two on each side of
of improper fluids is destructive to rubber the brake disc. The piston bores on each side of the
components of brakes resulting in loss of torque plate are interconnected by internal passages
braking and possible catastrophic failure.
When the brake is actuated, hydraulic oil enters brake
Exercise extreme caution while working head and forces pistons against brake pads which are,
on the braking system. in turn, forced against each side of the brake disc,
slowing or stopping the disc and wheel rotation.
SM 2180 11-02 1
Brake Parts - Brake Parts - Rear
Section 165-0010
SM - 049
2 SM 2180 11-02
Brake Parts - Brake Parts - Rear
Section 165-0010
1. Position the vehicle in a level work area, apply the Note: Make sure torque pins (3 & 5) do not touch brake
parking brake and switch off the engine. Operate disc (2, Fig. 1). If they do, loosen bolts (2) and adjust
steering right and left several times to relieve any torque pins to clear disc by 1.5 - 3.2 mm
pressure in the steering system. (0.06 - 0.125 in). Check to make sure that bolts (2) fully
engage in torque pin grooves and retighten bolts.
WARNINGS 11. Pump brake pedal until brake pads (4) contact
Hydraulic fluid pressure will remain within the brake disc (2, Fig. 1).
braking system after engine shutdown. Operate
the brake pedal continuously until the pressure 12. When new brake pads are installed on a machine,
has dissipated before carrying out any work on the brake pad friction material should be burnished in
the braking system or serious injury could accordance with the following procedure to achieve
result. maximum braking performance:
To prevent possible personal injury, keep a. Drive vehicle at 8 - 30 km/h (5 - 20 mile/h) with
hands and fingers etc. clear of the area between brakes applied at just enough pressure to produce a
the disc and the brake head pistons. noticeable drag. Heavy smoke and foul odour from the
brake pad friction material is normal during this
2. Block all road wheels, except the wheel to be procedure.
removed, and place the battery master switch in the
'Off' position. Note: An infrared thermometer pointed at the disc after
stopping, can safely and easily determine brake disc
3. Remove wheel from the machine following temperature. Refer to 'Special Tools'.
instructions in Section 160-0050, WHEEL RIM AND
TYRE. b. Continue cycle until the brake disc achieves a
temperature of 315° - 370° C (600° - 700° F).
4. Loosen bolts (2) securing large torque pins (3) at the
end of torque plate (16). It is not necessary to loosen or c. Permit disc to cool to less than 95° C (200° F).
remove the two smaller torque pins (5) at opposite end.
d. Repeat Steps a and b.
5. Move the two unlocked torque pins (3) away from
brake disc (2, Fig. 1). e. Allow brake to cool to within 10° C (50° F) of ambient
temperature, while driving the vehicle with the brakes
6. Remove dust cap (15) from bleeder valve (1) and released.
attach a bleeder hose to bleeder valve. Open bleeder
valve (1). Use a screwdriver or pry bar inserted between f. Repeat Steps a and b until full braking performance
brake disc (2, Fig. 1) and brake pads (4) to press (per applicable government regulations) is achieved.
pistons (11) back as far as possible, into the piston
bores of torque plate (16). Close bleeder valve.
BRAKE REMOVAL AND DISASSEMBLY
7. Rotate brake pads (4) out of the opened end of Numbers in parentheses refer to Fig. 2, unless
torque plate (16). Inspect boots (12) for deterioration. otherwise specified.
SM 2180 11-02 3
Brake Parts - Brake Parts - Rear
Section 165-0010
1. Position the vehicle in a level work area, apply the 9. Clean torque plate (16) making sure no solvent
parking brake and switch off the engine. Operate remains in fluid passages or grooves. Inspect boot (12)
steering right and left several times to relieve any and seal (10) grooves, and land areas between grooves
pressure in the steering system. for damage or cracks. Minor nicks and scratches may
be blended with crocus cloth. Replace torque plate (16)
if corrosion is excessive or boot (12) and seal (10)
WARNINGS grooves are damaged, prohibiting proper rebuild of the
Hydraulic fluid pressure will remain within the brake head.
braking system after engine shutdown. Operate
the brake pedal continuously until the pressure 10. Inspect pistons (11) for minor scratches and nicks
has dissipated before carrying out any work on and blend with crocus cloth. If piston (11) is badly
the braking system or serious injury could nicked or scratched, or if the chrome plate is worn
result. off, replace piston (11).
To prevent possible personal injury, keep 11. Torque pins (3 & 5) that are deeply grooved should
hands and fingers etc. clear of the area between be replaced.
the disc and the brake head pistons.
3. Remove wheel from the machine following 1. Lubricate seals (10), packings (13) and pistons
instructions in Section 160-0050, WHEEL RIM AND (11) with petroleum base oil or vaseline.
TYRE.
5. Remove hydraulic fluid inlet line at brake head 2. Install backup rings (14), packings (13) and boots
assembly. Plug line and brake head to prevent ingress (12) in torque plate (16) piston bores. Lubricate per
of dirt. Step 1.
6. Remove bolts (4, Fig. 1) and washers (5, Fig. 1) 3. Install pistons (11) in torque plate (16) as follows:
from mounting at axle housing and remove brake head Position lubricated piston (11) into boot (12) and piston
assembly to a clean working area. bore, holding piston at a slight angle. Insert forefinger
between piston (11) and boot (12) and rotate forefinger
around outside diameter of piston (11), lifting inside
WARNING diameter of boot (12) over outside diameter of piston (11).
Hydraulic fluid may cause irritation. Avoid skin Make sure outside diameter lip of boot (12) remains in the
and eye contact with fluid. groove in piston (11) bore.
7. Disassemble brake head assembly in sequence of 4. After piston (11) is through boot (12), centre piston
index numbers in Fig. 2. Items (1, 2 & 3) may be left in by feel over packing (13). Apply by hand, a turning
torque plate (16) when servicing packings (13), seals (10), thrusting pressure, working piston (11) into and through
backup rings (14), and boots (12) if desired. packing (13).
Note: Repair kits are available which include new 5. When assured pistons (11) are through packings
boots (12), backup rings (14), packings (13) and (13), pressure other than hand pressure may be used
seals (10), in quantities sufficient to rebuild a brake to press pistons the remainder of the way into the
head assembly. Refer to vehicle parts book for repair piston bores. Snap open end of boot (12) into groove
kit part number. All parts included in a repair kit should of piston (11).
be replaced each time a brake head is rebuilt.
6. Lubricate seals (10) and install seals and piston
8. Inspect brake pads (4) per Step 1 in 'General plugs (9) in open end of piston bores of torque plate (16).
Inspection' procedure.
4 SM 2180 11-02
Brake Parts - Brake Parts - Rear
Section 165-0010
7. Attach cover plate (8) to torque plate (16) and housing.
secure with bolts (6) and washers (7). Tighten bolts (6)
to a torque of 505 - 515 Nm (370 - 380 lbf ft). 5. Install wheel on the vehicle following instructions in
Section 160-0050, WHEEL RIM AND TYRE.
8. When installing torque pins (3 & 5) and bolts (2)
make sure the groove in the pin is directly under the
bolt so the bolt can perform its locking and retaining BLEEDING THE BRAKING SYSTEM
function. Numbers in parentheses refer to Fig. 2.
Note: Lubricate torque pins (3 & 5) with a corrosion In order to obtain satisfactory braking, the system
resistant lubricant prior to installation to facilitate next should be bled as follows to eliminate any air in the
pin removal. hydraulic brake lines.
9. Inspect brake disc (2, Fig. 1), if worn, per 1. Fill the hydraulic tank with oil specified in Section
instructions under 'General Inspection' in this section. 300-0020, LUBRICATION SYSTEM. Start the engine
Refer to Section 160-0030, AXLE GROUP (HUB) for and allow systems to reach normal operating
brake disc replacement instructions. conditions.
2. Position brake head (3) over brake disc (2) on brake 5. Crack open the bleeder valve (1) and gently operate
mounting plate, aligning bolt holes. Install assembled treadle valve several times to bleed air in the brake
bolts (4) and washers (5) through mounting plate and lines.
into torque plate, and tighten bolts (4) to a torque of
515 Nm (380 lbf ft). 6. When the oil from the brake head is clear (not cloudy
or creamy) close bleeder valve (1) and remove tubing.
Note: Make sure torque pins (3 & 5, Fig. 2) do not
touch brake disc (2). If they do, loosen bolts (2, Fig. 2)
and adjust pins to clear disc by 1.5 - 3.2 mm WARNING
(0.06 - 0.125 in). Check to make sure that bolt (2, Fig. 2) Do not operate the vehicle until all air is bled
fully engages in pin groove and tighten bolt (2, Fig. 2) from the braking system.
to a torque of 43 - 51 Nm (32 - 38 lbf ft).
7. Perform steps 4 through 6 for the remaining 11 brake
3. Attach hydraulic fluid inlet line at brake head head assemblies.
assembly.
SM 2180 11-02 5
Brake Parts - Brake Parts - Rear
Section 165-0010
* * * *
6 SM 2180 11-02
PARKING BRAKE - Parking Brake and Mounting
Section 170-0010
SM - 2801
11 13
10
14 3 2
7,8
4,5 16
1 1
6 12 6
15
SM 2181 11-02 1
Parking Brake - Parking Brake and Mounting
Section 170-0010
REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 2.
otherwise specified.
1. Remove calliper head assembly as described under
removal.
WARNINGS
To prevent personal injury and property 2. Remove snap ring (13) from power screw shaft (18),
damage, be sure wheel blocks, blocking and remove fasteners securing control strap (27) to
materials and lifting equipment are properly slack adjuster (14).
secured and of adequate capacity to do the job
safely. 3. Slide slack adjuster (14) from power screw shaft (18).
Hydraulic fluid pressure will remain 4. Remove and discard washer (16), wave spring
within the braking system after engine shut washer (15) and packing (17) from power screw
down. Operate the treadle pedal continuously shaft (18).
until the pressure has dissipated before
carrying out any work on the braking system or 5. Remove bolts (2) and washers (3) securing cap
serious injury could result. assembly (21) to calliper (6).
1. Position the vehicle on a level surface, apply the 6. Remove as a unit, power screw shaft (18),
parking brake, block all road wheels and place the piston (5) and cap assembly (19 through 22) from
steering lock bar in the 'Locked' position. calliper (6).
2. Raise the body and install body safety prop to 7. Slide power screw shaft (18) and piston (5) from cap
secure in partially raised position. assembly (21).
3. Pull out push control to release the parking brake. 8. Unscrew piston (5) from power screw shaft (18).
4. Release spring tension on slack adjuster clevis pin 9. Remove and discard thrust bearing (19) from power
(7) by unscrewing tensioning bolt on slack adjuster (3) screw shaft (18) and gasket (20) from cap
until clevis pin (7) feels loose. Remove cotter pin (8) assembly (21).
and clevis pin (7) from actuator (9).
10. Remove and discard piston seal (4) from calliper (6).
Note: On engine shutdown the parking brake will
automatically apply. Ensure there is sufficient
clearance for actuator rod travel. INSPECTION
Numbers in parentheses refer to Fig. 2.
5. Switch off the engine and place the battery master
switch in the 'Off' position. 1. Thoroughly clean all parts. Inspect journal bearing
(22) in cap assembly (21) for wear. Journal bearing (22)
6. Disconnect and plug hydraulic line from actuator (9). ID should not exceed 38.35 mm (1.51 in). Replace if
Cap actuator (9) to prevent ingress of dirt. necessary.
7. Remove nuts (10) and washers (11) securing 2. Replace cap assembly (21) if excessively worn.
actuator (9) to cap assembly (13). Remove actuator (9)
from cap assembly (13). 3. Inspect all brake parts for cracks, excessive wear or
scoring. Replace brake parts as required.
8. Support calliper head assembly (2) and remove bolts
(4 & 16), washers (5) and nuts (6) securing mounting
plates (1) to mounting bracket on the frame. ASSEMBLY
Numbers in parentheses refer to Fig. 2.
9. Remove mounting plates (1) and calliper head
assembly (2) from the vehicle. 1. Install new piston seal (4) into seal groove in calliper
(6).
2 SM 2181 11-02
Parking Brake - Parking Brake and Mounting
Section 170-0010
SM - 2802
18
19 20
21
6 3
2
12
'A'
11
22 26
24 25
17
10 15
14
16 7
1
'A'
27
4
8
23 5
9 13
AT POSITION 'A'
face of new thrust bearing (19). 6. Line up gasket (20) and bolt cap assembly (21), with
assembled power screw shaft (18) and piston (5), to
3. Install and seat new thrust bearing (19) over splined calliper (6) using bolts (2) and washers (3). Tighten bolts
end of power screw shaft (18) with greased side of (2).
thrust bearing (19) against thrust collar of power screw
shaft (18). Note: Care should be taken not to push piston seal (4)
out of seal groove in calliper (6) when assembling cap
Note: Ensure correct installation of thrust bearing (19) assembly (21), with piston (5) and power screw shaft
by verifying that installation was made over the larger (18), to calliper (6).
diameter end of power screw shaft (18), and, that thrust
bearing (19) ID lip is towards splined end of power 7. Install new packing (17), wave spring washer (15)
screw shaft (18). and washer (16) over power screw shaft (18), in the
order shown in Fig. 2.
4. Lubricate threads of power screw shaft (18) with
grease (Lubriplate Aero or equivalent) and screw power 8. Mount actuator (12) on cap assembly (21) with nuts
screw shaft (18) into piston (5). (10), lockwashers (25) and washers (11). Tighten nuts
(10) finger tight only at this stage.
5. Coat outside of piston (5) with grease (Lubriplate
Aero or equivalent) then slide assembled power screw 9. Apply coat of grease (Lubriplate Aero or equivalent)
shaft (18) and piston (5) into cap assembly (21), shaft to mounting spline of slack adjuster (14).
end first.
SM 2181 11-02 3
Parking Brake - Parking Brake and Mounting
Section 170-0010
10. With adjusting screw facing towards actuator (12) 6. Align actuator (9) to slack adjuster (3) and tighten
slide slack adjuster (14) on power screw shaft (18) nuts (10).
aligning slack adjuster (14) arm with clevis (7).
7. Loosen bolt (15) at the control arm of slack adjuster
11. Install snap ring (13) on power screw shaft (18). (3) and control strap (12).
12. Remove nuts (10), lockwashers (25) and washers 8. Position control arm of slack adjuster (3) in fully
(11) securing actuator (12) to cap assembly (21). released position (forcing it in a direction away from
Remove actuator (12) from cap assembly (21) to aid in actuator (9)) by turning adjustment screw (14) on the
installation. slack adjuster (3), until it comes to a positive stop
inside the control strap (12).
1. Attach suitable lifting device and position mounting 11. Remove feeler gauge and apply brake several
plates (1) in mounting bracket and calliper head times. The automatic slack adjuster will adjust the
assembly (2) over brake disc. Secure mounting plates brake pad clearance with each application, which can
(1) to mounting bracket on the frame with bolts (4 & be seen by the rotation of the adjustment screw (14).
16), washers (5) and nuts (6). Tighten nuts (6) to a
torque of 75 Nm (55 lb ft). 12. When the adjustment screw (14) stops rotating, the
specified clearance has been obtained and the brake is
2. Remount actuator (9) on cap assembly (21, Fig. 2) ready for normal operation.
and install washers (11), lockwashers (25, Fig. 2) and
nuts (10). Tighten nuts (10) finger tight only at this 13. Remove wheel blocks and place the steering lock
stage. bar in the 'Stowed' position.
WARNING MAINTENANCE
Do not pressurize actuator until the following
instruction has been carried out. Pressurizing Every 250 hours
the actuator beforehand can result in serious Test park brake for proper operation. Check brake pads
brake damage. and disc for wear. Replace brake pads when lining
thickness is 3.0 mm (0.125 in) or less. Replace disc
3. Turn adjustment screw (14) on the slack adjuster (3) when worn by 3.0 mm (0.125 in) or more.
in a clockwise direction until the brake pads in calliper
head assembly (2) are tight against the brake disc.
Brake Pad Replacement
4. Connect hydraulic line to actuator (9). Place the 1. Remove calliper head assembly as described under
battery master switch in the 'On' position, start the 'Removal'.
engine and pull out parking brake control knob to
extend the actuator. 2. Replace worn brake pad and carrier assemblies.
5. Connect slack adjuster (3) to actuator (9) by 3. Install calliper head assembly and adjust slack
inserting clevis pin (7) through clevis (7, Fig. 2) on adjuster as described in 'Installation'.
actuator (9). Secure clevis pin (7) with cotter pin (8).
4 SM 2181 11-02
Parking Brake - Parking Brake and Mounting
Section 170-0010
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.
* * * *
SM 2181 11-02 5
SUSPENSION SYSTEM - Front Suspension
Section 180-0020
SM - 2803
18
18
4
5 30
29
12
13
14 15
8 2
27 9,10,11 31 16 31 16
6
16 7
2
7 9,10,11
8
15
19
20 12,13,14
20 19
21
17 16 6
17
22
1
26 25 3 29
23 27
28
24
DESCRIPTION (4 & 5) and front frame. In addition, there are are four
Numbers in parentheses refer to Fig. 1. heavy duty double acting shock absorbers (27) (two off
each side) to smooth out the ride. Two chain and
The front axle assembly is mounted on the leading shackle assemblies (23) provide extra retention on
arms of suspension frame (1) which pivots on the front rebound.
frame.
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 - Rear Suspension
Section 180-0040
SM - 2805
33
26 31 24
25 30 11
34 9
27 27
28 28
7 6
23 8
23 B
19
FR
ON 18
T 2 30 24
16,17 25
A
A 3,4
22 A C
23 26
1 27
6 16,17 16,17
5 A 28
30 8
7
26 24 29
A DETAIL B
25 A
25
27 16,17 A
9 21
28 11
13 32
1 10 23
A 12 C 5 19
15 22
14 A 30 3,4
A B
23
16,17 30
20 31 26
20
B 2
27 27
23
16,17 A 28 23
29 28 A
DETAIL A 19 DETAIL C
SM 2183 11-02 1
Suspension System - Rear Suspension
Section 180-0040
12. Remove bolts (24) and lockwashers (25) securing
WARNING interleaf mounts (30) to suspension link brackets (1 &
Hydraulic fluid pressure will remain 2) mounted on the centre and rear axles. Remove
within the braking system after engine shut interleaf mounts (16).
down. Operate the treadle pedal continuously
until the pressure has dissipated before 13. Remove bolts (14) and lockwashers (15) securing
carrying out any work on the braking system or end cap (11) to equaliser beam (6). Remove end
serious injury could result. cap (11).
1. Position the vehicle in a level work area, raise the 14. Remove bolts (12) and lockwashers (10) securing
body and install the body safety prop to secure the retainer (9) to spindle on the frame. Remove retainer (9).
body in the partially raised position.
15. Using suitable lifting equipment, support equaliser
2. Apply the parking brake and switch off the engine. beam (6) and withdraw from spindle on the frame.
Turn steering wheel several times to relieve any
pressure in the steering system. 16. Remove and discard 'V' seal (8) from bushing (7). If
required, remove bushing (7) from spindle on the frame.
3. Block the front road wheels, place the steering lock
bar and oscillation lock pin in the 'Locked' position and 17. Repeat steps 13 through 16 to remove the opposite
the battery master switch in the 'Off' position. equaliser beam (6).
4. Using suitable blocking equipment, block equaliser 18. Remove locknuts (19), hardened washers (23) and
beams (6) to prevent movement when raising the bolts (18) securing centre control links (16) to cross
trailer frame. shaft mounting brackets.
5. Whilst the rear road wheels are still on the ground, 19. Remove locknuts (29), hardened washers (23) and
loosen the wheel nuts. bolts (20) securing centre control links (16) to
suspension link brackets (5). Remove centre control
6. Using suitable lifting equipment, raise the trailer links (17).
frame until the rear wheels are off the ground. Support
the vehicle with suitable stands and blocking 20. Remove locknuts (29), hardened washers (23) and
equipment at the trailer frame, articulation pivot area bolts (20) securing control link (16) to bracket
and centre and rear axles. assembly (2) on the rear axle and the LH frame
mounting bracket. Remove control link (16).
7. Support one tyre and rim assembly with suitable
lifting equipment and remove wheel nuts and 21. Remove locknuts (29), hardened washers (23) and
lockwashers securing the rim to the axle. Remove tyre bolts (20) securing control link (16) to bracket
and rim assembly. assembly (1) on the centre axle and the LH frame
mounting bracket. Remove control link (16).
8. Repeat step 7 for the remaining rear tyre and rim
assemblies. 22. Remove locknuts (29), hardened washers (23) and
bolts (20) securing control link (16) to bracket
9. With a suitable container in position, disconnect assembly (1) on the rear axle and the RH frame
hydraulic brake lines from the tee pieces at the centre mounting bracket. Remove control link (16).
and rear axle assemblies. Cap lines and fittings to
prevent entry of dirt. 23. Remove locknuts (29), hardened washers (23) and
bolts (20) securing control link (16) to bracket
10. Remove mounting hardware connecting brake line assembly (2) on the centre axle and the RH frame
guards (33 & 34) to axles and remove brake line mounting bracket. Remove control link (16).
guards.
24. Remove locknuts (28), hardened washers (27) and
11. Remove blocking materials from equaliser bolts (26 & 31) securing suspension link bracket (2) on
beams (6). Remove locknuts (29), lockwashers (25) the rear axle. Remove suspension link bracket (2).
and bolts (21) securing interleaf mounts (30) to
equaliser beams (6). 25. Remove locknuts (28), hardened washers (27) and
bolts (26) securing suspension link bracket (1) on the
2 SM 2183 11-02
Suspension System - Rear Suspension
Section 180-0040
rear axle. Remove suspension link bracket (1). suspension link bracket (1) to centre axle with bolts
(26), hardened washers (27) and locknuts (28). Tighten
26. Remove bolts (22) and hardened washers (23) bolts (26) to a torque of 671 Nm (495 lbf ft).
securing suspension link bracket (5) on the rear axle.
Remove suspension link bracket (5). 5. Apply Loctite 243 to bolts (24) and secure interleaf
mounts (30) to centre axle with bolts (24) and
27. Remove locknuts (28), hardened washers (27) and lockwashers (25). Tighten bolts (24) to a torque of 165
bolts (26) securing suspension link bracket (1) on the Nm (122 lbf ft).
centre axle. Remove suspension link bracket (1).
6. Install suspension link bracket (5) on rear axle.
28. Remove locknuts (28), hardened washers (27) and Apply Loctite 270 to bolts (22) and secure suspension
bolts (26 & 31) securing suspension link bracket (2) on link bracket (5) to rear axle with bolts (22) and washers
the centre axle. Remove suspension link bracket (2). (23). Tighten bolts (22) to a torque of 324 Nm (239 lbf
ft).
29. Remove bolts (22) and hardened washers (23)
securing suspension link bracket (5) on the centre axle. 7. Install suspension link bracket (2) on LH side of the
Remove suspension link bracket (5). rear axle. Apply Loctite 243 to bolts (26 & 31) and
secure suspension link bracket (2) to rear axle with
30. If either axle assembly requires to be removed from bolts (26 & 31), hardened washers (27) and locknuts
under the vehicle; raise axle assembly with suitable (28). Tighten bolts (26 & 31) to a torque of 671 Nm (495
lifting equipment, remove blocking from under the axle lbf ft).
assembly and lower axle assembly onto a suitable
trolley. Slide the axle assembly from under the vehicle 8. Install suspension link bracket (1) on RH side of the
to a suitable work area. rear axle. Apply Loctite 243 to bolts (26) and secure
suspension link bracket (1) to rear axle with bolts (26),
hardened washers (27) and locknuts (28). Tighten bolts
INSTALLATION (26) to a torque of 671 Nm (495 lbf ft).
Numbers in parentheses refer to Figs. 1, 2 & 3.
9. Apply Loctite 243 to bolts (24) and secure interleaf
WARNING SM - 1425
To prevent personal injury and property
damage, be sure wheel blocks, blocking 9 7
materials and lifting equipment are properly 12,10
secured and of adequate capacity to do the job
safely.
SM 2183 11-02 3
Suspension System - Rear Suspension
Section 180-0040
mounts (30) to rear axle with bolts (24) and SM - 2806
lockwashers (25). Tighten bolts (24) to a torque of 165
Nm (122 lbf ft).
12. Clean bores on equalising beams (6) and, using washers (23) and locknuts (29). Tighten bolts (20) to a
suitable lifting equipment, install beams onto bushings torque of 556 Nm (410 lbf ft).
(7). Apply Loctite 243 to bolts (12) and secure retainers
(9) to spindles with bolts (12) and lockwashers (10). 19. Install control link (3) between suspension link
Tighten bolts (12) to a torque of 150 Nm (110 lbf ft). bracket (2) and RH frame mounting bracket and secure
at suspension link bracket (2) with bolts (32), hardened
13. Apply Loctite 243 to bolts (14) and Loctite 574 washers (23) and locknuts (19). Tighten bolts (32) to a
gasket eliminator to mounting face of end caps (11). torque of 556 Nm (410 lbf ft).
Secure end caps (11) to equalising beams (6) with
bolts (14) and lockwashers (15). Tighten bolts (14) to a 20. Secure control link (3) at RH frame mounting
torque of 75 Nm (55 lbf ft). bracket with bolts (20), hardened washers (23) and
locknuts (19). Tighten bolts (20) to a torque of 556 Nm
14. If removed, install lube fittings (13) in end caps (11). (410 lbf ft).
Lubricate with grease specified in Section 300-0020,
LUBRICATION SYSTEM, until excess lube is seen. 21. Install control link (3) between suspension link
bracket (2) and LH frame mounting bracket and secure
15. Apply Loctite 243 to bolts (21) and secure interleaf at suspension link bracket (2) with bolts (32), hardened
mounts (30) to equaliser beams (6) with bolts (21), washers (23) and locknuts (19). Tighten bolts (32) to a
lockwashers (25) and locknuts (29). Tighten bolts (21) torque of 556 Nm (410 lbf ft).
to a torque of 165 Nm (122 lbf ft).
22. Secure control link (3) at LH frame mounting
16. Install centre control links (17) between suspension bracket with bolts (20), hardened washers (23) and
link brackets (5) and cross shaft mounting brackets. locknuts (19). Tighten bolts (20) to a torque of 556 Nm
Secure at cross shaft mounting brackets with bolts (410 lbf ft).
(18), hardened washers (23) and locknuts (19). Tighten
bolts (18) to a torque of 556 Nm (410 lbf ft). 23. Remove caps and connect hydraulic brake lines to
the tee pieces at the centre and rear axle assemblies.
17. Secure centre control links (17) at suspension link Clip brake lines with clips removed during removal.
brackets (5) with bolts (20), hardened washers (23) and
locknuts (29). Tighten bolts (20) to a torque of 556 Nm 24. Connect brake line guards (33 & 34) to axles and
(410 lbf ft). secure with mounting hardware removed during
removal.
18. Install control links (17) between rear and centre
axle suspension link brackets (1 & 2) and frame 25. Using suitable blocking equipment, block equaliser
mounting brackets and secure with bolts (20), hardened beams (6) to prevent movement when installing the
4 SM 2183 11-02
Suspension System - Rear Suspension
Section 180-0040
rear tyre and rim assemblies. 31. Remove wheel blocks from the front road wheels
and place the steering lock bar and oscillation lock pin
26. Using suitable lifting equipment, position one tyre in the 'Stowed' position.
and rim assembly on one rear wheel and secure with
wheel nuts and lockwashers.
MAINTENANCE
27. Repeat step 26 for remaining tyre and rim Numbers in parentheses refer to Fig. 1.
assemblies.
Pre-Starting Inspection: Visually check condition and
28. Using suitable lifting equipment, raise the trailer mounting of equaliser beams (6), interleaf mounts (30)
frame sufficiently to remove stands and blocking and control links (3 & 16).
equipment from the centre and rear axles, articulation
pivot area and trailer frame. Lower vehicle to the Every 250 Hours: Lubricate bushings (7) in equaliser
ground and remove the lifting equipment. beams (6) through lube fittings (13), with grease
specified in Section 300-0020, LUBRICATION
29. With the vehicle lowered to the ground, tighten all SYSTEM, until excess lube is seen.
wheel nuts to a torque of 590 Nm (435 lbf ft).
30. Place the battery master switch in the 'On' position, SERVICE TOOLS
start the engine and check hydraulic brake lines for There are no special tools required for the procedures
leaks. Bleed all air from the hydraulic brake lines as outlined in this section. Refer to Section 300-0070,
described in Section 165-0020, HYDRAULIC BRAKING SERVICE TOOLS, for part numbers of general service
SYSTEM SCHEMATIC. tools and adhesives required during the removal and
installation of the rear suspension. These tools and
adhesives are available from your dealer.
* * * *
SM 2183 11-02 5
SUSPENSION SYSTEM - Rear Suspension
Section 180-0040
SM - 3308
33 26 31 24
34 R.H.S. 25 30 11
27 9
27
28 28 46
L.H.S. 45 43 44
7 6 47 38
23 8 48
FR 23
ON 19 DETAIL C
T B
18
2
32
17 30
3,4 24
A 32
22
16 A 25
23 A C
26
1
17 32
3,4 27
5
A 28
6 3,4
8
7
24 2
30 A
25 29 A 35 40
25 A 41
5 3,4 37
9 21 32 39 35
26 11 37
C 22 35 42,49
27 1 13
10 32 23
28 A 12 39
15 46 37
14 A 30 16 17 45
A 47
B 32
3,4 17 36 36
32
31 26 35
44 35
29 38
B 2 48
23 27
27 43 2
20 3,4 A
28 A 28
DETAIL A DETAIL B DETAIL D
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 K14 - Start Interlock Relay S1 - Battery Master Switch
A5 - Radio/Cassette Speaker K15 - Headlamp Relay S2 - Starter Keyswitch
K17 - Reverse Relay S7 - Emerg/Park Brake Switch
B2 - Coolant Temp Sender K21 - Trans Shift Clutch S9 - Washer Switch, F
B7 - Coolant Level Sensor K22 - Lockup Clutch S10 - Wiper Switch, F
B8 - Fuel Level Sender K23 - Ignition Sensed Relay S11 - Rear Wash/Wipe Switch
B13 - Rotational Speed Sensor K27 - Difflock Relay S13 - Horn Button
B19 - Throttle Position Sensor K33 - Radiator Fan Relay S14 - Hazard w/l Switch
B21 - Trans Oil Temp Sender K34 - Horn Relay S15 - Direction Ind Switch
B32 - Trans Oil Ret Temp Sender K40 - Radiator Fan Clutch S18 - Lights Switch
B35 - Trans Oil Cooler Fan Temp K47 - Intermittent Wipe Relay S19 - Dipswitch
Sender K50 - Brake Lights Control Relay S20 - Headlamp Flash Switch
B36 - Brake Pedal Potentiometer K51 - Brake Pedal Ret Control S22 - Body Proximity Switch
Relay S31 - Park Brake w/l Switch
E3 - Interior Light K52 - Body Proximity Switch Relay S37 - Axle Difflock Swt (Unused)
E5 - Reverse Light K57 - Sound Power Relay No. 1 S41 - Auxiliary Lights Switch
E6 - Flashing Amber Reverse K58 - Sound Power Relay No. 2 S48 - Acc Press Switch (Tractor)
Light S49 - Acc Press Switch (Trailer)
E7 - Instrument Panel Lights L3 - Reverse Alarm S57 - Steering Press Switch
E11 - Side Marker Light, L L5 - Electric Horn S60 - Difflock Request Switch
E12 - Taillight, L L6 - Reverse Camera S68 - Eng Diag/Request Switch
E13 - Side Marker Light, R L7 - Reverse Camera Monitor S69 - Accel Idle Validation Switch
E14 - Taillight, R S74 - Kickdown Switch
E15 - High/Low Beam H'lamp, L M1 - Starter Motor S78 - Body Lower Emergency
E16 - High/Low Beam H'lamp, R M4 - Washer Motor, F Switch
E19 - Rear Fog Lamp M5 - Wiper Motor, F S79 - Heated Mirror Switch
E21 - Rotating Beacon M6 - Wiper Motor, B S81 - Ret/Eng Brake 1st Stage
E23 - Work Light M7 - Washer Motor, B Retardation Request Swt
E26 - High Beam H'lamp, L M13 - Air Seat Compressor S82 - Eng Brake 2nd Stage
E27 - High Beam H'lamp, R Retardation Request Swt
E35 - Heated Mirror N3 - Voltage Convertor 24V/12V S90 - Trans Filter Restriction Swt
N4 - Speedo Frequency Divider
G1 - Generator/Alternator N5 - Brake Pedal Interface X1 - Handlamp Socket
G2 - Battery Module
Y3 - Retarder Valve
H6 - Direction Indicator; F, L P1 - Speedometer/Odometer Y4 - Emerg/Park Brake Solenoid
H7 - Direction Indicator; B, L P2 - Tachometer Y7 - Difflock Solenoid (Trans/
H8 - Direction Indicator; F, R P3 - Coolant Temp Gauge mid-axle)
H9 - Direction Indicator; B, R P4 - Fuel Gauge Y26 - Body Raise Solenoid
H10 - Brake Light, L P12 - Hourmeter Y27 - Body Lower Solenoid
H11 - Brake Light, R P15 - Trans Temp Gauge Y32 - Trans oil cooler fan solenoid
H29 - Cigar Lighter Illumination Y33 - System Hyd Unloader Valve
R7 - Cigar Lighter Y34 - System Hyd Float Valve
K1 - Starter Relay R10 - Rkr Switch 'Locating' LED Y36 - Trans oil cooler fan isolation
K4 - Dir Ind Flasher Unit R11 - Rkr Switch 'Function' LED solenoid
K5 - A/C Comp Clutch/Relay
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 Wire Colours
O - Orange
B - Black
L - LEFT, R - RIGHT, F - FRONT, B - BACK Y - Yellow
N - Brown
P - Purple
U - Blue
DIODE RESISTOR FUSE PLUG W - White
R - Red
S - Slate
TRAILER G - Green
K - Pink
CONNECTION L - Light Green
FUSES
Location Fuse No. Circuit Current Rating
1 Ignition Sensed Relay Contacts (Heater) 30A
2 Keyswitch 15A
4 Rear Wash/Wipe 10A
5 Horn Relay Coil, Front Wash/Wipe 10A
Main Fuse Box - 6 Air Seat Compressor 10A
Column A 7 Lights Supply 10A
8 Main Beam/Flash 10A
9 Wiper Park Front and Rear 7.5A
10 Hazards 7.5A
11 Transmission System Ignition Supply 7.5A
12 Reverse System 7.5A
13 Brake Lights 5A
14 Interior Light, Handlamp 5A
15 Direction Indicators/Rocker Switch LEDs 5A
16 Emergency/Park Brake 3A
Main Fuse Box - 17 Warning Light Module 3A
Column B 18 Heated Mirrors 15A
19 Gauges/Ignition Sensed Relay Coils 3A
21 Neutral Start 3A
22 Washers, Front 3A
23 Washers, Rear 3A
24 Horn 10A
25 Ignition Sensed Relay Contacts (Air Conditioning) 30A
26 Air Cond/Heater/Ventilation System 15A
28 Front Working Lights 15A
Main Fuse Box - 29 Rear Working Lights 15A
Column C 30 Rotating Beacon 5A
31 Auxiliary Fused Supply (Cab Manufacturers Harness) 3A
35 Brake Pedal Interface Module 15A
36 Cigar Lighter 10A
38 Reverse Camera Monitor Supply 10A
Main Fuse Box - 39 Reverse Camera Supply 10A
Column D 40 Body Proximity Switch 10A
47 Sound Power Legislation Relay No. 1 Supply 3A
48 TOC8 Hydraulics Electronic Control Module Supply 30A
49 QSM ECM Battery Supply 7.5A
50 QSM ECM Battery Supply 7.5A
51 QSM ECM Ignition Sensed Supply 5A
55 Radio/Cassette Voltage Convertor Supply 10A
Battery Box 56 Body Hydraulics Auxiliary/Emergency Dump Switch 10A
Fuse Box 58 Spare Battery Supply 10A
59 Transmission Battery System Supply 7.5A
61 Alternator Charge Cable (Power Fuse) 100A
62 Cab Busbar Supply Cable (Power Fuse) 100A
RELAYS
Location Relay Circuit
K23 Ignition Sensed Relay - Air Con
Main Fuse Box - K23 Ignition Sensed Relay - Wipers
Column E K34 Horn
K15 Headlamps
K17 Reverse Alarm/Lights
Main Fuse Box - K14 Neutral Start
Column F K5 Air Conditioner Compressor
K51 Brake Pedal Retarder Control
K50 Brake Lights Control
Main Fuse Box - K23 Ignition Sensed Relay - Engine Ignition
Column G K33 Radiator Fan
K4 Indicator Flasher Unit
Main Fuse Box - K52 Body Proximity Switch
Column H K27 Diff-lock
K23 Ignition Sensed Relay - Radio/Cassette
Below Right K47 Intermittent Wipe
Hand Console K57 Sound Power Legislation Relay No. 1
K58 Sound Power Legislation Relay No. 2
SM - 2807
Column A B C D E F G H
SM - 2808 SM - 3395
F54 F60
F53 F59
F58
K47
F52
F51 F57
Fig. 2 - Battery Box Fuse Box - Fuse Location Fig. 3 - Relays Below Right Hand Console
SM - 2858
SM - 2861
DESCRIPTION
The hydraulic electronic control unit (ECU) (Fig. 1) is a
A
stand alone control which controls the machines
hydraulic systems, including body hoist and B
transmission oil cooler fan drive. The IQAN-TOC8
ECU communicates with a variety of input and output
devices. It utilises analog/digital inputs, proportional
current outputs and digital outputs.
WARNING
ECU Inputs
Before any welding is done on a machine Refer to Figs. 3 & 4 and Section 190-0000, CIRCUIT
equipped with an IQAN-TOC8 hydraulic DIAGRAMS.
system, disconnect the following in this order:
Battery earth cable, battery supply cable, Ignition Switch - connected to the starter keyswitch,
alternator earth cables, alternator supply rendering the circuit energised or de-energised.
cables and electrical connections at the engine
ECM, transmission ECU, body control lever, Starter Motor Relay - when starter motor relay is
hydraulics ECU and cab bulkhead to avoid activated, a digital signal is fed to the ECU.
damage to electrical components. Turn off
battery master switch to isolate the batteries Body Control Lever - three position lever sends
before disconnecting any components. analog signals to ECU.
After welding connect all of the above in the Transmission Cooler Fan Drive Temperature
reverse order. Sensor - sensor at transmission sends analog signal
to ECU.
SM 2200 2-03 1
Electrical System - Hydraulic System ECU
Section 190-0085
SM - 2859
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 Transmission Oil Cooler Fan Drive Proportional
ECU depending on position of body. Solenoid - the transmission cooler fan drive
temperature sensor feeds back to the ECU, which
Body Lower Emergency Switch - located in the cab, outputs a signal to the fan drive proportional solenoid
the switch sends a digital signal to ECU when (typically 150 - 210 mA measured across pins 19 and
pressed. This is used to lower the body in the event of 20, resulting in a delivery between 38 - 83 bar (551 -
system failure. 1204 lbf/in2)). This causes the fan speed to increase
proportionally. Refer to Section 215-0050, MAIN
HYDRAULIC VALVE ASSEMBLY.
ECU Outputs
Cold Start Solenoid - when ECU receives input from Transmission Oil Cooler Fan Drive Isolation
starter motor relay, the ECU sends an ouput signal to Solenoid - the transmission cooler fan drive
activate cold start solenoid. This prevents the engine temperature sensor feeds back to the ECU, which
starting under hydraulic load. outputs a signal to the fan drive isolation solenoid.
Refer to Section 210-0060, TRANSMISSION OIL
Body Raise/Lower - when ECU receives signals from COOLER.
body control lever, ECU sends output signals to the
raise and lower proportional control valves to shift the Body-Up Warning Light - the body-up proximity
main control valve spool accordingly. Typical output switch sends a signal to the ECU, and depending on
from ECU is 250 - 800 mA, providing a delivery the body position, the ECU sends a signal to
pressure between 4 - 25 bar (58 - 363 lbf/in2) at main illuminate the warning light in the cab.
control valve spool. For raise proportional control
valve, measure current output across pins 17 and 18 Body Float Solenoid - the body lower emergency
on ECU. For lower proportional control valve, measure switch sends a signal to the ECU, which outputs a
across pins 31 and 32. signal to energise body float solenoid. This ensures
2 SM 2200 2-03
Electrical System - Hydraulic System ECU
Section 190-0085
SM - 2860
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
that the hoist side of the body cylinders are vented to damaged, especially when body is laden.
tank, allowing body to lower onto chassis under it's
own weight. Check the body float solenoid across pin 23 on ECU
and vehicle ground. Solenoid is rated at 15 W, 0.6 A,
The body float solenoid is always energised when the 42 ohms.
body-up proximity switch is made. This prevents the
body being powered down onto the chassis. Also Body Control Lever Detent - when the body control
prevents pressure being trapped in the hoist side of lever is pushed fully forward to power down the body,
cylinders when travelling, ensuring body is resting on the ECU energises a detent solenoid within the lever
the chassis. If body is not resting on the chassis when to hold the lever fully forward. This continues until the
travelling, hinge points and cylinders may be body-up proximity switch is made, when the ECU de-
SM 2200 2-03 3
Electrical System - Hydraulic System ECU
Section 190-0085
SM - 2862
2 Input errors
3 VREF error
4 Supply voltage
error
5 Temp critical or
checksum error
6 Fatal software
error
energises the detent solenoid so that the lever returns signal verification. If any software error is detected,
to the neutral position, and the body float solenoid is appropriate precautions will be taken.
energised (see Body Float Solenoid).
System Safety If there are no errors, the bottom LED flashes yellow
Input/Output Protection - all inputs to the ECU are to indicate normal status. Some errors will cause the
designed to withstand the maximum specified supply ECU to stop operating or at least shut down the
voltage. The outputs are protected against short outputs to increase safety. The green LED indicates
circuit. Additionally, an error on one input/output will power on.
not influence other inputs/outputs. External fuse (10A),
located in the battery box, will blow if supply exceeds
35 V. WARNING
Do not use the machine if an error code is
Current Check - for the current outputs, a current present. Shutdown the machine until the
check is performed. The ECU compares the return problem is resolved.
current with the output's set-value. If current deviation
occurs, the user will be notified through an appropriate Refer to table of error codes for corrective action. The
error code on the unit's LED. ECU has a RS232 interface below the right hand
console which plugs directly into a laptop. This allows
If the ECU detects a short circuit to battery supply, the communication with the ECU using IQANdevelop
unit will shut off the outputs in order to increase safety. software, and gain more information about the ECU's
status.
Memory Test - the ECU will perform a self test during
operation to verify the software. The test includes a
processor and memory verification, and an internal
4 SM 2200 2-03
Section 190-0085
SM 2200 2-03 5
Electrical System - Hydraulic System ECU
Section 190-0085
* * * *
6 SM 2200 2-03
ELECTRICAL SYSTEM - Switches and Sensors
Section 190-0270
SM - 2810
11
FUEL
12
P1S
TANK 3 PBS
2
HYD. ACC2S 9
VALVE
10
7
13
8
REAR FRAME RAIL
TRANS RETARDER
HOUSING RHS
4 14
IN
25
20
15
10
5
7
1 - Engine Coolant Temperature Sender 6 - Transmission Oil Temp Sender 10 - Front Brake Pressure Switch
2 - Engine Coolant Level Sensor 7 - Trans Oil Cooler Fan Temp Sensor 11 - Park Brake Pressure Switch
3 - Fuel Level Sender 8 - Retarder Oil Temperature Sensor 12 - Steering System Pressure Switch
4 - Starter Relay 9 - Rear Brake Pressure Switch 13 - Body Up Proximity Switch
5 - Air Cleaner Restriction Gauge 14 - Hydraulic Filter Restriction Gauge
SM - 2811
1 2 3 4 5 6
˚C
˚C 100 120
80 100
60 250
40 175 210 120 50 210 150
175
105 ˚F 250 120 ˚F 300
50 10
1
4
4
0 4
40 ENGINE HOURS 20
000000
20 30 30 15
20 10 min-1 20
x100
20 20
10 40
5 25
20
Mph
0 50 0 30
MPH
7 8 9 10 11 12 13 14 15 16 17
STOP
STOP
1 2 P
18 19 20 21 22 23 24 25 26 27 28
Tachometer Calibration
1. Ensure all three encoding switches at the back of
the tachometer are OFF.
Speedometer Calibration Table - number is displayed then release the button for a few
seconds until the next digit flashes.
All units with standard tyres
Unit Transmission Pulses 4. Repeat step 3 to obtain the desired impulses/
TA25 6 WG 210 333650 revolution. The speedometer is now calibrated.
TA27 6 WG 260 232100
TA30 6 WG 310 232100 Transmission Oil Temperature Sender (6) - The
sender, located on the elbow at the retarder housing,
sends a signal to indicate transmission oil temperature
SM - 2813
on the transmission oil gauge in the cab (4, Fig. 2).
Braking System
Rear Brake Pressure Switch (9) - The normally
closed (NC) pressure switch, located in port ACC2S of
the main hydraulic valve, senses the pressure in the
rear brake circuit. The pressure switch sends a signal
to illuminate 'Red' rear brake accumulator pressure
warning light (20, Fig. 2) when pressure drops to 122
Fig. 4 - Speedometer Calibration bar (1769 lbf/in2). An audible buzzer also sounds.
* * * *
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 - 2816
6 5
3,4
MAINTENANCE
PEDAL CALIBRATION
Limited repair of the electronic foot pedal assembly is
The pedal calibration must be checked if the harness is by replacement of parts only. Refer to vehicle Parts
disconnected or the pedal replaced. Using Cummins Book for part numbers.
INSITE diagnostic reader, the pedal can be checked as
follows:
SPECIAL TOOLS
1. With engine off, turn keyswitch to position '1', and Refer to Section 300-0070, SERVICE TOOLS, for part
connect diagnostic reader. numbers of Cummins engine INSITE diagnostic tools
which can be used to check pedal calibration. These
tools are available from your dealer.
* * * *
SM - 2817
15 2
1 4
13
14
12 7 11 5
8 3
6
10
9
1 - Header Tank 5 - Charge Air Inlet Pipe 9 - Radiator Outlet Pipe 13 - Filter Inlet Line
2 - Radiator Assembly 6 - Engine Oil Cooler 10 - Radiator Inlet Pipe 14 - Filter Outlet Line
3 - Engine Water Pump 7 - Thermostat Housing 11 - Deaeration Line 15 - Charge Air Outlet Pipe
4 - Coolant Filter 8 - Make-up Line 12 - Deaeration Line
The use of antifreeze is mandatory with the cooling 1 - Air-to-Air Charge Cooler 3 - Outlet Pipe
2 - Inlet Pipe 4 - Inlet Pipe
system. Refer to 'Recommended Coolants'. The lack of
coolant flow through the radiator with the thermostats
closed allows the coolant in radiator assembly (2) to Fig. 2 - Air-to-Air Charge Cooler Lines and Flow
freeze under low ambient temperature conditions.
enters air-to-air charge cooler (1). The hot air travels
Coolant Filter through a series of tubes in air-to-air charge cooler (1)
core, where the air temperature is lowered. From here
The cooling system is protected by a replaceable spin-
the air flows through outlet pipe (3) and into the engine
on type coolant filter (4) mounted on the left hand side
intake manifold through inlet pipe (4). From the engine
of the engine. The filter provides mechanical filtration
intake manifold the air travels into the cylinders where
by means of a closely packed element through which
it mixes with atomized fuel from the injectors. This
the coolant passes. Any impurities such as sand and
cooler air aids combustion, thereby increasing fuel
rust particles suspended in the cooling system will be
economy.
removed by the straining action of the element. The
removal of these impurities will contribute to longer
engine water pump (3) life and proper operation of the PREVENTIVE MAINTENANCE
thermostats.
To ensure the continued efficient functioning of the
cooling system, certain checks and operations should
Coolant flows from the engine block (3) through filter
be performed at regular intervals.
inlet line (13) and into coolant filter (4). Coolant flows
through the filter element and exits through filter outlet
line (14) and back into the engine block. Shut-off cocks
WARNING
on both filter lines allow coolant filter (4) to be replaced
Do not remove the pressure control cap from
with the minimum loss of coolant.
the radiator header tank or attempt to drain the
coolant until the engine has cooled. Once the
Air-To-Air Charge Cooling engine has cooled, use extreme caution when
removing the cap. Remove cap slowly as the
Numbers in parentheses refer to Fig. 2.
sudden release of pressure from a heated
cooling system can result in a loss of coolant
In the air system used on the Quantum engines,
and possible personal injury (scalding) from
outside air is drawn into the engine through the air
the hot liquid.
cleaner, passes through the air filter element and is
pulled into the turbocharger where it is compressed. It
then exits the turbocharger through inlet pipe (2) and
Note: Fuel oil, kerosene or gasoline should not be used 5. Start coolant filter on the filter adaptor and tighten it
to clean fins. by hand until the seal touches the adaptor filter head.
Tighten an additional 1/2 to 3/4 of a turn after contact,
Note: It may be necessary to clean radiator and or as specified by the filter manufacturer.
air-to-air charge cooler fins more frequently if the
vehicle is being operated in extremely dusty or dirty Note: Mechanical tightening of coolant filter is not
areas. necessary and will distort or crack the adaptor. Tighten
coolant filter by hand only.
WARNING 6. Open shut off valves at coolant filter inlet and outlet
To prevent possible injury when using lines, and install pressure cap on header tank.
compressed air, wear adequate eye protection
and do not exceed 2.75 bar (40 lbf/in²). 7. Start the engine and check for leaks. If any leaks are
noted, have them corrected. Add recommended coolant
as required.
Every 1 000 Hours
Coolant Filter - Replace coolant filter as follows: Note: Any time a significant amount of coolant is added,
the coolant concentration MUST be checked.
Note: There is a shut off valve at the coolant inlet and
outlet lines of coolant filter. Closing these valves will
enable coolant filter to be replaced without an Every 7 500 Hours
excessive loss of coolant. Check the coolant concentration using Terex Pro-Cool
Test Strips (see special tools). Add Terex Pro-Cool
Booster if necessary.
Cleaning The Cooling System 7. Shut off the engine and drain the cooling system.
5. Shut off the engine and drain the cooling system. Terex Pro-Cool extended life antifreeze coolant meets
the performance of ASTM D4985 specification for
6. Fill the cooling system with clean water and operate heavy duty engines.
the engine at high idle for 5 minutes with the coolant
temperature above 85° C (185° F). The following table provides mixing information. Clean
tap water or demineralized water is recommended for
dilution. A 40% to 70% concentration range is
WARNING suggested for optimum corrosion protection, however a
Do not remove the filler cap from the radiator Terex Pro-Cool solution is recommended and is used
header tank or attempt to drain the coolant until as a factory fill. Concentrations over 70% are not
the engine has cooled to below 50° C (120° F). recommended because of poor heat transfer capability,
adverse freeze protection and possible silicate dropout.
Concentrations below 30% offer little freeze, boil over
or corrosion protection.
* * * *
SM - 2819
1
2 8
3
7
4
5
6
34 33
32 31 29
27
30
14 9
28 15 23
24 22 21
25 15 14
38 26 20
37 27 14 19
35 14
37 12
36 17 13 10
14 11
15
18 14
17 16
SM 2189 1-03 1
Cooling System - Radiator and Mounting
Section 210-0040
SM - 2820
5
3
11 1
10 6
4
9
7
4 - Bottom Column 8 - LH Fan Guard
1 - Charge Air Cooler Core 5 - LH Column 9 - RH Fan Guard
2 - Radiator Core 6 - RH Column 10 - Fan Plate Assy
3 - Top Column 7 - Mount 11 - Fan Cowl Assy
2 SM 2189 1-03
Cooling System - Radiator and Mounting
Section 210-0040
7. Remove plug (23) and open shut-off valve (22) at the SM - 2818
bottom of radiator assembly and drain coolant into a
3
suitable container. Close shut-off valve (22) when
coolant is completely drained and refit plug (23). 1
Note: Refer to Section 260-0130, AIR CONDITIONING 1 - Charge Air Cooler 3 - Outlet Pipe
before disturbing the air conditioning circuit. 2 - Inlet Pipe 4 - Inlet Pipe
Fig. 3 - Air-To-Air Charge Cooler Piping
11. Ensure hydraulic lines connected to hydraulic oil
cooler mounted on front of radiator (2, Fig. 2) are
identified for ease of installation and with suitable 18. Slacken clamps (14) and remove coolant inlet pipe
containers available to catch leakage, disconnect (19), hoses (15) and clamps (14) from radiator
hydraulic lines. Fit blanking caps to open lines and assembly and engine thermostat housing.
ports.
19. Slacken clamps (14 & 17) and remove coolant
12. Disconnect deaeration line (28) from connector (9) outlet pipe (16), hoses (15 & 18) and clamps (14 & 17)
in radiator and deaeration line (30) from elbow (29) in from bottom of radiator assembly and engine water
engine. Identify lines for ease of installation and cap pump inlet.
open lines and elbows.
20. Install two eye bolts in lifting bosses on side of
13. Disconnect all clips and clamps securing air radiator assembly. Using suitable lifting equipment
conditioning lines, hydraulic lines and deaeration lines support radiator assembly.
to radiator assembly. Move all lines away from radiator
assembly to prevent fouling on removal of radiator 21. Remove bolts (11) and washers (10) securing
assembly. radiator assembly to the frame.
14. Remove bolts, washers and nuts securing fan 22. Remove radiator assembly from the vehicle to a
guards (8 & 9, Fig. 2) to radiator assembly. Remove clean area for disassembly. Support radiator standing
fan guards (8 & 9, Fig. 2) from radiator assembly. upright to allow access to front and rear of radiator.
15. Slacken clamps securing cooler hoses to air inlet Note: If Header Tank (32) requires to be removed,
pipe (2, Fig. 3) and remove air inlet pipe from charge air follow steps 23 through 28.
cooler (1, Fig. 3) and engine turbocharger.
23. Disconnect electrical harness from coolant level
16. Remove nut, washers and clamp securing air outlet sensor at bottom of header tank (32).
pipe (3, Fig. 3).
24. With a suitable container available to catch
17. Slacken clamps securing cooler hoses to air outlet leakage, remove drain plug from radiator header tank
pipe (3, Fig. 3) and remove air outlet pipe (3, Fig. 3) (32) and drain coolant. Apply Loctite 225 to drain plug
from charge air cooler (1, Fig. 3) and inlet pipe (4, Fig. and reinstall in header tank.
3).
25. Ensure all cooling lines connected to header tank
SM 2189 1-03 3
Cooling System - Radiator and Mounting
Section 210-0040
are identified for ease of installation and with suitable INSPECTION
containers available to catch leakage, disconnect
Numbers in parentheses refer to Fig. 2.
deaeration lines (28 & 30) and overflow line (34). Fit
blanking caps to all open lines.
1. Steam clean all parts thoroughly with a suitable
solvent.
26. Slacken clamp (27) and disconnect make-up line
(31) from header tank (32). Blank off open line end.
2. Examine charge air cooler core (1), radiator core (2),
condenser core and hydraulic oil cooler core carefully
27. Following removal instructions in Section
for possible damage. Repair any damage discovered if
100-0040, HOOD AND MOUNTING, remove goalpost
equipped to do so, or, have repairs made at a reputable
and header tank (32) as an assembly from the vehicle.
radiator repair shop.
28. Remove bolts (36), nuts (38) and washers (37)
securing header tank (32) to goalpost. Remove header ASSEMBLY
tank (32) from goalpost. Numbers in parentheses refer to Fig. 2, unless
otherwise specified.
DISASSEMBLY
Note: Tighten all fasteners to standard torques listed in
Numbers in parentheses refer to Fig. 2, unless
Section 300-0080, STANDARD BOLT AND NUT
otherwise specified.
TORQUE SPECIFICATION.
Note: Take care not to damage charge air cooler core
1. Fit RH column (6) and LH column (5) to charge air
(1), radiator core (2), condenser core and hydraulic oil
cooler core (1) and radiator core (2) using fasteners
cooler core during disassembly.
removed during 'Disassembly'.
1. Remove drain cock assembly (12, 13 & 20 - 23, Fig.
2. Secure mounts (7) to bottom column (4) with bolts
1) from bottom of radiator core (2). Remove connector
removed during 'Disassembly'.
(9, Fig. 1) from radiator core (2).
3. Fit top column (3) and bottom column (4) to radiator
2. Remove receiver drier and mounting from rear of
assembly using fasteners removed during
radiator assembly.
'Disassembly'.
3. Remove mounting hardware securing hydraulic oil
4. Position fan cowl assembly (11) to radiator
cooler to radiator assembly. Remove hydraulic oil
assembly and secure with fasteners removed during
cooler from radiator assembly.
'Disassembly'.
4. Remove mounting hardware securing air conditioning
5. Position fan plate assembly (10) to radiator
condenser to radiator assembly. Remove condenser
assembly and secure with fasteners removed during
from radiator assembly.
'Disassembly'.
5. Remove bolts, washers and nuts securing fan plate
Note: When installing radiator, ensure clearance around
assembly (10) to radiator assembly. Remove fan plate
cooling fan tips to plate assembly is of equal
assembly (10) from radiator assembly.
dimension all round.
6. Remove bolts and washers securing fan cowl
6. Install air conditioning condenser and hydraulic oil
assembly (11) to radiator assembly. Remove fan cowl
cooler to radiator assembly picking up mounting
assembly (11) from radiator assembly.
locations and hardware as identified at 'Disassembly'.
7. Remove bolts securing mounts (7) to bottom of
7. Fit connector (9, Fig. 1) to radiator core (2). Fit drain
radiator, and remove mounts (7).
cock assembly (12, 13 & 20 - 23, Fig. 1) to bottom of
radiator core (2).
8. Remove remaining bolts and washers securing top
column (3), LH column (5), RH column (6) and bottom
8. Install receiver drier to rear of radiator assembly
column (4) to charge air cooler core (1) and radiator
picking up mounting locations and hardware as
core (2).
identified at 'Disassembly'.
4 SM 2189 1-03
Cooling System - Radiator and Mounting
Section 210-0040
7. Secure air outlet pipe (3, Fig. 3) with clamp, nut and 20. Remove blanking caps from deaeration lines
washers removed during 'Removal'. (28 & 30) and connect to appropriate fittings on header
tank (32), as noted on removal.
8. Install air inlet pipe (2, Fig. 3) between engine
turbocharger and charge air cooler (1, Fig. 3) and 21. Connect overflow line (34) to header tank (32).
secure with hoses and clamps.
22. Secure all lines with clips and tie clips as removed
9. Feed electrical harness from engine cooling fan during removal. Ensure no lines are chaffing on sharp
through hole in fan plate assembly (10, Fig. 2). Fit edges or resting against areas where heat will be
grommet if previously removed. evident.
10. Connect engine cooling fan electrical harness to 23. Connect electrical harness to coolant level sensor
main electrical harness. at bottom of header tank (32).
11. Install LH and RH fan guards (8 & 9, Fig. 2) to 24. Refer to Section 210-0000, COOLING SYSTEM for
correct selection of coolant. Fill the cooling system
SM 2189 1-03 5
Cooling System - Radiator and Mounting
Section 210-0040
through filler in header tank (32) with coolant until External Cleaning
coolant level stabilizes at the bottom of filler neck.
Note: If a build up of dirt is apparent during routine
inspection, the following cleaning procedure should be
25. Check all line and pipe connections for leaks prior
adopted.
to starting the vehicle. Tighten as required.
6 SM 2189 1-03
Cooling System - Radiator and Mounting
Section 210-0040
MAINTENANCE
Refer to Section 210-0000, COOLING SYSTEM for
recommended preventive maintenance procedures,
service intervals and coolant selection procedures.
SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
adhesives are available from your dealer.
* * * *
SM 2189 1-03 7
COOLING SYSTEM - Transmission Oil Cooler
Section 210-0060
SM - 2821
12,
13,14
6
16
TRANS. RETARDER 21
HOUSING 5
7
19
12,
13,14
16
8,9,10,11 3 TRANSMISSION
OIL COOLER
15
2 8,9,10,11
15 20
1 17
18
TO HYDRAULIC TO HYDRAULIC
TANK OIL COOLER
TRANSMISSION OIL
TEMP. SENDER
FROM MAIN
HYDRAULIC
VALVE
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 - 3374
24
23
25 1
21
9 8
10
13
11 26 14
20 12 15
19 16
18
4
20 6
18 19
29
9 5
8
17
3
25
24
3
2 22
7
23
25
20
19
18
1. 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
4
7 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 - 2826
17
15 7
11 3
4
10 6
16
16
6
5 1
TO TANK RETURN
4 5
TUBE ASSY.
OUT 4
8
18
14
9
13
2
19
12
IN
8
7 9
4
10
11
FROM TEE AT CHECK
VALVE ON RH FENDER
SM 2191 1-03 1
Cooling System - Hydraulic Oil Cooler
Section 210-0100
5. Remove inlet line (10) from elbow (9) and connector
(8) in hydraulic oil cooler (1). Drain oil from inlet line WARNING
(10) into a suitable container. Plug inlet line and cap To prevent personal injury and property
port to prevent ingress of dirt. damage, be sure wheel blocks and lifting
equipment are properly secured and of
6. Remove outlet line (11) from elbow (9) and connector adequate capacity to do the job safely.
(8) in hydraulic oil cooler (1). Drain oil from outlet line
(11) into a suitable container. Plug outlet line and cap 1. If removed, secure bracket assemblies (2 & 3) to
port to prevent ingress of dirt. the radiator assembly with bolts (4) and hardened
washers (5), and install horns.
7. Remove mounting hardware securing hydraulic oil
cooler (1) to bracket assemblies (2 & 3). Remove 2. Secure hydraulic oil cooler (1) to bracket
hydraulic oil cooler (1) from its mounting. assemblies (2 & 3) with mounting hardware, as
removed at 'Removal'.
8. If required, remove horns along with bolts (4) and
washers (7) securing bracket assemblies (2 & 3) to the 3. Install inlet line (10) and outlet line (11) in their
radiator assembly. respective ports, as removed at 'Removal'.
CLEANING AND INSPECTION 4. Fill hydraulic tank with oil. Refer to Section
230-0040, HYDRAULIC TANK, for correct fill level and
1. Inspect fins on hydraulic oil cooler carefully, for Section 300-0020, LUBRICATION SYSTEM for
trapped debris and damage. If hydraulic oil cooler fins specifications of oil to be used.
show signs of leakage or are excessively damaged, it
must be replaced as an assembly. 5. Place the battery master switch in the 'On' position,
start engine and operate the body hydraulics several
2. Check connectors in hydraulic oil cooler ports for times to circulate the oil. Check hydraulic oil cooler (1)
damaged threads. Replace if required. and lines for leaks. Tighten fittings as required.
3. After hydraulic oil cooler is completely drained, 6. Install front grille assembly to the hood with
circulate a solution of Agmasol PS40 through the mounting hardware, as removed at 'Removal'.
cooler tubes.
7. Remove wheel blocks from all road wheels.
4. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through the hydraulic oil cooler, in
the reverse direction to normal flow, for approximately MAINTENANCE
15 minutes. The duration of circulation depends on Check and clean hydraulic oil cooler every 4 000
how badly clogged the cooler tubes are. Flush hours, or more frequently, if required. Debris in the
thoroughly with clean hot water. cooling fins can restrict the flow of air through the
cooler which significantly reduces the cooling effect.
INSTALLATION
Note: In the event of a hydraulic failure, hydraulic oil
Numbers in parentheses refer to Fig. 1. cooler should be removed and cleaned to prevent
clogging.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. SERVICE TOOLS
There are no special tools required for procedures
Note: Tighten all hydraulic lines fitted with ORFS outlined in this section. Refer to Section 300-0070,
connections, as described in Section 220-0000, SERVICE TOOLS, for part numbers of general service
STEERING SYSTEM SCHEMATIC. Renew all tools and adhesives required. These tools are available
'O' rings where used. from your dealer.
* * * *
2 SM 2191 1-03
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
SM - 2828 closed. As the main pump starts rotating it builds up
residual pressure and the priority valve opens, feeding
the main pump pressure through to the fan drive (17 &
18) & body tipping (5 & 29) valves.
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
3 4
2
Section 215-0050
47
8 9 33
6 7
13
10 11
12 44 30
16
14
17
45
15 18 32
31 31
19 21 22
46
20
25
24
23
26
29
27
1 - Orifice 10 - Check Valve 19 - Emergency Steer Valve 29 - Proportional Pressure Control Valve
2 - Bleed Down Sequence Valve 11 - Orifice 20 - Orifice 44 - Orifice
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
3
Transmission Cooler Fan Drive
The transmission cooler fan speed is modulated by
proportionally controlling the pressure at the fan motor.
Fan speed is a function of the pressure at the fan RHS
motor. 1 - Transmission Oil Temp. Sender
2 - Trans. Cooler Fan Drive Temp. Switch
On a cold start, the transmission cooler fan will not 3 - Retarder Oil Temperature Switch
rotate. A fan drive solenoid valve, mounted on the right
hand fender next to the transmission cooler, will remain Fig. 3 - Trans. Cooler Fan Drive Temperature Switch
closed, blocking actuating pressure until the
SM 2192 Rev 2 5-04 3
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
Trans. Cooler Fan Drive Temperature Switch - Typical Analog Outputs (Mv) Vs' Oil Temperature (°C)
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 - 3315
14
13
10 11 9
11 12
7 15,16 1 5
3 6
2 14
13
A 4
4
20 8 20
18 18
19 19
PART OF PART OF
FRAME FRAME
17 17
A
ORIENTATION OF
22 22
CUSHION SLEEVE
21
23
SM 2349 10-04 1
Steering System - Steering Cylinder
Section 220-0120
REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.
WARNINGS WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure lifting equipment is properly
materials and lifting equipment are properly secured and of adequate capacity to do the job
secured and of adequate capacity to do the job safely.
safely.
1. Ensure clean working conditions, remove any port
Hydraulic fluid pressure will remain plugs thus allowing easy entry of air into the cylinder,
within the system after engine shutdown. preventing a vacuum when parts are withdrawn from
Operate the treadle pedal continuously until the cylinder body (1).
pressure has dissipated before carrying out any
work on the hydraulic system or serious injury 2. Remove circlips (14) from base end of cylinder body
could result. (1) and piston rod (2) end. Press out spherical
bearings (13).
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering 3. Using special tool which can be fabricated as shown
wheel several times to relieve any pressure in the in Fig. 2, unscrew end cap (3) until thread is
steering circuit. Operate brake pedal continuously to disengaged from cylinder body (1).
relieve pressure in the braking system.
4. Pull end cap (3) and piston rod (2) out of cylinder
2. Place steering lock bar in the 'Locked' position. body (1) as an assembly.
Block all road wheels and place the battery master
switch in the 'Off' position. 5. Place piston rod (2) on supports which will not
damage the chrome piston rod diameter.
3. Identify, tag and with a suitable container in position
to catch the spillage, disconnect all hydraulic lines on 6. Remove and discard piston seal (12) and wear rings
one steering cylinder. Cap all lines and fittings to (11) from piston (9).
prevent ingress of dirt.
7. Remove grub screw (10) from wear ring groove in
4. Support steering cylinder with a suitable lifting piston (9).
device.
8. Provide an anti-torsion device through piston rod (2)
5. Remove bolt (20), lockwasher (19) and hardened eye to allow unscrewing of piston (9). Using special
washer (18) securing pin (17) at base end of the tool which can be fabricated as shown in Fig. 3,
cylinder. Remove pin (17) securing base end to the unscrew piston (9) from piston rod (2).
front frame.
9. Remove and discard 'O' ring (5) from piston (9).
6. Remove bolt (20), lockwasher (19) and hardened Remove and retain cushion sleeve (8) from piston rod
washer (18) securing pin (17) at piston rod (2) end of (2).
the cylinder. Remove pin (17) securing piston rod (2)
end to the articulation and oscillation pivot. 10. Pull end cap (3) assembly off piston rod (2).
Remove and discard back up ring (15) and 'O' ring (16)
7. Remove cylinder assembly from the machine. from end cap (3) outer grooves. Remove and discard
Spacers (21,22 & 23 ) will come free at this time. wiper (7) and rod seal (6) from end cap (3) inner
grooves.
8. Remove cylinder assembly to a clean area for
disassembly. Drain oil from cylinder assembly into a 11. If damaged, remove lube fittings (4) from cylinder
suitable container. body (1) and piston rod (2).
2 SM 2349 10-04
Steering System - Steering Cylinder
Section 220-0120
SM 2349 10-04 3
Steering System - Steering Cylinder
Section 220-0120
3. Install seals spacers (22) either side of base end of 8. Place the steering lock bar in the 'Stowed' position
cylinder and insert pin (17). Secure pin (17) to front and remove wheel blocks.
frame with bolt (20), lockwasher (19) and hardened
washer (18). 9. Place the battery master switch in the 'On' position,
start the engine and operate the steering, from lock to
4. Connect hydraulic lines to steering cylinder ports, as lock several times, to purge air out of the hydraulic
tagged during removal. lines. Check hydraulic lines and fittings for leaks.
Tighten lines and fittings as required.
5. Repeat steps 1 through 4 for installation of opposite
steering cylinder.
MAINTENANCE
6. Lubricate pins (17) through lube fittings (4) with Inspect steering cylinders regularly for leaks or
lubricant, as specified in Section 300-0020, damage, repair as required. Lubricate cylinder pins
LUBRICATION SYSTEM. every 250 hours, as specified in Section 300-0020,
LUBRICATION SYSTEM.
7. Check oil level in hydraulic tank and add oil if low.
Refer to Section 230-0040, HYDRAULIC TANK, for
correct fill level. Refer to Section 300-0020, SPECIAL TOOLS
LUBRICATION SYSTEM, for the type of oil used. Special tools can be fabricated as shown in Figs. 2 & 3.
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools
are available from your dealer.
SM - 407
DRILL
RAD
DEEP
RAD TYP
BURN OUT
SQUARE
Dimensions in mm (inches)
Fig. 2 - End Cap Torque Tool
4 SM 2349 10-04
Steering System - Steering Cylinder
Section 220-0120
SM - 633
SILVER STEEL
SQUARE
Dimensions in mm (inches)
Fig. 3 - Piston Torque Tool
* * * *
SM 2349 10-04 5
BODY SYSTEM - Body System Schematic
Section 230-0000
SM - 2848
18
LOWER
ACC3
RAISE
1
DL
5
PPA
PP B A
1
9 33 47
T
13
30
R
15 32
P1
31 31
L
LSM
21 22
46
25
PP
26
PPB
29
T LSP T
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
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).
SM 2202 3-03 1
Body System - Body Control Lever
Section 230-0081
2. Operate the treadle valve continuously to relieve 8. Reconnect main harness to body control lever
pressure in the hydraulic system. harness.
3. Block all road wheels, place the steering lock bar in 9. Place the battery master switch in the 'On' position,
the 'Locked' position and the battery master switch in start the engine and bring hydraulic oil to operating
the 'Off' position. temperature. Operate the body control lever to ensure
correct operation.
4. Disconnect body control lever harness from main
harness. 10. Remove wheel blocks and place the steering lock
bar in the 'Stowed' position.
5. Support body control lever and remove screws
securing body control lever on the right hand dash
panel. TROUBLESHOOTING
A faulty body control lever will cause an input error at
6. Remove body control lever from mounting location. the hydraulic ECU. Refer to Section 190-0085,
HYDRAULIC SYSTEM ECU.
7. Secure new body control lever on the right hand
dash panel with screws.
SPECIAL TOOLS
Note: Ensure harness from body control lever is at the There are no special tools required for procedures
front when lever is installed. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.
* * * *
2 SM 2202 3-03
BODY SYSTEM - Body Cylinder
Section 230-0130
SM - 2468
20 21 23 7 22,6 17,18 9 4 5 11 14 13 14 18 19 23 21 20
3 10 1 16 12 15
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)
90 (3.54) 10
DRILL 13 (0.51) (0.394) 11
RAD X 25 (0.984) (0.433)
DEEP
10 (0.394)
RAD TYP
150 (5.90) DIA
(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
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 calliper disc-type. The
design wherein constant pressure is stored in calliper head is designed for use with hydraulic oil as
accumulators and is regulated as required to retard or specified in Section 300-0020, LUBRICATION
stop the machine. SYSTEM. DO NOT use BRAKE FLUID (J 1703).
A brief description of the individual components used The brake head is bolted to a mounting plate on the
in the braking system are listed below. Detailed axle housing and the brake disc is bolted to the wheel.
service and operating instructions can be found in the There are 2 brake heads and one brake disc at each of
relevant component sections of this manual. the six road wheels.
SM 2198 2-03 1
Braking System - Braking System Schematic
Section 250-0000
Each brake head assembly consists of a torque plate, Hydraulic Tank
two brake pads (one on each side of the brake disc)
Refer to Section 230-0040, HYDRAULIC TANK.
and four brake pistons (two on each side of the brake
disc). The piston bores on each side of the torque
The hydraulic tank is the common reservoir for the
plate are interconnected by internal passages.
steering, braking and body hoist systems. It is
mounted off the frame and fender bracket on the rear
When the treadle valve is actuated, hydraulic oil enters
right hand side of the tractor.
the brake head and forces the pistons against the
brake pads which are in turn forced against each side
Integral with the hydraulic tank assembly are the
of the brake disc slowing or stopping the brake disc
hydraulic oil filter, oil strainer and oil level sight gauge.
and wheel rotation.
Located on the top of the tank assembly is the filler
cap and breather.
In an emergency situation, application of the park/
emergency valve will actuate the service brakes and
the parking brake to bring the machine to a halt. In this Main Hydraulic Pump (5)
condition, a restriction in the 'PB' line will slow oil flow
Refer to Section 230-0050, MAIN HYDRAULIC PUMP.
from the parking brake allowing the service brakes to
actuate momentarily ahead of the parking brake.
Mounted off the transmission power takeoff, the main
hydraulic pump supplies hydraulic oil for operating the
Parking Brake steering, body, brakes and transmission cooler fan
drive circuits.
Refer to Section 170-0010, PARKING BRAKE AND
MOUNTING.
The main hydraulic pump is an axial piston, variable
displacement type, with load sense and pressure
The parking brake consists of a sliding calliper acting
regulator.
on a brake disc on a rear driveline and is of 'Inverted
Design' i.e. requiring pressure to hold it off.
Parking Brake Pressure Switch (14)
Operation is by a spring applied/hydraulically released
Located on the main hydraulic valve assembly it
actuator. The actuator is connected through a slack
senses pressure in the parking brake (PB) line. The
adjuster to the power screw shaft that is screwed into the
pressure switch closes at a pressure of 5 bar (70 lbf/
piston in the calliper head assembly. The calliper head
in²) and sends a signal to illuminate the parking brake
assembly slides on anchor plate guides in a bracket
indicator light when the parking brake is applied.
assembly bolted to the trailer frame.
A push control on the right hand dash panel activates Brake Circuit Pressure Switches (13)
the park brake solenoid valve (6) on the main hydraulic
Front and rear brake circuit pressure switches are both
valve assembly, controlling oil pressure from the rear
located on the main hydraulic valve assembly. The
brake circuit accumulator to the actuator. Application of
pressure switches sense pressure in the front and rear
the push control releases oil from the actuator allowing
brake circuits and sends a signal to warning lights on
internal springs in the actuator to apply the parking
the dash (a buzzer also sounds) when the pressure
brake. Pulling out the push control directs oil pressure
drops below 122 bar (1 770 lbf/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.
2 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000
the body pilot pressure system. All three accumulators Advanced Retarder Braking
are of the piston type and are precharged with nitrogen
Mounted on the brake treadle valve is a potentiometer
to 95 bar (1 380 lbf/in²). It consists of a charging valve
and brake pedal interface module.
assembly, cylinder assembly and piston. The charging
valve is equipped with a locking feature which, when
The first 5° movement of the brake pedal engages the
opened, will allow precharge to be checked or
transmission retarder, providing that the transmission
accumulator charged.
'Stop' warning light is OUT, the transmission is in
'lockup' and the oil temperature is within safe operating
The piston acts as a separator dividing the cylinder
range. Further movement of the brake pedal applies the
assembly into two sections. The bottom section
service brakes in addition to the transmission retarder.
nearest the charging valve contains the nitrogen
The transmission retarder will disengage when the
precharge. Hydraulic oil from the main hydraulic pump
brake pedal is released, or when any of the operating
flows through check valves in the main hydraulic valve
conditions become out of range.
and into the top section of the accumulators.
Accumulator pressure is monitored by pressure
switches (13) in the brake lines. Valves 1, 2, 3, 4, 6, 7, 8, 10, 11, 12, 15, 16,
21 & 25
SM - 2855
These valves form part of the brake cuircuit and are an
intregal part of the main hydraulic valve assembly,
mounted on the left hand side of the tractor frame. Ref.
Section 215-0050, MAIN HYDRAULIC VALVE
(F) ASSEMBLY.
13
OPERATION
13
14
(R) Numbers in parentheses refer to Figs. 1, 2 and 9.
Brake Charging
The valves integral of the main hydraulic valve
assembly automatically maintain the brake
accumulator pressures between a lower and upper
limit.
13 - Service Brake Circuit Pressure Switches If the pressure in accumulator (18) is below the lower
14 - Park Brake Pressure Switch charge limit of 165 bar (2390 lbf/in2) the brake system
Fig. 2 - Brake System Pressure Switch Locations charge valve (8) spring closes the brake system
charge valve (8). The pressure then builds up in the
Brake Treadle Valve (9) load sense line from brake system charge valve (8) to
the shuttle valve (21) and onto the priority valve (15)
Refer to Section 250-0070, TREADLE VALVE. spring chamber where it helps this valve to close,
ensuring flow priority is to the brake charging. At the
The treadle valve controls the level of hydraulic fluid same time it also acts upon the main hydraulic pump
pressure applied to front and rear brakes and the load sense line via shuttle valve (25) to supply enough
maximum pressure available to these circuits. It is flow to charge the accumulators.
operated by a foot pedal in the operators cab and, with
the engine running, is automatically applied by the park As soon as the pressure in accumulator (18) reaches
brake solenoid valve (6) on the main hydraulic valve. the upper charge limit of 185 bar (2680 lbf/in2) the brake
system charge valve (8) opens and unloads the load
sense line to tank. This action unloads the main
hydraulic pump back to its standby pressure of 25 bar
SM 2198 2-03 3
Braking System - Braking System Schematic
Section 250-0000
(360 lbf/in2). SM - 2880
SM - 2852
12 24 36 48
K23
A K17 K50 K32
K23 K23 K52
B K14 C
K34 K5 K33 K27
K23
K15 K51 K4 D 1 - Brake Treadle Potentiometer
2 - Brake Interface Module
1 13 25 37
Fig. 3 - Fuse Box Layout (Operators Cab) Fig. 4 - Brake Treadle Potentiometer (Advanced Retarder)
1
BRAKE LIGHT 0V
(BROWN)
SIG
RETARDER 0V (VIOLET)
BRAKE
(GREEN) PEDAL 0V PEDAL
2 INTERFACE
(BLUE)
POTENTIOMETER
RETARDER OUTPUT SIGNAL MODULE
(ORANGE) +5V
(GREY)
(+) BATTERY
(RED)
(-) BATTERY
(BLACK)
4 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000
1 - Pump LS Pressure 7 - Trans. Converter Press. Hydraulic fluid pressure will remain
2 - Front Brake Pressure 8 - Body System Press.
within the system after engine shut down.
3 - Rear Brake Pressure 9 - Trans. System Pressure
4 - Park Brake Pressure P - Primary Accumulator Operate the brake treadle pedal continuously
5 - Steering Pressure FB - Front Brake Accumulator until the pressure has dissipated before
6 - Trans. Retarder Press. RB - Rear Brake Accumulator carrying out any work on the system or serious
Fig. 7 - Diagnostic Pressure Check Points (Battery Box) injury could result.
hydraulic valve assembly to the hydraulic tank. With no 1. Position the vehicle in a level work area, apply the
pressure in the parking brake circuit to hold the parking parking brake, switch off the engine and turn steering
brake off, the parking brake is applied. wheel in both directions several times to relieve any
pressure in the steering circuit.
When the emergency brake switch is deactivated
(pulled out), the electrical signal between the switch 2. Operate the brake treadle valve continuously to
and park brake solenoid valve (6) is closed, energizing relieve pressure in the braking system. Block all road
park brake solenoid valve (6). Oil flows through park wheels, place the steering lock bar in the 'Locked'
brake solenoid valve (6) and exits the main hydraulic position and the battery master switch in the 'Off'
valve assembly to the parking brake circuit to release position.
the parking brake.
3. Connect a hydraulic gauge, capable of recording a
Return oil from the 'PP' port on the brake treadle valve pressure of 0 - 345 bar (0 - 5 000 lbf/in²), to park brake
flows through the directional control valve (2) through diagnostic pressure point (4, Fig. 7) inside battery box.
park brake solenoid cartridge (6) and exits the main
hydraulic valve assembly to the hydraulic tank. 4. Place the battery master switch in the 'On' position,
start the engine and release park/emergency button
When the engine is shutdown, transmission pilot (pull out), to energise the park brake line. Monitor
pressure at directional control valve (2) is lost, causing system pressure gauge. Pressure setting should be
6 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000
7. Place the battery master switch in the 'On' position, Fig. 8 - Assembly of Typical ORFS Connector
start the engine and apply park/emergency brake (push
button in), to apply service brakes. Monitor system
pressure gauge. Brake actuating pressure for the front 'O' RING FACE SEALS (ORFS)
brake circuit is 105 +/- 5.1 bar (1500 +/- 75 lbf/in²).
Where hydraulic lines are fitted with ORFS
8. Repeat steps 6 & 7 at rear brake diagnostic pressure connections, the following procedure should be carried
point (3, Fig. 7) inside battery box. Brake actuating out during 'Installation'. Refer to Fig. 8.
pressure for the rear brake circuit is 105 +/- 5.1 bar
(1500 +/- 75 lbf/in²). a. Ensure 'O' ring/seal is in place and that the joining
surfaces are clean. If necessary, retain 'O' ring/seal in
Note: When brakes are released, a residual pressure of place with a light coating of grease or vaseline.
0.5 bar (7 lbf/in²) should remain.
b. Initially, the nuts should be tightened by hand.
9. If necessary, pressure setting can be adjusted via
brake system relief valve (7) on the main hydraulic c. Where a hose is fitted, ensure that it is not twisted
valve assembly. The operator cab will require to be or kinked when the nuts are tightened so that it is
raised to access brake system relief valve (7). Refer to allowed to adopt a natural position.
Section 260-0010, CAB AND MOUNTING.
d. Where a tube is fitted, ensure that the connection is
10. Shut off the engine and remove the pressure gauge aligned correctly.
from diagnostic check point.
e. Tighten the nut a further 1/4 to 1/2 a turn using the
11. Remove wheel blocks, place the steering lock bar correct size spanner (wrench).
in the 'Stowed' position, start the engine and check the
braking system for proper operation. f. Check that a satisfactory hose or tube routing has
been achieved.
SM 2198 2-03 7
Braking System - Braking System Schematic
Section 250-0000
8 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000
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
SM 2198 2-03 9
Braking System - Braking System Schematic
Section 250-0000
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.
10 SM 2198 2-03
Braking System - Braking System Schematic
Section 250-0000
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.
SM 2198 2-03 11
Braking System - Braking System Schematic
Section 250-0000
* * * *
12 SM 2198 2-03
BRAKING SYSTEM - Accumulator
Section 250-0060
SM - 2873
OPERATION
Numbers in parentheses refer to Fig. 1.
SM 2203 3-03 1
Braking System - Accumulator
Section 250-0060
SM - 2872 SM - 1273
P
FB
RB
2 SM 2203 3-03
Braking System - Accumulator
Section 250-0060
1. Position the vehicle in a level work area, apply the available from a local compressed gas dealer.
parking brake, switch off the engine and turn steering
wheel in both directions several times to relieve any
pressure in the steering circuit. WARNINGS
Do not use Oxygen or any gas other than
2. Operate the treadle valve continuously to relieve Nitrogen to charge an accumulator. Oxygen
pressure in the braking system. Block all road wheels under pressure coming into contact with oil or
and place battery master switch in the 'Off' position. grease will cause a violent explosion. Always
double check to make sure you are using
3. Check accumulator mountings to be sure the Nitrogen to prevent personal injury and
accumulator is held tightly in position. property damage.
4. Remove cap (1A, Fig. 1) from accumulator charging A high pressure nitrogen pressure
valve (1, Fig. 1). Attach charging line (1) to charging regulator must be used with the charging
valve by rotating 'T' handle of valve chuck (2) assembly kit. Failure to use pressure regulator
anticlockwise until it stops then screw the swivel nut could cause property damage, personal injury
down on the valve. Loosen locknut (1D, Fig. 1) by or death.
turning anticlockwise one to two turns.
1. Attach line (1) and the swivel nut to charging valve
5. Turn 'T' handle clockwise until charging valve core (1, Fig. 1) as described in steps 1 through 4 under the
is depressed. Be sure bleeder valve (10) is tight and heading 'Testing Precharge Pressure'. Be sure valves
does not leak, and valves (4 & 6) are closed. (4 & 6) are closed.
6. To read accumulator precharge pressure, slowly 2. Attach gauging head to nitrogen bottle by screwing
open cylinder valve (4). Pressure gauge (5) will down on gland nut (8).
register precharge pressure, it should be 95 bar
(1 380 lbf/in²) at 20° C (68° F) ambient temperature. 3. Open tank valve (6) slowly; pressure shown on
Refer to the table at the end of this section for nitrogen pressure gauge (5) is tank pressure.
pressures at ambient temperatures of other than 20° C
(68° F). 4. Open cylinder valve (4) slowly and charge
accumulator to 95 bar (1 380 lbf/in2) at 20° C (68° F)
7. Close cylinder valve (4) and open bleeder valve (10) ambient temperature, closing valve occasionally. Refer
to dissipate gauge pressure. Close bleeder valve (10) to the table at the end of this section for nitrogen
after pressure is relieved. If the accumulator needs pressures at ambient temperatures of other than 20° C
charged, leave line (1) and valve chuck (2) attached to (68° F).
charging valve (1, Fig. 1)). Charge the accumulator as
described under 'Charging The Accumulator'. 5. To check accumulator charge, close tank valve (6),
relieve pressure between tank and pressure gauge (5)
8. If precharge pressure is correct, rotate 'T' handle by opening bleeder valve (10) momentarily. This will
anticlockwise until it stops. Tighten locknut (1D, Fig. 1) allow gauge needle to settle, thus giving correct
on charging valve (1, Fig. 1) to 11 Nm (100 lbf in). pressure reading of accumulator charge.
Loosen the swivel nut and remove gauging head.
6. When the correct pressure for the ambient
9. Install cap (1A, Fig. 1) on charging valve (1, Fig. 1) temperature has been reached, close valves (4 & 6)
and tighten finger tight. tightly. Bleed pressure off pressure gauge (5) by
opening bleeder valve (10). Close bleeder valve when
10. Remove wheel blocks and place the battery master all pressure is bled off from the gauge and unscrew
switch in the 'On' position. gland nut (8) from the nitrogen bottle.
SM 2203 3-03 3
Braking System - Accumulator
Section 250-0060
DISCHARGING NITROGEN 7. Remove accumulators to a clean area for
Numbers in parentheses refer to Fig. 1. disassembly.
4 SM 2203 3-03
Braking System - Accumulator
Section 250-0060
ASSEMBLY
Numbers in parentheses refer to Fig. 1. WARNING
To prevent personal injury and property
1. Lubricate ‘O’ ring (9), wear rings (8), backup rings damage, be sure lifting equipment is properly
(6), 'V' section ring (7) and inside of cylinder (12) with secured and of adequate capacity to do the job
hydraulic oil prior to assembly. safely.
2. Install new 'V' section ring (7), backup rings (6) and 1. Position accumulators in battery box with the oil inlet
wear rings (8) on piston (5). ports at the top.
3. Insert piston (5) into cylinder (12) with cupped end 2. Attach clamps securely with nuts, washers and
facing the open end of the cylinder. Do not let bolts.
'V' section ring (7) drag on cylinder threads. Use a
hammer and wood block to tap piston into place until 3. Remove caps installed at removal and install
all of piston is 50 mm (2.0 in) below beginning of hydraulic lines securely to the oil inlet ports at the top
honed bore. Keep pressure against piston while of the accumulators.
tapping 'V' section ring (7) through the bore chamfer,
otherwise piston will bounce back, damaging the 4. Charge the accumulator with Nitrogen gas as
'V' section ring. described under 'Charging the Accumulator' in this
section.
4. Install new 'O' ring (9) on end cap (10) and install
end cap (10) in cylinder (12). Tighten cap so that it is 5. Install cover to bottom of battery box.
flush with the end of cylinder (12) within 1.59 - 2.38 mm
(0.0625 - 0.0938 in) above or below. 6. Check oil level in hydraulic tank and add oil as
required. Refer to Section 230-0040, HYDRAULIC
5. Install charging valve (1). Tighten locknut (1D) TANK, for correct fill level and Section 300-0020,
clockwise to 11 Nm (100 lbf in) to close charging LUBRICATION SYSTEM, for oil specification.
valve, insert valve core (1B), replace valve cap (1A)
and tighten finger tight. 7. Place the battery master switch in the 'On' position,
start the engine and check for leaks. Tighten lines and
6. Test accumulator hydraulically for leakage or failure fittings as required. Remove wheel blocks.
at 255 - 276 bar (3 700 - 4 000 lbf/in²). Discharge after
testing.
MAINTENANCE
Inspect accumulator assembly for leaks. If leaks are
INSTALLATION found, disassemble and replace all 'O' rings and seals.
Note: Tighten all fasteners without special torques Inspect hydraulic lines for wear and leaks. Replace/
specified to torques listed in Section 300-0080, tighten lines as required.
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
SPECIAL TOOLS
Note: Tighten all hydraulic lines fitted with ORFS Refer to Section 300-0070, SERVICE TOOLS, for part
connections, as described in Section 250-0000, numbers of the charging assembly kit and other
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings general service tools required. These tools are
where used. available from your dealer.
SM 2203 3-03 5
Braking System - Accumulator
Section 250-0060
TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft lbf in
1 1D 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 2203 3-03
BRAKING SYSTEM - Treadle Valve
Section 250-0070
SM - 2874
3
4 14
5 15
11
36
6
23
7
16 24
8
25
9 26
27
17
10 28
35
18 29
19
11
20 30
12 1
21 31
13 32
22
33
34
SM 2208 3-03 1
Braking System - Treadle Valve
Section 250-0070
SM - 2875 SM - 2876
9 9
PP PP
SUPPLY SUPPLY
FROM FROM
P1 P1
TO FRONT A1 MAIN HYDRAULIC FROM FRONT A1 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC1 BRAKES VALVE, PORT ACC1
T1 T1
SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC2 BRAKES VALVE, PORT ACC2
T2 T2
Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release
(36) mounted on a dashboard support, underneath the assembly. Spools (10 & 13) have closed off the inlet
dashboard. The brake pedal interface module (36) ports, outlet ports and the tank ports and will remain in
converts voltage signals from the potentiometer (35) to this position as long as pedal (1) assembly is not
activate the rear brake lights and the transmission moved. If the operator further depresses pedal (1)
retarder when the treadle valve is depressed. Refer to assembly, spools (10 & 13) will move up and build
Fig. 7. more pressure in the brake until it balances the pedal
force.
OPERATION
Numbers in parentheses refer to Fig. 1. Normal Service Brake Release
Refer to Fig. 3. When the operator releases pedal (1)
Normal Service Brake Application assembly, spools (10 & 13) will become unbalanced
Refer to Fig. 2. When the operator depresses pedal and move downwards, opening outlet ports 'A1' and
assembly (1), push rod (33) is moved up and pushes 'A2' to tank. At this point, oil in the 'A1' and 'A2' lines is
on pistons (24 & 27) which in turn, pushes spools (10 released to tank through tank ports 'T1' and 'T2',
& 13) up. As spools (10 & 13) move up, the metering releasing the brakes.
notches move out of the tank cavity and close outlet
ports 'A1' and 'A2' off to tank ports 'T1' and 'T2'. Spools
(10 & 13) continue to move upwards until the metering
Emergency Stop Brake Application/
notches become exposed to the inlet pressure ports. Release
This movement opens inlet ports 'P1' and 'P2' to outlet Refer to Fig. 4. Pushing in the park/emergency control
ports 'A1' and 'A2' respectively. As hydraulic pressure results in the de-energization of the park brake
builds in the brake, oil flows through the small orifice in solenoid valve within the main hydraulic valve. This
spools (10 & 13) and into the cavities above the allows full pressure to enter the 'PP' port in the treadle
spools. As pressure rises in the brake it also rises in valve simulating a full and immediate depression of
the cavities above the spools forcing spools (10 & 13) pedal (1) assembly, i.e. pushing spools (10 & 13)
downwards closing outlet ports 'A1' and 'A2'. Spools upwards and thereby applying maximum braking
(10 & 13) are now balanced between the brake action.
pressure and the pressure of springs (20 - 22)
generated by the operators force on pedal (1) Refer to Fig. 5. Pulling out the park/emergency control
2 SM 2208 3-03
Braking System - Treadle Valve
Section 250-0070
SM - 2877 SM - 2878
9 9
SUPPLY
FROM TO TANK VIA
PP PP MAIN HYDRAULIC
MAIN HYDRAULIC
VALVE, PORT PBP VALVE, PORT PBP
SUPPLY
SUPPLY FROM
P1 P1
TO FRONT A1 FROM FROM FRONT A1 MAIN HYDRAULIC
BRAKES MAIN HYDRAULIC BRAKES VALVE, PORT ACC1
T1 VALVE, PORT ACC1 T1
SUPPLY SUPPLY
FROM FROM
P2 P2
TO REAR A2 MAIN HYDRAULIC FROM REAR A2 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC2 BRAKES VALVE, PORT ACC2
T2 T2
will energize the park brake solenoid valve within the 'Stop' warning light is OUT, the transmission is in
main hydraulic valve, allowing the pressure in the 'PP' 'lockup' and the oil temperature is within safe operating
line to fall via the return to tank port opened within the range. Further movement of the pedal (1) applies the
park brake solenoid valve. Outlet ports 'A1' and 'A2' are service brakes in addition to the transmission retarder.
opened to tank ports 'T1' and 'T2' allowing oil in the 'A1' The transmission retarder will disengage when the
and 'A2' lines to return to tank, releasing the brakes. pedal (1) is released, or when any of the operating
conditions become out of range.
SM 2208 3-03 3
Braking System - Treadle Valve
Section 250-0070
REMOVAL SM - 2879
A
WARNINGS P2
P
To prevent personal injury and property
A2
T T2
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job P1
P
safely.
T T1
A1
Hydraulic oil pressure will remain A
within the system after engine shut down.
Operate the treadle pedal continuously until the PP
pressure has dissipated before carrying out any
work on the braking system or serious injury PP
could result.
4 SM 2208 3-03
Braking System - Treadle Valve
Section 250-0070
SM - 2853
1
BRAKE LIGHT 0V
(BROWN)
SIG
RETARDER 0V (VIOLET)
BRAKE
(GREEN) PEDAL 0V PEDAL
2 INTERFACE
(BLUE)
POTENTIOMETER
RETARDER OUTPUT SIGNAL MODULE
(ORANGE) +5V
(GREY)
(+) BATTERY
(RED)
(-) BATTERY
(BLACK)
5. Separate pilot housing (30) and valve housing (16) (16). Note: Be careful not to scratch housing bore.
by removing screws (31). Remove 'O' ring (17) from
valve housing (16). 13. Separate spacer (15) and spools (10 & 13) from
sleeves (9 & 12). Note: Excessive wear on either
6. Remove piston (27) from pilot housing (30). Note: Be spools (10 & 13) or sleeves (9 & 12) may require
careful not to scratch housing bore. replacement. Spool (10)/sleeve (9) and spool (13)/
sleeve (12) are matched sets and MUST be replaced
7. Remove 'O' rings (26 & 28) and back-up rings (25 & as matched sets - DO NOT intermix.
29) from piston (27), being careful not to damage 'O'
ring and piston grooves. 14. Remove 'O' ring (11) and cup (14) from spacer (15).
Remove other 'O' rings (11) from sleeve (12) and 'O'
8. Remove piston (24), springs (20, 21 & 22) and shims rings from sleeve (8). Note: Be careful not to damage
(19) from valve housing bore. cup and 'O' ring grooves and bores.
10. Remove retainer assembly (18) from housing bore. Lubricate all new rubber components with clean
Note: Ball is pressed into retainer. hydraulic oil used in the braking system. Refer to
Section 300-0020, LUBRICATION SYSTEM.
11. Loosen nut (2) and remove end plug (5) from
housing. Remove spring (7), retainer (6), nut (2), 1. Clean all parts thoroughly before assembly.
washer (3) and 'O' ring (4) from end plug (5).
2. Install new cup (14) in spacer (15) and one new 'O'
12. Remove spacer (15), sleeves (9 & 12) and spools ring (11) on spacer (15). Note direction of cup.
(10 & 13) assembly from housing bore. This assembly
must be removed through end plug (5) end of housing 3. Install other new 'O' rings (11) on sleeve (12) and
SM 2208 3-03 5
Braking System - Treadle Valve
Section 250-0070
new 'O' rings (8) on sleeve (9). 17. Install new boot (34) on push rod (33).
4. Lubricate spool (13) with clean hydraulic oil and 18. Assemble cam assembly and secure with circlips.
carefully insert into sleeve (12). Note direction of spool.
19. Install mounting plate to treadle valve.
5. Insert spacer (15) into housing bore through end plug
(5) end. Note direction of spacer.
INSTALLATION
6. Lubricate sleeve (12) and spool (13) assembly with Numbers in parentheses refer to Fig. 1.
clean hydraulic oil and carefully insert into housing bore
using a wooden dowel. Note direction of assembly. Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
7. Carefully insert sleeve (9) into housing until it rests TORQUE SPECIFICATIONS.
against sleeve (12). Lubricate spool (10) with clean
hydraulic oil and carefully insert into sleeve (9). Note Note: Tighten all hydraulic lines fitted with ORFS
direction of spools and sleeves. connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
8. Install spring (7) and retainer (6) into housing bore. where used.
9. Install end plug (5) and torque to 11 - 20 Nm (96 - 1. Secure treadle valve and mounting plate assembly
180 lbf in) to seat sleeves. Then turn back end plug 1/4 to front of cab using four bolts removed previously.
turn and torque to 1 - 7 Nm (10 - 60 lbf in). Install new
'O' ring (4), washer (3) and nut (2). Hold end plug and 2. Connect electrical connection to the brake pedal
torque nut to 68 - 81 Nm (50 - 60 lbf ft). potentiometer (35).
10. Install new 'O' ring (17) on valve housing (16). 3. Remove blanking caps and connect hydraulic lines
to the treadle valve assembly as noted at 'Removal'.
11. Install retainer assembly (18) in housing. Note:
Depress retainer (18) until it bottoms on spacer (15). 4. If previously removed install engine air intake tube,
Spools (10 & 13) and retainer (18) should return when or if applicable, lower the cab. Refer to Section 260-
released. If the spools and retainer do not return when 0010, CAB AND MOUNTING.
released, the bore of sleeves (9 & 12) were possibly
damaged when installed. 5. Fill hydraulic tank with oil specified in Section
300-0020, LUBRICATION SYSTEM.
12. Install shims (18), springs (20, 21 & 22) and piston
(24) in valve housing bore. Note: For proper brake 6. Place the battery master switch in the 'On' position,
pressure setting, install the same number of shims and start the engine and bring hydraulic oil to operating
spacer that were removed during disassembly. If temperature.
spools (10 & 13), sleeves (9 & 12), or spring (22) were
replaced, shim adjustment may be required. 7. Apply the brakes and check for oil leaks. Tighten
line connections and fittings as necessary.
13. Install new 'O' rings (26 & 28) and new back-up
rings (25 & 29) on piston (27). Note order of back-up Note: When performing Step 8, make sure that parking
rings and 'O' rings. brake applies and releases appropriately.
14. Lubricate piston (27) with clean hydraulic oil and 8. Check brake operations by actuating pedal and park/
insert into pilot housing (30) through valve housing (16) emergency control. Ensure that the pedal assembly is
end. Be sure to install piston (27) as far as it will go free to operate.
into pilot housing bore.
9. Shut off engine and check hydraulic tank oil level.
15. Carefully attach pilot housing (30) to valve housing Replenish as necessary.
(16) using screws (31). Torque screws to 24 - 30 Nm
(18 - 22 lbf ft).
16. Install spring (32) and push rod (33) into pilot
housing (30) bore.
6 SM 2208 3-03
Braking System - Treadle Valve
Section 250-0070
1. Position the vehicle in a level work area, apply the SPECIAL TOOLS
parking brake, switch off the engine and turn steering There are no special tools required for the procedures
wheel in both directions several times to relieve any outlined in this section. Refer to Section 300-0070,
pressure in the steering circuit. SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
2. Operate the treadle valve continuously to relieve adhesives are available from your dealer.
pressure in the braking system. Block all road wheels,
place the steering lock bar in the 'Locked' position and
the battery master switch in the 'Off' position.
SM 2208 3-03 7
Braking System - Treadle Valve
Section 250-0070
8 SM 2208 3-03
Braking System - Treadle Valve
Section 250-0070
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 2208 3-03 9
OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010
SM - 2880
14,18 20,21
19
15
16
17
22
13 13
12 12 20,21
11 11
31, 32
33, 34
CAB - R.H.S.
RH LH LH RH
27
30
23
29 28 29
6 2 6
23 3
4 10
24 25
6 5 LH
1 26 9 8
7
6
RH
26
SM 2209 9-05 1
Operators Compartment - Cab and Mounting
Section 260-0010
SM - 2882
11
9
8 CAB BRACKET
10 5
13
3 9 12
6
BRACKET IN 11
1 BATTERY BOX
FRAME BRACKET
12 13
16
2
15
14
2 SM 2209 9-05
Operators Compartment - Cab and Mounting
Section 260-0010
4. Disconnect the electrical cables in the following Disconnect earth strap at rear right hand cab support
order to prevent damage to the electrical components: (23).
a. Battery earth cable. 11. Lower cab safety prop (7) and place in the stowed
b. Battery supply cable. position, then using lifting equipment, slowly lower cab
c. Alternator earth cables. until horizontal.
d. Alternator supply cables.
e. Electrical harnesses at cab bulkhead. 12. Remove spring pins (6) to allow right hand pins (24)
to be driven out using a suitable driver.
9. Attach suitable slings to the cab lifting points and 5. Install and connect steering valve hoses as noted on
raise lifting equipment to take up the slack. Disconnect removal. Connect earth strap at rear right hand cab
cab raise cylinder (7, Fig. 2) from cab floor by removing support.
bolt (11, Fig. 2), washer (12, Fig. 2) and nut (13, Fig.
2). 6. Connect and secure any other harnesses and hoses
that were previously removed.
10. Tag and disconnect any other harnesses and
hoses that may be affected by cab removal. 7. Place cab safety prop (7) in the stowed position.
SM 2209 9-05 3
Operators Compartment - Cab and Mounting
Section 260-0010
Using hand pump (1, Fig. 2) to control lowering of cab, SM - 2881
gently lower cab until cab brackets align with cab
supports (23). Install pins (1) and secure with spring
pins (6).
TILTING THE CAB 5. Using hand pump (1), charge the cab raise cylinder
Numbers in parentheses refer to Fig. 2, unless (7) sufficiently to allow left hand pins (1, Fig. 1) to be
otherwise stated. removed. Hold cylinder (7) in this position by locking
hand valve on hand pump (1).
WARNINGS 6. Remove spring pins (6, Fig. 1), then drive out pins
To prevent damage, always ensure hood is (1, Fig. 1). Carefully raise or lower the cab as
raised before tilting or lowering the cab. necessary to facilitate removal of pins (1, Fig. 1).
Never work near or under an unblocked 7. Once pins (1, Fig. 1) have been safely removed,
or unsupported cab. Always use the cab safety continue to raise the cab using hand pump (1) until the
prop. cab safety prop (1, Fig. 3) can be fitted.
1. Position the vehicle in a level work area, apply the 8. Remove pin assembly (8, Fig. 1) to allow cab safety
parking brake and switch off the engine. prop (1, Fig. 3) to swing down to a vertical position on
top of the front left hand cab leg.
2. Operate the brake pedal continuously to relieve
pressure in the hydraulic system. 9. Lock the cab safety prop (1, Fig. 3) in position using
pin assembly (8, Fig. 1), locating through holes on
3. Block all road wheels, place the battery master bracket at front left hand cab leg.
switch in the 'Off' position and lift the hood assembly.
10. Lock off hand valve on hand pump (1). Remove
4 SM 2209 9-05
Operators Compartment - Cab and Mounting
Section 260-0010
lever (6) from pump (1) and place in the stowed 2. Remove mirror arm bracket (11) and ball bearings
position. (14) from mounting brackets.
WARNINGS Installation
To prevent damage, always ensure hood is Numbers in parentheses refer to Fig. 1.
raised before tilting or lowering the cab.
Note: Tighten all fasteners without special torques
Never work near or under an unblocked specified to standard torques listed in
or unsupported cab. Always use the cab safety Section 300-0080, STANDARD BOLT AND NUT
prop. TORQUE SPECIFICATIONS.
1. Support mirror arm bracket (11) and remove locknuts To replace a glass assembly, proceed as follows:
(17), hardened washers (15) and springs (16) securing
mirror arm assembly to mounting brackets. Note: Ensure the glass is supported adequately before
SM 2209 9-05 5
Operators Compartment - Cab and Mounting
Section 260-0010
starting to cut the adhesive seal. 9. Clean off any excess adhesive using a suitable
solvent.
1. Using a pointed tool, pierce a hole in the adhesive
seal, it is advisable to start at the top edge of the
glass. Unscrew one handle of the special tool and feed Water Leaks
the wire through the opening. Pierce a second hole in Test for leaks by directing a stream of water along the
the adhesive on the side directly opposite the first. adhesive seal, while an assistant marks the spot of
leakage inside the cab. Care should be taken to note
2. From inside the cab pull the wire through and feed it whether the leak is between adhesive and glass. Then
back out through the second hole. apply a sealing compound from the outside. Start from
a point near the leak and continue applying the sealer
3. Re-fit the handle on the special tool. Pull both until well beyond the suspected point of entry.
handles outwards until wire is taut.
This should stop the leak immediately, but since some
4. Manoeuvre the special tool around the edge of the sealing compounds should be allowed to set before
glass, keeping the wire taut, to cut the adhesive seal. getting wet, wait a few minutes before testing.
Ensure the glass is supported adequately before
completing the cut.
MAINTENANCE
5. Clean the remains of the adhesive from the edge of
the panel opening using a suitable solvent.
General
Ensure that hand pump hydraulic tank (2, Fig. 2) is
6. Coat the edge of the replacement glass with primer filled with clean hydraulic oil as specified in Section
and apply adhesive around the lip of the window 300-0020, LUBRICATION SYSTEM. Capacity is 0.75
aperture, as per the manufacturers recommendations. litre (0.2 US gallon).
* * * *
6 SM 2209 9-05
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
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
16. Slacken nut (21) and bolt (20). Adjust bolt (20) to fan guard assembly to radiator assembly. Refer to
release tension on drive belt (3). Section 210-0040, RADIATOR AND MOUNTING.
17. Drive belt (3) should now be free to slide off the 20. If required, remove bolts (28), lockwashers (18),
groove in compressor (1). washers (13) and bracket (2) from engine.
18. Support compressor (1) and remove bolts (25), 21. If required, remove bolts (24), lockwashers (23),
washers (26) and nuts (27) securing compressor (1) to washers (22) and bracket (19).
bracket (2). Remove compressor (1) from the vehicle.
Note: If fitted, coolant filter will have to be removed.
Note: If drive belt (3) does not require replacement do
not remove from engine pulley. If drive belt (3) requires 22. If required, disconnect all clamps and clips
replacement, proceed with steps 19 and 20. securing refrigerant hoses and harnesses to the
vehicle. Remove hoses and harnesses from the
19. If required, remove mounting hardware securing vehicle.
4 SM 2211 Rev1 10-04
Operators Compartment - Air Conditioning
Section 260-0130
SM - 3318
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.
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)
8. Store belts in a cool, dry place. If stored on a Use only refrigerant oil as specified in Section
machine, relieve all belt tension by loosening the 300-0020, LUBRICATION SYSTEM.
drive belt tightener.
9. Never attempt to check or adjust belts while they are System Leak Testing
running. Recommended Equipment Required:
Electronic Leak Detector
Refrigerant Oil Switch off the engine and check all connections
throughout the system for leaks. A large leak point will
have an oily or greasy appearance. The refrigerant
WARNINGS carries compressor oil with it and deposits it around the
To prevent personal injury always wear rubber leak area. Check all such points for loose connections
gloves when handling refrigerant oils. and tighten.
Too much refrigerant oil will dampen the Using a suitable leak detector, search for leaks around
cooling effect and too little refrigerant oil may all joints, connections, seals and control devices. If a
lead to compressor failure. If in doubt flush leak is located, purge the system of refrigerant and
the system. repair. Fully evacuate and charge the system to make
it operational.
Oil is required to lubricate the compressor. The oil
mixes with the refrigerant and is carried around the
system. The compressor is supplied with an oil DISCHARGING THE SYSTEM
charge. However, additional oil is required, the Note: Refer to all WARNINGS listed under
amount depending on the length of refrigerant hose 'Maintenance' prior to discharging the system.
being used. The quantity added should be calculated
using the following equation: Recommended Equipment Required:
Portable High Vacuum Charging Station
Amount of oil to add in fl oz. = Suitable Canister
(0.47 x total length of hoses in m) - 2.15 or Standard Service Manifold (Refer to Fig. 4)
6. Connect both service hoses from the two fittings (2 14. Vent the refrigerant mix to atmosphere by
& 3) in the bottom of the manifold to the two service removing the service hose (yellow) from the Nitrogen
ports on the compressor. High side (red) to compressor cylinder and opening the low side hand valve on the
discharge valve, low side (blue) to compressor suction manifold. Re-evacuate the system to below 6 mb
valve. (steps 7 to 10).
7. Switch vacuum pump on, open vacuum pressure 15. Lower hood assembly and remove wheel blocks.
valve (1) until less than 6 mb is reached on vacuum
gauge (A). The vacuum gauge (A) should remain at
this value when vacuum pressure valve (1) is closed CHARGING THE SYSTEM
to indicate that there are no leaks. Note: Refer to all WARNINGS listed under
'Maintenance' prior to charging the system.
8. Open the low side hand valve on the manifold and
vacuum pressure valve (1) and watch that the Recommended Equipment Required:
gauges start to register that a vacuum is being drawn. Portable High Vacuum Charging Station
If the gauges do not register the vacuum thena Electronic Leak Detector
blockage is present. Open the high side and pump or Standard Service Manifold (Refer to Fig. 4)
down until a vacuum of 10 mb is achieved.
For New Or Completely Empty System 8. Start vacuum pump to evacuate the complete air
conditioning system.
Note: The charging procedure must be done in ambient
temperatures above 15.5° C (60° F) with the R-134a
9. Run vacuum pump for approximately 30 minutes.
canister temperature equal to the outside ambient
Ideal gauge readings should be 29.92 inches of
temperature.
mercury. The pressure will vary with altitude; it will be
approximately 0.03 bar (0.5 lbf/in²) less for each 305 m
1. Shut off engine and block all road wheels.
(1 000 ft) of elevation.
2. Pull on handle to release hood catch and raise the
10. Before disconnecting power supply from vacuum
hood.
pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
3. Remove protective caps from 'quick coupler' valves
R-134a source.
on rear of compressor.
11. Open R-134a source. Loosen, but do not remove,
4. Connect low pressure gauge hose (blue hose and
yellow supply hose at manifold on gauges to remove all
gauge) to suction side or low side fitting on
air in the yellow supply hose, replacing the air with R-
compressor. The suction side can be identified by the
134a. This is done in a few seconds. Tighten yellow
size of the hose connected to the fitting. This will be
supply hose.
the largest diameter hose of the system.
12. Open low side of R-134a gauges slowly. When
5. Connect the high pressure gauge hose (red hose and
gauge reads zero open both sides completely. Vacuum
gauge) to discharge or high side fitting on compressor.
in the system will draw R-134a gas into the system.
6. Connect yellow supply hose to suction port on
Hold until both gauge readings equalize.
vacuum pump.
Note: Never charge with liquid R-134a. Charge on
7. Open both sides of gauges, low and high, completely.
the low pressure side only.
SM - 2424
Gauges: Valves: 5. With the system completely charged, shut off the
A - Vacuum Gauge 1 - Vacuum Pressure engine. Close the valve on the R-134a canister and
B - Low Pressure Gauge 2 - Suction Line remove the yellow supply hose. Remove both the low
C - High Pressure Gauge 3 - Discharge Line
D - Charging Cylinder 4 - Refrigerant Gas pressure (blue) hose and high pressure (red) hose from
Pressure Gauge 5 - Refrigerant Liquid the filling ports on the compressor.
Port:
6 - Vacuum Connection Note: Some R-134a will escape as the hoses are being
Fig. 4 - Standard Service Manifold removed.
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.
2. Vibration/Noise in Compressor
area
3. Noise - Evaporator
5. Electrical Trouble
Blower motor or condenser fan Defective circuit breaker or bad Replace. Clean and tighten
motor inoperable wiring connections connections
* * * *
SM - 2883
10
1
6
15
5
13
4
7 A A
8
A
14
17
BODY
18 1
19 3
21
16
8
17
18
11
20 2
22 12 9
L.H. FRAME RAIL
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 - 3299
19 31 19 19
5 18 1 32 4 30 15 20 10 23 3 23 10 11 22 15 11 35 12 20 15 13
33 17 14 16 34 6 7 23 15 10 29 2 28 25 11 9 21 27 23 20 15 23 12 35 15 13
19 19 19
Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and
'Miscellaneous Servicing' contained on the following pages.
Notes on Lubrication and Service Chart Note 5 - Change safety element after every third
primary element service.
Note - Capacities given are approximate - work to
dipstick, sight gauges or level plugs. EO - Engine Oil. Refer to 'Recommended
Lubricants' and 'Engine Oil Drain Intervals'.
Note 1 - Lubricate slowly until excess lube is seen.
HO - Hydraulic Transmission Oil. Refer to
Note 2 - Capacity of front and rear differentials is 'Recommended Lubricants'.
17 litres (4.5 US gal). Capacity of centre
differential is 18.5 litres (4.9 US gal). This EPL - Extreme Pressure Gear Lubricant spec.
includes 1.5 litre (3.2 pints) for priming the MIL-L-2105D.
3rd differential unit. EP, NLGI- Extreme Pressure Lithium No. 2 Grease
Note 3 - Clean radiator and cooler fins more often (without 'Molybdenum').
when operating under extremely dusty PAG Oil - Polyalklene Glycol (PAG) Compressor
conditions. Lubricating Oil - Low Viscosity (ISO46).
Note 4 - Remove plug from port on underside of
oscillation hub. Plug is removed to drain the
cavity of any oil that enters the cavity when
filling. Remove grommet and level plug on
side of oscillation hub. Add oil if required.
Refit all plugs.
RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE
Engine Crankcase Engine Oil with 1.00% 41 litre CH-4 15W-40
(Including Filters) sulphated ash limit is (10.8 US gal) (See Note 1)
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission Engine Oil with 1.85% 63 litre (See Note 2) CH-4 15W-40
(Including cooler) max. sulphated ash limit (16.6 US gal) See Trans.
Oil Table.
Transmission Engine Oil with 1.85% 8.25 litre (See Note 2) CH-4 15W-40
Cooler max. sulphated ash limit (2.18 US gal) See Trans.
Oil Table.
Hydraulic System Hydraulic Transmission Oil 202 litre See Hydraulic Oil Table
(Including Lines) (53.4 US gal) (See Note 3)
Cooling System TEREX Pro-Cool 54 litre
(14.3 US gal)
Differential Extreme Pressure 17 litre each MIL-L-2105 D GL-5 80W-90 LS
(Front & Rear) Gear Lubricant (4.5 US gal) (See Note 4)
Differential Extreme Pressure 18.5 litre MIL-L-2105 D GL-5 80W-90 LS
(Centre) Gear Lubricant (4.9 US gal) (See Note 4)
Planetaries Extreme Pressure 3 litre each MIL-L-2105 D GL-5 80W-90 LS
Gear Lubricant (0.8 US gal) (See Note 4)
Fuel Tank Diesel Fuel Oil with 390 litre DIN EN590
max. sulphur 0.5% (103 US gal)
Grease Nipples Extreme Pressure No.2
Lithium Grease Consistency
Driveshaft through Extreme Pressure (See Note 4 - Page 3) MIL-L-2105 D GL-5 80W-90
Bearings Gear Lubricant
Articulation Extreme Pressure No.2
Bearings Lithium Grease Consistency
Air Conditioning Polyalklene Glycol (PAG) 0.125 litre ISO46
Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10
Low Viscosity
* - Capacities given are approximate, work to dipstick, Note 3 - Hydraulic Transmission Oil meeting
sight gauges or level plugs. Specification EMS19058 is suitable for use in the
hydraulic system.
Note 1 - The use of low viscosity oils, such as 10W-30
or 5W-30, can be used to aid in starting the engine and Note 4 - Axles have limited slip differentials. If use of
providing sufficient oil flow at low ambient standard SAE 90 oil results in very loud noise and
temperatures. Continuous use of low viscosity oils can jerking of the wheels when driving slowly round sharp
decrease engine life due to wear. corners, an EP oil with limited slip additives should be
used.
Note 2 - Operation below the minimum temperatures
listed for the oil used without proper preheat or warm-up Note 5 - Automatic Transmission Fluids (ATF) may
results in greatly reduced transmission life. Proper only be used when the ambient temperature is less
warm-up requires 20 minutes minimum operation in than -10° C (14° F). Should the temperature increase, it
neutral (with engine at part throttle) before operating the is necessary to switch to engine oil.
transmission in gear.
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.
* * * *
SM - 625
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
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
Dimensions in mm (in)
Fig. 4 - End Cap Torque Tool (Section 230-0130, BODY CYLINDER)
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
0
2 PLACES 2 PLACES
10
40˚
114
R 20
71
31
48 16
* * * *
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
1.12 - 7 366 270 800 590 1 132 835 1 302 960 1 447 1 067
1.12 - 12 407 300 902 665 1 274 940 1 451 1 075 1 624 1 198
1.25 - 7 515 380 1 132 835 1 600 1 180 1 830 1 350 2 043 1 507
1.25 - 12 569 420 1 254 925 1 776 1 310 2 034 1 500 2 267 1 672
1.38 - 6 664 490 1 478 1 090 2 095 1 545 2 400 1 770 2 676 1 974
1.38 - 12 759 560 1 688 1 245 2 393 1 765 2 739 2 020 3 056 2 254
1.50 - 6 881 650 1 966 1 450 2 786 2 055 3 186 2 350 3 556 2 623
1.50 - 8 936 690 2 088 1 540 2 962 2 185 3 390 2 500 3 781 2 789
1.50 - 12 990 730 2 217 1 635 3 145 2 320 3 593 2 650 4 010 2 958
1.75 - 5 - - - - 4 393 3 240 5 016 3 700 5 604 4 133
1.75 - 12 - - - - 5 091 3 755 5 830 4 300 6 497 4 792
1.88 - 8 - - - - 6 006 4 430 6 874 5 070 7 664 5 653
1.88 - 12 - - - - 6 304 4 650 7 213 5 320 8 048 5 936
2.00 - 4.5 - - - - 6 623 4 885 7 565 5 580 8 448 6 231
2.00 - 8 - - - - 7 342 5 415 8 406 6 200 9 367 6 909
2.00 - 12 - - - - 7 687 5 670 8 786 6 480 9 811 7 236
2.25 - 4.5 - - - - 9 701 7 155 11 090 8 180 12 377 9 129
2.25 - 8 - - - - 10 629 7 840 12 148 8 960 13 566 10 006
2.25 - 12 - - - - 11 050 8 150 12 636 9 320 14 102 10 401
2.50 - 12 - - - - 15 280 11 270 17 463 12 880 19 500 14 383
Note: Where materials other than GM Standards are used, refer to the conversion table below.
Types of Steel Rockwell Hardness Applicable Torque Values SAE Bolt Head Symbols
Range
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
* * * *
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.
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2 SM 1239 2-98