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B25B 6X6 ADT EXPORT (MKII)

VIN : AEB 476812 TRO 00379 to 00524


VIN : AEB 476812 TRA 00376 to 00526
VIN : AEB 476812 VRO 00565 to 00825
VIN : AEB 476812 VRA 00527 to 00860

PARTS MANUAL

Document Part Number 872057

Issue : SEPTEMBER 1998

Technical Documentation
BELL EQUIPMENT COMPANY
Richards Bay
IMPORTANT

Due to BELL’s policy of continuous product improvement, the information contained in this manual was correct
upto the time of printing (Issue date of manual). Any changes after this date will only be included in the next
update of this manual.

Illustrations in this manual are pictorial representations of the component and are not drawn to scale.
INTRODUCTION
This manual has been produced to assist you in ordering of parts for the maintenance of your BELL machine.

The information contained in the manual is in a logical sequence. Each illustrated breakdown is supported with
a parts list.

The parts manual has been produced by the Technical Documentation Department of BELL EQUIPMENT Co.
Every effort has been made to ensure that the information in this manual was correct at the time of publication.
BELL EQUIPMENT Co. has a policy of continuous product development, improvement and design. BELL
EQUIPMENT Co. reserves the right to change, amend and update the design of its product at any time without
prior notice. With this policy, changes may have occurred that are not included in this manual.

Whilst every endeavor has been made to provide accurate and reliable information, BELL EQUIPMENT Co.
specifically disclaims any actual or implied warranty and under no circumstances shall be liable for any loss,
damage or injury to person or property suffered, whether direct, or indirect or consequential, arising from the
use of this manual. In particular and without detracting from the above, the disclaimer also applies in the event
of any specification, warning, or representation contained in this manual being inadequate, inaccurate, or
unintentionally misleading.

The user is urged to strictly comply with the instructions and warnings that are given in the interests of general
safety. Please do not hesitate to contact your BELL Product Support Representative whenever you have a query
on you BELL product or this manual. The address of your nearest BELL branch or dealer is as follows:-

The following address list was correct as at 31 July 1996.

R.S.A.
RICHARDS BAY (HEAD OFFICE):
Carbonode Cell ☎ (0351)9079111 P.O. Box 198
Alton Fax : (0351) 974336 RICHARDS BAY
RICHARDS BAY Telex: 661011 3900
3900

RICHARDS BAY (TRAINING):


Carbonode Cell ☎ (0351)974302/3 P.O. Box 198
Alton Fax : (0351) 973699 RICHARDS BAY
RICHARDS BAY 3900
3900

BLOEMFONTEIN:
23 George Lubbe Street ☎ (051) 353900/1 P.O. Box 1878
Hamilton A/H : (051) 478888 BLOEMFONTEIN
BLOEMFONTEIN Radio Page 7255 (Parts) 9300
9300 Fax : (051) 353899

CAPE TOWN:
Milan St. ☎ (021) 3862252 P.O. Box 162
Airport Industria A/H : (021) 9811425 EPPINGDUST
CAPE TOWN Fax : (021) 3862260 7475
7525

EMPANGENI:
15 Brons Street ☎ (0351) 26106 P.O. Box 7332
EMPANGENI RAIL A/H : (0351) 923391 EMPANGENI RAIL
3910 Fax : (0351) 924342 3910
GEORGE:
Pioneer Road ☎ (0441) 8780930/1 P.O. Box 1697
Pacaltsdorp A/H : (0441) 741996 GEORGE
GEORGE Fax : (0441) 8780932 6530
6534

JOHANNESBURG (JET PARK):


Griffith Road ☎ (011) 928 9700 to 22 P.O. Box 25391
Jet Park Fax : (011) 928 9730 EAST RAND MALL
KEMPTON PARK BOKSBURG
1619 1462

JOHANNESBURG (SALES):
Griffith Road ☎ (011) 928 9700 to 22 P.O. Box 25391
Jet Park Fax : (011) 928 9730 EAST RAND MALL
KEMPTON PARK BOKSBURG
1619 1462

JOHANNESBURG (USED/REBUILD DIVISION):


Griffith Road ☎ (011) 928 9700 to 22 P.O. Box 25391
Jet Park Fax : (011) 928 9730 EAST RAND MALL
KEMPTON PARK BOKSBURG
1619 1462

JOHANNESBURG (NATIONAL DISTRIBUTION):


Griffith Road ☎ (011) 928 9700 to 22 P.O. Box 25391
Jet Park Fax : (011) 928 9730 EAST RAND MALL
KEMPTON PARK BOKSBURG
1619 1462

KURUMAN:
8 Acacia Street ☎ (05373) 30698 P.O. Box 1396
KURUMAN Fax : (05373) 30697 KURUMAN
1619 8460

MIDDLEBURG:
9 Celcius Street ☎ (0132) 461169 P.O. Box 2821
Building B A/H : (0132) 29877 MIDDLEBURG
Industrial Area Fax : (0132)461229 1050
MIDDLEBURG
1050

NELSPRUIT:
3 Christie Crescent ☎ (01311) 552110 to 6 P.O. Box 1672
Vintonia 2 A/H : (01311) 551560 NELSPRUIT
NELSPRUIT Fax : (01311) 552117 1200
1200 Radio Page 8036 (Store)
Radio Page 8037 (W/Shop)

PIET RETIEF:
6A Retief Street ☎ (01343) 4110 P.O. Box 1221
PIET RETIEF ☎ (01343) 50916 VRYHEID
2380 ☎ (01343) 3467 3100
A/H (01343) 807029
A/H (01343) 3550
Fax : (01343) 4110
PIETERMARITZBURG:
7 Van Eck Place ☎ (0331) 69319 P.O. Box 100436
MKONDENI A/H : (0331) 964601 SCOTSVILLE
3201 Fax : (0331) 61837 3209

PONGOLA:
☎ (03841) 31720 P.O. Box 681
A/H : (03841) 31162 PONGOLA
Fax : (03841) 31735 3170

PORT ELIZABETH:
134 Patterson Road ☎ (041) 541721/2 P.O. Box 3443
NORTH END ☎ (041) 541794/5 NORTH END
6056 ☎ (041) 541732/9 6056
A/H : (041) 514526
Fax : (041) 542060

PORT SHEPSTONE:
Shop 5 Industrial Park ☎ (0391) 4124/5 P.O. Box 560
Cnr. Main Harding and A/H : (0391) 77821 PORT SHEPSTONE
Isotsha Road Fax : (0391) 815155 4240
PORT SHEPSTONE
4240

RUSTENBURG:
No. 16 Vanadium Street ☎ (0142) 961003/4/5 P.O. Box 3701
Border Industry A/H : (0142) 28364 RUSTENBURG
RUSTENBURG Fax : (0142) 961005 0300
0300 Radio Page 610 (Parts)
Radio Page 600 (W/Shop)

SPRINGBOK:
Drive Inn Road ☎ (0251) 23710 P.O. Box 618
Industrial Park ☎ (0251) 21124 SPRINGBOK
SPRINGBOK ☎ (0251) 21130 8240
8240 A/H (0251) 23344
A/H (0251) 22556
Fax : (0251) 81314

TZANEEN:
8 Impala Street ☎ (0152) 3071129 P.O. Box 2102
Industrial Sites ☎ (0152) 3071180 TZANEEN
TZANEEN ☎ (0152) 3074812 0850
0850 A/H (0152) 3074503
Fax : (0152) 3073095

UMHLALI:
Old Main Road ☎ (0322) 71637 P.O. Box 39
UMHLALI Fax : (0322) 71367 UMHLALI
4390 4390
VRYHEID:
Bloekom Street ☎ (0381) 5541/2 P.O. Box 1221
VRYHEID ☎ (0381) 5555 VRYHEID
3100 A/H (0381) 808112 3100
Fax : (0381) 809752

U.S.A.
GARDEN CITY (HEAD OFFICE):
2843 Hwy 80 ☎ (912) 966-2615
Garden City Fax : (912) 964-1594
GEORGIA
GA 31408

NEW ZEALAND
NEW ZEALAND (BELL EQUIPMENT (NZ) LTD):
19 Nikau Road ☎ (09) 276-2424 P.O. Box 22585
Otahuhu Fax : (09) 276-6379 Otahuhu
AUCKLAND AUCKLAND

AUSTRALIA
AUSTRALIA (BELL EQUIPMENT):
12 Granite Place ☎ (0961) 3561033 P.O. Box 34 SPC
Welshpool Fax : (0961) 3565229 Welshpool
WESTERN AUSTRALIA WESTERN AUSTRALIA
6106 6986

PACIFIC RIM REGION (WESTERN AUSTRALIA):


12 Granite Place ☎ (0961) 3505346 P.O. Box 34 SPC
Welshpool Fax : (0961) 3505437 Welshpool
WESTERN AUSTRALIA WESTERN AUSTRALIA
6106 6986

SOUTH AMERICA
ARGENTINA:
Avda Santa Fe 1838, 9 Piso ☎ 54 1 811-9630
C.P. 1123 Fax : 54 1 811-9630
Capital Federal
Buenos Aires
ARGENTINA

SOUTH AMERICA (BELL EQUIPMENT CHILE SA):


Collao 1944 ☎ (041) 312100 Cassilla 22-C
Concepcion Fax : (041) 313020 Concepcion
CHILE CHILE
SOUTH EAST ASIA
SOUTH EAST ASIA (BELL EQUIPMENT (SEA) LTD):
Lam Soon Industrial Building ☎ (09) 65 7698394 Lam Soon Industrial Building
Unite # 03-05 Fax : (09) 65 7698029 Unite # 03-05
63 Hillview Avenue 63 Hillview Avenue
SINGAPORE SINGAPORE
2366 2366

EUROPE
BELL FRANCE SARL:
Z.A. Rte d’ Argenton-sur-Creuse ☎ (09) 33 55 89 23 56
23800 Fax : (09) 33 55 89 23 24
Dun-Le-Palestel
FRANCE

DEALER

Please supply your dealer details here:


USER’S COMMENT FORM
Should you , as user of this manual, have any suggestion for improving the manual, or you find any errors or
omissions, then we would like to know.

Please complete a facsimile of this form and hand it in to your nearest BELL Product Support Representive or
post it directly to your nearest BELL Branch. Addresses are given at the beginning of this manual.

YOUR COMMENTS, SUGGESTIONS, OR QUERIES:

MACHINE MODEL:

SERIAL NUMBER:

VIN:

DOCUMENT PART NUMBER AND ISSUE:

PAGE NUMBER:

DOES THE MANUAL MEET YOUR NEEDS ? YES NO

DID YOU FIND THE INFORMATION ACCURATE ? YES NO

DID YOU FIND THE INFORMATION EASY TO READ AND UNDERSTAND ? YES NO

DID YOU FIND THE INFORMATION EASY TO RETRIEVE ? YES NO

DID YOU FIND THE INFORMATION WELL ILLUSTRATED ? YES NO

NAME:

COMPANY:

TITLE:

ADDRESS:

TELEPHONE NUMBER:

Thank you for your cooperation.


CONTENTS
SECTION 1. GENERAL INFORAMTION

SECTION 2. ENGINE

SECTION 3. POWER TRAIN

SECTION 4. SYSTEMS

SECTION 5. FRAME AND BODY


TABLE OF CONTENTS

SECTION 1. GENERAL INFORMATION 1-1


BULLETINS 1-3
LIST OF ABBREVIATIONS 1-5
ORDERING OF PARTS 1-7
MACHINE DIMENSIONS 1-9
SERIAL NUMBER PLATES 1-11
SERVICE KITS 1-13
SECTION 2 ENGINE 2-2
ENGINE AND MISCELLANEOUS PARTS 2-3
ENGINE COUPLING 2-7
AIR CLEANER SYSTEM (ADE 366TI) 2-9
AIR CLEANER 2-11
PRE CLEANER 2-13
EXHAUST SYSTEM 2-15
FUEL SYSTEM 2-19
THROTTLE ASSEMBLY 2-21
STOP CABLE ASSEMBLY 2-23
COOLING SYSTEM (AIR TO AIR) 2-25
COOLING SYSTEM HEADER TANK 2-29
SECTION 3 POWER TRAIN 3-2
TRANSMISSION AND MISCELLANEOUS PARTS 3-3
TRANSMISSION DIFFERENTIAL LOCK ACTUATOR 3-5
OIL COOLER ASSEMBLY (With Retarder) 3-7
OIL COOLER ASSEMBLY 3-9
PROPSHAFT LAYOUT 3-11
PROPSHAFT ASSEMBLY (UPTO 02/04/97) 3-13
PROPSHAFT ASSEMBLY 3-15
PROPSHAFT ASSEMBLY 3-17
PROPSHAFT 3-19
PROPSHAFT ASSEMBLY 3-21
PROPSHAFT ASSEMBLY (FROM 14.01.97) 3-23
PROPSHAFT ASSEMBLY (FROM 22.11.96) 3-25
PROPSHAFT ASSEMBLY (FROM 02.04.97) 3-27
DRIVELINE 3-29
PARK BRAKE ACTUATOR 3-31
PARK BRAKE ASSEMBLY 3-33
FRONT AXLE AND MISCELLANEOUS PARTS 3-35
FRONT AXLE ASSEMBLY (4.11:1X4.82:1) 3-37
REAR AXLE MOUNTINGS 2-41
THRU-DRIVE AXLE ASSEMBLY (4.11:1X4.82:1) 3-45
REAR DRIVE AXLE ASSEMBLY (4.11:1X4.82:1) 3-49
DIFFERENTIAL ASSEMBLY (4.11:1) 3-53
DIFFERENTIAL ASSEMBLY 3-61
DIFFERENTIAL ASSEMBLY (4,11:1) 3-65
BRAKE ASSEMBLY 3-69
BRAKE CALIPER 3-73
BRAKE CALIPER COVER PLATES 3-75
WHEEL ASSEMBLY (23.5R25 - FROM 21.08.96) 3-77
SPECIAL TOOLS 3-79
SECTION 4A HYDRAULIC SYSTEM 4-3
HYDRAULIC SYSTEM 4-4
HYDRAULIC TAILGATE SYSTEM (OPTIONAL) Up to 01/02/98 4-10
HYDRAULIC TAILGATE SYSTEM (OPTIONAL) From 01/02/98 4-12
HYDRAULIC TANK 4-14
EMERGENCY STEERING SYSTEM (OPTIONAL - UPTO 28.02.97)) 4-16
EMERGENCY STEERING SYSTEM (OPTIONAL - FROM 01.03.97) 4-20
MOTOR, PUMP, EMERGENCY STEERING 2-24
TIP LEVER EXTENSION (OPTIONAL) 4-26
HYDRAULIC FILTER / BREATHER ASSEMBLY 4-28
FLOW AMPLIFIER 4-30
CONTROL VALVE (ONE BANK) 4-34
STEERING VALVE (FROM 01.12.94) 4-38
HYDRAULIC PUMP 4-40
HYDRAULIC FILTER ASSEMBLY 4-44
TIP CYLINDER 4-46
STEERING CYLINDER 4-48
STEERING CYLINDER (LHS - FROM 02.03.97) 4-50
STEERING CYLINDER (RHS - FROM 02.03.97) 4-52
STEERING CYLINDER 4-54
SPECIAL TOOLS 4-56
SECTION 4B PNEUMATIC SYSTEM 4-59
FRONT PNEUMATIC SYSTEM (UPTO 01.02.97) 4-60
FRONT PNEUMATIC SYSTEM (FROM 02.02.97) 4-66
REAR PNEUMATIC SYSTEM (FROM 02.02.97) 4-70
AIR SPRING ASSEMBLY 4-72
SOLENOID VALVE 4-74
PARK BRAKE 4-76
PRESSURE PROTECTION VALVE 4-80
LEVELLING VALVE 4-82
UNOADER VALVE WITH INTEGRAL AIR DRIER ASSEMBLY 4-84
CONTROL VALVE 4-88
BRAKE VALVE 4-90
BRAKE VALVE ADAPTOR 4-94
AIR/ HYDRAULIC BRAKE ACTUATOR 4-96
SECTION 4C ELECTRICAL SYSTEM 4-99
HARNESS LAYOUT 2-100
ELECTRICAL CIRCUIT - STARTING / CHARGING 4-102
ELECTRICAL CIRCUIT - LIGHTING 4-104
ELECTRICAL CIRCUIT - STOP LIGHT / HORN 4-106
ELECTRICAL CIRCUIT - REVERSE AND EXHAUST BRAKE 4-108
ELECTRICAL CIRCUIT - GAUGES AND WARNING LIGHTS 4-110
ELECTRICAL CIRCUIT - INDICATOR / HAZARD 4-112
ELECTRICAL CIRCUIT - BLOWER AND WIPER 4-114
ELECTRICAL CIRCUIT - AIRCON AND WIPER 4-116
EST 17 TRANSMISSION (CAB) 4-118
EST 17 TRANSMISSION (EXTERIOR) 4-120
EST 25 TRANSMISSION (CAB) 4-122
EST 25 TRANSMISSION (EXTERIOR) 4-124
CONNECTORS 1 & 2 4-126
CONNECTORS 3,4,5 & 6 4-128
CONNECTORS 7,8, 9 & 10 4-130
ELECTRONIC SPEEDO AND OTHER ACCESSORIES 4-132
INSTRUMENT PANEL ASSEMBLY 4-134
COLD START INSTRUMENT PANEL 4-136
DISTRIBUTION BOX 4-138
BATTERY, CLAMPS AND CABLES 4-140
WINDSCREEN WIPER ASSEMBLY 4-142
HORN ASSEMBLY 4-144
SPECIAL TOOLS 4-146
SECTION 5 FRAME AND BODY 5-2
CAB AND COWLING 5-3
BONNET LATCH 5-5
CAB EXTERIOR FITTINGS 5-7
DOOR HANDLE ASSEMBLY 5-11
CAB INTERIOR FITTINGS 5-13
SEAT ASSEMBLY (FROM NOV 1996) 5-17
STEERING COLUMN ASSEMBLY 5-19
ADJUSTABLE STEERING COLUMN 5-21
AIR CONDITIONER ASSEMBLY (RED DOT) 5-23
HYDRAULIC TAILGATE ASSEMBLY (OPTIONAL) 5-27
BIN HEATER KIT 2-29
FRONT FRAME 5-31
ARTICULATION AND OSCILATION ASSEMBLY 5-37
STEERING CYLINDER MOUNTINGS (Up To 01.09.97) 5-41
STEERING CYLINDER MOUNTINGS (From 01.06.97) 5-43
REAR FRAME 5-45
TIP CYLINDER MOUNTINGS 5-49
DECAL LAYOUT 5-51
DECALS 5-53
SECTION 1. GENERAL INFORMATION 1-1

SECTION 1
GENERAL INFORMATION

872057 September 16, 1998


1-2 SECTION 1. GENERAL INFORMATION

872057 September 16, 1998


SECTION 1. GENERAL INFORMATION 1-3

BULLETINS

Record the relevant information from the Technical Documentation Bulletins, Service Bulletins and Parts Bulle-
tins into this manual as follows:-

i. Ensure the manual number (87——) reflected in the bulletin is the same as the 87—— number at
the bottom right hand corner of this page.

ii. Carry out the instructions as detailed in the bulletin.

iii. Record the required information below.

File the bulletins in numerical order in a suitable 3 or 4 ring binder.

TECHNICAL DOCUMENTATION BULLETIN RECORD

INSERTED BY
BULLETIN NO. DATE RECEIVED
NAME SIGNATURE

872057 September 16, 1998


1-4 SECTION 1. GENERAL INFORMATION

TECHNICAL DOCUMENTATION BULLETIN RECORD

INSERTED BY
BULLETIN NO. DATE RECEIVED
NAME SIGNATURE

872057 September 16, 1998


SECTION 1. GENERAL INFORMATION 1-5

LIST OF ABBREVIATIONS

ADE Atlantic Diesel Engines GAL/min Gallon Per Minute


o
C Degree Celsius Gr Grade

Ω Ohm hex Hexagonal

A Ampere HT High Tensile

A/R As Required hz Hertz

AC Alternating Current ID Internal Diametre

Ah Ampere Hours in3 Cubic Inch

API American Petroleum Institute incl Including

approx Approximately ISO International Orginisation of Standards

Apr April Jan January

assy Assembly JIC Joint Industry Conference Standards

ATDC After Top Dead Centre Jul July

Aug August Jun June

BHP Brake Horse Power kg Kilogram

BSP British Standard Pipe km/h Kilometre Per Hour

BTDC Before Top Dead Centre kPa Kilopascal

CGA Compressed Gas Association Inc kW Kilowatt

CO2 Carbon Dioxide l/min Litre Per Minute

CTD Control Traction Differential lb Pound

db Decibels LED Light Emitting Diode

DBH Diametre at Breast Height LH Left Hand

DC Direct Current lube Lubrication

Dec December m Metre

deg or o Degree m3 Cubic Metre

dia Diametre mA Miliampere

diff Differential Mar March

E.G.S. Electronic Gear Shifting max Maximum

ext Extension min Minimum

Feb February mm Millimetre

FMC Front Mount Cab mm3 Cubic Milimetre

872057 September 16, 1998


1-6 SECTION 1. GENERAL INFORMATION

Nm Newton Metre SAE Society of Automotive Engineers

No. Number Sep September

Nov November SMC Side Mounted cab

N/O Normally Open SMR Service Metre Reading

NPT National Pipe Thread std Standard

NSI Non Stock Item strt Straight

Oct October TBN Total Base Number

OD Outside Diametre TDC Top Dead Centre

P/N Part Number temp Temperature

press Pressure thru Through to and Including

psi Pound per Square Inch UNC Unified National Coarse

PTO Power Take Off USGAL United States Gallon (3.7854 litre)

Qty Quantity V Volt

REV Reverse W Watt

rev/min Revolutions Per Minute W/O With out

RH Right Hand ZF Zahnradfabrik Passau Gmbh

RSG Recommended Service Guide

SABS South African Bureau of Standards

872057 September 16, 1998


SECTION 1. GENERAL INFORMATION 1-7

ORDERING OF PARTS

To facilitate the ordering of parts, the following information is required to determine the correct part for your
BELL product.

1. The model and serial number of your BELL product.


2. The serial number of the relevant assembly.
3. The part number.
4. The section, page and item number where the part appears in the parts manual.
5. The quantity required.
6. Your order number.
7. The delivery address.
8. The method of delivery.

Any other information which will assist us in getting the parts to you with the least amount of trouble or delay
should be given. This information will be noted and filed for future reference.

872057 September 16, 1998


1-8 SECTION 1. GENERAL INFORMATION

872057 September 16, 1998


SECTION 1. GENERAL INFORMATION 1-9

MACHINE DIMENSIONS

70 °
o
6 016 (19' 9")

4 981 (16' 4")

B25B
3 215 (10' 7")
2 622 (8' 7")
1 868 (6' 2")
975 (3' 2")

29°o
400 (1' 4")

1 342 800 800


(4' 5") (2' 7") (2' 7") 4 157 (13' 8") 1 960 (6' 5")
9 059 (29' 9")
3 220 (10' 7")
439 (1' 5")

2 780 (9' 1")


X000373

Figure 1

872057 September 16, 1998


1-10 SECTION 1. GENERAL INFORMATION

872057 September 16, 1998


SECTION 1. GENERAL INFORMATION 1-11

SERIAL NUMBER PLATES

BELL EQUIPMENT CO. S.A. (PTY) LTD.


RICHARDS BAY
SOUTH AFRICA

YEAR

MODEL

SERIAL NUMBER

POWER KW

MASS EMPTY Kg

LOADED Kg
P/N202319

B25B

AEB 476812 TRA XXXXX

ATLANTIS DIESEL ENGINES (PTY) LTD


LICENCE DAIMLER-BENZ AG
ENGINE No. DB

ADE

MADE IN RSA

X000505

Figure 2

872057 September 16, 1998


1-12 SECTION 1. GENERAL INFORMATION

872057 September 16, 1998


SECTION 1. GENERAL INFORMATION 1-13

SERVICE KITS

SERVICE KIT : 100 SMR, P/N 360613

PART NUMBER QTY DESCRIPTION

AD200732 1 GASKET, Rocket Cover

Z0750 131 060 1 FILTER, Transmission

140184 1 O RING

210466 2 ELEMENT, Spin On

220090 1 FILTER, Fuel, Spin On

221382 1 KIT, Filter

221384 2 FILTER, Fuel

SERVICE KIT : 250/750 SMR, P/N 360614

PART NUMBER QTY DESCRIPTION

220090 1 FILTER, Fuel, Spin On

221382 1 KIT, Filter

221384 2 FILTER, Fuel

SERVICE KIT : 500 SMR, P/N 360615

PART NUMBER QTY DESCRIPTION

AD67320134 1 BELT, Drive

AD200732 1 GASKET, Rocket Cover

Z0750 131 060 1 FILTER, Transmission

200443 1 FILTER, Air, Primary

200444 1 FILTER, Air, Safety

210466 2 ELEMENT, Spin On

220010 1 ELEMENT, Filter

220090 1 FILTER, Fuel, Spin On

221382 1 KIT, Filter

221384 2 FILTER, Fuel

280016 1 LOCTITE

872057 September 16, 1998


1-14 SECTION 1. GENERAL INFORMATION

SERVICE KIT : 1 000 SMR, P/N 360615

PART NUMBER QTY DESCRIPTION

AD63080164 1 WASHER, Sealing

AD67320134 1 BELT, Drive

AD200732 1 GASKET, Rocket Cover

Z0750 131 060 1 FILTER, Transmission

140184 1 O RING

200443 1 FILTER, Air, Primary

200444 1 FILTER, Air, Safety

210466 2 ELEMENT, Spin On

220010 1 ELEMENT, Filter

220088 2 ELEMENT, Air Cleaner

220090 1 FILTER, Fuel, Spin On

221382 1 KIT, Filter

221384 2 FILTER, Fuel

280016 1 LOCTITE

872057 September 16, 1998


.
September 18, 1998 SECTION 2 ENGINE 2-1
SECTION 2
ENGINE

September 18, 1998 SECTION 2 ENGINE 2-2


ENGINE AND MISCELLANEOUS PARTS
34
31
32 36
34 27 2
35 37
12

25 26
11 33

17
13
7

18
9
23

10 15
38

19
8
5 16
6 17
29
4
28 18
30
3 24
20 14
1
21 19

22 16

P004757

December 7, 1998 ADT00345 2-3


ENGINE AND MISCELLANEOUS PARTS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 AD6732 0134 BELT, Drive Includes Both Drive Belts
2 250109 1 ENGINE, ADE, 366TI (Local - non emissions certified (grey) engine).
2 250375 1 ENGINE, ADE, 366TI (USA/Europe - certified (black) engine).
3 DC100598 1 SCREW, Filter Bowl Long
4 AD140039 1 WASHER, Sealing
5 AD6312 0147 1 GASKET
6 AD7548 0192 1 PLUG, Sealing
7 AD6626 0062 1 SENDER UNIT, Water Pump
8 AD6646 0707 1 BOWL, Filter
9 221382 1 KIT, Filter Includes Items 7 and 10
10 AD6324 0991 1 RING, Seal
11 221384 2 FILTER, Fuel
12 AD6666 0028 2 SEAL, O Ring
13 AD7434 0576 2 BOWL, Filter
14 100482 4 BOLT, Hex. Head
15 100256 8 SCREW, Hex. Head
16 100413 4 NUT, Cleavelock
17 100728 4 BOLT, Hex. Head
18 160445 4 WASHER, Spacer
19 203760 4 MOUNTING, Engine, Rubber
20 200861 1 STRAP, Earth, Engine To Chassis
21 AD63080164 1 WASHER, Sealing
22 AD7548 0011 1 PLUG
23 182730 2 MOUNTING, Engine, Rear
24 172064 2 MOUNTING, Engine, Front
25 AD7204 0836 1 COVER, Head Cylinder
26 AD200732 1 GASKET,Rocket Cover
27 AD200568 1 SEPERATOR,Oil
28 AD7620 0708 1 FAN
29 AD200520 1 VISCOUS FAN COUPLING OPTION Fitted as standard to 366TI (From 01.11.96).
29 AD100301 1 NUT
29 AD200520 1 COUPLING
29 AD200521 1 ADAPTOR
29 AD100286 6 BOLT
30 204008 1 COVER, Alternator Includes Bolts

December 7, 1998 ADT00345 2-4


ENGINE AND MISCELLANEOUS PARTS
34
31
32 36
34 27 2
35 37
12

25 26
11 33

17
13
7

18
9
23

10 15
38

19
8
5 16
6 17
29
4
28 18
30
3 24
20 14
1
21 19

22 16

P004757

December 7, 1998 ADT00345 2-5


ENGINE AND MISCELLANEOUS PARTS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
31 261734 1 KIT, Breather, Crankcase Before 12.06.97, See ER 1326 for Ref.
32 AD200621 1 ATMOSPHERIC BREATHER PIPE
33 AD120175 1 CLAMP, Pipe
34 200089 2 CLAMP, Hose
35 AD130021 1 HOSE
36 AD200622 1 RUBBER, Cap
37 AD63570852 1 CLAMP
38 161813 4 SLEEVE, Rubber, Engine, Mounting

December 7, 1998 ADT00345 2-6


ENGINE COUPLING

8
6

P004285

June 22, 1998 255032 2-7


ENGINE COUPLING
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 255032 1 ENGINE COUPLING
2 100089 12 SCREW, Hex. Head
3 180693 1 ELEMENT, Rubber, Elastomeric
4 202207 1 SLEEVE
5 202121 1 DISC, Friction
6 160511 1 HOUSING, Coupling
7 100507 8 SCREW, Cap
8 160512 1 ADAPTOR, Output

June 22, 1998 255032 2-8


AIR CLEANER SYSTEM (ADE 366TI)
2

19 1
20

10
11
6 9 3 1
5

19 20

15
18

12
8

10 11
9 16
12 13 17
4 14
23

24

21

23
22 25

P002333

November 26, 1998 B25B002 2-9


AIR CLEANER SYSTEM (ADE 366TI)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100310 2 NUT, Nyloc
2 290230 1 PRE CLEANER
3 290055 1 AIR CLEANER
4 200464 1 VALVE, Vacuator
5 200466 1 INFORMER, 20"
6 200633 2 BAND, Mounting
7 100082 2 SCREW, Hex. Head
8 100283 2 NUT, Hex
9 100089 4 SCREW, Hex. Head
10 100064 4 WASHER, Flat
11 100314 4 NUT, Nyloc
12 203536 2 CLAMP, T Bolt
13 203534 1 CLAMP, T Bolt
14 203532 1 CLAMP, T Bolt
15 200641 1 ELBOW, Rubber
16 181829 1 DUCT, Air
17 201663 1 REDUCER, Rubber Hump
18 190515 1 STRIP, Seal
19 100081 2 SCREW, Hex. Head
20 100358 2 WASHER, Flat
21 100670 1 CLAMP, U Bolt
22 NSI 1 U BOLT
23 100276 2 WASHER
24 100314 2 NUT, Nyloc
25 NSI 1 BODY

November 26, 1998 B25B002 2-10


AIR CLEANER

6
7

2
9

10

P001994

April 17, 1998 290055 2-11


AIR CLEANER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290055 AIR CLEANER
2 200634 1 COVER, End
3 140259 1 SEAL
4 200637 2 NUT, Wing
5 200443 1 FILTER, Air, Primary
6 200444 1 FILTER, Air, Primary
7 NSI 2 WASHER
8 NSI 1 BODY, Air Cleaner
9 200464 1 VALVE, Vactuator
10 200653 1 CABLE TIE

April 17, 1998 290055 2-12


PRE CLEANER

P001995

February 7, 1996 290230 2-13


PRE CLEANER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290230 PRE CLEANER
2 202860 1 BOWL, Pre Cleaner
3 NSI 1 COVER, Pre Cleaner
4 NSI 1 BODY, Pre Cleaner
5 NSI 1 NUT, Wing

February 7, 1996 290230 2-14


EXHAUST SYSTEM
1

22
12
17 6
29 7
30 33
38
39
41
28 2
35 42
36 31
34
40
17 37

4 24 27 5

26 32
18
23 19
10
8
9 2
17 11
19

16 2
21

20
3

25 15

14 P003797
3 13

November 26, 1998 B25B003 2-15


EXHAUST SYSTEM
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 204340 1 STACK, Exhaust
2 201212 4 CLAMP, Exhaust
3 204035 3 CLAMP, Seal From 01/07/97
4 AD100072 2 BOLT, Hex
5 171989 1 MOUNTING, Silencer Upto 01/07/97
5 173425 1 MOUNTING, Silencer From 01/07/97
6 100199 4 BOLT, Hex. Head
7 100312 4 NUT, Nyloc
8 203546 1 SILENCER
9 182727 1 MOUNTING, Silencer, Heatshield
10 100092 2 BOLT, Hex. Head
11 203826 1 HEATSHIELD
12 171522 1 CLAMP, Stack
13 202385 1 PIPE, Exhaust
14 203825 1 HEATSHIELD
15 100079 2 SCREW, Hex. Head
16 202386 1 PIPE, Exhaust
17 AD77321149 3 GASKET
18 202387 1 PIPE, Exhaust Upto 01/11/97
18 204561 1 PIPE, Exhaust From 01/11/97
19 100702 7 BOLT, Hex. Head
20 100271 3 NUT, Cleavelock
21 100316 3 NUT, Nyloc
22 AD100054 3 BOLT, Hex
23 100238 4 SCREW, Hex. Head
24 101309 4 WASHER
25 100358 2 WASHER, Flat
26 100288 3 NUT, Hex
27 100314 2 NUT, Nyloc
28 NSI 1 BRAKE, Exhaust
29 AD200288 1 HOUSING ASSY
30 AD77171030 1 SHAFT ASSY
31 AD77171043 1 BUTTERFLY
32 NSI 1 HOUSING
33 AD100071 1 SCREW, Hex

November 26, 1998 B25B003 2-16


EXHAUST SYSTEM
1

22
12
17 6
29 7
30 33
38
39
41
28 2
35 42
36 31
34
40
17 37

4 24 27 5

26 32
18
23 19
10
8
9 2
17 11
19

16 2
21

20
3

25 15

14 P003797
3 13

November 26, 1998 B25B003 2-17


EXHAUST SYSTEM
ITEM PART NUMBER QTY DESCRIPTION REMARKS
34 AD100073 1 SCREW, Hex Head
35 AD200096 1 LEVER
36 100281 1 NUT, Hex
37 AD77170060 1 BUSH
38 230130 1 CYLINDER, Air-Push
39 NSI 1 COVER, Dust
40 AD77320823 1 STUD, Bearing
41 100062 1 WASHER, Flat
42 AD77320810 1 BRACKET

November 26, 1998 B25B003 2-18


FUEL SYSTEM

14
13 16
15

12 18

17 2

4 13
11

7 20 8 12
18
19

9
13

10
11

P001888

November 26, 1998 B25B004 2-19


FUEL SYSTEM
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290063 1 FILTER ASSY, Seperator, Water
2 220090 1 FILTER, Fuel, Spin On
3 201503 1 GASKET, Cork
4 170739 1 NECK, Filler
5 203650 1 CAP, Filler
6 100083 6 SCREW, Hex. Head
7 210187 3 SIGHT GLASS, Level
8 100519 3 NUT
9 120037 1 PLUG Up To 01/09/97
10 120019 1 PLUG
11 120052 2 ADAPTOR, Pushlock, Male
12 200062 2 CLAMP, Hose
13 130002 A/R HOSE, Pushlock
14 120218 2 FITTING, Pushlock
15 120217 2 ADAPTOR
16 100089 3 SCREW, Hex. Head
17 100314 2 NUT, Nyloc
18 120099 2 BANJO
19 181299 1 TANK, Fuel
20 140528 3 WASHER Dowty

November 26, 1998 B25B004 2-20


THROTTLE ASSEMBLY

16

11 13
7

6
18
2
4 17
12
5

10 8
9 14

10 15
1 3 8

1 P004758

November 26, 1998 ADT00346 2-21


THROTTLE ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100310 3 NUT, Nyloc
2 AD200040 1 LEVER
3 AD120096 1 CIRCLIP
4 172965 1 PLATE
5 100193 1 SCREW, Hex. Head
6 100382 2 SCREW, Hex. Head
7 201425 1 SWITCH, Interlock, Exhaust Brake Upto 31.10.96
8 200779 2 END, Tie Rod
9 162981 1 ROD
10 100281 2 NUT, Hex
11 172082 1 BRACKET
12 AD74240537 1 NUT
13 100309 2 NUT, Nyloc
14 100568 2 RIVET, Pop Upto 31.10.96
15 172403 1 LEVER Upto 31.10.96
16 260661 1 PEDAL, Assy
17 NSI 1 SCREW
18 AD200424 1 ROD, Control Assembly

November 26, 1998 ADT00346 2-22


STOP CABLE ASSEMBLY

5
1

2
3

9,14

11 15 6
13

10
12

P003373
P004773

November 26, 1998 B25B062 2-23


STOP CABLE ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 203954 1 Stop Cable Assy Includes Items 12 and 13
2 202548 1 SWITCH, Proximity
3 NSI 1 SENSOR
4 NSI 2 NUT
5 177108 1 LEVER
6 100309 2 NUT, Nyloc
7 100189 2 BOLT
8 203030 1 LEVER, Kill
9 174828 1 BRACKET, Mounting Up To 01/11/97
10 100684 3 BOLT Only 2 Bolts Used with Bracket 173279
11 174112 1 SPACER Up To 01/11/97
12 NSI 1 SCREW
13 201875 1 PIN, Stop Cable Retaining
14 173279 1 BRACKET, Mounting From 01/11/97
15 174175 2 WASHER, Spacer From 01/11/97

November 26, 1998 B25B062 2-24


COOLING SYSTEM (AIR TO AIR)
27
14 27
26
28 1
13
2
15 14 25
14 24 30
7 5 20 1
7 16
28 10 20 23
6 12
28

17
28
7 14
28
7
4
9 28 19
3 8 29
11

32 20
33 37
31 22
21
36
20

18
20
34
35 35
34

38

P003570

November 26, 1998 B25B007 2-25


COOLING SYSTEM (AIR TO AIR)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100332 8 NUT, Nyloc
2 161792 1 CONNECTOR, Manifold
3 203592 1 CLAMP, T Bolt
4 203037 1 PIPE, Steel
5 203804 1 COOLER, Air
6 203022 1 PIPE, Outlet
7 203036 4 HOSE
8 173062 1 BRACKET, Mounting
9 203974 1 PROTECTOR, C Clamp
10 100312 2 NUT, Nyloc
11 130051 1 HOSE, Radiator
12 100089 6 SCREW, Hex. Head
13 100731 2 SCREW, Hex. Head
14 100147 12 WASHER, Flat
15 203467 1 RUBBER, Flap, Radiator, LH
16 171481 1 PIPE, Radiator
17 201684 1 HOSE, Elbow
18 201677 1 HOSE, Radiator
19 100173 1 BOLT, Hex. Head
20 200089 7 CLAMP, Hose
21 203414 1 PIPE
22 203818 1 RADIATOR
23 173069 1 BRACKET, Mounting, Intercooler, RH
24 173068 1 BRACKET, Mounting, Intercooler, LH
25 173067 2 BRACKET, Mounting, Condenser
26 173923 1 PLATE, Top Intercooler Support
27 100085 8 SCREW, Hex. Head
28 203544 16 CLAMP, T Bolt From 20.06.97
29 100319 2 NUT, Nyloc
30 101361 6 NUT, Cage From 01.05.97
31 203668 1 COWLING
32 100358 10 WASHER, Flat
33 100080 10 SCREW, Hex. Head
34 100080 4 BOLT From 01.07.97
35 100310 4 NUT, Nyloc From 01.07.97

November 26, 1998 B25B007 2-26


COOLING SYSTEM (AIR TO AIR)
27
14 27
26
28 1
13
2
15 14 25
14 24 30
7 5 20 1
7 16
28 10 20 23
6 12
28

17
28
7 14
28
7
4
9 28 19
3 8 29
11

32 20
33 37
31 22
21
36
20

18
20
34
35 35
34

38

P003570

November 26, 1998 B25B007 2-27


COOLING SYSTEM (AIR TO AIR)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 174983 1 MOUNTING, Fan Guard, LHS From 03.03.97
37 174982 1 GUARD, Fan From 03.03.97
38 174984 1 MOUNTING, Fan Guard, RHS From 03.03.97

November 26, 1998 B25B007 2-28


COOLING SYSTEM HEADER TANK
19 18 17 16
6
15
3
3 5 2
6 3
4 9
5
20
3
8 3
23
3 9 20
24 5
7 5 3
21 20
5 22
20 3
23
3
24
14
3 11
6 22
4 3 22
10 12 3
25
3
13

22

P003882

December 10, 1998 B25B079 2-29


COOLING SYSTEM HEADER TANK
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 203818 1 RADIATOR
2 201655 1 TANK,Header
3 200062 14 CLAMP, Hose
4 120212 2 ADAPTOR
5 130001 A/R HOSE, Pushlock
6 120161 3 ADAPTOR, Barbed Hose
7 125024 1 TEE
8 173654 1 PIPE
9 172645 2 BRACKET
10 130051 A/R HOSE
11 201128 A/R PIPE
12 201644 A/R ELBOW, Rubber
13 162620 1 PLUG
14 202999 1 CAP
15 201319 8 MOUNTING, Circular
16 140273 1 O RING
17 120037 1 PLUG
18 161667 1 ADAPTOR
19 202485 1 SWITCH, Cooling Water Level
20 203927 4 GROMMET
21 205080 1 PIPE, Thermostat
22 200089 4 CLAMP, Hose
23 NSI 2 BOLT, Hexagon REFER to ADE Manual
24 NSI 2 WASHER, Flat REFER to ADE Manual
25 130021 1 HOSE, Pushlock

December 10, 1998 B25B079 2-30


September 18, 1998 SECTION 3 POWER TRAIN 3-1
SECTION 3
POWER TRAIN

September 18, 1998 SECTION 3 POWER TRAIN 3-2


TRANSMISSION AND MISCELLANEOUS PARTS

27 26 4 31
32 30

25

19 2
29,34 12

1
29,34
19
33 16
7
28 9
14
11

3
15
17
10 18
17 13
6 8
17
24 5
3 21 22
23

20 P003379

August 31, 1998 B25B082 3-3


TRANSMISSION AND MISCELLANEOUS PARTS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 Z0501 209 478 1 SWITCH, Pressure
2 250141 1 TRANSMISSION, ZF 6WG200 Z4644 026 287 (From 02.10.96)
3 100258 8 SCREW, Hex. Head
4 Z4644 303 568 1 FLANGE
5 100320 4 NUT, Cleavelock
6 160870 4 SPACER
7 160461 4 WASHER
8 100089 16 SCREW, Hex. Head
9 100314 16 NUT, Nyloc
10 170448 1 BRACKET, Mounting, LH
11 170449 1 BRACKET, Mounting, RH
12 174900 1 BRACKET, Mounting, Rear
13 202870 4 MOUNTING, Megi
14 260630 1 KIT, Dipstick Tube Extension
15 100464 2 SCREW, Cap
16 190321 1 TUBE, Dipstick
17 Z4642 331 216 3 GASKET
18 Z4642 331 056 1 PLATE, Baffle
19 100298 4 BOLT, Hex. Head
20 160623 1 SEAL PROTECTION
21 Z0636 305 016 1 PLUG
22 Z0634 801 074 1 RING, Seal
23 Z0636 015 289 2 SCREW, Hex. Head
24 Z4644 301 016 1 PLATE, Cover
25 200861 1 STRAP, Earth
26 Z0750 131 053 1 FILTER, Oil, Transmission
27 100085 1 SCREW, Hex. Head
28 200384 1 SENDER, Temp
29 202535 2 SWITCH, Hydraulic Pressure Up To 01/10/97
30 Z1269302164 1 WASHER
31 Z0636015127 1 SCREW, Hex
32 162460 1 WASHER
33 200694 1 SENDER, Oil Temperature
34 204044 2 SWITCH, Hydraulic Pressure From 02/10/97

August 31, 1998 B25B082 3-4


TRANSMISSION DIFFERENTIAL LOCK ACTUATOR

2
10

4 3

6 1

8
7 +

P001526

November 25, 1996 B25B008 3-5


TRANSMISSION DIFFERENTIAL LOCK ACTUATOR
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 202536 1 SWITCH, Sensor
2 170448 1 BRACKET, Mounting, Actuator
3 100354 2 WASHER, Copper
4 120138 1 BOLT, Banjo
5 120137 1 BANJO
6 200062 4 CLAMP, Hose
7 130020 A/R HOSE, Pushlock
8 Z0501 002 473 1 KIT, Differential Lock Air Actuator
9 171048 1 ROD, Link
10 210271 1 VALVE, Control, Differential Lock

November 25, 1996 B25B008 3-6


OIL COOLER ASSEMBLY (With Retarder)

13 4 11

10

14
10
1
3
9
12
3
13 4 11 9
3 1 5
8

6
6 7

P004706

November 4, 1998 ADT00327 3-7


OIL COOLER ASSEMBLY (With Retarder)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 190244 2 FITTING, Retarder
2 203802 1 COOLER
3 240247 3 HOSE, Assy
4 201377 4 MOUNTING, Rubber, Cooler
5 100083 6 SCREW, Hex Head
6 120035 4 CONNECTOR
7 100085 4 SCREW, Hex Head
8 171402 1 PIPE, Assy, Oil Cooler
9 120425 2 REDUCER
10 120242 2 CONNECTOR
11 100310 4 NUT, Nyloc
12 203522 1,3 HOSE, Protect, Spiral Wrap Per Metre
13 100080 4 SCREW, Hex Head
14 240835 1 HOSE, Assy

November 4, 1998 ADT00327 3-8


OIL COOLER ASSEMBLY
13 4 11

3
1
10
12 5

14
9
13 4 11

5
6 10 12
6 7

P004711

November 5, 1998 ADT00329 3-9


OIL COOLER ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 120033 2 CONNECTOR
2 201379 1 COOLER
3 240835 1 HOSE, Assy
4 201377 4 MOUNTING, Rubber, Cooler
5 140123 2 WASHER, Dowty
6 120035 4 CONNECTOR
7 100085 4 SCREW, Hex Head
8 171402 1 PIPE, Assy, Oil Cooler
9 240247 1 HOSE, Assy
10 240195 2 HOSE, Assy
11 100310 4 NUT, Nyloc
12 160581 2 ADAPTOR
13 100080 4 SCREW, Hex Head
14 203522 1,3 HOSE, Protect, Spiral Wrap Per Metre

November 5, 1998 ADT00329 3-10


PROPSHAFT LAYOUT

7,8

11 10
9

2,13

5 4 3,14

6,12

P004721

November 9, 1998 ADT00332 3-11


PROPSHAFT LAYOUT
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290180 1 PROPSHAFT
2 290069 1 PROPSHAFT Up To 14/01/97
3 290201 1 PROPSHAFT Up To 02/04/97
4 160953 1 SHAFT, Oscilation
5 290242 1 PROPSHAFT
6 290194 1 PROPSHAFT Up To 22/11/96
7 100271 8 NUT, Cleveloc
8 100150 8 BOLT, Hex. Head
9 100129 20 BOLT, Hex. Head
10 100720 8 BOLT, Hex. Head
11 100773 4 BOLT, Hex. Head
12 290587 1 PROPSHAFT From 22/11/96
13 290583 1 PROPSHAFT From 14/01/97 Note:Use 290069 for SparePart Requirments
14 290589 1 PROPSHAFT From 02/04/97 Note:Use 290201 for SparePart Requirments

November 9, 1998 ADT00332 3-12


PROPSHAFT ASSEMBLY (UPTO 02/04/97)

August 18, 1998 290069 3-13


PROPSHAFT ASSEMBLY (UPTO 02/04/97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290069 1 PROPSHAFT ASSEMBLY
2 203305 1 TUBE, Propshaft
3 200233 2 CROSS AND ROLLER

August 18, 1998 290069 3-14


PROPSHAFT ASSEMBLY

4 P002469

July 17, 1997 290180 3-15


PROPSHAFT ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290180 1 PROPSHAFT ASSEMBLY
2 NSI 1 TUBE
3 200228 2 CROSS AND ROLLER
4 200227 2 FLANGE, Yoke, Din 587.15
5 100211 16 SCREW, Hex. Head‘’ Not Included In 290180

July 17, 1997 290180 3-16


PROPSHAFT ASSEMBLY

P003856

November 26, 1998 290194 3-17


PROPSHAFT ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290194 1 PROPSHAFT
2 200233 1 U-JOINT ASSEMBLY
3 100129 8 BOLT, Hex. Head Not Included in 290194

November 26, 1998 290194 3-18


PROPSHAFT

P003856

April 24, 1998 290201 3-19


PROPSHAFT
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290201 1 PROPSHAFT
2 202500 1 U-JOINT ASSEMBLY
3 203301 1 PROPSHAFT, Centre
4 100720 8 BOLT, Hex. Head Not Part of 290201

April 24, 1998 290201 3-20


PROPSHAFT ASSEMBLY

P003400

December 2, 1996 290242 3-21


PROPSHAFT ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290242 1 PROPSHAFT ASSY
2 200233 2 U JOINT ASSY
3 100129 8 SCREW Not Included in 290242

December 2, 1996 290242 3-22


PROPSHAFT ASSEMBLY (FROM 14.01.97)
1

P003726

June 15, 1998 290583 3-23


PROPSHAFT ASSEMBLY (FROM 14.01.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290583 1 PROPSHAFT ASSEMBLY
2 NSI 1 TUBE
3 200233 2 CROSS AND ROLLER
4 100773 8 BOLT, Hex Head

June 15, 1998 290583 3-24


PROPSHAFT ASSEMBLY (FROM 22.11.96)

P003507
3
2

June 4, 1998 290587 3-25


PROPSHAFT ASSEMBLY (FROM 22.11.96)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290587 1 PROPSHAFT ASSEMBLY
2 100773 8 BOLT, Hex Head
3 NSI 8 WASHER
4 200233 2 CROSS AND ROLLERS
5 NSI 1 TUBE
6 NSI 1 GREASE NIPPLE

June 4, 1998 290587 3-26


PROPSHAFT ASSEMBLY (FROM 02.04.97)

P003729

June 15, 1998 290589 3-27


PROPSHAFT ASSEMBLY (FROM 02.04.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290589 1 PROPSHAFT ASSEMBLY
2 NSI 1 PROPSHAFT, Centre
3 202500 2 CROSS AND ROLLERS
4 100720 8 BOLT, Hex

June 15, 1998 290589 3-28


DRIVELINE

29 19,22
28 10
18 21 11
9 28
27

28 5 1
7,23

20,24

6
4

16 30
3
2 15
8
2

3
12
4
6

7,23

25 13

10 14

17
9
11 P004559

May 7, 1998 B25B078 3-29


DRIVELINE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 160953 1 SHAFT, Drive
2 150116 2 BEARING
3 140301 4 SEAL, Oil
4 160954 2 PLATE, Cover, Seal
5 100089 16 SCREW, Hex. Head
6 140108 2 V RING
7 170943 2 FLINGER
8 162054 1 HOUSING, Bearing, Rear
9 160737 2 WASHER
10 100405 2 NUT, Castle
11 100430 2 PIN, Split
12 100271 8 NUT, Self-lock
13 161732 1 FLANGE, Output
14 160566 1 DISC
15 100115 8 SCREW, Hex. Head
16 162053 1 HOUSING, Bearing, Front
17 290096 1 FLANGE, Adapter
18 201756 1 YOKE, 8,5C Up To 14.03.97
19 162902 1 YOKE, 8,5C, Complete
20 222779 1 SPEEDY SLEEVE
21 204560 1 YOKE, 8,5C Thru Drive From 14.03.97
22 162902 1 YOKE, 8,5C, Complete
23 170943 2 FLINGER
24 222779 1 SPEEDY SLEEVE
25 100711 8 BOLT, Hex. Head
26 280039 A/R LOCTITE Not Illustrated
27 173703 1 PIPE, Grease-Bundy
28 120106 1 CONNECTOR
29 200038 1 NIPPLE, Grease
30 120148 2 CONNECTOR

May 7, 1998 B25B078 3-30


PARK BRAKE ACTUATOR

4 3
21
22 23
24

12

25
6

5
7
8 26
11
2 16

13
28 9
27 17
29
14
18
10
10
30 19
15
20

P003435

February 12, 1997 290098 3-31


PARK BRAKE ACTUATOR
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290098 1 PARK BRAKE ACTUATOR
2 220135 2 PADS, Brake
3 220139 1 KIT, Overhaul Includes Items Marked **
4 NSI 1 CALIPER, Brake
5 NSI 1 PLUG
6 ** 1 FITTING, Pressure Relief
7 ** 1 SEAL, Piston
8 ** 1 PISTON
9 220137 1 ACTUATOR ASSY Includes Items Marked *
10 * 1 ACTUATOR
11 NSI 1 SHAFT
12 2 20138 1 LEVER
13 ** 1 BEARING, Thrust
14 ** 1 GASKET
15 NSI 1 CAP ASSY
16 ** 4 WASHER
17 ** 4 BOLT, Hex. Head
18 NSI 2 NUT
19 NSI 2 WASHER
20 220136 1 BOOT KIT
21 NSI 1 BEARING, Journal
22 ** 1 O RING
23 ** 1 WASHER
24 ** 1 WASHER, Spring
25 ** 1 RING, Retaining
26 220138 1 ADJUSTER, Slack
27 NSI 1 PIN, Yoke
28 NSI 1 YOKE ASSY
29 NSI 1 PIN, Cotter
30 220140 1 KIT, Actuator Seal

February 12, 1997 290098 3-32


PARK BRAKE ASSEMBLY

6 9

12
5

1 11

9
10
2 4

10
P003444

August 25, 1997 B25B034 3-33


PARK BRAKE ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100711 8 BOLT, Hex. Head
2 100271 8 NUT, Clevelock
3 160566 1 DISC, Park, Brake
4 290096 1 FLANGE, Adaptor
5 183788 1 MOUNTING, Bracket, Top
6 174951 A/R SHIM, 1.6 mm
6 174921 A/R SHIM, 0.5 mm
7 183787 1 MOUNTING, Bracket, Bottom
8 100992 7 SCREW, Cap
9 100010 14 WASHER, Flat
10 100320 7 NUT, Cleavelock
11 290098 1 PARK BRAKE ACTUATOR ASSY
12 183784 1 MOUNTING

August 25, 1997 B25B034 3-34


FRONT AXLE AND MISCELLANEOUS PARTS

18

17

13 14 15 16

12
11
5
1

3 4

2
19
7 9

6 8

10

P004719

November 9, 1998 ADT00331 3-35


FRONT AXLE AND MISCELLANEOUS PARTS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 200170 4 SHOCK ABSORBER
2 100293 8 NUT, Hex
3 100174 4 STUD, Shock Absorber
4 100316 8 NUT, Nyloc
5 201224 4 BUFFER, Rubber
6 200614 1 STRAP, Cable
7 100323 2 NUT, Nyloc
8 100162 2 BOLT, Hex. Head
9 100314 16 NUT, Nyloc
10 200174 2 AIR SPRING ASSY Includes Items 9 and 19
11 160312 2 BUSH, Bronze
12 160459 2 PIN, Pivot
13 100085 4 SCREW, Hex. Head
14 170031 2 TAG, Lock
15 170467 2 PLATE, Retainer
16 120148 2 CONNECTOR
17 240112 2 HOSE ASSY
18 200038 4 GREASE NIPPLE
19 200238 2 BAG, Air

November 9, 1998 ADT00331 3-36


FRONT AXLE ASSEMBLY (4.11:1X4.82:1)

31
30
32 34
4

11
3 10 23
9 24 25
8
6 7
2 5

18
19 16 22
12
33

28 29
20
21 27
26
41 46
14
13 15
14 17
42 42

43

40
35
28

46

45 44
42 42
36,37
P003382
47 16
38 39

March 29, 1996 320491 3-37


FRONT AXLE ASSEMBLY (4.11:1X4.82:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 320491 1 FRONT AXLE ASSEMBLY
2 120128 2 PLUG
3 100210 12 SCEW, Set, Hex
4 160180 2 PLATE, Cover, Hub
5 140191 2 O RING
6 160194 2 PLUG, Thrust, Bronze
7 201926 2 CIRCLIP, External
8 160193 2 RING, Steel
9 202010 2 PINION, Sun, Heavy Duty
10 160192 2 RING, Thrust Upto 01.10.96
10 160956 2 RING, Thrust From 02.10.96
11 202039 2 SHAFT, Side
12 100211 48 SCREW, Set, Hex
13 160181 6 PIN, Planet
14 160182 12 SHIM, Planet
15 202011 6 PINION, Planet
16 100436 2 PIN, Hilti
17 150030 6 BEARING, Inner Race
18 190092 2 CARRIER, Planet, 3 Cage
19 170222 2 CIRCLIP
20 150018 480 BEARING, Roller
21 160263 2 NUT, Lock
22 190141 2 WASHER
23 100149 16 SCREW, Set, Hex
24 160360 8 PLATE, Lock
25 171108 8 PLATE, Retainer
26 202012 2 GEAR, Ring
27 161719 2 CARRIER, Ring Gear
28 150069 4 BEARING
29 190365 2 PLUG, Hex, Magnetic
30 161787 2 HUB
31 100268 24 STUD, Wheel
32 100351 24 NUT, Tapered
33 162077 2 DISC, Brake
34 100228 64 SCREW, Cap

March 29, 1996 320491 3-38


FRONT AXLE ASSEMBLY (4.11:1X4.82:1)

31
30
32 34
4

11
3 10 23
9 24 25
8
6 7
2 5

18
19 16 22
12
33

28 29
20
21 27
26
41 46
14
13 15
14 17
42 42

43

40
35
28

46

45 44
42 42
36,37
P003382
47 16
38 39

March 29, 1996 320491 3-39


FRONT AXLE ASSEMBLY (4.11:1X4.82:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
35 140471 2 SEAL, Cassette
36 120332 4 PLUG
37 120379 4 ELBOW
38 201420 6 P CLIP
39 100310 6 NUT, Nyloc
40 100264 12 SCREW, Cap
41 160571 2 SHAFT, Stub, Extra Heavy Duty
42 183677 1 HOUSING, Axle
43 290385 4 BRAKE CALIPER ASSY
44 100709 12 BOLT, Durlock, Gr 12.9
45 310191 1 DIFFERENTIAL ASSY, 4.11:1 Up to 10.05.97
45 310150 1 DIFFERENTIAL ASSY, 4.11:1 From 10.05.97
46 220014 3 PLUG, Drain
47 203672 1 FLANGE

March 29, 1996 320491 3-40


REAR AXLE MOUNTINGS

12
1 27
4 25 13
5 10
2 3 6 9
7 16 14
10 19
8 37 17
11 7 36
21 38 15
13
12
6 29 42 34
13
18
14 16 22
19 20
17
33
15 35 33
13 23 30
24
22 33 40
30 18
29 33
31
40
37 31
32
32
38
35
26 31
27
31
39

32

ALL DRAG LINKS AND STABILISER BARS USE


THE SAME MOUNTING STUDS, SPHERICAL
28 31
BEARINGS, WASHERS AND NUTS

P004722

November 9, 1998 ADT00333 2-41


REAR AXLE MOUNTINGS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100389 8 SCREW, Hex. Head
2 200038 2 GREASE NIPPLE
3 120149 2 REDUCER
4 160588 2 PLATE, Retainer
5 173269 4 SHIM
6 140207 4 O RING
7 160371 4 WASHER, Thrust
8 160788 2 BUSH, Ertalyte
9 180887 2 BEAM, Walking
10 100119 16 BOLT, Hex. Head
11 100148 16 WASHER, Flat
12 170549 4 PLATE, Spacer
13 170548 8 PLATE, Lock
14 200091 4 BLOCK, Sandwich
15 190228 4 TIE, Chain
16 100211 24 SCREW, Hex. Head
17 100316 16 NUT, Nyloc
18 100325 32 NUT, Nyloc
19 100521 96 WASHER
20 100183 6 SCREW, Grub
21 160369 1 SHAFT, Pivot
22 172044 24 WASHER
23 200180 12 BEARING, Spherical Up to 06/11/97 Superceded by 203888 (see item 23 Below)
23 203888 12 JOINT, Ball From 06/11/97
24 162366 12 LINK, Pin
25 100083 16 SCREW, Hex. Head
26 100231 2 SCREW, Cap
27 200613 4 MAT, Bin Shock
28 182818 1 BAR, Stabilizer
29 260147 2 LINK ASSY
30 210016 2 BREATHER, Reservoir Up To 01/11/97
30 210689 2 BREATHER, Reservoir From 01/11/97 Used with Item 40
31 120156 6 ADAPTOR Up To 01/11/97
31 120161 6 ADAPTOR From 01/11/97
32 130020 A/R HOSE, Pushlock Up To 01/11/97

November 9, 1998 ADT00333 2-42


REAR AXLE MOUNTINGS

12
1 27
4 25 13
5 10
2 3 6 9
7 16 14
10 19
8 37 17
11 7 36
21 38 15
13
12
6 29 42 34
13
18
14 16 22
19 20
17
33
15 35 33
13 23 30
24
22 33 40
30 18
29 33
31
40
37 31
32
32
38
35
26 31
27
31
39

32

ALL DRAG LINKS AND STABILISER BARS USE


THE SAME MOUNTING STUDS, SPHERICAL
28 31
BEARINGS, WASHERS AND NUTS

P004722

November 9, 1998 ADT00333 2-43


REAR AXLE MOUNTINGS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
32 130001 A/R HOSE, Pushlock From 01/11/97
33 182819 4 LINK, Drag
34 180884 1 BAR, Stabilizer
35 261756 1 KIT, Brake Pipe Guards Optional Includes Items 36 to 39
36 174979 1 GUARD, Brake Pipe, Rear, RHS Optional
36 174977 1 GUARD, Brake Pipe, Rear, LHS Optional
37 100111 10 SCREW, Hex. Head Optional
38 100148 10 WASHER Optional
39 174978 1 GUARD, Brake Pipe, Middle, RHS Optional
39 174976 1 GUARD, Brake Pipe, Middle, LHS Optional
40 120188 2 REDUCER From 01/11/97 Used with Item 30, Part Number 210689
41 180793 1 MOUNTING, Link, Middle Axle Welded onto Axle
42 180806 1 MOUNTING, Transverse Link, Drive Axle Welded onto Axle

November 9, 1998 ADT00333 2-44


THRU-DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)

31
30
1 34
32
4

11
10
3 9 24 23
8 25
7
6
2 5

18 22
19 16
12
33

2
28 29

21 27
26

14
13
17 16 15
14 39 40
36 20 37
43
38

45
46 18
41 48
35

28 49

52,42 47 44
50 51
P003383

November 20, 1996 320492 3-45


THRU-DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 320492 1 THRU-DRIVE AXLE ASSEMBLY (4.11:1x4.82:1)
2 120128 2 PLUG
3 100210 12 SCREW, Set, Hex
4 160180 2 PLATE, Cover, Hub
5 140191 2 O RING
6 160194 2 PLUG, Thrust, Bronze
7 201926 2 CIRCLIP, External
8 160193 2 RING, Steel
9 202010 2 PINION, Sun, Heavy Duty
10 160192 2 RING, Thrust Upto 01.10.96
10 160956 2 RING, Thrust From 02.10.96
11 202039 2 SHAFT, Side
12 100211 48 SCREW, Set, Hex
13 160181 6 PIN, Planet
14 160182 12 WASHER, Thrust
15 202011 6 PINION, Planet
16 150018 480 ROLLER, Bearing
17 150030 6 BEARING, Inner-Race
18 190092 2 CARRIER, Planet, 3 Cage
19 170222 2 CIRCLIP
20 201420 6 P-CLIP
21 160263 2 NUT, Lock
22 190141 2 WASHER
23 100149 16 SCREW, Set, Hex
24 160360 8 PLATE, Lock
25 171108 8 PLATE, Retainer
26 202012 2 GEAR, Ring
27 161719 2 CARRIER, Ring Gear
28 150069 4 BEARING
29 190365 1 PLUG, Magnetic, Hex
30 161787 2 HUB
31 100268 24 STUD, Wheel
32 100351 24 NUT, Tapered
33 162077 2 DISC, Brake
34 100228 64 SCREW, Cap

November 20, 1996 320492 3-46


THRU-DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)

31
30
1 34
32
4

11
10
3 9 24 23
8 25
7
6
2 5

18 22
19 16
12
33

2
28 29

21 27
26

14
13
17 16 15
14 39 40
36 20 37
43
38

45
46 18
41 48
35

28 49

52,42 47 44
50 51
P003383

November 20, 1996 320492 3-47


THRU-DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
35 140471 1 SEAL, Cassette
36 100310 6 NUT, Nyloc
37 120332 1 PLUG
38 203673 1 FLANGE
39 140159 2 O RING
40 100008 24 BOLT
41 160571 2 SHAFT, Stub, Extra Heavy Duty
42 120379 4 ELBOW
43 100436 6 PIN, Hilti
44 100709 12 BOLT, Durlock, Gr 12.9
45 310158 1 DIFFERENTIAL ASSY, 4.11:1
46 220014 3 PLUG, Drain
47 183674 1 HOUSING, Axle
48 290385 2 BRAKE CALIPER ASSY
49 120334 1 PLUG, Magnetic, Hex
50 203674 1 FLANGE
51 202677 1 COVER

November 20, 1996 320492 3-48


REAR DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)

31
30 34
1 32

11
3 10 23
9 25 24
8
7
6
2 5

18 22
16
19
12
33

2
28 29

21 27
26
41
14
15 39
13 14 17 38
16

48
45
42 44 42
40
35
28 46

36,37 47

43 P003384

November 21, 1996 320493 3-49


REAR DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 320493 1 REAR DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)
2 120128 2 PLUG
3 100210 12 SCREW, Set, Hex
4 160180 2 PLATE, Cover, Hub
5 140191 2 O RING
6 160194 2 PLUG, Thrust, Bronze
7 201926 2 CIRCLIP, Internal
8 160193 2 RING, Steel
9 202010 2 PINION, Sun, Planet
10 160192 2 RING, Thrust Upto 01.10.96
10 160956 2 RING, Thrust From 02.10.96
11 202039 2 SHAFT, Side
12 100211 48 SCREW, Set, Hex
13 160181 6 PIN, Planet
14 160182 12 SHIM, Planet
15 202011 6 PINION, Planet
16 100436 2 PIN, Hilti
17 150030 6 BEARING, Inner, Race
18 190092 2 CARRIER, Planet, 3 Cage
19 170222 2 CIRCLIP
20 150018 480 BEARING, Roller
21 160263 2 NUT, Lock
22 190141 2 WASHER
23 100149 16 SCREW, Set, Hex
24 170031 1 TAG, Lock
25 171108 8 PLATE, Retainer
26 202012 2 GEAR, Ring
27 161719 2 CARRIER, Ring Gear
28 150069 4 BEARING
29 190365 2 PLUG, Hex, Magnetic
30 161787 2 HUB
31 100268 24 STUD, Wheel
32 100351 24 NUT, Tapered
33 162077 2 DISC, Brake
34 100228 64 SCREW, Cap

November 21, 1996 320493 3-50


REAR DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)

31
30 34
1 32

11
3 10 23
9 25 24
8
7
6
2 5

18 22
16
19
12
33

2
28 29

21 27
26
41
14
15 39
13 14 17 38
16

48
45
42 44 42
40
35
28 46

36,37 47

43 P003384

November 21, 1996 320493 3-51


REAR DRIVE AXLE ASSEMBLY (4.11:1X4.82:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
35 140471 2 SEAL, Cassette
36 120332 1 PLUG
37 120379 4 ELBOW
38 201420 6 P CLIP
39 100310 6 NUT, Nyloc
40 100760 24 SCREW, Hex. Head
41 160571 2 SHAFT, Stub, Extra Heavy Duty
42 290385 2 BRAKE CALIPER ASSY
43 120334 1 PLUG, Magnetic
44 100709 12 BOLT, Durlock
45 310191 1 DIFFERENTIAL ASSY, 4.11:1 Up to 10.05.97
45 310150 1 DIFFERENTIAL ASSU, 4.11:1 From 10.05.97
46 220014 3 PLUG, Drain
47 183673 1 HOUSING, Axle
48 203675 1 FLANGE

November 21, 1996 320493 3-52


DIFFERENTIAL ASSEMBLY (4.11:1)

1
15 8
10 14
12 2 98
11 99
101 13
18
7

24
5 19
9 21
101 22 34
100 32
16 35 30

17 6 36

20 37
23
24
29 19 20 40
41
42 38
39
3 4
26 47
28 46 45

31 27 48
25 97
33 52 43 49 46
44
50
53 54 35
55 83
58 73
74
56
84 57
61 51
28
90
87 78
85 79
86 82 59
91 80
95 77
81
88
89 63 76
64
65
72 66 67
92
93 94 62 68
96 69 70
71
60
P004167

November 22, 1996 310158 3-53


DIFFERENTIAL ASSEMBLY (4.11:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 310158 1 DIFFERENTIAL (4,11:1)
2 222004 1 WASHER, Output Shaft
3 221502 1 KIT, Diff Carrier And Bearing Caps Includes Items 14, 15, 17, 35 and 36
4 NSI 1 CARRIER, Diff
5 NSI 1 BEARING, Cap, LH
6 NSI 1 BEARING, Cap, RH
7 200511 1 LOCK, Adjuster
8 200883 1 PIN, Cotter
9 100765 11 BOLT Not Included in 310158
10 100766 1 BOLT Not Included in 310158
11 201492 1 CIRCLIP Not Included in 310158
12 222003 1 NUT, Output Shaft
13 222054 4 WASHER, Flat
14 222053 4 SCREW, Bearing Cap
15 NSI 4 LOCKWIRE
16 221031 1 PIN, Cotter
17 221030 1 LOCK, Bearing Adjuster
18 221957 12 SCREW, Diff Case, Cap
19 221946 2 WASHER, Thrust Side Gear
20 221945 2 GEAR, Side
21 221948 4 WASHER, Thrust Side Pinion
22 221947 4 PINION, Side
23 221949 1 SPIDER
24 222058 1 CASE, Gear Support
25 221163 1 KIT, Nut And Bolt Includes Items 26 and 27
26 221164 16 BOLT, Ring Gear
27 221091 16 NUT, Ring Gear
28 222063 1 CROWN WHEEL AND PINION
29 221955 1 CONE, Diff, Bearing, RH
30 222057 1 CONE, Diff, Bearing, LH
31 222056 1 CUP, Diff, Bearing, RH
32 150064 1 CUP, Diff, Bearing, LH
33 221942 1 ADJUSTER, Diff, Bearing
34 222055 1 ADJUSTER, Diff, Bearing
35 221133 2 PLUG, Pipe

November 22, 1996 310158 3-54


DIFFERENTIAL ASSEMBLY (4.11:1)

1
15 8
10 14
12 2 98
11 99
101 13
18
7

24
5 19
9 21
101 22 34
100 32
16 35 30

17 6 36

20 37
23
24
29 19 20 40
41
42 38
39
3 4
26 47
28 46 45

31 27 48
25 97
33 52 43 49 46
44
50
53 54 35
55 83
58 73
74
56
84 57
61 51
28
90
87 78
85 79
86 82 59
91 80
95 77
81
88
89 63 76
64
65
72 66 67
92
93 94 62 68
96 69 70
71
60
P004167

November 22, 1996 310158 3-55


DIFFERENTIAL ASSEMBLY (4.11:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 221171 2 PIN, Dowel
37 222005 1 KIT, Out-Put Shaft Nut And Bushing
38 222010 1 SPRING
39 221008 1 BEARING, Thrust
40 222006 2 O-RING
41 221105 2 RING, Side Gear Snap
42 222007 1 CUP, Bearing
43 222008 1 CONE, Bearing
44 222009 1 GEAR, Side Out-Put Shaft
45 222011 1 INTER AXLE DIFF ASSY Includes Items 46 to 51
46 NSI 2 Case, Diff
47 222014 4 WASHER, Thrust Side Pinion
48 222013 4 PINION, Side
49 222015 1 SPIDER
50 222012 8 BOLT, Diff, Case
51 221108 8 NUT, Case
52 222016 1 RING, Snap
53 222017 1 HELICAL SIDE GEAR ASSY
54 222018 2 BUSH
55 222019 1 WASHER, Thrust
56 222021 1 CLUTCH, Lockout Sliding
57 222022 1 SHAFT, Input
58 222020 1 D-WASHER, Side Gear
59 222033 1 NUT
60 222035 1 LOCKOUT ASSY Includes Items 61 to 71
61 222034 1 FORK, Shift
62 222036 1 KIT, Repair Includes Items 63 to 67
63 NSI 1 WASHER, Shoulder
64 NSI 1 SPRING
65 NSI 1 PISTON
66 NSI 1 O-RING
67 NSI 1 NUT, Lock
68 NSI 1 HOUSING, Piston
69 NSI 1 BRACKET, Mounting
70 NSI 2 WASHER, Lock

November 22, 1996 310158 3-56


DIFFERENTIAL ASSEMBLY (4,11:1)

1
15 8
10 14
12 2 98
11 99
101 13
18
7

24
5 19
9 21
101 22 34
100 32
16 35 30

17 6 36

20 37
23
24
29 19 20 40
41
42 38
39
3 4
26 47
28 46 45

31 27 48
25 97
33 52 43 49 46
44
50
53 54 35
55 83
58 73
74
56
84 57
61 51
28
90
87 78
85 79
86 82 59
91 80
95 77
81
88
89 63 76
64
65
72 66 67
92
93 94 62 68
96 69 70
71
60
P004167

November 22, 1996 310158 3-57


DIFFERENTIAL ASSEMBLY (4,11:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
71 NSI 2 SCREW, Lock
72 221501 1 COVER, Diff, Case
73 221132 9 WASHER, Lock
74 221129 4 SCREW, Cap, Short
75 222059 5 SCREW, Cap, Long
76 222029 5 SCREW, Cap Bearing Cover
77 222024 1 SHIM, 003"
77 222025 1 SHIM, 005"
77 222026 1 SHIM, 010"
77 222027 1 SHIM, 020"
78 222028 1 INPUT BEARING COVER ASSY
79 222031 1 SEAL, Oil
80 221120 1 CUP, Bearing
81 222030 5 WASHER, Lock
82 222032 1 WASHER, Flat
83 222023 1 CONE, Input Shaft Bearing
84 227533 1 BEARING, Pinion Pilot
85 221997 1 CONE, Inner Pinion Bearing
86 222037 1 SPACER, Pinion, 472"
86 222038 1 SPACER, Pinion, 475"
86 222039 1 SPACER, Pinion, 480"
86 222040 1 SPACER, Pinoni, 485"
86 222041 1 SPACER, Pinion, 491"
86 222042 1 SPACER, Pinion, 495"
86 222043 1 SPACER, Pinion, 499"
86 222044 1 SPACER, Pinion, 506"
87 221998 1 CONE, Outer Pinion Bearing
88 221140 1 SHIM, 003"
88 221141 1 SHIM, 005"
88 221142 1 SHIM, 010"
88 221143 1 SHIM, 020"
88 221144 1 SHIM, 030"
89 221999 1 PINION BEARING CAGE AND CUP ASSY
90 222000 1 CUP, Outer Pinion Bearing
91 221074 1 CUP, Inner Pinion Bearing

November 22, 1996 310158 3-58


DIFFERENTIAL ASSEMBLY (4,11:1)

1
15 8
10 14
12 2 98
11 99
101 13
18
7

24
5 19
9 21
101 22 34
100 32
16 35 30

17 6 36

20 37
23
24
29 19 20 40
41
42 38
39
3 4
26 47
28 46 45

31 27 48
25 97
33 52 43 49 46
44
50
53 54 35
55 83
58 73
74
56
84 57
61 51
28
90
87 78
85 79
86 82 59
91 80
95 77
81
88
89 63 76
64
65
72 66 67
92
93 94 62 68
96 69 70
71
60
P004167

November 22, 1996 310158 3-59


DIFFERENTIAL ASSEMBLY (4,11:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
92 100328 6 WASHER, Lock
93 221145 6 SCREW, Cap
94 222001 1 GEAR, Pinion
95 221150 1 NUT, Flanged
96 NSI 1 PIN (Not Used)
97 100726 12 BOLT
98 140503 1 SEAL, Oil
99 150128 1 BEARING Not Included in 310158
100 202677 1 COVER, Axle Housing , Thru Drive Not Included in 310158
101 101321 12 WASHER, Spring Not Included in 310158

November 22, 1996 310158 3-60


DIFFERENTIAL ASSEMBLY

5 37
9 2 11 13 29
15 2
35
31
28
34
27
23

8 36
33
32 30
23
18
19
16
4 17
3

16 14
18
19 12
20
26
10

25 21
24 4
3
22

2
P003429

September 23, 1997 310191 3-61


DIFFERENTIAL ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 310191 1 DIFFERENTIAL ASSEMBLY UPTO 30.04.97
2 NSI 1 DIFFERENTIAL CARRIER AND BEARING CAPS
3 222053 4 SCREW, Bearing, Cap
4 222054 4 WASHER, Flat
5 NSI 1 WASHE (Not Used)
6 200511 1 LOCK, Adjustor, RH
7 200883 1 PIN, Cotter
8 221030 1 LOCK, Adjustor, LH
9 221031 1 SPLIT PIN
10 221942 1 ADJUSTOR, RH
11 222055 1 ADJUSTOR, LH
12 150064 1 CUP, Bearing RH
13 222056 1 CUP, Bearing LH
14 221955 1 CONE, Bearing RH
15 222057 1 CONE, Bearing LH
16 222058 1 CASE, Differential, Halves
17 221957 1 SCREW, Cap
18 221945 2 GEAR, Side
19 221946 2 WASHER, Thrust, Side, Gear
20 221947 4 PINION, Side
21 221948 4 WASHER, Thrust Side, Pinion
22 221949 1 SPIDER
23 222069 1 CROWN WHEEL AND PINION 5,29:1
24 221163 1 KIT, Ring Gear and Nut
25 221164 16 BOLT
26 221091 16 NUT
27 227533 1 BEARING, Pilot
28 222071 1 CONE, Bearing (Inner)
29 221950 1 CONE, Bearing (Outer)
30 221971 A/R SPACER, Pinion Bearing 635"
30 221972 A/R SPACER, Pinion Bearing 638"
30 221973 A/R SPACER, Pinion Bearing 640"
30 221974 A/R SPACER, Pinion Bearing 642"
30 221975 A/R SPACER, Pinion Bearing 646"
31 222073 1 PINION BEARING CAGE AND CUP ASSY

September 23, 1997 310191 3-62


DIFFERENTIAL ASSEMBLY

5 37
9 2 11 13 29
15 2
35
31
28
34
27
23

8 36
33
32 30
23
18
19
16
4 17
3

16 14
18
19 12
20
26
10

25 21
24 4
3
22

2
P003429

September 23, 1997 310191 3-63


DIFFERENTIAL ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
32 221074 1 CUP, Bearing Inner
33 150074 1 CUP, Bearing Outer
34 200543 A/R SHIM, 003"
34 2210951 A/R SHIM, 005"
34 200545 A/R SHIM, 010"
34 200547 A/R SHIM, 020"
35 221979 6 SCREW, Cap
36 140348 1 SEAL, Oil
37 221196 1 NUT, Flanged

September 23, 1997 310191 3-64


DIFFERENTIAL ASSEMBLY (4,11:1)
35

1 33 52

11
31
11
7 8 2 10
9 3 34

55

2 13
6 15
5 17
29
30
36
27 32 38
26
4
39 40
41
21 42
43
44
28
24 2
16 25

23
54
37 32
22 45
20 57
46
47 56
19
14 18 48
49
12

50 51
53
P003788

August 26, 1997 310150 3-65


DIFFERENTIAL ASSEMBLY (4,11:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 310150 1 DIFFERENTIAL 4,11:1 FROM 01.05.97
2 NSI 1 DIFFERENTIAL CARRIER AND BEARING CAPS
3 200511 1 LOCK, Adjuster, RH
4 221978 1 LOCK, Adjuster, LH
5 200883 1 PIN, Cotter
6 221035 2 BUSHING, Dowel
7 221027 4 SCREW, Cap
8 221028 4 WASHER, Flat
9 221032 2 BUSHING, Dowel
10 221034 2 SCREW, Cap
11 221029 2 LOCKWIRE
12 221954 1 ADJUSTER, Bearing, LH
13 221942 1 ADJUSTER, Bearing, RH
14 221943 1 CUP, Bearing, LH
15 150064 1 CUP, Bearing, RH
16 221944 1 CONE, Bearing, LH
17 221955 1 CONE, Bearing, RH
18 221956 1 KIT, Wheel Diff Case
19 221957 12 SCREW, Cap
20 NSI 1 CASE, Diff
21 NSI 1 CASE, Gear, Support
22 221946 1 WASHER, Thrust
23 221945 1 GEAR, Side
24 221959 1 GEAR, Curvic Side
25 221949 1 SPIDER
26 221947 4 PINION, Side
27 221948 4 WASHER, Thrust
28 221960 1 WASHER, Thrust
29 221961 8 BOLT
30 221968 8 COVER, Case
31 221962 8 NUT
32 221179 1 CROWN WHEEL AND PINION 4,11:1
33 221964 8 PLATE, Friction, (O.D. Splined)
34 221965 7 PLATE, Friction, (I.D. Splined)
35 221966 1 PLATE, Pressure

August 26, 1997 310150 3-66


DIFFERENTIAL ASSEMBLY (4,11:1)
35

1 33 52

11
31
11
7 8 2 10
9 3 34

55

2 13
6 15
5 17
29
30
36
27 32 38
26
4
39 40
41
21 42
43
44
28
24 2
16 25

23
54
37 32
22 45
20 57
46
47 56
19
14 18 48
49
12

50 51
53
P003788

August 26, 1997 310150 3-67


DIFFERENTIAL ASSEMBLY (4,11:1)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 221038 1 PLUG, Upper Expansion
37 200536 1 PLUG, Lower Expansion
38 221037 1 SHIFT FORK SHAFT AND O-RING ASSY
39 221941 1 FORK, Shift
40 221041 2 STUD
41 200078 1 SHIFT FORK SEAL AND SPRING ASSY
42 210330 1 ACTUATOR
43 221044 2 WASHER, Flat
44 221045 2 NUT, Stud
45 222071 1 CONE, Pinion Bearing
46 221970 A/R SPACER, Bearing
46 221971 A/R SPACER, Bearing
46 221972 A/R SPACER, Bearing
46 221973 A/R SPACER, Bearing
46 221974 A/R SPACER, Bearing
46 221975 A/R SPACER, Bearing
47 221074 1 CUP, Pinion Bearing
48 200543 A/R SHIM, Bearing Cage, .003"
48 221951 A/R SHIM, Bearing Cage, .005"
48 200545 A/R SHIM, Bearing Cage, .010"
48 200547 A/R SHIM, Bearing Cage, .020"
49 221195 1 CROWN WHEEL AND PINION
50 221979 1 SCREW, Cap
51 221958 1 SEAL, Oil
52 221967 1 KIT, Compression Spring
53 221196 1 NUT, Lock, Hex
54 200563 1 BEARING, Pilot
55 221963 1 CLUTCH, Sliding
56 221950 1 CONE, Pinion Bearing
57 150074 1 CUP, Pinion Bearing

August 26, 1997 310150 3-68


BRAKE ASSEMBLY

2 37 1
35
1 7
2 37 35 7

24 6 26
14 5 8
4 3 19
19 6 19 29
5 4 3 8
10 33
19 33
20
9 28 29 23 22 22 23
20 34 11 30 28
22 23 36 34
18 11 9
15
15 36 28 29

10 21 13
21 30 21
12
14 14
14

31 21
21 32 14
21
28 29
17
16 16
22 23
20 28 29
19 22 23
23 22
20
28
19 19
29 25
19 14 27

P004724

November 10, 1998 ADT00334 3-69


BRAKE ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 201415 2 RESERVOIR, Brake Fluid Includes Items 2 and 37
2 221249 2 CAP, Reservoir
3 100085 4 SCREW, Hex. Head
4 100064 4 WASHER, Flat
5 100314 4 NUT, Nyloc
6 120056 2 FITTING
7 130002 A/R HOSE, Pushlock
8 120052 2 ADAPTOR, Pushlock, Male
9 120169 2 BUSH, Reducing
10 260145 2 MASTER CYLINDER, Actuator Assembly
11 120352 2 ADAPTOR
12 240271 1 HOSE ASSY
13 171333 1 PIPE, Brake
14 120308 6 TEE, Bulkhead
15 173701 2 PIPE ASSY
16 173702 2 PIPE ASSY
17 173700 1 PIPE ASSY
18 173699 1 PIPE ASSY
19 120379 8 ELBOW
20 171079 4 PIPE ASSY
21 201420 18 P CLIPS
22 101201 18 STUD
23 100310 18 NUT, Nyloc
24 174452 1 GUARD, Mid RHS Upto 19.03.97
24 174978 1 GUARD, Mid RHS From 20.03.97
25 174453 1 GUARD, Mid LHS Upto 19.03.97
25 174976 1 GUARD, Mid LHS From 20.03.97
26 174451 1 GUARD, Rear RHS Upto 19.03.97
26 174979 1 GUARD, Rear RHS From 20.03.97
27 174450 1 GUARD, Rear LHS Upto 19.03.97
27 174977 1 GUARD, Rear LHS From 20.03.97
28 100111 10 SCREW, Hex. Head
29 100148 10 WASHER, Flat
30 100209 4 SCREW, Hex. Head
31 240271 1 HOSE ASSY

November 10, 1998 ADT00334 3-70


BRAKE ASSEMBLY

2 37 1
35
1 7
2 37 35 7

24 6 26
14 5 8
4 3 19
19 6 19 29
5 4 3 8
10 33
19 33
20
9 28 29 23 22 22 23
20 34 11 30 28
22 23 36 34
18 11 9
15
15 36 28 29

10 21 13
21 30 21
12
14 14
14

31 21
21 32 14
21
28 29
17
16 16
22 23
20 28 29
19 22 23
23 22
20
28
19 19
29 25
19 14 27

P004724

November 10, 1998 ADT00334 3-71


BRAKE ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
32 240698 1 HOSE ASSY
33 120107 2 ELBOW
34 100530 2 WASHER
35 190471 2 ADAPTOR
36 100523 2 WASHER
37 221248 2 DIAPHRAGM

November 10, 1998 ADT00334 3-72


BRAKE CALIPER

2
5

17 6

3
7

10

11
4
16
15

10

7
12

13
14

P001544

November 6, 1996 290385 3-73


BRAKE CALIPER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290385 1 BRAKE CALIPER
2 NSI 1 HOUSING
3 223905 4 PLATE, End
4 100039 8 SCREW, Hex. Head
5 NSI 4 PLUG
6 201428 2 BLEEDER, Hydraulic, Valve
7 * 4 O RING
8 * 4 RING, Backup
9 223907 4 PISTON
10 * 4 COVER, Dust
11 223906 2 PAD, Disc
12 * 2 O RING
13 223908 2 HEAD, Cylinder
14 120332 1 PLUG
15 223909 1 KIT, Seal, Brake Caliper Includes Items Marked *
16 100264 6 SCREW, Cap Item Not Included With Caliper
17 188127 2 SCRAPER Optional Extra / Item Not Included With Caliper

November 6, 1996 290385 3-74


BRAKE CALIPER COVER PLATES

2
3

P004759

November 26, 1998 ADT00347 3-75


BRAKE CALIPER COVER PLATES
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 260142 2 BRAKE CALIPER COVER PLATES OPTIONAL EXTRA
2 183084 2 MOUNTING, Cover Plate
3 100089 4 SCREW, Hex. Head
4 173907 1 PLATE, Top
5 173908 1 PLATE, Bottom

November 26, 1998 ADT00347 3-76


WHEEL ASSEMBLY (23.5R25 - FROM 21.08.96)

1
7

5
10
+

G
-

O O
R L

D
Y
E
A
R
2

*
T
V K

B R
3
4

I D
G
E
S
T
O
NE

6 10

8 11

12
P004768

June 4, 1998 261279 3-77


WHEEL ASSEMBLY (23.5R25 - FROM 21.08.96)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 261279 1 SET, Wheel Includes Items 2 to 6 (From 21.08.96)
2 200437 1 VALVE, Jumbo, Swivel
3 200438 1 SPUD, Tubeless
4 200743 1 Valve, Reducer with Cap
5 202979 1 TYRE, 23.5R25, 1*,Mud Sand
6 190291 1 RIM, 5 Piece Includes Items 7 and 8
7 177024 1 RIM, Centre
8 200435 1 RIM, Base, 5 Piece Includes Items 9 to 12
9 140228 1 O RING
10 202942 2 FLANGE
11 202945 1 BAND, Bead Set
12 202947 1 LOCKRING

June 4, 1998 261279 3-78


SPECIAL TOOLS

P001204

September 18, 1998 B25B096 3-79


SPECIAL TOOLS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 280185 1 SPANNER, Wheel

September 18, 1998 B25B096 3-80


September 18, 1998 SECTION 4A HYDRAULIC SYSTEM 4-2
SECTION 4A
HYDRAULIC SYSTEM

September 18, 1998 SECTION 4A HYDRAULIC SYSTEM 4-3


HYDRAULIC SYSTEM

27 55 35
32 52 72 38
53 30 40
31 57
40
42
36 41
74
1 51
15 51
15 16 55 54
25
12 36
65 37
T L
64
P R 56
72
24
15 15 18 40

6 67 50
63 3 2 60 39
1 10 68
1
23 1 43 29
1 14 15 4
44 40
15 8 34 9 71
19 21 4 41
28 70
69 47
49
15 P R T L CL CR 5 49 46

25 69
13 48 47
PP LS HT HP EF 44 40
12 61 9 42
11 43
22 45,73
12 26
53 22 43
66 7 62 44
27 59
60 9
11 33 P004599
17 58

March 13, 1997 B25B016 4-4


HYDRAULIC SYSTEM
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 240041 5 HOSE ASSY
2 240418 2 HOSE ASSY
3 210106 1 STRAINER, Suction, 90 Micron
4 203538 2 CLAMP, T Bolt
5 203448 1 HOSE, Suction Hydraulic Tank Pump
6 210431 1 PUMP, Hydraulic
7 240606 1 HOSE ASSY
8 210162 1 AMPLIFIER, Flow
9 101350 12 SCREW, Cap
10 120316 1 CONNECTOR
11 190343 3 ADAPTOR
12 121045 2 ADAPTOR
13 240507 1 HOSE ASSY
14 120365 1 ELBOW
15 120355 8 ADAPTOR
16 120252 1 ELBOW
17 201873 1 TEST POINT
18 100143 4 SCREW, Hex. Head
19 240766 1 HOSE ASSY
20 210413 1 VALVE, Steering
21 160586 2 FITTING, Bullnose
22 120100 2 ELBOW
23 120150 4 CONNECTOR
24 170453 1 T PIECE ASSY
25 240166 4 HOSE ASSY
26 190535 1 ELBOW
27 230285 1 CYLINDER, Steering, LHS
27 230290 1 CYLINDER, Steering, RHS
28 240755 1 HOSE ASSY
29 120049 1 CONNECTOR
30 120933 1 CONNECTOR
31 210283 1 VALVE, Control, 1 Bank
32 240753 1 HOSE ASSY
33 240247 1 HOSE ASSY
34 240245 1 HOSE ASSY

March 13, 1997 B25B016 4-5


HYDRAULIC SYSTEM

27 55 35
32 52 72 38
53 30 40
31 57
40
42
36 41
74
1 51
15 51
15 16 55 54
25
12 36
65 37
T L
64
P R 56
72
24
15 15 18 40

6 67 50
63 3 2 60 39
1 10 68
1
23 1 43 29
1 14 15 4
44 40
15 8 34 9 71
19 21 4 41
28 70
69 47
49
15 P R T L CL CR 5 49 46

25 69
13 48 47
PP LS HT HP EF 44 40
12 61 9 42
11 43
22 45,73
12 26
53 22 43
66 7 62 44
27 59
60 9
11 33 P004599
17 58

March 13, 1997 B25B016 4-6


HYDRAULIC SYSTEM
ITEM PART NUMBER QTY DESCRIPTION REMARKS
35 170655 1 PLATE, Mounting
36 120298 4 BUKLHEAD
37 181291 1 TANK, Hydraulic
38 240281 2 HOSE ASSY
39 180541 1 PIPE ASSY
40 120004 8 CONNECTOR
41 240223 4 HOSE ASSY
42 230054 2 CYLINDER, Tip
43 140132 3 O RING
44 120222 6 FLANGE, Half
45 210467 1 ELEMENT, Spin On Twin, Head
46 120052 1 ADAPTOR, Pushlock, Male
47 120183 2 BUSH, Reducing
48 210012 1 FILTER ASSY
49 130020 A/R HOSE, Pushlock
50 120237 2 FLANGE, Half
51 120811 2 ELBOW
52 120033 1 CONNECTOR
53 120002 4 CONNECTOR
54 170893 1 PLATE, Mounting
55 240427 2 HOSE ASSY
56 120209 1 ADAPTOR, Flanged
57 240540 1 HOSE ASSY
58 240631 1 HOSE ASSY
59 190610 1 T PIECE, Modified
60 120035 4 CONNECTOR
61 120243 1 CONNECTOR
62 120284 2 REDUCER
63 240600 1 HOSE ASSY
64 201737 1 TEST POINT
65 121042 1 CONNECTOR
66 121024 1 T PIECE
67 140131 1 O RING
68 240647 1 HOSE ASSY
69 120059 2 ADAPTOR, Pushlock, Male

March 13, 1997 B25B016 4-7


HYDRAULIC SYSTEM

27 55 35
32 52 72 38
53 30 40
31 57
40
42
36 41
74
1 51
15 51
15 16 55 54
25
12 36
65 37
T L
64
P R 56
72
24
15 15 18 40

6 67 50
63 3 2 60 39
1 10 68
1
23 1 43 29
1 14 15 4
44 40
15 8 34 9 71
19 21 4 41
28 70
69 47
49
15 P R T L CL CR 5 49 46

25 69
13 48 47
PP LS HT HP EF 44 40
12 61 9 42
11 43
22 45,73
12 26
53 22 43
66 7 62 44
27 59
60 9
11 33 P004599
17 58

March 13, 1997 B25B016 4-8


HYDRAULIC SYSTEM
ITEM PART NUMBER QTY DESCRIPTION REMARKS
70 120983 1 REDUCER
71 160316 1 NIPPLE
72 120299 4 NUT, Bulkhead
73 210466 2 ELEMENT, Spin On
74 210413 1 VALVE, Steering

March 13, 1997 B25B016 4-9


HYDRAULIC TAILGATE SYSTEM (OPTIONAL) Up to 01/02/98

14
6

15 6

10
15
1
6
7
5
8 12,13 11
DOWN
8
9
4 3 2

UP

5
7
10 9 6

8 12,13 11

15

15 6

6 14

P003364

December 3, 1998 ADT00348 4-10


HYDRAULIC TAILGATE SYSTEM (OPTIONAL) Up to 01/02/98
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 180541 1 PIPE ASSY Not part of Tailgate Kit No. 260744
2 120386 2 T PIECE Part of Tailgate Kit No. 260744
3 120035 2 CONNECTOR Not part of Tailgate Kit No. 260744
4 240418 2 HOSE ASSY Not part of Tailgate Kit No. 260744
5 120984 2 REDUCER Part of Tailgate Kit No. 260744
6 120002 6 CONNECTOR Part of Tailgate Kit No. 260744
7 240467 2 HOSE ASSY Part of Tailgate Kit No. 260744
8 121055 4 UNION Part of Tailgate Kit No. 260744
9 121030 2 T PIECE Part of Tailgate Kit No. 260744
10 240406 4 HOSE ASSY Part of Tailgate Kit No. 260744
11 181776 2 PIPE ASSY Includes Item No. 12 and 13
12 120880 4 SLEEVE Part of Tailgate Kit No. 260744
13 120890 4 NUT Part of Tailgate Kit No. 260744
14 230083 2 CYLINDER, Steering Part of Tailgate Kit No. 260744
15 120814 4 ELBOW Part of Tailgate Kit No. 260744

December 3, 1998 ADT00348 4-11


HYDRAULIC TAILGATE SYSTEM (OPTIONAL) From 01/02/98

14
6

15 6

10
15
1
6
7
5
8 12,13 11
DOWN
8
9
4 3 2

UP

5
7
10 9 6

8 12,13 11

15

15 6

6 14

P003364

December 8, 1998 ADT00412 4-12


HYDRAULIC TAILGATE SYSTEM (OPTIONAL) From 01/02/98
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 180541 1 PIPE ASSY
2 120386 2 T PIECE
3 120035 2 CONNECTOR
4 240418 2 HOSE ASSY
5 120984 2 REDUCER
6 120002 6 CONNECTOR
7 240467 2 HOSE ASSY
8 121055 4 UNION
9 121030 2 T PIECE
10 240406 4 HOSE ASSY
11 181776 2 PIPE ASSY Includes Item No. 12 and 13
12 120880 4 SLEEVE
13 120890 4 NUT
14 230083 2 CYLINDER, Steering
15 120814 4 ELBOW
16 120968 1 CONNECTOR
17 210573 1 VALVE, Check, Pilot
18 121045 1 ADAPTOR
19 240882 1 HOSE ASSY
20 120387 1 TEE, Run
21 120998 1 REDUCER
22 120106 1 CONNECTOR
23 120355 1 ADAPTOR

December 8, 1998 ADT00412 4-13


HYDRAULIC TANK

16
17

15

1
14

P003345

October 16, 1996 B25B017 4-14


HYDRAULIC TANK
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100148 4 WASHER, Flat
2 181291 1 TANK, Hydraulic
3 100220 6 SCREW, Cap
4 210099 1 BREATHER, Filler, Pressurised
5 NSI 1 CAP
6 NSI 1 NECK, Filler
7 140502 2 SEAL
8 NSI 1 FILTER
9 100083 20 SCREW, Hex. Head
10 173304 1 LID, Hydraulic Tank
11 203774 1 GASKET
12 210106 1 FILTER, Suction, 90 micron
13 210187 2 SIGHT GLASS, Level
14 100394 4 NUT, Nyloc
15 100430 4 SCREW, Set, Hex
16 140528 2 WASHER, Dowty
17 100519 1 NUT, Sight Glass

October 16, 1996 B25B017 4-15


EMERGENCY STEERING SYSTEM (OPTIONAL - UPTO 28.02.97))
38 36

4
5 14 37
25 39
9 2
17

18
10 14
13
17
26
27 9 11
16
15 23
CR A
8 9 41
8 43
P 7
22 24 16
42 M
40
3
6 43

12 21 28 29 30

31 32
35

P R T L CL CR
1

19 34
PP LS HT HP EF

20 23
33
P003390

November 13, 1996 B25B064 4-16


EMERGENCY STEERING SYSTEM (OPTIONAL - UPTO 28.02.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210162 1 FLOW AMPLIFIER
2 210431 1 PUMP
3 181291 1 TANK
4 261236 1 KIT, Emergency Steering
5 210328 1 ACCUMULATOR
6 210346 1 BLOCK, Emergency Steering
7 210303 1 MOTOR, Electric
8 120818 3 ELBOW
9 120967 4 ADAPTOR
10 240279 1 HOSE ASSY
11 240223 1 HOSE ASSY
12 240278 1 HOSE ASSY
13 120812 1 ELBOW
14 120035 2 CONNECTOR Upto 28.02.97
15 120028 1 CONNECTOR
16 120386 1 T PIECE
17 120284 2 REDUCER Upto 28.02.97
18 210091 1 CHECK VALVE
19 240596 1 HOSE ASSY
20 190343 1 ADAPTOR
21 120968 1 CONNECTOR
22 121191 1 CONNECTOR
23 120100 2 ELBOW
24 240547 1 HOSE ASSY
25 240412 1 HOSE ASSY
26 100083 3 SCREW, Hex. Head
27 100062 3 WASHER, Flat
28 100415 4 NUT, Nyloc
29 100010 4 WASHER, Flat
30 100146 4 SCREW, Hex. Head
31 100812 4 WASHER, Flat
32 100732 4 BOLT, Hex. Head
33 100085 4 SCREW, Hex. Head
34 174800 1 PLATE
35 204874 1 HARNESS

November 13, 1996 B25B064 4-17


EMERGENCY STEERING SYSTEM (OPTIONAL - UPTO 28.02.97))
38 36

4
5 14 37
25 39
9 2
17

18
10 14
13
17
26
27 9 11
16
15 23
CR A
8 9 41
8 43
P 7
22 24 16
42 M
40
3
6 43

12 21 28 29 30

31 32
35

P R T L CL CR
1

19 34
PP LS HT HP EF

20 23
33
P003390

November 13, 1996 B25B064 4-18


EMERGENCY STEERING SYSTEM (OPTIONAL - UPTO 28.02.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 100143 4 SCREW, Cap
37 120237 2 FLANGE, Half
38 120209 1 ADAPTOR, Flanged
39 140131 1 O RING
40 120469 1 ADAPTOR Ref Service Bulletin 98/419
41 120529 1 T-PIECE Ref Service Bulletin 98/419
42 140525 2 WASHER, Dowty Ref Service Bulletin 98/419
43 190862 2 SWITCH,Emergency Steering Ref Service Bulletin 98/419

November 13, 1996 B25B064 4-19


EMERGENCY STEERING SYSTEM (OPTIONAL - FROM 01.03.97)
34
39

4 38
5 40
25
17
9 2

18
10 14
13
36
26
27 9 11
16
15 23
CR A
8
8 9 42
44 7
P
22 24 16
43 M
41
3
6 44

12 21 28 29 30

31 32
35

P R T L CL CR
1

19 34
PP LS HT HP EF

20 23
33
P003501

March 11, 1997 B25B067 4-20


EMERGENCY STEERING SYSTEM (OPTIONAL - FROM 01.03.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210162 1 FLOW AMPLIFIER
2 210431 1 PUMP
3 181291 1 TANK
4 261236 1 KIT, Emergency Steering
5 210328 1 ACCUMULATOR
6 210346 1 BLOCK, Emergency Steering
7 210303 1 MOTOR, Electric
8 120818 3 ELBOW
9 120967 4 ADAPTOR
10 240279 1 HOSE ASSY
11 240223 1 HOSE ASSY
12 240278 1 HOSE ASSY
13 120812 1 ELBOW
14 120035 1 CONNECTOR From 01.03.97
15 120028 1 CONNECTOR
16 120386 1 T PIECE
17 121452 1 ADAPTOR From 01.03.97
18 210091 1 CHECK VALVE
19 240596 1 HOSE ASSY
20 190343 1 ADAPTOR
21 120968 1 CONNECTOR
22 121191 1 CONNECTOR
23 120100 2 ELBOW
24 240547 1 HOSE ASSY
25 240412 1 HOSE ASSY
26 100083 3 SCREW, Hex. Head
27 100062 3 WASHER, Flat
28 100415 4 NUT, Nyloc
29 100010 4 WASHER, Flat
30 100146 4 SCREW, Hex. Head
31 100812 4 WASHER, Flat
32 100732 4 BOLT, Hex. Head
33 100085 4 SCREW, Hex. Head
34 174800 1 PLATE
35 204874 1 HARNESS

March 11, 1997 B25B067 4-21


EMERGENCY STEERING SYSTEM (OPTIONAL - FROM 01.03.97)
34
39

4 38
5 40
25
17
9 2

18
10 14
13
36
26
27 9 11
16
15 23
CR A
8
8 9 42
44 7
P
22 24 16
43 M
41
3
6 44

12 21 28 29 30

31 32
35

P R T L CL CR
1

19 34
PP LS HT HP EF

20 23
33
P003501

March 11, 1997 B25B067 4-22


EMERGENCY STEERING SYSTEM (OPTIONAL - FROM 01.03.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 121000 1 REDUCER From 01.03.97
37 120209 1 ADAPTOR, Flanged
38 120237 2 FLANGE, Half
39 100143 4 SCREW, Cap
40 140131 1 O RING
41 120469 1 ADAPTOR Ref Service Bulletin 98/419
42 120529 1 T - PIECE Ref Service Bulletin 98/419
43 140525 2 WASHER, Dowty Ref Service Bulletin 98/419
44 190862 2 SWITCH, Emergency Steering Ref Service Bulletin 98/419

March 11, 1997 B25B067 4-23


MOTOR, PUMP, EMERGENCY STEERING
6
22 23
1
24

2 6

6 21
20
19
15
4
3 8

32
6

5 9 30
17 18
16
12 s 31
10

10 13

14
5
9 13

11

30
11
29
9 28

27
26 13
25

P004641

December 8, 1998 210303 2-24


MOTOR, PUMP, EMERGENCY STEERING
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 201303 1 MOTOR PUMP, Emergency Steering Assembly Includes Items 2 to 32
2 220238 1 PUMP, Assembly Includes Items 3 to 15
3 NSI 4 NUT
4 NSI 1 COVER, Rear
5 220213 2 SEAL, Kit
6 NSI 2 PLATES, Wear
7 NSI 1 GEAR, Drive
8 NSI 1 GEAR, Idler
9 NSI 4 PIN, Dower
10 NSI 1 FLANGE, Port, Assembly
11 NSI 1 FLANGE, Port, Assembly
12 NSI 1 HOUSING, Body
13 NSI 3 BOLT, Steering, Kit
14 NSI 1 GROUP 2, Male, LH, Body
15 NSI 4 BOLT
16 NSI 1 SEAL, Shaft
17 NSI 1 CIRCLIP, Shaft
18 NSI 1 SPACER, Centre
19 NSI 1 COUPLING, Pump
20 NSI 1 WASHER, Shaft
21 NSI 1 NUT, Shaft
22 NSI 1 HOUSING, Power Steering
23 220237 1 SLEEVE, Nylon
24 NSI 1 KEY
25 NSI 1 NUT, Hub Retainer
26 NSI 1 WASHER, Hub
27 NSI 1 COUPLING, Motor
28 NSI 1 SHAFT, Motor
29 NSI 1 KEY
30 NSI 2 BOLT and WASHER, Kit
31 NSI 1 BOLT and WASHER, Kit
32 NSI 1 MOTOR
33
34
35

December 8, 1998 210303 2-25


TIP LEVER EXTENSION (OPTIONAL)

7
2
8

5 6

P003392

November 14, 1996 B25B065 4-26


TIP LEVER EXTENSION (OPTIONAL)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210283 1 VALVE, SP18 Includes Items 2 and 3
2 223597 1 ADAPTOR, Splined
3 223575 1 BALL
4 100238 1 SCREW, Hex. Head
5 174042 1 EXTENSION, Tip Lever
6 174405 1 PLATE, Cover
7 100083 2 SCREW, Hex. Head
8 100062 2 WASHER, Flat

November 14, 1996 B25B065 4-27


HYDRAULIC FILTER / BREATHER ASSEMBLY

January 16, 1996 210012 4-28


HYDRAULIC FILTER / BREATHER ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210012 1 HYDRAULIC FILTER / BREATHER ASSEMBLY
2 220010 1 ELEMENT, Filter
3 NSI 1 SEAL
4 NSI 1 HEAD, Filter
5 NSI 1 VALVE, Bypass
6 NSI 1 SCREW, Grub

January 16, 1996 210012 4-29


FLOW AMPLIFIER

January 26, 1996 210162 4-30


FLOW AMPLIFIER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210162 1 FLOW AMPLIFIER
2 NSI 16 SCREW
3 100065 16 WASHER, Spring
4 100228 2 SCREW, Cap
5 100044 2 WASHER, Spring
6 NSI 1 COVER
7 NSI 1 COVER
8 * 4 O RING
9 * 4 O RING
10 * 2 O RING
11 NSI 1 PLATE, Seal
12 NSI 1 PLATE, Seal
13 NSI 1 PLUG
14 * 1 O RING
15 NSI 1 PLUG
16 * 1 SEAL
17 221201 1 VALVE, Relief, Pressure
18 NSI 1 BODY, Valve
19 NSI 1 ADJUSTER, Pressure
20 NSI 1 SPRING
21 NSI 1 POPPET
22 * 1 SEAL
23 NSI 1 SCREW, Orifice
24 NSI 1 VALVE, Throttle Check
25 NSI 1 BODY, Valve
26 NSI 1 PLUG
27 NSI 1 BALL
28 NSI 1 SPRING
29 NSI 1 AMPLIFIER SPOOL ASSY
30 NSI 1 VALVE, Check
31 NSI 1 GUIDE, Spring
32 NSI 1 SPRING
33 NSI 1 BALL
34 NSI 1 PLUG
35 * 1 O RING

January 26, 1996 210162 4-31


FLOW AMPLIFIER

January 26, 1996 210162 4-32


FLOW AMPLIFIER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 NSI 1 SPOOL, Amplifier
37 NSI 1 PIN, Slug
38 NSI 1 PIN
39 NSI 2 RING, Retaining
40 NSI 1 SLUG
41 NSI 1 SPRING
42 NSI 1 PLUG
43 NSI 1 SCREW, Orifice
44 NSI 1 PLUG
45 NSI 1 SPOOL, Priority
46 NSI 1 SPRING
47 NSI 1 STOP
48 NSI 2 SCREW, Orifice
49 NSI 1 SPOOL, Directional
50 NSI 2 CONTROL, Spring
51 NSI 2 SPRING
52 NSI 2 SPRING
53 NSI 2 STOP
54 221200 2 VALVE, Shock and Suction
55 NSI 1 NUT
56 NSI 1 SCREW, Orifice
57 NSI 1 STOP
58 NSI 1 SPRING
59 NSI 1 POPPET
60 NSI 1 GUIDE, Spring
61 * 1 O RING
62 NSI 1 SPRING
63 NSI 1 SPRING
64 NSI 1 BODY, Valve
65 * 1 O RING
66 NSI 1 INSERT, Valve
67 NSI 1 VALVE
68 NSI 1 HOUSING, Valve
69 220655 1 KIT, Seal, Flow Amplifier Includes Items Marked *

January 26, 1996 210162 4-33


CONTROL VALVE (ONE BANK)

10,59

December 7, 1998 210283 4-34


CONTROL VALVE (ONE BANK)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210283 1 CONTROL VALVE (ONE BANK) Includes Items 2 to 55 and 59
2 NSI 1 BODY, Section, Work Includes Item 3
3 NSI 1 SPOOL
4 223566 1 VALVE, Check Includes Items 5 to 8
5 NSI 1 PLUG
6 NSI ** 1 O RING
7 NSI 1 SPRING
8 NSI 1 POPPET
9 223567 1 HANDLE ASSY Includes Items 10 to 21 and 59
10 223575 1 KNOB
11 NSI 1 HANDLE
12 100288 1 NUT, Hex
13 NSI 1 LEVER, Ball
14 NSI 1 COVER, Dust
15 NSI 1 PIN
16 NSI 1 COVER, End
17 223048 4 SCREW, Cap
18 NSI 1 PLATE
19 ** 2 RING, Wiper
20 ** 2 O RING
21 NSI 1 END, Spool
22 223576 1 NEUTRAL POSITION ASSY Includes Items 23 to 30
23 NSI 2 SEAT, Spring
24 NSI 1 SPRING
25 NSI 1 COLLAR, Stop
26 ** 1 O RING
27 ** 1 RING, Wiper
28 NSI 1 PLATE
29 NSI 1 COVER, End
30 NSI 2 SCREW, Cap
31 223574 3 VALVE, Pressure Relief Includes Items 32 to 44
32 NSI 1 PLUG
33 ** 1 O RING
34 ** 1 O RING
35 NSI 1 SPRING

December 7, 1998 210283 4-35


CONTROL VALVE (ONE BANK)

10,59

December 7, 1998 210283 4-36


CONTROL VALVE (ONE BANK)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 NSI 1 COVER, Seal
37 NSI 1 NUT, Lock
38 NSI 1 SCREW, Adjusting
39 NSI 1 POPPET
40 NSI 1 SEAT, Valve
41 NSI 1 BODY, Valve, Relief
42 ** / *** 1 O RING
43 ** / *** 1 RING, Backup
44 ** / *** 1 O RING
45 * 2 O RING
46 * 1 O RING
47 * 1 RING, Thrust
48 * 1 O RING
49 NSI 1 SECTION, Inlet
50 NSI 2 PLATE, Mounting
51 NSI 4 SCREW, Cap
52 NSI 1 COVER
53 NSI 1 PLUG
54 NSI 3 STUD
55 100314 6 NUT, Nyloc
56 140558 2 KIT, Seal, Between Section Includes Items Marked *
57 140559 1 KIT, Seal, Seperate Section Includes Items Marked **
58 140560 1 KIT, Seal, Relief Valve Includes Items Marked ***
59 223597 1 ADAPTOR, Slined Part of Item 9

December 7, 1998 210283 4-37


STEERING VALVE (FROM 01.12.94)

January 31, 1996 210413 4-38


STEERING VALVE (FROM 01.12.94)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210413 1 STEERING VALVE
2 * 1 RING, Seal, Dust
3 NSI 1 HOUSING, SPOOL AND SLEEVE ASSY
4 NSI 1 BALL
5 NSI 1 SEAT
6 * 1 O RING
7 * 1 KIN RING
8 222601 1 BEARING ASSY
9 NSI 1 RING
10 NSI 1 PIN, Cross
11 NSI 1 SHAFT, Cardan
12 NSI 1 SPACER
13 * 1 O RING
14 NSI 1 PLATE, Distributor
15 NSI 1 GEAR WHEEL SET
16 * 3 O RING
17 NSI 1 COVER, End
18 * 7 WASHER
19 * 1 PIN, Roll
20 NSI 1 SCREW, With Bore
21 NSI 6 SCREW
22 NSI 1 PLATE, Name
23 NSI 2 SCREW, Drive
24 222602 1 SPRING SET
25 221202 1 KIT, Seal, Steering Valve Includes Items Marked *

January 31, 1996 210413 4-39


HYDRAULIC PUMP

May 7, 1998 210431 4-40


HYDRAULIC PUMP
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210431 1 HYDRAULIC PUMP
2 223219 4 SCREW, Cap
3 223247 1 VALVE, Pilot
4 223220 1 PLUG
5 223218 3 O RING
6 100256 4 SCREW, Cap
7 223244 4 O RING
8 223234 1 PLATE, Port
9 223213 2 PIN, Double Break Off
10 223214 1 PIN, Dowel
11 223246 2 PLUG, Seal
12 223257 1 PISTON, Control
13 223258 1 GUIDE, Piston
14 223259 1 PISTON, Counter
15 223261 1 SPRING
16 223260 1 GUIDE, Piston
17 223231 1 ROTARY GROUP
18 223250 1 PLATE, Distributor
19 223255 1 CIRCLIP, Internal
20 223253 1 SPRING
21 223254 1 PIN, Pressure
22 223249 1 CYLINDER
23 223252 1 BALL, Retaining
24 223251 1 PLATE, Retaining
25 223248 9 PISTON
26 223238 1 DISC, Tuning
27 223240 1 BEARING, Roller, Taper
28 223237 1 DISC
29 223235 1 PLATE, Swash
30 223241 2 BEARING, Plate, Swash
31 223236 1 SHAFT, Drive
32 223239 1 BEARING, Roller, Taper
33 223243 1 O RING
34 223233 1 HOUSING, Pump
35 223212 1 PLUG

May 7, 1998 210431 4-41


HYDRAULIC PUMP

May 7, 1998 210431 4-42


HYDRAULIC PUMP
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 140062 1 O RING
37 223245 1 CIRCLIP, Internal
38 223242 1 SEAL, Shaft

May 7, 1998 210431 4-43


HYDRAULIC FILTER ASSEMBLY

2
3

4
1

P001903

December 8, 1998 210467 4-44


HYDRAULIC FILTER ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210467 1 HEAD, Spin On, Twin Element Includes Items 2 to 7
2 NSI 1 HOUSING
3 210446 2 ELEMENT, Spin On, 5 Mic Includes Item 4
4 NSI 2 SEAL, Rubber
5 NSI 4 PLUG
6 NSI 1 VALVE, Bypass
7 NSI 1 SPRING ,Bypass Valve

December 8, 1998 210467 4-45


TIP CYLINDER

16
20
7
11
18
17
19

7
10

2
15
14
44
13
12 5

21

June 11, 1998 230054 4-46


TIP CYLINDER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 230054 1 TIP CYLINDER
2 200036 1 GREASE NIPPLE
3 180509 1 ROD
4 100341 1 NUT, Castle
5 200732 4 CIRCLIP, Internal
6 150096 2 BEARING, Spherical
7 161312 1 PISTON
8 180756 1 BARREL
9 200732 4 CIRCLIP, Internal
10 150096 2 BEARING, Spherical
11 160556 1 NECKBUSH
12 140576 1 KIT, Seal, Tip Cylinder
13 NSI 1 PIN, Split
14 NSI 1 O RING
15 NSI 1 SEAL, Piston
16 NSI 1 SEAL, Wiper
17 NSI 1 RING, Backup
18 NSI 1 O RING
19 NSI 1 O RING
20 NSI 1 U SEAL
21 140239 1 BOOT, Cylinder

June 11, 1998 230054 4-47


STEERING CYLINDER

1
4

19
18
9
11

17
16
15

13
10
3
12
6
14

P003674

June 26, 1997 230046 4-48


STEERING CYLINDER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 230046 1 STEERING CYLINDER
2 180507 1 ROD Includes items 3 to 5
3 100333 1 NUT, Castle
4 150093 1 BEARING, Spherical
5 201495 1 CIRCLIP, Internal
6 180506 1 BARREL Includes items 7 & 8
7 150093 1 BEARING, Spherical
8 201495 1 CIRCLIP
9 160236 1 NECKBUSH
10 161317 1 PISTON
11 140575 1 KIT, Seal Includes items 12 to 19
12 NSI 1 SPLIT PIN
13 NSI 1 O RING
14 NSI 1 SEAL, Piston
15 NSI 1 O RING
16 NSI 1 RING, Anti extrusion
17 NSI 1 O RING
18 NSI 1 U SEAL
19 NSI 1 SEAL, Wiper

June 26, 1997 230046 4-49


STEERING CYLINDER (LHS - FROM 02.03.97)

1
2 12

3
15

13
10

17
16 11
4 18
9
5
19
14

8
7

P002757

June 11, 1998 230285 4-50


STEERING CYLINDER (LHS - FROM 02.03.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 230285 1 STEERING CYLINDER (Left Hand Side)
2 180507 1 ROD Includes Items 3 to 5
3 100333 1 NUT, Castle
4 201495 4 CIRCLIP, Internal
5 150095 2 BEARING, Spherical
6 181973 1 BARREL Includes Items 7 and 8
7 201495 4 CIRCLIP, Internal
8 150095 2 BEARING, Spherical
9 160236 1 NECKBUSH
10 161317 1 PISTON
11 140575 1 KIT, Seal Includes Items 12 to 19
12 100430 1 PIN, Split
13 140150 1 O RING
14 140479 1 SEAL, Wiper
15 140031 1 SEAL, Piston
16 140103 1 RING, Backup
17 140020 1 O RING
18 140159 1 O RING
19 140165 1 U SEAL

June 11, 1998 230285 4-51


STEERING CYLINDER (RHS - FROM 02.03.97)

1
2 12

3
15

13
10

17
16 11
4 18
9
5
19
14

8
7

P002756

June 11, 1998 230290 4-52


STEERING CYLINDER (RHS - FROM 02.03.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 230290 1 STEERING CYLINDER (Right Hand Side)
2 180507 1 ROD Includes Items 3 to 5
3 100333 1 NUT, Castle
4 201495 4 CIRCLIP, Internal
5 150095 2 BEARING, Spherical
6 181975 1 BARREL Includes Items 7 and 8
7 201495 4 CIRCLIP, Internal
8 150095 2 BEARING, Spherical
9 160236 1 NECKBUSH
10 161317 1 PISTON
11 140575 1 KIT, Seal Includes Items 12 to 19
12 100430 1 PIN, Split
13 140150 1 O RING
14 140479 1 SEAL, Wiper
15 140031 1 SEAL, Piston
16 140103 1 RING, Backup
17 140020 1 O RING
18 140159 1 O RING
19 140165 1 U SEAL

June 11, 1998 230290 4-53


STEERING CYLINDER

February 5, 1996 230083 4-54


STEERING CYLINDER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 230083 1 STEERING CYLINDER (Used on Hyd. Tailgate)
2 180771 1 ROD
3 100333 1 NUT, Castle
4 160270 1 NECKBUSH
5 161315 1 PISTON
6 180770 1 BARREL
7 140571 1 KIT, Seal, Steering Cylinder
8 NSI 1 PIN, Split
9 NSI 1 U SEAL
10 NSI 1 O RING
11 NSI 1 SEAL, Piston
12 NSI 1 SEAL, Wiper
13 NSI 1 O RING
14 NSI 1 O RING
15 NSI 1 O RING

February 5, 1996 230083 4-55


SPECIAL TOOLS

October 16, 1996 B25B018 4-56


SPECIAL TOOLS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 280136 1 TOOL, Danfoss Steering Valve
2 280007 1 SPANNER, Neckbush 100 mm Bore Cylinders.

October 16, 1996 B25B018 4-57


September 18, 1998 SECTION 4B PNEUMATIC SYSTEM 4-58
SECTION 4B
PNEUMATIC SYSTEM

September 18, 1998 SECTION 4B PNEUMATIC SYSTEM 4-59


FRONT PNEUMATIC SYSTEM (UPTO 01.02.97)
29 15
15

4 58 39 39 58 21 20
46 45 9 10 61 61
68 68
15 19
47
17 73 13 58 4 58 4
46 58 58 4
18 3 5 6 47 73 19 27 51 58 9 28 9 28
21 30
45 20 54
2 26 63 52 58 20
13 73 12 21
10 19 10 28
12 16 73 13 58
13 9 41 58
9 19 25 28 42
4 9
12 10
11
13 11 9 20 21 4 9 10
9 57
73 58 13
9 9 14 73
34 10 4 47 9 35 40
44 14 22
13 39 10
13 46
9 45
13 9 45 46 9 9
64 13 73 11 69
9 28 45 38
53 9 13 10 11 47 73 50 10
10 10
14 7 9 75 9 16 13 48
45 73 9 70 62
47 13 9 45 45 45 9
46 4
10 8
59
47 43 45
73 45 73 12 9 9 13 12 73 13 37
13 47
13 13
74 9 4 10
58 39 65
17 41 73
13 73 58
39 9 45
9 45 39
9 10 4
45 36 31 65 52 58 71
46 8 39 14 1 13 72
4 39 58 52 49
47 10 58 58 58 4
58 39 65 58
73 4 39 58 55
16 56
13 66 58 39 60 39
17
67 23 32
12 13 73 24 23
66 60 33
58 39 33 P003387
39 4 58 39
73 41 58 58
4
13 60 39 58
73
12

June 30, 1997 B25B019 4-60


FRONT PNEUMATIC SYSTEM (UPTO 01.02.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210276 1 VALVE, Brake Adaptor
2 AD64000305 1 COMPRESSOR
3 121231 1 CONNECTOR
4 130020 A/R HOSE, Pushlock
5 201669 1 HOSE
6 120258 1 ELBOW
7 172418 1 COIL, Cooling
8 203531 2 CLAMP, T Bolt
9 200061 A/R CLAMP, Hose
10 130026 A/R HOSE
11 160242 4 CONNECTOR
12 120399 7 PLUG
13 140370 25 O RING
14 160550 4 NIPPLE, Swage
15 100277 4 WASHER
16 200317 3 RESERVOIR, Air, 20 Liter
17 200318 6 BAND, Mounting
18 100523 1 WASHER, Seal, Aluminium
19 100354 8 WASHER, Copper
20 120138 4 BOLT, Banjo
21 120137 4 BANJO
22 121221 2 PLUG
23 210100 2 VALVE, Solenoid
24 210056 1 VALVE
25 130042 1 HOSE
26 200174 2 AIR SPRING ASSY
27 210179 1 VALVE, Levelling
28 120161 7 ADAPTOR, Hose, Barbed
29 210271 1 VALVE, Control, Diff Lock
30 Z0501002473 1 DIFF LOCK ACTUATOR KIT
31 120191 1 NIPPLE
32 200380 1 GAUGE, Air Pressure
33 100802 2 SCREW, Set, Hex
34 100706 3 BOLT
35 120164 2 ADAPTOR

June 10, 1997 B25B019 4-61


FRONT PNEUMATIC SYSTEM (UPTO 01.02.97)
29 15
15

4 58 39 39 58 21 20
46 45 9 10 61 61
68 68
15 19
47
17 73 13 58 4 58 4
46 58 58 4
18 3 5 6 47 73 19 27 51 58 9 28 9 28
21 30
45 20 54
2 26 63 52 58 20
13 73 12 21
10 19 10 28
12 16 73 13 58
13 9 41 58
9 19 25 28 42
4 9
12 10
11
13 11 9 20 21 4 9 10
9 57
73 58 13
9 9 14 73
34 10 4 47 9 35 40
44 14 22
13 39 10
13 46
9 45
13 9 45 46 9 9
64 13 73 11 69
9 28 45 38
53 9 13 10 11 47 73 50 10
10 10
14 7 9 75 9 16 13 48
45 73 9 70 62
47 13 9 45 45 45 9
46 4
10 8
59
47 43 45
73 45 73 12 9 9 13 12 73 13 37
13 47
13 13
74 9 4 10
58 39 65
17 41 73
13 73 58
39 9 45
9 45 39
9 10 4
45 36 31 65 52 58 71
46 8 39 14 1 13 72
4 39 58 52 49
47 10 58 58 58 4
58 39 65 58
73 4 39 58 55
16 56
13 66 58 39 60 39
17
67 23 32
12 13 73 24 23
66 60 33
58 39 33 P003387
39 4 58 39
73 41 58 58
4
13 60 39 58
73
12

June 30, 1997 B25B019 4-62


FRONT PNEUMATIC SYSTEM (UPTO 01.02.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 200385 1 SWITCH, Stop Light
37 260145 1 ACTUATOR, Brake, Air/Hydraulic
38 180544 1 PIPE ASSY
39 120156 20 ADAPTOR, Hose, Barbed
40 170655 1 PLATE, Mounting
41 120166 3 VALVE, Drain
42 201321 1 ACTUATOR, Park Brake
43 120012 1 NIPPLE
44 100111 2 SCREW, Set, Hex
45 120162 18 ADAPTOR, Hose, Barbed
46 120107 6 ELBOW
47 120169 8 BUSH, Reducing
48 210208 1 VALVE, Foot
49 202438 1 SWITCH, Overstroke
50 172029 1 MANIFOLD
51 100199 1 BOLT
52 120053 4 ADAPTOR
53 210197 1 VALVE, Unloader
54 210125 1 BRAKE, Park
55 120173 1 FITTING, Male Stud
56 130029 1 PIPE
57 210126 1 VALVE, Protection, Pressure
58 200033 A/R CLAMP, Hose
59 120019 1 PLUG
60 120212 3 ADAPTOR, Swivel
61 100488 2 BOLT, Banjo
62 100314 2 NUT, Nyloc
63 120126 2 REDUCER
64 100083 1 SCREW, Set, Hex
65 120185 3 T-PIECE
66 120350 2 FITTING
67 120417 1 COUPLING, Swivel
68 100489 2 FITTING, Banjo
69 100177 2 SCREW, Set, Hex
70 100364 2 BOLT

June 10, 1997 B25B019 4-63


FRONT PNEUMATIC SYSTEM (UPTO 01.02.97)
29 15
15

4 58 39 39 58 21 20
46 45 9 10 61 61
68 68
15 19
47
17 73 13 58 4 58 4
46 58 58 4
18 3 5 6 47 73 19 27 51 58 9 28 9 28
21 30
45 20 54
2 26 63 52 58 20
13 73 12 21
10 19 10 28
12 16 73 13 58
13 9 41 58
9 19 25 28 42
4 9
12 10
11
13 11 9 20 21 4 9 10
9 57
73 58 13
9 9 14 73
34 10 4 47 9 35 40
44 14 22
13 39 10
13 46
9 45
13 9 45 46 9 9
64 13 73 11 69
9 28 45 38
53 9 13 10 11 47 73 50 10
10 10
14 7 9 75 9 16 13 48
45 73 9 70 62
47 13 9 45 45 45 9
46 4
10 8
59
47 43 45
73 45 73 12 9 9 13 12 73 13 37
13 47
13 13
74 9 4 10
58 39 65
17 41 73
13 73 58
39 9 45
9 45 39
9 10 4
45 36 31 65 52 58 71
46 8 39 14 1 13 72
4 39 58 52 49
47 10 58 58 58 4
58 39 65 58
73 4 39 58 55
16 56
13 66 58 39 60 39
17
67 23 32
12 13 73 24 23
66 60 33
58 39 33 P003387
39 4 58 39
73 41 58 58
4
13 60 39 58
73
12

June 30, 1997 B25B019 4-64


FRONT PNEUMATIC SYSTEM (UPTO 01.02.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
71 100083 2 SCREW, Set, Hex
72 120901 1 FITTING, Bulkhead
73 100590 20 G RING
74 210211 1 VALVE, Air Spillover
75 120010 1 T PIECE

June 10, 1997 B25B019 4-65


FRONT PNEUMATIC SYSTEM (FROM 02.02.97)
65 To Rear Axle 70 29
19 15 15
(see rear Pneumatic System) 20 19 20
4 39 39 4 21 58 39 39 58 21
21 61 61 20
58 9 10
58 46 45 58 68 68
4 15
52 58 19
47
17 38 13 4 58 4 58 4
46 58 58 4
13 3 5 6 47 38 58 19 27 51 58 9 28 9 28
21 30
45 20 54
2 26 63 20
13 39 21
38 12 52 19 10
10 13 58 28
12 16 38
13 9 41 58 25
9 58 19
4 9 28
12 10
11
13 11 9 20 21 4 9 10
9 57
38
9 9 14 38
34 10 4 58 9 35 40
44 14 22 58
13 10
13 39 39
50
13 9 45 46
64 13 38 11
53 9 13 10 11 47 38 9
10
28 10
14 7 9 16 13 48
38 8 62
47 13 4 45
9
10 9 10 46
45 45 38 12 9 9 13 12 43 13 37
45 47
13 13
9 4 10
59
58 39 65
17 41 38
58
45 39 9 45
39
9 10 4
45 36 31 65 52 58 42
46 39 14 1 18 69
4 39 58 52 49
47 10 58 58 58 4
58 39 65 58
38 4 39 58 55
16 56
13 66 58 39 60 39
17
67 23 32
12 13 38 24 23
66 60 33
58 39 33
39 4 58 39
38 41 58 58
4
13 60 39 58
38 P004208
12

October 15, 1996 B25B068 4-66


FRONT PNEUMATIC SYSTEM (FROM 02.02.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210276 1 VALVE, Brake Adaptor
2 AD64000305 1 COMPRESSOR
3 121231 1 CONNECTOR
4 130020 A/R HOSE, Pushlock
5 201669 1 HOSE
6 120258 1 ELBOW
7 172418 1 COIL, Cooling
8 100364 2 BOLT
9 200061 A/R CLAMP, Hose
10 130026 A/R HOSE
11 160242 4 CONNECTOR
12 120399 7 PLUG
13 140370 23 O RING
14 160550 4 NIPPLE, Swage
15 100277 4 WASHER
16 200317 3 RESERVOIR, Air, 20 Liter
17 200318 6 BAND, Mounting
18 140370 1 O RING
19 100354 12 WASHER, Copper
20 120138 6 BOLT, Banjo
21 120137 6 BANJO
22 121221 2 PLUG
23 210100 2 VALVE, Solenoid
24 210056 1 VALVE
25 130042 1 HOSE
26 200174 2 AIR SPRING ASSY
27 210179 1 VALVE, Levelling
28 120161 7 ADAPTOR, Hose, Barbed
29 210271 1 VALVE, Control, Diff Lock
30 Z0501002473 1 DIFF LOCK ACTUATOR KIT
31 120191 1 NIPPLE
32 200380 1 GAUGE, Air Pressure
33 100802 2 SCREW, Set, Hex
34 100706 3 BOLT
35 120164 2 ADAPTOR

October 15, 1996 B25B068 4-67


FRONT PNEUMATIC SYSTEM (FROM 02.02.97)
65 To Rear Axle 70 29
19 15 15
(see rear Pneumatic System) 20 19 20
4 39 39 4 21 58 39 39 58 21
21 61 61 20
58 9 10
58 46 45 58 68 68
4 15
52 58 19
47
17 38 13 4 58 4 58 4
46 58 58 4
13 3 5 6 47 38 58 19 27 51 58 9 28 9 28
21 30
45 20 54
2 26 63 20
13 39 21
38 12 52 19 10
10 13 58 28
12 16 38
13 9 41 58 25
9 58 19
4 9 28
12 10
11
13 11 9 20 21 4 9 10
9 57
38
9 9 14 38
34 10 4 58 9 35 40
44 14 22 58
13 10
13 39 39
50
13 9 45 46
64 13 38 11
53 9 13 10 11 47 38 9
10
28 10
14 7 9 16 13 48
38 8 62
47 13 4 45
9
10 9 10 46
45 45 38 12 9 9 13 12 43 13 37
45 47
13 13
9 4 10
59
58 39 65
17 41 38
58
45 39 9 45
39
9 10 4
45 36 31 65 52 58 42
46 39 14 1 18 69
4 39 58 52 49
47 10 58 58 58 4
58 39 65 58
38 4 39 58 55
16 56
13 66 58 39 60 39
17
67 23 32
12 13 38 24 23
66 60 33
58 39 33
39 4 58 39
38 41 58 58
4
13 60 39 58
38 P004208
12

October 15, 1996 B25B068 4-68


FRONT PNEUMATIC SYSTEM (FROM 02.02.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 200385 1 SWITCH, Stop Light
37 260145 1 ACTUATOR, Brake, Air/Hydraulic
38 100590 17 G RING
39 120156 25 ADAPTOR, Hose, Barbed
40 170655 1 PLATE, Mounting
41 120166 3 VALVE, Drain
42 100083 2 SCREW, Set, Hex.
43 100590 1 O RING
44 100111 2 SCREW, Set, Hex
45 120162 12 ADAPTOR, Hose, Barbed
46 120107 5 ELBOW
47 120169 7 BUSH, Reducing
48 210208 1 VALVE, Foot
49 202438 1 SWITCH, Overstroke
50 172029 1 MANIFOLD
51 100199 1 BOLT
52 120053 4 ADAPTOR
53 210197 1 VALVE, Unloader
54 210125 1 BRAKE, Park
55 120173 1 FITTING, Male Stud
56 130029 1 PIPE
57 210126 1 VALVE, Protection, Pressure
58 200033 A/R CLAMP, Hose
59 120010 1 T PIECE
60 120212 3 ADAPTOR, Swivel
61 100488 2 BOLT, Banjo
62 100314 2 NUT, Nyloc
63 120126 2 REDUCER
64 100083 1 SCREW, Set, Hex
65 120185 4 T-PIECE
66 120350 2 FITTING
67 120417 1 COUPLING, Swivel
68 100489 2 FITTING, Banjo
69 120901 1 FITTING, Bulkhead
70 201217 1 VALVE, Push Button From 10.05.97

October 15, 1996 B25B068 4-69


REAR PNEUMATIC SYSTEM (FROM 02.02.97)
Rear Axle

7 6 17

10
12 13 14 15
9

11

16 8

6,7
3 4 15 14

2 1 2 2

P004209

March 18, 1997 B25B069 4-70


REAR PNEUMATIC SYSTEM (FROM 02.02.697)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 171685 1 PIPE, Brake
2 203349 3 K CLAMP
3 120820 1 ELBOW
4 120169 1 REDUCER
5 240844 1 HOSE
6 200033 1 CLAMP, Hose From 10.05.97
7 120156 1 ADAPTOR, Barbed Hose From 10.05.97
8 120285 1 UNION
9 240941 1 HOSE
10 120002 2 CONNECTOR
11 120418 1 COUPLING, Swivel
12 120416 1 COUPLING, Swivel Elbow
13 120409 1 COUPLING, Stud, Male
14 100590 2 G RING
15 140370 2 O RING
16 210338 1 TEST CONNECTOR
17 130020 A/R HOSE, Pushlock From 10.05.97

March 18, 1997 B25B069 4-71


AIR SPRING ASSEMBLY

January 16, 1996 200174 4-72


AIR SPRING ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 200174 2 AIR SPRING ASSEMBLY
2 100314 8 NUT, Nyloc
3 NSI 1 PLATE, Top
4 NSI 1 PLATE, Base
5 NSI 2 PLATE, Retaining
6 200238 1 BAG, Air

January 16, 1996 200174 4-73


SOLENOID VALVE

January 12, 1996 210100 4-74


SOLENOID VALVE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210100 1 SOLENOID VALVE 24V
2 NSI 1 CLIP, Retaining
3 NSI 1 PLATE, Information
4 NSI 1 WASHER
5 NSI 1 SCREW
6 NSI 1 WASHER
7 NSI 1 CONNECTOR, Electrical
8 NSI 1 PACKING, Preformed
9 NSI 1 COIL
10 NSI 1 TUBE, Coil
11 NSI 2 O RING
12 NSI 1 SPRING AND CORE
13 NSI 1 PLUG, Head, Hex
14 NSI 1 SPRING, Compression
15 NSI 1 VALVE
16 NSI 1 BODY, Valve

January 12, 1996 210100 4-75


PARK BRAKE

1
32
31 34

22 35
21

23 33 36

3 24
20
23 38 37
38
25

26
37
19 27
18
28

4 29
17 39

5 16

15 40
6
30 2
7 14
41
8 46
42
9 14
10 43
44
11
45
12
13 P003193

April 28, 1998 210601 4-76


PARK BRAKE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210601 1 PARK BRAKE VALVE
2 220143 1 KIT, Repair INCLUDES ITEMS MARKED *
3 NSI 1 HOUSING
4 * 1 VALVE
5 * 1 O RING
6 * 1 SLEEVE
7 * 1 SPRING
8 NSI 1 VALVE
9 * 1 O RING
10 * 1 O RING
11 NSI 1 PIPE, Outlet
12 NSI 1 PLATE
13 NSI 2 SCREW
14 * 2 O RING
15 * 1 SPRING
16 * 1 O RING
17 * 1 VALVE
18 * 1 O RING
19 NSI 1 HOUSING, Spring
20 * 1 SPRING
21 NSI 1 PISTON
22 NSI 1 PISTON
23 NSI 3 WASHER
24 NSI 1 SPRING
25 NSI 1 GUIDE, Spring
26 NSI 1 NUT
27 NSI 1 STUD, Setting
28 * 1 O RING
29 NSI 1 PISTON
30 * 1 SPRING
31 NSI 2 SCREW
32 NSI 1 COVER
33 NSI 1 PLATE
34 NSI 1 KNOB
35 * 2 PIN

April 28, 1998 210601 4-77


PARK BRAKE

1
32
31 34

22 35
21

23 33 36

3 24
20
23 38 37
38
25

26
37
19 27
18
28

4 29
17 39

5 16

15 40
6
30 2
7 14
41
8 46
42
9 14
10 43
44
11
45
12
13 P003193

April 28, 1998 210601 4-78


PARK BRAKE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 NSI 1 LEVER
37 * 2 SPRING
38 * 2 GUIDE, Spring
39 NSI 1 COVER
40 NSI 1 GUIDE
41 NSI 1 PLATE, Mounting
42 NSI 1 SPACER
43 * 1 O RING
44 * 1 O RING
45 NSI 1 GUIDE
46 NSI 1 PISTON, Port

April 28, 1998 210601 4-79


PRESSURE PROTECTION VALVE

April 21, 1998 210126 4-80


PRESSURE PROTECTION VALVE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210126 1 PRESSURE PROTECTION VALVE
2 * 4 COVER, Dust
3 NSI 4 SCREW, Adjusting
4 NSI 12 SCREW
5 NSI 4 HOUSEING, Spring, Compression
6 NSI 4 SEAT, Sadjusting, Spring
7 * 4 SPRING, Compression
8 * 4 SEAT, Spring
9 * 4 DIAPHRAGM
10 * 4 SEAT, Spring
11 * 4 SPRING, Compression
12 * 1 CIRCLIP, Internal
13 NSI 1 COVER
14 * 1 O RING
15 * 2 SPRING, Compression
16 * 2 PISTON, Rubber
17 NSI 1 BODY, Valve
18 221432 1 KIT, Repair, Pressure Protection Valve

April 21, 1998 210126 4-81


LEVELLING VALVE

1 2
3
4
15 5

6
10 22
7
8

14

13
9

11

16
21 12
17

18

20 19
P004175

April 28, 1998 210179 4-82


LEVELLING VALVE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210179 1 LEVELLING VALVE INCLUDES ALL ITEMS
2 NSI 1 CONNECTION
3 NSI 1 O RING
4 NSI 1 VALVE
5 NSI 1 SPRING
6 NSI 1 VALVE
7 NSI 1 INSERT ASSEMBLY
8 NSI 1 O RING
9 NSI 1 O RING
10 NSI 1 VALVE BODY ASSEMBLY
11 NSI 1 PEG, Location
12 NSI 1 HOOD, Exhaust
13 NSI 1 SLEEVE
14 NSI 1 SEAL
15 NSI 1 SHAFT
16 NSI 1 SPRING
17 NSI 1 O RING
18 NSI 1 SLIDE ASSEMBLY
19 NSI 1 WASHER
20 NSI 1 NUT
21 NSI 1 PLUG
22 NSI 1 FILTER

April 28, 1998 210179 4-83


UNOADER VALVE WITH INTEGRAL AIR DRIER ASSEMBLY

NOTE
REFER TO PNEUMATIC SYSTEM
DIAGRAM FOR VARIATIONS
ON THIS AREA

April 21, 1998 210197 4-84


UNLOADER VALVE WITH INTEGRAL AIR DRIER ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210197 1 UNLOADER VALVE WITH INEGRAL AIR DRIER ASSY
2 222604 1 RESERVOIR, Air
3 171067 1 PIPE ASSY
4 210277 1 UNLOADER VALVE INTEGRAL AIR DRIER
5 ** 1 CIRCLIP, Internal
6 NSI 1 COVER
7 ** 1 O RING
8 ** 1 SPRING
9 NSI 1 PLUNGER
10 ** 1 O RING
11 ** 1 SPRING
12 ** 1 STOP, Rubber
13 ** 1 O RING
14 NSI 1 COVER
15 NSI 1 CIRCLIP, Internal
16 220949 1 FILTER, Air Drier Not Part of Item 4, Order Seperatly
17 ** 1 O RING
18 NSI 1 CIRCLIP, Internal
19 NSI 1 COVER
20 NSI 1 SEAT, Spring
21 NSI 1 SPRING
22 ** 3 SHIM, Brass
23 NSI 1 PLUNGER
24 ** 1 O RING
25 NSI 1 ROTOR
26 NSI 1 SPACER
27 ** 1 O RING
28 NSI 1 BODY, Valve
29 NSI 1 VALVE, Unloader
30 NSI 1 COVER, Valve, Unloader
31 NSI 1 SCREW, Adjusting
32 NSI 1 SCREW, Cap
33 NSI 1 O RING
34 NSI 1 SPRING, Adjusting, Seat
35 NSI 1 SEAT, Spring

April 21, 1998 210197 4-85


UNLOADER VALVE WITH INTEGRAL AIR DRIER ASSEMBLY

NOTE
REFER TO PNEUMATIC SYSTEM
DIAGRAM FOR VARIATIONS
ON THIS AREA

April 21, 1998 210197 4-86


UNLOADER VALVE WITH INTEGRAL AIR DRIER ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 NSI 1 SPRING
37 * 1 CIRCLIP, Internal
38 NSI 1 SEAT, Spring
39 NSI 1 WASHER
40 * 1 DIAPHRAGM
41 NSI 1 SEAT, Spring
42 NSI 1 SPRING
43 * 1 SEAL
44 NSI 1 PLUNGER
45 220960 1 KIT, Repair, Unloader Valve Includes Items Marked *
46 220959 1 KIT, Repair, Air Drier Includes Items Marked **
47 100523 1 WASHER, Aluminium

April 21, 1998 210197 4-87


CONTROL VALVE

April 22, 1998 210271 4-88


CONTROL VALVE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210271 CONTROL VALVE
2 NSI 1 KNOB, Selector
3 NSI 1 NUT
4 NSI 1 WASHER
5 NSI 1 PIN
6 NSI 1 BODY, Valve
7 NSI 1 PIN, Spring

April 22, 1998 210271 4-89


BRAKE VALVE

April 21, 1998 210208 4-90


BRAKE VALVE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210208 1 BRAKE VALVE
2 100041 1 PIN, Split
3 NSI 1 PIN
4 NSI 1 ROLLER
5 222673 1 PIN, Roll
6 NSI 1 PIN, Pivot
7 NSI 1 PEDAL, Brake
8 100197 3 SCREW, Cap
9 100065 3 WASHER, Spring
10 * 1 COVER, Dust
11 NSI 1 PLUNGER, Brake Actuator
12 * 1 STOP, Rubber
13 NSI 1 PLATE, Mounting
14 NSI 2 GASKET
15 NSI 1 BOLT
16 NSI 1 WASHER, Flat
17 NSI 1 DISC, Spacer
18 * 1 PACKING, Rubber
19 * 4 O RING
20 NSI 1 VALVE
21 * 1 CIRCLIP, External
22 * 1 SPRING, Compression
23 NSI 1 VALVE
24 * 1 SEAL, Valve
25 * 1 O RING
26 NSI 1 SEAT, Spring
27 * 1 SPRING, Compression
28 NSI 1 SEAT, Ring
29 * 1 O IRNG
30 NSI 1 CIRCLIP, Internal
31 NSI 1 DISC, Retaining
32 * 1 NUT
33 * 1 VALVE
34 * 1 SPERING, Compression
35 NSI 1 CIRCLIP, Internal

April 21, 1998 210208 4-91


BRAKE VALVE

April 21, 1998 210208 4-92


BRAKE VALVE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
36 NSI 1 SCREW
37 NSI 1 DISC, Retaning
38 * 1 GASKET, Rubber
39 NSI 1 SPACER
40 * 1 ORING
41 NSI 1 SEAT, Spring
42 * 1 SPRIG, Compression
43 NSI 1 SEAT, Spring
44 * 1 O RING
45 * 1 SEAL, Valve
46 NSI 1 BOLT
47 * 1 WASHER, Copper
48 NSI 1 BODY, Valve
49 220956 1 KIT, Repair, Footvalve

April 21, 1998 210208 4-93


BRAKE VALVE ADAPTOR

January 12, 1996 210276 4-94


BRAKE VALVE ADAPTOR
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 210276 1 BRAKE VALVE ADAPTOR
2 NSI 4 SCREW
3 NSI 1 COVER, Inlet
4 * 1 O RING
5 NSI 1 PISTON, Primary
6 NSI A/R SHIM
7 NSI 1 SPRING, Compression
8 NSI 1 SEAT, Spring
9 NSI 1 CIRCLIP, Internal
10 * 1 O RING
11 NSI 1 PISTON, Secondary
12 * 1 O RING
13 NSI 1 SPRING, Compression
14 * 2 VALVE, Rubber
15 NSI 1 STEM, Valve
16 * 1 RETAINER, Spring
17 * 1 O RING
18 NSI 1 BODY, Valve
19 120399 1 PLUG
20 100523 * 1 WASHER, Sealing
21 221431 1 KIT, Seal, Brake Valve Adaptor

January 12, 1996 210276 4-95


AIR / HYDRAULIC BRAKE ACTUATOR

34

33

February 6, 1996 260145 4-96


AIR / HYDRAULIC BRAKE ACTUATOR
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 260145 1 AIR / HYDRAULIC BRAKE ACTUATOR
2 220954 1 CHAMBER, Air
3 100083 8 SCREW, Set, Hex
4 100312 8 NUT, Nyloc
5 171006 1 BRACKET, Mounting
6 NSI 1 GASKET, Mounting Bracket
7 * 1 FILTER, Packing
8 NSI 1 PLATE, End
9 * 1 O-RING
10 NSI 1 SPRING, Compression
11 * 1 SEAL
12 NSI 1 PISTON
13 NSI 1 SHAFT, Piston
14 NSI 1 NUT
15 NSI 1 BODY, Air Actuator
16 203358 1 CYLINDER, Master
17 100086 3 SCREW, Set
18 100060 3 WASHER, Spring
19 NSI 1 WASHER, Copper
20 NSI 1 CLIP, Retaining
21 NSI 1 WASHER
22 NSI 1 NIPPLE, Bleed
23 NSI 1 COVER, Bleed Nipple
24 ** 1 RING, Retaining
25 NSI 1 WASHER
26 ** 1 SEAL, Rubber
27 ** 1 PLUNGER
28 ** 1 SHIM
29 ** 1 SEAL, Spring
30 NSI 1 SPRING ASSY, Compression
31 NSI 1 BODY, Hydraulic Actuator
32 NSI 1 NUT, End, Reducing
33 ** 1 VALVE, Non Return
34 202438 1 SWITCH, Overstroke Machines Manufactured Before 01/04/97. Refer to ER1346
35 220951 1 KIT, Repair, Air Chamber Includes Items Marked *
36 220341 1 KIT, Repair, Master Cylinder Includes Items Marked **

February 6, 1996 260145 4-97


September 18, 1998 SECTION 4C ELECTRICAL SYSTEM 4-98
SECTION 4C
ELECTRICAL SYSTEM

September 18, 1998 SECTION 4C ELECTRICAL SYSTEM 4-99


HARNESS LAYOUT

1,5

2,6

4,8 3,7

P004785

November 30, 1998 ADT00368 2-100


HARNESS LAYOUT
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 204889 1 HARNESS, Assembly Up To 01/11/97 Includes Items 2 to 4
2 206096 1 HARNESS, Cab
3 203485 1 HARNESS, Artic
4 206095 1 HARNESS, Front
5 204052 1 HARNESS, Assembly From 01/11/97 to the last B25B Includes Items 6 to 8
6 206094 1 HARNESS, Cab
7 206092 1 HARNESS, Artic
8 206093 1 HARNESS, Front
9 202182 1 HARNESS, Rear Not Included in Items 1 and 5

November 30, 1998 ADT00368 2-101


ELECTRICAL CIRCUIT - STARTING / CHARGING
8
GN 2.5 P01/A GN 2.5
P01/B
7
MAIN CIRCUIT BREAKER P01/C RD 6.3
GN 6.3 P01/D
IGNITION SWITCH
CB1 P01/E RD/BK 1.6
60A P01/J BK/WH 2.5
4 0 1 2 3 15 50A 19 17
BATTERY 12V

P01/K
BN/RD 1.6
12 13 P01/L
GN 6.3

GN 1.6

GN 6.3

RD/BK 1.6
GY 16

YL/RD 1.6
RD 6.3

BK/ WH 2.5
30

GY/RD 1.6
IGNITION SOLENOID
6 BK 1.6 E4
STARTER BUTTON

GY/RD 1.6

YL/RD 1.6
GN 1.6 A 6 HAZARDS CIRCUIT
CONT
3 BL 1.6 B 2 PARK LIGHTS

CB2
15A
WH/BK 1.6 C 2 HEADLIGHTS SWITCH
BATTERY 12V

2 RD 1.6 D 2 HEADLIGHTS SUPPLY"30"


12 13

BN / WH 1.6

BN/RD 1.6

CB3
15A
9

TO TACHOMETER & OVER REV WARNING


5

RD 4.0
3 HORN
GN/BK 1.6 E

NEUTRAL START RELAY


3 STOP LIGHTS
BK/RD 1.6 F

TO CHARGE LIGHT & HOURMETER


85 30 RD 1.6 G 5 GAUGES AND WARNING LIGHTS

1 TO COLD START MODULE YL/RD 1.6 RD/YL 1.6 H 4 EXHAUST BRAKE

CB4
M

TO TRANSMISSION CIRCUIT

15A
I
TO COLD START MODULE GN 6.3

WH/RD 1.6
4 REVERSE LIGHT SWITCH

RD 4.0
RD 6.3

86 87 87a 9
STARTER
1 0 RD 1.6 J 11 & 9 TRANSMISSION

10

CB5
RD 4.0
E1 E4

5A
ALTERNATOR

B+

RD 2.5 K 7 & 8 AIRCON UNIT/ BLOWER / INTERIOR


LIGHT / WIPER WASHER
D+ W

RD 1.6 L 6 INDICATORS
A

15A
CB6
9

RD 4.0
RD 1.6 M 15 CIGARETTE LIGHTER
RD 1.6 N 16 COLD START CONTROL MODULE

16 15 1 2 3 17 O

CB7
7 & 8 SPARE

20A
16 16 5 5 11 16 P 7 & 8 SPARE 70009801-A 1
9
P003411

October 18, 1996 B25B023 4-102


ELECTRICAL CIRCUIT - STARTING / CHARGING
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 205174 1 DISCONNECTOR, Battery
2 202537 1 SOLENOID
3 200865 2 BATTERY, 12 V
4 205259 1 CIRCUIT BREAKER, 60 A
5 201311 1 RELAY, Change Over, 24 V
6 200706 1 SWITCH, Press Button, Starter
7 200398 1 SWITCH, Ignition
8 224800 1 KEY, Ignition Switch
9 201468 4 CIRCUIT BREAKER, 15 A
10 201467 1 CIRCUIT BREAKER, 5 A
11 203830 1 CIRCUIT BREAKER, 20 A
12 100079 2 SCREW, Hex. Head
13 100061 2 WASHER, Flat
14 204889 1 HARNESS, Front Chassis Not Illustrated
15 202182 1 LOOM, Rear Chassis Not Illustrated

October 18, 1996 B25B023 4-103


ELECTRICAL CIRCUIT - LIGHTING
15
BL 1.6
1 1 1
BK 1.6 WH 1.6
B C D

0
BL 1.6
BK 1.6 3
P02/ C BL 1.6
10 BL 1.6
11,12

CB 3 WH/BK 1.6
CB 3 RD 1.6
CB2 BL 1.6
BL 1.6

BK 1.6 P01/ S

P01/ T
E4 9,15
P01/ U

2
BL 1.6

DASH PANEL

HEADLIGHT
6
DASH PANEL

HIGHBEAM
BK 1.6

SWITCH
BL 1.6 BL 1.6

WH/BK 1.6

3
BL 1.6

GY 1.6

GY 1.6
WH 1.6

WH 1.6
BL 1.6

1
BK 1.6
BK 1.6 BL 1.6 3,6,7,8
RD/GY 1.6
BK 1.6
SWITCH & GAUGE NIGHTLIGHTS
WH/BK 1.6
13 13
BK 1.6 BK 1.6

P09/ 6

P10/ 6
P10/ 4

P10/ 5
85 30

BRIGHT RELAY
30

DIP RELAY
TAILLIGHT
5
TAILLIGHT

5 85
WH-1.0 WH-1.0

WH/GY 1.6
4 4 86 86 87
87a 87a

GY/WH 1.6
87
4 7 BK 1.6
BL 1.6 BL 1.6
BK 1.6 BK 1.6
FRONT PARK
FRONT PARK

P0
P0

P0
LIGHT

4/
4/

4/
LIGHT

E4

3
1

5
3 3

DIP BRIGHT SWITCH

56b
56a
BL 1.6 BL 1.6
GY 1.6 0

E3 BK 1.6 BK 1.6 BK 1.6 GY 1.6


HEADLIGHT

HEADLIGHT

HEADLIGHT

HEADLIGHT

56
2 14

70009802-A 2
1 WH 1.6
WH-1.6 WH-1.6 WH-1.6
P004792

November 30, 1998 ADT00375 4-104


ELECTRICAL CIRCUIT - LIGHTING
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 202934 4 BULB, 24 V 75/70 W
2 202573 4 HEADLAMP
3 200200 2 BULB, 24 V 2 W
4 203487 2 HARNESS, Pigtail
5 202561 2 LAMP, Brake
6 202571 1 HOLDER, Lens
7 202419 1 LENS, High Beam Warning
8 202572 1 HOLDER, Bulb
9 204933 5 BULB, 24 V 3 W
10 202570 2 HOLDER, Lamp
11 202409 1 SWITCH, 3 Position
12 202415 1 LENS, Headlamp Switch
13 201311 2 RELAY, Change Over, 24 V
14 201371 1 SWITCH, Indicator Light
15 204935 7 HOLDER, Lamp

November 30, 1998 ADT00375 4-105


ELECTRICAL CIRCUIT - STOP LIGHT / HORN

STEERING COLUMN
GN/BK 1.6

HORN SWITCH
2
3 P04/ 7 GN/BK 1.6 CB4 E 1

E3 CB4 F 1
GN/BK 1.6 P04/ 8

BK/RD 1.6
H GN/BK 1.6 P01/ W GN/BK 1.6

HORN

P02/ B
RD 1.6 BK/RD 1.6

WH 1.6 BK 1.6

BK/RD 1.6
STOP /TAIL LIGHTS

BRAKE PRESSURE
4

SWITCH
RD 1.6 BK/RD 1.6

P
WH 1.6 BK 1.6

STOP /TAIL LIGHTS

BK/RD 1.6
CHASSIS COMPONENT
FROM OTHER REAR

EARTHS

P09/ 5

4 70009803-A 3
4

P004581

September 3, 1998 B25B085 4-106


ELECTRICAL CIRCUIT - STOP LIGHT / HORN
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 202561 2 LAMP, Brake, 24V
2 200448 1 HORN
3 201371 1 SWITCH, Indicator Light
4 204453 1 SWITCH, Stop Light (Pneumatic Brakes Only)

September 3, 1998 B25B085 4-107


ELECTRICAL CIRCUIT - REVERSE AND EXHAUST BRAKE
2

FLYBACK DIODE FUNCTION : This is important and must

FROM REAR LIGHTS BK 1.6


not be left out of the circuit. Its function is to quench the EMF CB 4 H 1

3 4 generated by the solenoid. If the diode is not used damage CB 4 I 1


may occur to the proximity switch and also the ZF
transmission processor .

E4
BK 1.6 P01/ Z BK 1.6
FLYBACK DIODE
3 4
EXHAUST BRAKE
BK 1.6
BK 1.6
BK 1.6

FUNCTION

RD/YL 1.6 P01/ H RD/YL 1.6

1
2
WH/RD 1.6
2

WH/RD 1.6
RD/YL 1.6

RD/YL 1.6
5
B E.V.B/ EXHAUST BRAKE/
RETARDER SOLENOID
E7 VALVE
WH/RD 1.6 6

P
WH/RD 1.6

3 REVERSE LIGHTS RD/YL 1.6

LOCKUP PRESSURE
SWITCH
P02/ K

7
IDLE RELAY P02/ Q
87a
30
RD/YL 1.6 RD/YL 1.6
11 5 ZF WIRING 15 WAY CONNECTOR (EST 25 ONLY) RD/GY 1.6 87
85 86
P02/ K

PROXIMITY
SWITCH
+ BN P03/ 1 12 5
REVERSE PRESSURE
SIG BK P03/ 2
- BL
SWITCH
P03/ 3 11 5

P09/ 3 WH/RD 1.6 WH/RD 1.6 P02/ D


70009804-A 4

1 8 P004582

November 30, 1998 ADT00376 4-108


ELECTRICAL CIRCUIT - REVERSE AND EXHAUST BRAKE
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 202548 1 SENSOR, Proximity Switch
2 201333 1 ALARM, Backup
3 202563 2 LAMP, Reverse
4 201357 1 DIODE
5 210100 2 VALVE, Solenoid
6 204044 1 SWITCH, Pressure
7 201311 1 RELAY, Change Over, 24 V
8 202535 1 SWITCH, Hydraulic Pressure

November 30, 1998 ADT00376 4-109


ELECTRICAL CIRCUIT - GAUGES AND WARNING LIGHTS
1
E4 G
BK 1.6 RD 1.6 RD 1.6
RD 1.6 RD 1.6

GENERAL WARNING
LOW WATER LEVEL
RD 1.6

15 13 RD 1.6

85
85

30

LIGHTS
30

IGNITION + 24V RD 4.0


RD 1.6

87a
22

87
86
86
RD 1.6
11

BK 1.6
6
22

_
9

LOW WATER
LEVEL
CB No 4
OR 1.6

RD 1.6
3,4 RD 1.6 RD 1.6 RD 1.6 RD 1.6 RD 1.6

INTERAXLE LOCK
TRANS OIL PRESS
RD 1.6

RD 1.6
BRAKE OVERSTROKE
8 BK 1.6 BK 1.6 BK 1.6 BK 1.6
GENERAL WARNING

16,31,32
LOW AIR PRESSURE

+
BL/WH 1.6
ENG OIL PRESS
ALT CHARGE

OIL TEMP
TRANSMISSION

40 120
50 150

ENG TEMP
HOURS

RPM

KPA
PL/BL 1.6
BN/BL 1.6

C
B

C
GN/BL1.6
30

85

PL 1.6

RD 1.6
_
_

S
21,31,32

S
10 11

S
7 17,18,31,32 19,31,32

S
PL/WH1.6

BN/WH1.6
BK 1.6
YL/RD YL/RD 1.6 4 4
5
87a

86

GN/WH 1.6 20,31,32 12 11 23,24,31,30


6
GY/GN1.6
WH/BN1.6
GN 1.6

PK 1.6

P02/ - BIN UP SWITCH


1

P01/ M
P01/ Q

P01/ G
BN/BL 1.6 P01/ N

P01/ P

P01/ Z
P01/ F

P02/ N
ENGINE REV
RD 1.6

LIMITER SOLENOID PL 1.6 P09/ 1


P02/ G

YL/RD 1.6
P02/ H

BN/WH 1.6
P02/ U

PL/WH 1.6
GY/RD 1.6
PL/BL 1.6
P02/ S
P02/ F

P02/ J
P02/ T

BK 1.6
2 RD 1.6
GN 1.6 29 BL/WH 1.6
PK 1.6

GN/WH1.6
GN/BL1.6
GY/GN1.6
3,4 P09/ 4 26

FROM ALT 'W'


WH/BN1.6 INTERAXELE LOCK 25

FROM D+
PK 1.6

TRANS OIL TEMP


B 12 12 13 TRANS OIL

WK
PK 1.6

G
G

G
W

W
PRESS S+ _

SENDER
P

FUEL
Q

t
t

P
2
P

1
P

LOW AIR PRESS 2 1 LOW


BK 1.6 ENG TEMP COOLANT
BRAKE 1 1
ENG OIL
SEND/SWITCH LEVEL
BRAKE OVERSTROKE OVERSTROKE
14 70009805-A 5
15 28 27
P004583

November 30, 1998 ADT00377 4-110


ELECTRICAL CIRCUIT - GAUGES AND WARNING LIGHTS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 200851 1 SWITCH, Low Air Pressure
2 203571 1 BUZZER, Warning, 12-24 V
3 202566 2 LAMP, Square (Red Stop)
4 202568 2 BULB, 24 V 15 W
5 200208 1 BUZZER, Warning, 24 V
6 210606 1 VALVE, Quick Exhaust
7 202522 1 LENS, Park Brake, Warning
8 202418 1 LENS, Alternator Charge Warning
9 202528 1 LENS, Coolant Level
10 202523 1 LENS, Transmission Pressure
11 202527 1 LENS, Interaxle Lock Warning
12 202438 2 SWITCH, Overstroke
13 Z0501 209 478 1 SWITCH, Pressure
14 202536 1 SWITCH, Sensor, Interaxle D/Lock
15 200694 1 SENDER, Oil Temperature
16 201074 1 GAUGE, Hourmeter
17 200859 1 GAUGE, Temperature
18 Z 0501 204 074 1 GAUGE, Retarder Use With ZF WG Series Retarder Transmission
19 201075 1 GAUGE, Tachometer
20 201403 1 GAUGE, Oil Pressure
21 201404 1 GAUGE, Temperature
22 201311 2 RELAY, Change Over, 24 V
23 200863 1 GAUGE, Fuel FROM 28.07.97
24 200853 1 SENDER, Fuel Lever Action FROM 28.07.97
25 200725 1 SENDER, Fuel, Tubular FROM 28.07.97
26 203319 1 SWITCH, C ooling Water Level FROM 10.09.97
27 AD66260062 1 SENDER, Water Temperature
28 AD66580030 1 SENDER, Oil Pressure
29 202547 1 SWITCH, Micro
30 204933 6 BULB, 24V
31 204935 6 HOLDER, Wedge Base, Bulb

November 30, 1998 ADT00377 4-111


ELECTRICAL CIRCUIT - INDICATOR / HAZARD
1 1
A L
GN 1.6
3,4
RD 1.6

CB 2 GN 1.6

CB 6 RD 1.6
REAR LEFT INDICATOR REAR RIGHT INDICATOR FRONT RIGHT INDICATOR FRONT LEFT INDICATOR

2 8 3
WH 1.6

0 1
RD 1.6

BL 1.6
WH 1.6

RD 1.6

BK 1.6

BK 1.6
BL 1.6
1 1 2 2
6 1 5 10

BN/YL 1.6

BN 1.6
F
BN/YL 1.6
BK 1.6 BK 1.6 YL/BN 1.6
5 FLASHER UNIT
BN 1.6

YL 1.6
YL 1.6
BK 1.6

YL 1.6
BK 1.6
BN 1.6
E7 BK 1.6 LEFT TURN
P10/01

P10/02

P10/03

BN 1.6

DASH PANEL INDICATOR


P04

P04
P04
P09/08
P09/07

E4

/04

/06
/02

BK 1.6
BK 1.6
E3 YL 1.6

RIGHT TURN
BK/WH/GN
P01/ V BN 1.6
R
P01/ R YL 1.6 BK/GN
7,8,9,10
INDICATOR
L TURN
BK/WH
SWITCH
YL 1.6 P02/ A YL 1.6

R
BN 1.6 P02/ R BN 1.6

0
L
70009806-A 6
P003351

October 21, 1996 B25B028 4-112


ELECTRICAL CIRCUIT - INDICATOR / HAZARD
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 202562 2 LAMP, Indicator
2 203444 2 LIGHT, Indicator
3 202411 1 SWITCH, Hazard
4 202416 1 LENS, Hazard Switch
5 200583 1 FLASHER UNIT, 24 V
6 201371 1 SWITCH, Indicator Light
7 202420 2 LENS, Turn Warning
8 200200 2 BULB, 24 V 2 W
9 202571 2 HOLDER, Lens
10 202572 2 HOLDER, Bulb

October 21, 1996 B25B028 4-113


ELECTRICAL CIRCUIT - BLOWER AND WIPER
1 1 1
P O K M
P06/ - RD 2.5

BL/RD 1.6 BL/RD 1.6 P06/ -

FROM CB 8 RD1.6
FROM CB 8 RD1.6
FROM CB 5 RD2.5
P06/ -
BK 1.6
P06/ -

RD/BL 1.6

RD/BL 1.6
CAB

BK 1.6
6,7
FAN/BLOWER

FAN/BLOWER

BK 1.6
WH 1.6 P07/
P07/

P07/
COMPARTMENT

INTERIOR LIGHT

0
SPARE PLUG & WIRES
3
M

1
SPARE +
SPARE +
5
RD 2.5
1

4,5 BLOWER FAN SWITCH

BK 1.6

P02/ Y
6,8

0
WH 1.6

1
5
RD 2.5
TRANSMISSION 1
E2
COMPARTMENT
SPARE PLUG & WIRES
INTERIOR LIGHT SWITCH

BK 1.6 P05/ 3 BK 1.6

GN 1.6 P05/ 1 GN 1.6

YL 1.6 P05/ 2 YL 1.6 1 2


1
P

WIPER MOTOR

RD 1.6 P05/ 4 RD 1.6 1

0
M

PK 1.6
+
_

WASHER PUMP

2
WINDSCREEN

5
M

7
1 9,10

4
BK 1.6 WIPER WASHER SWITCH 70009807-A 7
P003352

October 21, 1996 B25B029 4-114


ELECTRICAL CIRCUIT - BLOWER AND WIPER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 203984 1 KIT, Windscreen Washer
2 201471 1 MOTOR, Wiper
3 200582 2 BLOWER
4 201222 1 LIGHT, Interior
5 202930 1 BULB, 24 V 18 W
6 202408 2 SWITCH, 2 Position
7 202412 1 LENS, Fan Switch
8 202414 1 LENS, Interior Light Switch
9 205152 1 SWITCH, Wiper / Switch
10 205159 1 LENS, Wipe/Wash Switch

October 21, 1996 B25B029 4-115


ELECTRICAL CIRCUIT - AIRCON AND WIPER
1 1 1
BK/WH 2.0 P O K M
RD 2.0 P06/ - RD 2.5
BK 2.0
P06/ -

FROM CB 8 RD1.6
FROM CB 8 RD1.6
FROM CB 5 RD2.5
ENGINE CAB
COMPARTMENT P06/ -
COMPARTMENT
SPARE PLUG & WIRES SPARE PLUG & WIRES P06/ -

RD/BL 1.6

RD/BL 1.6
BK 1.6
RD /WH1.6 P06/ -
7,8

BK 1.6
AIRCON COMPRESSOR

WH 1.6 P03/
P03/

P03/

INTERIOR LIGHT

0
CLUTCH SOLENOID
AIR CONDITIONER
UNIT

1
SPARE +
SPARE +
5
RD 2.5
1

BLOWER FAN SWITCH

WH 1.6

P01/ X

P02/ Y
12 4 5,6
7,9
BINARY SWITCH

0
WH 1.6
P

1
5
RD 2.5
RD/WH 1.6 TRANSMISSION 1
E2
COMPARTMENT
RD/WH 1.6 SPARE PLUG & WIRES
INTERIOR LIGHT SWITCH
3
BK 1.6 P05/ 3 BK 1.6

GN 1.6 P05/ 1 GN 1.6

YL 1.6 P05/ 2 YL 1.6 1 2


1
P

WIPER MOTOR

RD 1.6 P05/ 4 RD 1.6 1


0
10,11
M

PK 1.6
+
_

WASHER PUMP

2
WINDSCREEN

5
M

7
1

4
BK 1.6 WIPER WASHER SWITCH 70009808-A 8

P003353

October 21, 1996 B25B030 4-116


ELECTRICAL CIRCUIT - AIRCON AND WIPER
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 203984 1 KIT, Windscreen Washer
2 201471 1 MOTOR, Wiper
3 202058 1 SWITCH, Binary
4 290501 1 SOLENOID, Clutch, Aircon Compressor
5 201222 1 LIGHT, Interior
6 202930 1 BULB, 24 V 18W
7 202408 2 SWITCH, 2 Position
8 202412 1 LENS, Fan Switch
9 202414 1 LENS, Interior Light Switch
10 205152 1 SWITCH, Wiper/Washer
11 205159 1 LENS, Wipe/Wash Switch
12 202902 1 AIR CONDITIONER UNIT

October 21, 1996 B25B030 4-117


EST 17 TRANSMISSION (CAB)
1
BULKHEAD CANNON PLUG
PX4/ Z Z-734
PX4/ Y J
TO TRANSMISSION

PX4/ F F-420 628 P8 /13


PX4/ X X-726 608 P8 / 8
G-424 604

5
PX4/ G P8 / 7
PX4/ R R-452 600 P8 / 6
PX4/ S S-456 580 P8 / 1 RD 1.6

'9
PX4/ N N-444 612 P8 / 9 RD 1.6 CB No5
PX4/ Q Q-448 616 P8 /10
PX4/ H H-428 596 P8 / 5
PX4/ E 624 P8 /12
PX4/ M M-440 636 P8 /15 BK 1.6

N
PX4/ A 632 P8 /14
PX4/ B B-404 P8 / 4
PX4/ C P8 / 2 BN/RD 1.6
D-412

A
PX4/ D P8 / 3
PX4/ W W-722 P8 / 11

BK 1.6
J

584
588
592
C-408
E-416
Y-730

RD 1.6
O
E4

P T
Y U

P02/ L
N L

BN/RD 1.6
RD 1.6
PX2/ 1
PX2/ 2

PX2/ 7
PX2/ 8
PX2/ 6
PX2/10
PX2/ 4
PX2/ 5
PX2/ 6

P--/--
P--/--
P--/--
10
16
15
19
18
17

14
13
12

2
4
7

3
6
32

11

1
30

25
24
23
22

5
9
35
34
33

31

21
20
29
28
27
26

O
682
654
658

EST 17
MICRO PROCESSOR 3
GEAR

ZF
SHIFT

1
8
12
70009809-A 9
1 2 P003354

November 30, 1998 ADT00379 4-118


EST 17 TRANSMISSION (CAB)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 Z6009 054 115 MICRO PROCESSOR Not Used in the B25B MkII Export
2 Z6006 022 211 SELECTOR, Range Not Used in the B25B MkII Export

November 30, 1998 ADT00379 4-119


EST 17 TRANSMISSION (EXTERIOR)

544 PX4/ Z

TRANSMISSION BULK HEAD PLUG (ON CAB)


540 PX4/ Y

A 450 PX4/ F

'9
B 504 PX4/ X

C 430 PX4/ G

D 444 PX4/ R

N
420 PX4/ S
E
494 PX4/ N
TRANSMISSION F

A
VALVE BANK 434 PX4/ Q
440 PX4/ H

J
400 PX4/ E

404 PX4/ A

1 408 PX4/ B

O
412 PX4/ C
416 PX4/ D

T 500 PX4/ W

TRANSMISSION

U P
LY
N
DOUBLE STEP VALVE
INDUCTIVE SENSOR

INDUCTIVE SENSOR

LOCK UP SOLENOID
TURBINE SPEED

OUTPUT SPEED

SOLENOID
O
G
G

2
70009810-A 10
2 3 4 P003355

November 30, 1998 ADT00380 4-120


EST 17 TRANSMISSION (EXTERIOR)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 NSI 1 TRANSMISSION VALVE BANK Not Used in the B25B MkII Export
2 Z6041 315 008 2 SENSOR, Inductive Not Used in the B25B MkII Export
3 Z0501 310 470 1 SOLENOID, Valve, Double Step Not Used in the B25B MkII Export
4 Z0501 310 470 1 SOLENOID, Lock Up Not Used in the B25B MkII Export

November 30, 1998 ADT00380 4-121


EST 25 TRANSMISSION (CAB)
PX4/ C 714 1
PX4/ Z Z-734
PX4/ Y J
PX4/ F F-420 628 P8 /13 RD 1.6
BULKHEAD CANNON PLUG

PX4/ X X-726 608 P8 / 8


PX4/ G G-424 604 P8 / 7
TO TRANSMISSION

PX4/ R R-452 600 P8 / 6


PX4/ S S-456 580 P8 / 1
PX4/ N N-444 612 P8 / 9 RD 1.6 CB 5
PX4/ Q Q-448 616 P8 /10 RD 1.6
PX4/ H H-428 596 P8 / 5
PX4/ E 624 P8 /12
PX4/ M M-440 636 P8 /15 BK 1.6
PX4/ A 632 P8 /14
BK 1.6
PX4/ B B-404 P8 / 4
PX4/ C P8 / 2 BN/RD 1.6
PX4/ D D-412 P8 / 3
PX4/ W W-722 P8 /11 E4
PX4/ J J-432
C-408
E-416
Y-730

584
588
592
MANUAL /AUTO
SWITCH
0 1

1
5
4,5

WH/BK 1.6
RD/GY 1.6

RD 1.6

BK/WH 2.5 TO STARTING CHARGING CIRCUIT

RD/GN 1.6 TO OVERREV RELAY"85" CIRCUIT

WH 1.6 TO SPEEDOMETER
PX2/ 1
PX2/ 2

PX2/ 7
PX2/ 8
PX2/ 6
PX2/10

PX6/ 2
PX6/ 1

PX6/ 3
PX2/ 4
PX2/ 5
PX2/ 6
10
16
15
19
18
17

14
13
12

2
4
7

3
6
32

11

1
30

25
24
23
22

5
9
35
34
33

31

21
20
29
28
27
26

RD 1.6 CB 4
3

RD 1.6
WH/BK

RD/GY
EST 25
MICRO PROCESSOR
14

SHIFT
GEAR
ZF
15

9 5 8 3 6 10
2 DISPLAY UNIT 12 4 12 1 5 5 70009811-A 11
1 P003356

October 21, 1996 B25B031 4-122


EST 25 TRANSMISSION (CAB)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 Z6009 047 525 1 MICRO PROCESSOR
2 Z6006 022 211 1 SELECTOR, Range
3 Z6007 203 214 1 DISPLAY, Digital
4 202408 1 SWITCH, 2 Position
5 203853 1 LENS, Auto / Manual Switch

October 21, 1996 B25B031 4-123


EST 25 TRANSMISSION (EXTERIOR)

544 PX4/ Z

TRANSMISSION BULK HEAD PLUG (ON CAB)


540 PX4/ Y

A 450 PX4/ F

B 504 PX4/ X

C 430 PX4/ G

D 444 PX4/ R
420 PX4/ S
E
494 PX4/ N
TRANSMISSION F
VALVE BANK 434 PX4/ Q
440 PX4/ H
400 PX4/ E

404 PX4/ A

408 PX4/ B
412 PX4/ C

2 416 PX4/ D

500 PX4/ W

WH/BK 1.6 9 11

RD1.6 8 11

1 3
4 5 6
KICK DOWN

DOUBLE STEP VALVE

LOCK UP SOLENOID
INDUCTIVE SENSOR

INDUCTIVE SENSOR
TURBINE SPEED

OUTPUT SPEED
ALL ZF PART NUMBERS ARE FOR

SOLENOID
WH/1.6 6WG200 TRANSMISSIONS
G
G

70009812-A 12

P003357

October 21, 1996 B25B032 4-124


EST 25 TRANSMISSION (EXTERIOR)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 Z6007 203 107 1 SWITCH, Kick Down
2 NSI 1 TRANSMISSION VALVE BANK
3 Z6041 315 007 1 TRANSMITTER, Inductive (Turbine)
4 Z60413 15 008 1 SENSOR, Inductive (Output)
5 Z0501 310 470 1 SOLENOID, Double Step Valve
6 Z0501 310 470 1 SOLENOID, Lock Up

October 21, 1996 B25B032 4-125


CONNECTORS 1 & 2

D C B A D C B A
J H G F E J H G F E
Q P N M L K 24 WAY CANNON CONNECTOR -DISTRIBUTION BOX TO ENGINE Q P N M L K 24 WAY CANNON CONNECTOR -DISTRIBUTION BOX TO
P1 HARNESS. P2 ARTIC HARNESS
V U T S R V U T S R
Z Y X W Z Y X W

PAGE WIRE COLOUR FUNCTION TEST LIGHT PAGE WIRE COLOUR FUNCTION TEST LIGHT

PIN /SOCKET
PIN /SOCKET

P02/AB
P02/AB

? GN 1.6 ? ? GN 1.6 ?
WIRE WIRE WIRE WIRE

A 1 GREEN 2.5 BATTERY LIVE +24V A 6 YELLOW RIGHT REAR INDICATOR FLASHING
1 RED 1.6 +24V 3 BLACK/RED 1.6 STOP LIGHTS
B B
C RED 1.6 +24V C 2 BLUE 1.6 PARK LIGHTS -REAR SWITCHED
1
D RED 1.6 +24V D 4 WHITE/RED 1.6 REVERSE SWITCH SWITCH CLOSED
1
E 1 RED/BLACK 1.6 ISOLATION SOLENOID TO IGN SWITCH SWITCHED E
F 5 BLUE/ WHITE 1.6 COOLANT LEVEL SIGNAL IN COOLANT F 5 GREY/GREEN 1.6 AXLE LOCK WL TO SWITCH SWITCH CLOSED
G 5 RED 1.6 COOLANT LEVEL +24V G 5 PINK 1.6 BRAKE OVERSTROKE WL TO SWITCH SWITCH CLOSED
H 4 RED/YELLOW 1.6 E.V.B / EXHAUST BRAKE +24 FROM SW H 5 GREEN1.6 LOW AIR PRESSURE SWITCH
J 1 BLACK/ WHITE 2.5 STARTER SOLENOID SWITCHED J 5 PURPLE 1.6 BIN UP SWITCH
K 1 YELLOW/RED 1.6 ALTERNATOR "D+" TO CHARGE LIGHT K 4 RED/YELLOW 1.6 +24V TO LOCKUP PRESSURE SWITCH SWITCHED
L 1 GREY/RED 1.6 ALTERNATOR "W" TO TACHO&E-MODS. L 15 RED 1.6 +24V TO ROTATING BEACON
M 5 BROWN/WHITE 1.6 ENGINE TEMPERATURE GAUGE DO NOT DO THIS M 5 PINK 1.6 OVERREV SOLENOID SWITCHED
N 5 BROWN/BLUE 1.6 ENGINE TEMPERATURE WARNING LIGHT N 5 GREY 1.6 FUEL GAUGE TO SENDER SWITCHED
P 5 PURPLE/WHITE 1.6 OIL PRESSURE GAUGE TO SENDER DO NOT DO THIS P
Q 5 PURPLE/BLUE 1.6 OIL PRESSURE WARNING LIGHT->SW. Q 4 RED/YELLOW 1.6 LOCKUP PRESSURE SWITCH SWITCHED
R 6 YELLOW 1.6 RIGHT FRONT INDICATOR LIGHT FLASHING R 6 BROWN 1.6 LEFT REAR INDICATOR FLASHING

S 2 BLUE 1.6 PARK LIGHTS FRONT SWITCHED S 5 GREEN/WHITE 1.6 TRANSMISSION TEMP GAUGE TO SEND. DO NOT DO THIS
T 2 GREY 1.6 HEADLIGHTS DIP SWITCHED T 5 GREEN/BLUE 1.6 TRANSMISSION TEMP WL TO SWITCH SWITCH CLOSED
U 2 WHITE 2.5 HEAD LIGHTS BRIGHT SWITCHED U 5 WHITE/BROWN 1.6 TRANSMISSION PRESS WL TO SWITCH SWITCH CLOSED
V 6 BROWN 1.6 LEFT FRONT INDICATOR FLASHING V
W 8 RED/WHITE 1.6 AIRCON SWITCHED W
X 3 GREEN/BLACK 1.6 HORN SWITCHED X 5 RED 1.6 SPARE
Y 4 BLACK/WHITE 1.6 RELAY"86" TO PROXIMITY SIGNAL SWITCHED Y 8 WHITE 1.6 SPARE
Z 4&5 BLACK 2.5 EARTH Z 6 BLACK 2.5 EARTH

13

70009813-A
P003358

October 21, 1996 B25B057 4-126


October 21, 1996 B25B057 4-127
CONNECTORS 3,4,5 & 6
3 WAY PLASTIC CONNECTOR -MAIN HARNESS TO PROXIMITY
SWITCH WIRES (ON INJECTOR PUMP).
NOTE : PIN / SOCKET NUMBERING IS NOT RELATED TO POSITION
ON THE CONNECTOR. WIRE COLOUR IS CLEARLY VISIBLE ON THIS
P03
TYPE OF CONNECTOR. WIRE COLOURS ARE DIFFERENT ON THE PROXIMITY
SWITCH AND CARE MUST BE TAKEN TO ENSURE THE CORRECT WIRES ARE 4 WAY PLASTIC CONNECTOR -DISTRIBUTION HARNESS TO WIPER
USED . THE WIRE COLOURS ARE FOUND ON THE SCHEMATIC.IF A DIFFERENT MOTOR .(INSIDE CAB ).
P05 NOTE : PIN / SOCKET NUMBERING IS NOT RELATED TO POSITION
MAKE OF SWITCH IS USED THE MANUFACTURERS INSTRUCTIONS MUST BE
FOLLOWED TO ENSURE CORRECT CONNECTION. ON THE CONNECTOR. WIRE COLOUR IS CLEARLY VISIBLE ON THIS
TYPE OF CONNECTOR.

* * DO NOT CONNECT DIRECTLY TO POSITIVE AS THIS WILL DESTROY


THE INTERNAL ELECTRONICS OF THE UNIT

PAGE WIRE COLOUR FUNCTION TEST LIGHT PAGE WIRE COLOUR FUNCTION TEST LIGHT
PIN/SOCKET

PIN/SOCKET
P02/AB

P02/AB
? ?/ ? ? ? ?/ ? ?
WIRE WIRE WIRE WIRE

1 2 RED 1.6 24V SUPPLY FROM CB 5 1 7 GREEN 1.6 WIPER MOTOR PARK TO SWITCH"7" SWITCHED

*
2 2 BL/WH 1.6 SIGNAL TO EXHAUST BRAKE RELAY"85" 2 7 YELLOW1.6 +24 V TO CB & SWITCH"2"
3 2 BK 1.6 EARTH 3 7 BLACK 1.6 EARTH

4 7 RED 1.6 WIPER MOTOR RUN TO SWITCH"5"

6 WAY PLASTIC CONNECTOR -DISTRIBUTION HARNESS TO AIRCON


8 WAY PLASTIC CONNECTOR -DISTRIBUTION HARNESS TO INDICATOR
AND SPARE WIRES
LEVER SWITCH .(INSIDE CAB ). P06
P04 NOTE : PIN / SOCKET NUMBERING IS NOT RELATED TO POSITION
NOTE : PIN / SOCKET NUMBERING IS NOT RELATED TO POSITION
ON THE CONNECTOR. WIRE COLOUR IS CLEARLY VISIBLE ON THIS
ON THE CONNECTOR. WIRE COLOUR IS CLEARLY VISIBLE ON THIS TYPE OF CONNECTOR.
TYPE OF CONNECTOR.

PAGE WIRE COLOUR FUNCTION TEST LIGHT


PAGE WIRE COLOUR FUNCTION TEST LIGHT

PIN/SOCKET
PIN/SOCKET

P02/AB
?
P02/AB

? ?/ ? ? ? ?/ ?

WIRE WIRE
WIRE WIRE
1 6 & 7 BLACK 1.6 EARTH
1 2 GREY/WHITE HEADLIGHT DIP RELAY"86" TO SWITCH SWITCHED
2 6 & 7 RED 1.6 POSITIVE CB 6
2 6 BROWN LEFT INDICATORS SWITCHED
3
3 2 WHITE/GREY 1.6 BRIGHTS RELAY"86" TO SWITCH SWITCHED
4 6 & 7 RED/WHITE 1.6 AIRCON COMPRESSOR SWITCHING
4 6 YELLOW/BROWN 1.6 FLASHER UNIT TO SWITCH +24 SWITCHED
5 6 & 7 RED 1.6 POSITIVE CB 7
5 2 BLACK 1.6 EARTH
6 6 & 7 RED 1.6 POSITIVE CB 7
6 6 YELLOW 1.6 RIGHT INDICATORS SWITCHED
7 3 GREEN/BLACK 1.6 HORN +
3 GREEN/BLACK 1.6 HORN 70009814-A 14
8 SWITCHED

P003359

October 21, 1996 B25B058 4-128


October 21, 1996 B25B058 4-129
CONNECTORS 7,8, 9 & 10

4 WAY PLASTIC CONNECTOR -SPARE CIRCUIT PLUG (IN CAB)


P07 NOTE : PIN / SOCKET NUMBERING IS NOT RELATED TO POSITION 8 WAY PLASTIC CONNECTOR -ARTIC HARNESS TO REAR
ON THE CONNECTOR. WIRE COLOUR IS CLEARLY VISIBLE ON THIS P09 HARNESS .(AT ARTICULATION JOINT).
TYPE OF CONNECTOR.

PAGE WIRE COLOUR FUNCTION TEST LIGHT PAGE WIRE COLOUR FUNCTION TEST LIGHT
PIN/SOCKET

PIN/SOCKET
P02/AB

P02/AB
? ?/? ? ? ?/? ?
WIRE WIRE WIRE WIRE

1 8 RED 1.6 SPARE CAB VIA P2 TO CAB UNDERSIDE 1 5 PURPLE 1.6 BIN UP SWITCH
2 8 WHITE 1.6 SPARE CAB VIA P2 TO CAB UNDERSIDE 2
3 8 PINK 1.6 SPARE CAB VIA P1 TO ENGINE 3 4 WHITE/RED 1.6 REVERSE LIGHTS SWITCHED
4 8 GREEN 1.6 SPARE CAB VIA P1 TO ENGINE 4 5 PINK 1.6 BRAKE OVERSTROKE SWITCHES
5 3 BLACK/RED 1.6 STOP LIGHTS SWITCHED
1 2 3 6 2 BLUE 1.6 PARK LIGHTS SWITCHED
15 WAY AMP CONNECTOR -BELL TO ZF HARNESS ( P8 = CONNECTOR SWITCHED
4 5 6 7 6 BROWN 1.6 LEFT REAR INDICATOR
W1-X 3 IN ZF SCHEMATIC DIAGRAMS).
P08 6 SWITCHED
7 8 9 8 YELLOW 1.6 RIGHT REAR INDICATOR
10 11 12 = LIGHT DOES NOT SWITCH ON

13 14 15
= LIGHT DOES SWITCH ON

PAGE WIRE COLOUR FUNCTION TEST LIGHT


PIN /SOCKET

6 WAY PLASTIC CONNECTOR -ENGINE HARNESS TO HEADLIGHT


P02/AB

HARNESS
P10
? ?/? ? NOTE : PIN / SOCKET NUMBERING IS NOT RELATED TO POSITION
ON THE CONNECTOR. WIRE COLOUR IS CLEARLY VISIBLE ON THIS
WIRE WIRE TYPE OF CONNECTOR.
1 11 SPEEDO SIGNAL OUT DO NOT TEST WITH A TEST LIGHT
2 11 BROWN/RED 1.6 NEUTRAL START RELAY "85" OUT PAGE WIRE COLOUR FUNCTION TEST LIGHT

PIN/SOCKET
3

P02/AB
4 11 WHITE/BLACK 1.6 KICKDOWN SWITCH IN SWITCHED
5 11 RED/GREY 1.6 POSITIVE IDLE SWITCH SWITCHED
? ?/? ?
WIRE WIRE
6
7 1 6 YELLOW 1.6 RIGHT FRONT INDICATOR SWITCHED
8 11 RED 1.6 LOOP TO PIN 13 2 6 BROWN 1.6 LEFT FRONT INDICATOR SWITCHED
9 11 RED 1.6 POSITIVE 24V 3 6 BLACK 2.5 EARTH
10 11 RED 1.6 POSITIVE 24V 4 2 BLUE 1.6 PARK LIGHTS SWITCHED
11 11 BLACK/WHITE 1.6 EXTENDED LOCKUP SWITCH 5 2 GREY 1.6 DIP FILAMENT-HEADLIGHTS SWITCHED
12 6 2 WHITE 2.5 BRIGHT FILAMENT- HEADLIGHTS SWITCHED
13 11 RED 1.6 LOOP TO PIN 8
14 11 BLACK 1.6 EARTH
70009815-A 15
15 11 BLACK 1.6 EARTH

P003360

October 21, 1996 B25B059 4-130


October 21, 1996 B25B059 4-131
ELECTRONIC SPEEDO AND OTHER ACCESSORIES
FLASHING BEACON
RD 1.6 13 5

203067
WH 1.6 14 11
3
M P--------
GLOW PLUG
FLAME START CONTROL
MODULE 4
P-------

COLD START 5
LIGHT

COLD START
SOLENOID

6
3

3
7
8
1

4
5

P02/ V
ELECTRONIC SPEEDO

2
1
203797
KM/H
BL 6.3
GN 6.3 16 1
OR 1.6
2 BK 1.6
+

BK 1.6 PL 1.6

BK 1.6
RD 1.6 TWN
BK 1.6 BK 1.6 TWN
COLD START
TEMPERATURE SENDER
RD/GN 1.6 17 1

202726
YL/RD 1.6 15 1

RD 1.6
CIGARETTE
P02/ L

LIGHTER BK 1.6

1
RD 1.6 P02/ X N 1

RD 2.5 M 1

70009816-A 16
P003412

October 21, 1996 B25B033 4-132


ELECTRONIC SPEEDO AND OTHER ACCESSORIES
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 202726 1 LIGHTER, Cigarette
2 203797 1 GAUGE, Speedo
3 203067 1 BEACON, Flashing CE MARK
4 200200 1 BULB, 24 V 2W
5 261383 1 KIT, Cold Start

October 21, 1996 B25B033 4-133


INSTRUMENT PANEL ASSEMBLY

2,3,4 2,3,5 21 2,3,6 2,3,7 2,3,33 22,29 2,3,32 2,3,9 23,29 2,3,10 2,3,11 2,3,4

27

EXHAUST TRANS OIL


3,20 BRAKE PRESSURE

24,29

25

1 A

26
MAN/AUTO HAZARD
TACHOMETER

13 14 13 13 15 3,19 28 16 12 17 30 31 18 P003370

October 18, 1996 B25B035 4-134


INSTRUMENT PANEL ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 203853 1 LENS, Manual / Auto Switch
2 202571 10 HOLDER, Lens
2 202572 10 HOLDER, Bulb
3 200200 12 BULB, 24 V 2 W
4 202420 2 LENS, Turn Warning
5 203871 1 LENS, Exhaust Brake On
6 202527 1 LENS, Inter Axle Lock Warning
7 202419 1 LENS, High Beam Warning
8 202423 1 INSERT, Blank Switch
9 202528 1 LENS, Low Coolant Level Warning
10 202522 1 LENS, Park Brake Warning
11 202418 1 LENS, Alternator Charge Warning
12 202409 1 SWITCH, 3 Position
13 202408 3 SWITCH, 2 Position
14 202412 1 LENS, Fan Switch
15 202414 1 LENS, Interior Light Switch
16 202415 1 LENS, Head Lamp Switch
17 205159 1 LENS, Wiper/Washer Switch
18 202416 1 LENS, Hazard Switch
19 201075 1 GAUGE, Tachometer
20 200859 1 GAUGE, Transmission Temperature
21 201074 1 GAUGE, Hourmeter
22 200380 1 GAUGE, Air Pressure
23 201403 1 GAUGE, Oil Pressure
24 201404 1 GAUGE, Engine Temperature
25 200398 1 SWITCH, Ignition
26 200706 1 SWITCH, Press Button Start
27 202154 1 INSTRUMENT PANEL Upto 16.10.96
27 203657 1 INSTRUMENT PANEL From 17.10.96
28 202410 2 FRAME, Switch
29 200201 3 BULB, 24 V 3 W
30 205152 1 SWITCH, Wiper/Washer
31 202411 1 SWITCH, Hazard
32 202437 1 LENS, Warning, Red
33 202523 1 LENS, Transmission Pressure Warning

October 18, 1996 B25B035 4-135


COLD START INSTRUMENT PANEL
1

ENGINE COOLANT ENGINE OIL 2,3


TEMPERATURE PRESSURE
7 ENGINE OVERSPEED
TRANSMISSION BIN RAISED
OIL
TEMPERATURE

5
2,8
COLD START

6
EMERGENCY
STEERING
2,4
203250

P003418

January 21, 1997 B25B066 4-136


COLD START INSTRUMENT PANEL
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 202566 2 LAMP, Square (Red)
2 202571 4 HOLDER, Lens
2 202572 4 HOLDER, Bulb
3 201131 1 LENS, Preheat Warning
4 203870 1 LENS, Emergency
5 202410 1 FRAME, Switch
6 202423 3 INSERT, Blank Switch
7 203250 1 PANEL, Dash
8 202437 2 LENS, Red Warning

January 21, 1997 B25B066 4-137


DISTRIBUTION BOX

20

October 18, 1996 B25B038 4-138


DISTRIBUTION BOX
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 201468 4 CIRCUIT BREAKER, 15 A
2 201467 1 CIRCUIT BREAKER, 5 A
3 203830 1 CIRCUIT BREAKER, 20 A
4 NPN 1 BOX, Distribution Part of Cab Harness.

October 18, 1996 B25B038 4-139


BATTERY, CLAMPS AND CABLES

October 30, 1996 B25B036 4-140


BATTERY, CLAMPS AND CABLES
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100063 4 WASHER, Flat
2 200865 2 BATTERY, Delco, 24 V
3 190119 2 CABLE, Battery, Negative
4 190160 1 CABLE, Battery, Positive
5 200202 2 COVER, Terminal, Red
6 200203 2 COVER, Terminal, Black
7 100275 4 NUT, Wing
8 170111 2 BRACKET, Hold Down, Battery
9 100187 4 J BOLT
10 100209 1 SCREW, Hex. Head
11 100062 4 WASHER, Flat
12 200204 4 NUT, Terminal
13 100081 2 SCREW, Hex. Head
14 100310 2 NUT, Nyloc
15 202537 1 SOLENOID, Main Ignition
16 205259 1 CIRCUIT BREAKER, 60 A
17 100381 2 SCREW, Cheese Head
18 100309 2 NUT, Nyloc
19 205174 1 SWITCH, Battery Isolator
20 100358 2 WASHER, Flat
21 100147 1 WASHER, Flat

October 30, 1996 B25B036 4-141


WINDSCREEN WIPER ASSEMBLY

15

31

29
30 19
24
21 23 28
22
20

26

25 27

1 32

11 14
2 12

18
6
17 7 13
16 8
12
7 11
3
6
4 10
5 9
P003374

November 30, 1998 B25B037 4-142


WINDSCREEN WIPER ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 201471 1 WIPER MOTOR
2 NSI 1 MOTOR, Wiper
3 NSI 1 BRACKET, Mounting
4 NSI 2 WASHER, Flat
5 NSI 2 BOLT
6 NSI 2 NUT
7 NSI 2 COVER, Seal
8 NSI 2 SEAL
9 NSI 1 NUT
10 NSI 1 COVER
11 NSI 2 NUT
12 NSI 2 COVER, Seal
13 NSI 2 SEAL
14 201473 1 ARM, Wiper
15 203473 1 BLADE, Wiper From 01/10/96
16 100081 2 SCREW, Hex. Head
17 100061 2 WASHER, Flat
18 100310 2 NUT, Nyloc
19 203984 1 KIT, Windscreen Washer
20 NSI 1 BOTTLE, Water
21 NSI 1 PIPE, Clear
22 NSI 1 NUT
23 NSI 1 WASHER
24 NSI 1 FITTING, Elbow
25 NSI 1 PIPE, Black
26 NSI 1 CABLE TIE
27 NSI 3 CABLE TIE
28 NSI 1 NOZZLE
29 173571 1 MOUNTING, Nozzle
30 NSI 1 WIRE ASSY
31 NSI 3 CABLE TIE
32 NSI 2 SCREW

November 30, 1998 B25B037 4-143


HORN ASSEMBLY

1
3

4
2

8
P003924

November 30, 1998 200448 4-144


HOOTER ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 200448 1 HORN, 24V, Assembly Includes Items 2 to 7
2 NSI 1 HORN
3 NSI 2 SCREW
4 100283 1 NUT, Hex
5 100062 1 WASHER, Flat
6 NSI 2 WASHER
7 NSI 2 MOUNTING
8 100083 1 SCREW Not Included in Item 1

November 30, 1998 200448 4-145


SPECIAL TOOLS

11

October 18, 1996 B25B039 4-146


SPECIAL TOOLS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 870997 1 TEMPLATE, Adjustment, Headlight

October 18, 1996 B25B039 4-147


September 18, 1998 SECTION 5 FRAME AND BODY 5-1
SECTION 5
FRAME AND BODY

September 18, 1998 SECTION 5 FRAME AND BODY 5-2


CAB AND COWLING

8
4

14

13
9
9

10
7 20
6
1
16 19
5 18
17
12 11 P004794
18 15 12

November 30, 1998 ADT00382 5-3


CAB AND COWLING
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100362 2 SCREW, Hex. Head
2 172337 1 CAB, Rops, Fops Certified
3 202515 1 BONNET
4 910138 A/R PINCHWELD
5 101996 2 SCREW, Cap, Sochead
6 100314 2 NUT, Nyloc
7 171211 1 GRILL
8 100083 4 SCREW, Hex. Head
9 100312 6 NUT, Nyloc
10 201798 1 STRUT, Gas Includes Item Number 11
11 203051 1 ROD END
12 100044 6 WASHER, Spring
13 100304 2 WASHER, Flat
14 200305 2 RUBBER, Door Stopper
15 161516 2 HINGE
16 100210 2 SCREW, Hex. Head
17 100148 2 WASHER, Flat
18 100316 4 NUT, Nyloc
19 100064 2 WASHER, Flat
20 202867 1 STRAP, Bonnet

November 30, 1998 ADT00382 5-4


BONNET LATCH

13
14
23
22 15

24

15
9
14

16
17

7 19
18

21
10
12

8 3
1 20

23
11 6

P003643
P004587

September 4, 1998 B25B041 5-5


BONNET LATCH
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 NSI 1 PIN, Split
2 173800 1 HOUSING, Bonnet Catch
3 173801 1 TONGUE, Bonnet Catch
4 183380 1 PEG, Bonnet Catch
5 202872 1 SPRING
6 203954 1 CABLE, Stop
7 202917 1 SPRING
8 173802 1 CUP, Bonnet Catch
9 100083 8 SCREW, Hex. Head
10 100312 8 NUT, Nyloc
11 100227 1 SCREW, Hex. Head
12 100316 1 NUT, Nyloc
13 100320 1 NUT, Cleavelock
14 101301 2 WASHER, Flat
15 172043 2 WASHER, Rubber
16 100293 1 NUT, Hex
17 173542 1 MOUNTING, Bonnet Catch
18 100227 2 SCREW, Hex. Head
19 100148 2 WASHER, Flat
20 204032 1 CLEVIS, Cable
21 NSI 1 PIN
22 174716 1 PLATE, Adaptor
23 200034 1 ADJUSTER, Stop Cable

September 4, 1998 B25B041 5-6


CAB EXTERIOR FITTINGS
Pull
FOR EMERGENCY EXIT
REMOVE BEAD FROM WINDOW
RUBBER BEFORE PUSHING
OUT WINDOW

53 13 47
2 16 48
26
29 50
12 52
24 49
61

17
18 48
34
30
51
11 30 47
28 37
43 32
39

30 25 46
14 36
44 18 17 35
27

9 30
54
10
4 16
38 20
59 54
62 6 15 19
60 31
22 40 58
45 55
45 21 41
23,33
1
8 7
5 42
41
40 56
3

42
P003367

September 4, 1998 B25B089 5-7


CAB EXTERIOR FITTINGS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 202398 1 HANDLE, Door, Internal
2 172339 1 CAB, Standard
2 172337 1 CAB, ROPS / FOPS Certified Optional
3 100323 6 NUT, Nyloc
4 100165 6 BOLT, Hex. Head
5 101343 6 WASHER
6 100314 24 NUT, Nyloc
7 100364 24 SCREW, Hex. Head
8 201764 6 MOUNTING, Megi
9 NSI A/R SCREW, Self Tapping
10 NSI 1 PANEL, Door
11 203604 2 MIRROR, Safety
12 172688 2 BRACKET, Mirror
12 174736 2 BRACKET, Mirror CE MARK
13 204002 1 COVER, Cushion, Mirror Bracket
14 100734 4 BOLT, Hex. Head
15 100312 4 NUT, Nyloc
16 100210 4 SCREW, Hex. Head
17 100148 4 WASHER, Flat
18 100271 4 NUT, Cleavelock
19 201039 A/R INSULATION, Sound
20 200710 2 HINGE
21 100316 1 NUT, Nyloc
22 161505 1 PEG, Striker
23 172554 1 EXTENSION, Mudguard, LH Optional
24 202308 1 WINDSCREEN
25 202307 2 WINDOW, Front Side
26 202309 1 WINDOW, Rear
27 202310 1 WINDOW, Door
28 201442 1 WINDOW, Side, Sliding, Vertical
29 202495 1 WINDOW, Side, Sliding, RH
30 910018 A/R RUBBER, Glazing
31 173213 1 DOOR, Cab
32 201743 1 CLIP, Retainer
33 172553 1 EXTENSION, Mudguard, RH Optional

September 4, 1998 B25B089 5-8


CAB EXTERIOR FITTINGS
Pull
FOR EMERGENCY EXIT
REMOVE BEAD FROM WINDOW
RUBBER BEFORE PUSHING
OUT WINDOW

53 13 47
2 16 48
26
29 50
12 52
24 49
61

17
18 48
34
30
51
11 30 47
28 37
43 32
39

30 25 46
14 36
44 18 17 35
27

9 30
54
10
4 16
38 20
59 54
62 6 15 19
60 31
22 40 58
45 55
45 21 41
23,33
1
8 7
5 42
41
40 56
3

42
P003367

September 4, 1998 B25B089 5-9


CAB EXTERIOR FITTINGS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
34 200763 A/R PINCHWELD
35 200861 1 STRAP, Earth
36 100085 1 SCREW, Hex. Head
37 181179 2 LINK Up To 01/10/97
37 181194 2 LINK From 01/1097
37 181023 2 LINK (Bin Heating) CE MARK
38 100148 4 WASHER, Flat
39 202474 2 MIRROR, Extra Large
40 100085 12 SCREW, Hex. Head
41 100147 12 WASHER, Flat
42 100314 12 NUT, Nyloc
43 172283 1 PLATE, Bulkhead
44 100360 7 RIVET, Pop
45 100536 2 WASHER, Hardened
46 173915 1 PLATE, Blanking, Cab Vent
47 100089 6 SCREW, Hex. Head
48 100314 4 NUT, Nyloc
49 172473 1 GUARD, Rear Window (Standard)
49 174478 1 GUARD, Rear Window (Bin Heating)
50 203067 1 BEACON, Rotating, 24 V
51 172050 1 BRACKET, Mounting, Rotating Beacon
52 100083 3 SCREW, Hex. Head
53 204906 1 DECAL, EXIT BY WINDOW CE MARK
54 100733 2 BOLT CE MARK
55 100314 2 NUT, Nyloc CE MARK
56 170522 1 STEP CE MARK
57 203604 1 MIRROR, Wide Angle CE MARK
58 100083 4 BOLT
59 173079 2 PLATE, Cover
60 100984 4 NUT
61 201307 1 GLAZING Includes Items 24 to 27
62 6 WASHER No info at the time of print

September 4, 1998 B25B089 5-10


DOOR HANDLE ASSEMBLY

4 3
3

2
5

1
GHE

P004588

November 30, 1998 B25B043 5-11


DOOR HANDLE ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100076 4 SCREW, Cap
2 202398 1 HANDLE, Door, Interior, RH
3 100081 4 SCREW, Hex. Head
4 100310 4 NUT, Nyloc
5 202399 1 HANDLE, Door, External (With Key) Up to 10/07/97
5 204471 1 HANDLE, Door, External (With Key) Includes Item 6 From 10/07/97
6 204472 1 KEY

November 30, 1998 B25B043 5-12


CAB INTERIOR FITTINGS

6
ARTICULATED HAULER
MACHINE BUILD No. SERIAL NUMBERS:
MACHINE MODEL 21
ENGINE MODEL
TRANSMISSION MODEL
13
FRONT DIFF MODEL 31
MID DIFF MODEL
REAR DIFF MODEL

AXLE FRONT MID REAR TOTAL


TARE kg 24 E F

GROSS kg
PAYLOAD kg
LUBRICATION SCHEDULE - FACTORY FIRST FILL
2
1. ENGINE CRANKCASE
ADE / CUMMINS - CALTEX DELO SHP SAE 15W/40
5
DEUTZ - CALTEX DELO 500 SAE 40
2. HYDRAULIC SYSTEM - CALTEX RANDO Z56 4 20
3. TRANSMISSION - CALTEX DELO SHP SAE 15W/40 28 3
4. DIFFERENTIAL
5. BELL PLANIHUB
- CALTEX E.P. PLUS GEAR LUBE 460
- CALTEX E.P. PLUS GEAR LUBE 460
29
6. ALL GREASE POINTS - CALTEX MULTIFAK EP2
CONSULT THE OPERATOR AND
MAINTENANCE MANUAL FOR
MANUFACTURED BY:
BELL EQUIPMENT CO. (PTY) LTD
35 27
LUBRICATION SPECIFICATIONS ALTON, RICHARDS BAY
AND SAFETY PRECAUTIONS. P/N 200181 SOUTH AFRICA

34
33 16
5
BELL EQUIPMENT CO. S.A. (PTY) LTD.
RICHARDS BAY
19
SOUTH AFRICA

YEAR
23
MODEL 8 10
SERIAL NUMBER 9
POWER KW
32
MASS EMPTY Kg
23 14
LOADED Kg
30
P/N202319 17 11
22
10
26 25 17
16 15 14
16
1 19

12
7 WARNING ANY ALTERATION, MODIFICATION, REPAIR, STRUCTURAL DAMAGE OR ANY OVERTURN REDUCES THIS STRUCTURE'S

17 17 18
PROTECTION CAPABILITIES AND INVALIDATES THIS CERTIFICATION. CONSULT A BELL REPRESENTATIVE TO DETERMINE THIS STRUCTURE'S LIMITATIONS.

36 ROLLOVER (ROPS), FALLING OBJECT (FOPS) AND OPERATOR (OPS) PROTECTIVE STRUCTURE CERTIFICATION
PROTECTION STRUCTURE
MODEL No.
MACHINE DESCRIPTION

MACHINE MODEL No.


AT INSTALLATION, THIS STRUCTURE MEETS THE FOLLOWING PERFORMANCE
CRITERIA IF IT IS PROPERLY INSTALLED AND THE MACHINE WEIGHT IS NOT
INCREASED TO EXCEED THE CERTIFIED TEST WEIGHT:

FOPS CERTIFICATE No. SAE J1040 APR88 ISO 3471/1 1986 SAE J1084 APR 80
CERTIFIED MASS kg SAE JJ231 JAN 81 SAE 3449 1992
ROPS CERTIFICATE No.
TRACTOR MASS ONLY
BELL EQUIPMENT CO. S.A. (PTY) LTD
OPS CERTIFICATE No. WHOLE MACHINE MASS RICHARDS BAY, SOUTH AFRICA
203000

P003389

September 4, 1998 B25B044 5-13


CAB INTERIOR FITTINGS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 280185 1 SPANNER, Wheel
2 290372 1 SEAT ASSY, Vinyl From 01.11.96
2 290369 1 SEAT ASSY, Cloth
3 100231 4 SCREW, Cap
4 202184 1 PANEL, Dash
5 100360 8 RIVET, Pop
6 200181 1 PLATE, Name
7 100275 2 NUT, Wing
8 172223 1 PLATE, Seat, RH
9 173556 1 MOUNTING, Seat
10 100083 22 SCREW, Hex. Head Upto 30.11.96
10 100931 22 BOLT, Hex From 01.12.96
11 172205 1 PLATE, Seat, LH
12 171508 2 CLAMP, Pipe
13 201222 1 LIGHT, Interior
14 100062 18 WASHER, Flat Upto 30.11.96
14 101345 18 WASHER From 01.12.96
15 172419 1 FLOORBOARD Upto 30.11.96
15 172422 1 FLOORBOARD From 01.12.96
16 100197 6 SCREW, Cap
17 100312 10 NUT, Nyloc
18 172281 1 PLATE, Pedal
19 203000 1 PLATE, Name
20 Z6006 022 211 1 SELECTOR, Range
21 Z6007 203 214 1 DISPLAY, Digital
22 Z6009 047 509 1 PROCESSOR, Micro
23 100381 3 SCREW, Cheese Head
24 202566 2 LAMP, Square
25 260661 1 PEDAL ASSY
26 210208 1 VALVE, Brake
27 202397 1 ASHTRAY
28 202726 1 LIGHTER, Cigarette, 24 V
29 204907 1 PLATE, Power Point, 24 V
30 202319 1 PLATE, CE Mark
31 201860 1 GAUGE, Fuel FROM 26.06.97

September 4, 1998 B25B044 5-14


CAB INTERIOR FITTINGS

6
ARTICULATED HAULER
MACHINE BUILD No. SERIAL NUMBERS:
MACHINE MODEL 21
ENGINE MODEL
TRANSMISSION MODEL
13
FRONT DIFF MODEL 31
MID DIFF MODEL
REAR DIFF MODEL

AXLE FRONT MID REAR TOTAL


TARE kg 24 E F

GROSS kg
PAYLOAD kg
LUBRICATION SCHEDULE - FACTORY FIRST FILL
2
1. ENGINE CRANKCASE
ADE / CUMMINS - CALTEX DELO SHP SAE 15W/40
5
DEUTZ - CALTEX DELO 500 SAE 40
2. HYDRAULIC SYSTEM - CALTEX RANDO Z56 4 20
3. TRANSMISSION - CALTEX DELO SHP SAE 15W/40 28 3
4. DIFFERENTIAL
5. BELL PLANIHUB
- CALTEX E.P. PLUS GEAR LUBE 460
- CALTEX E.P. PLUS GEAR LUBE 460
29
6. ALL GREASE POINTS - CALTEX MULTIFAK EP2
CONSULT THE OPERATOR AND
MAINTENANCE MANUAL FOR
MANUFACTURED BY:
BELL EQUIPMENT CO. (PTY) LTD
35 27
LUBRICATION SPECIFICATIONS ALTON, RICHARDS BAY
AND SAFETY PRECAUTIONS. P/N 200181 SOUTH AFRICA

34
33 16
5
BELL EQUIPMENT CO. S.A. (PTY) LTD.
RICHARDS BAY
19
SOUTH AFRICA

YEAR
23
MODEL 8 10
SERIAL NUMBER 9
POWER KW
32
MASS EMPTY Kg
23 14
LOADED Kg
30
P/N202319 17 11
22
10
26 25 17
16 15 14
16
1 19

12
7 WARNING ANY ALTERATION, MODIFICATION, REPAIR, STRUCTURAL DAMAGE OR ANY OVERTURN REDUCES THIS STRUCTURE'S

17 17 18
PROTECTION CAPABILITIES AND INVALIDATES THIS CERTIFICATION. CONSULT A BELL REPRESENTATIVE TO DETERMINE THIS STRUCTURE'S LIMITATIONS.

36 ROLLOVER (ROPS), FALLING OBJECT (FOPS) AND OPERATOR (OPS) PROTECTIVE STRUCTURE CERTIFICATION
PROTECTION STRUCTURE
MODEL No.
MACHINE DESCRIPTION

MACHINE MODEL No.


AT INSTALLATION, THIS STRUCTURE MEETS THE FOLLOWING PERFORMANCE
CRITERIA IF IT IS PROPERLY INSTALLED AND THE MACHINE WEIGHT IS NOT
INCREASED TO EXCEED THE CERTIFIED TEST WEIGHT:

FOPS CERTIFICATE No. SAE J1040 APR88 ISO 3471/1 1986 SAE J1084 APR 80
CERTIFIED MASS kg SAE JJ231 JAN 81 SAE 3449 1992
ROPS CERTIFICATE No.
TRACTOR MASS ONLY
BELL EQUIPMENT CO. S.A. (PTY) LTD
OPS CERTIFICATE No. WHOLE MACHINE MASS RICHARDS BAY, SOUTH AFRICA
203000

P003389

September 4, 1998 B25B044 5-15


CAB INTERIOR FITTINGS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
32 223922 1 BOTTLE, Water
33 223923 1 BRACKET, Mounting
34 223921 1 LID, Bottle
35 130040 A/R HOSE, Clear You Should Only Require 2m
36 201217 1 VALVE, Push Button From 10.05.97

September 4, 1998 B25B044 5-16


SEAT ASSEMBLY (FROM NOV 1996)

11
13
13

13
13

14

November 30, 1998 290369 5-17


SEAT ASSEMBLY (FROM NOV 1996)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 290369 1 SEAT ASSEMBLY From November 1996
2 224756 1 KIT, Seat Cover Assy Black Vinyl Only
3 224757 1 KIT, Seat Cushion
4 224758 1 KIT, Suspension Assy
5 224759 1 KIT, Damper Assy
6 224760 1 KIT, Indicator, Bump Stop and Adjuster
7 224761 1 KIT, Stud Assy
8 224762 1 KIT, Handle Assy
9 224763 1 KIT, Suspension Cover
10 224764 1 KIT, Adjuster Slide Rail
11 224766 1 KIT, Arm Rest
12 224784 1 KIT, Back Cushion
13 224765 1 KIT, Seat Belt
14 100231 4 SCREW, Cap

November 30, 1998 290369 5-18


STEERING COLUMN ASSEMBLY
2

4 3

17
18 19
14
20
15
16

10
8 12
1 5
5

13
6

15 7
16 11

P003396

September 4, 1998 B25B090 5-19


STEERING COLUMN ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100285 2 NUT, Cleavelock
2 202913 1 CAP, Steering Wheel
3 200284 1 NUT, Steering Wheel
4 200282 1 WHEEL, Steering
5 200593 2 K CLAMP
6 NSI 2 BOLT, Hex
7 100027 4 SCREW, Cap Only two are used From 31/01/95 To 01/10/96
8 202405 1 COLUMN, Steering
9 210413 1 VALVE, Steering
10 173565 1 MOUNTING
11 100091 2 SCREW, Hex. Head
12 100062 8 WASHER, Flat From 31/01/95 To 01/10/96
13 100314 4 NUT, Nyloc From 31/01/95 To 01/10/96
14 174656 1 BRACKET, Mounting, Steering Column From 31/01/95 To 01/10/96
15 203926 4 GROMMET From 31/01/95 To 01/10/96
16 201888 4 GROMMET, Insert From 31/01/95 To 01/10/96
17 100961 2 SCREW, Cap From 31/01/95 To 01/10/96
18 101307 2 WASHER, Flat From 31/01/95 To 01/10/96
19 100083 4 SCREW, Hex Head From 31/01/95 To 01/10/96

September 4, 1998 B25B090 5-20


ADJUSTABLE STEERING COLUMN

1 21
25
23 3
24
11
17

15

16

20
10

18

15
8
12 9
14 13
10 19 7

6
11
2
4
22

P004800

November 30, 1998 190721 5-21


ADJUSTABLE STEERING COLUMN
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 190721 1 COLUMN, Tilt Steering Includes Item Numbers 2 and 3
2 101337 2 BOLT, Hex. Head
3 203982 1 COLUMN, Tiltable Steering Includes Item Numbers 3 to 24
4 224925 1 TUBE, Lower Casing
5 224700 2 SCREW, Grub
6 224701 1 INNER SHAFT, Lower
7 224702 1 JOINT, Universal Includes Item Numbers 8 and 9
8 NSI 2 NUT, Nyloc
9 NSI 2 BOLT
10 224705 2 BOOT, Rubber
11 224706 2 BRACKET, Boot
12 224707 1 WASHER, Shim
13 224708 1 BOLT, Stepped
14 224714 1 WINGNUT, Lever
15 224710 3 CIRCLIP
16 224711 1 SHIM
17 224712 1 WASHER, Rubber
18 224715 1 TUBE, Upper
19 224713 1 SPACER, Washer
20 224703 1 INNER, Shaft, Upper
21 224704 1 NUT, Steering Wheel
22 NSI 1 HOUSING, Universal Joint
23 NSI 8 SCREW
24 200282 1 WHEEL, Steering
25 202913 1 CAP, Steering Wheel

November 30, 1998 190721 5-22


AIR CONDITIONER ASSEMBLY (RED DOT)
24 26
28
30 29 27
1 8 4
9 25
11
35,38
7
5

2
34,37

28 18 3
31 42
20 17
32
6 41

19

19
22
20
14
36

15
33,39 19 43
10 18
13 16 21

44 23
45 40 19

12

April 15, 1996 260674 5-23


AIR CONDITIONER ASSEMBLY (RED DOT)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 260674 AIR CONDITIONER ASSEMBLY (RED DOT)
2 202904 1 RECEIVER DRIER AND BINARY SWITCH
3 290501 1 COMPRESSOR, Air
4 202903 1 CONDENSOR, Air
5 202902 1 EVAPORATOR ASSY
6 174302 6 COVER, Air Con
7 100275 1 NUT, Wing
8 201229 1 HOUSING, Filter, Outer
9 220088 1 ELEMENT, Air Cleaner
10 100090 2 SCREW, Hex Head
11 201228 1 HOUSING, Filter, Inner
12 161520 1 PULLEY, Drive
13 170873 1 BRACKET, Mounting Standard
13 171844 1 BRACKET, Mounting Retarder
14 170872 2 ARM, Adjusting
15 170875 1 CLIP, Belt, Drive, Top
16 170874 2 CLIP, Belt, Drive, Bottom
17 200726 4 BELT, Drive, Compressor
18 100364 4 SCREW, Hex. Head
19 100314 4 NUT, Nyloc
20 100147 4 WASHER, Flat
21 100226 2 SCREW, Cap
22 100083 1 SCREW, Hex. Head
23 100125 4 SCREW, Hex. Head
24 100210 4 SCREW, Hex. Head
25 100316 4 NUT, Nyloc
26 174261 2 BRACKET
27 100059 4 WASHER, Flat
28 100312 9 NUT, Nyloc
29 202083 1 CLAMP, Exhaust
30 100062 2 WASHER, Flat
31 NSI 4 RIVET, Pop
32 100082 6 SCREW, Hex. Head
33 240913 1 HOSE ASSY Up To 07/07/97
34 240914 1 HOSE ASSY Up To 07/07/97

April 15, 1996 260674 5-24


AIR CONDITIONER ASSEMBLY (RED DOT)
24 26
28
30 29 27
1 8 4
9 25
11
35,38
7
5

2
34,37

28 18 3
31 42
20 17
32
6 41

19

19
22
20
14
36

15
33,39 19 43
10 18
13 16 21

44 23
45 40 19

12

April 15, 1996 260674 5-25


AIR CONDITIONER ASSEMBLY (RED DOT)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
35 240912 1 HOSE ASSY Up To 07/07/97
36 261177 1 KIT, Aircon, Hose Assembly From 07/07/97
37 240914 1 HOSE ASSY From 07/07/97
38 240912 1 HOSE ASSY From 07/07/97
39 240913 1 HOSE ASSY From 07/07/97
40 240810 1 HOSE ASSY Up To and From 07/07/97
41 100062 6 WASHER, Flat
42 NSI 1 SCREW, Self Tapping
43 100064 2 WASHER, Flat
44 203879 1 SUPPORT, Aircon Hose, Gumstock
45 100559 5 RIVET, Pop

April 15, 1996 260674 5-26


HYDRAULIC TAILGATE ASSEMBLY (OPTIONAL)

4 3

7 6

8 10

7
6

11
P004823

December 9, 1998 B25B061 5-27


HYDRAULIC TAILGATE ASSEMBLY (OPTIONAL)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 181446 1 TAILGATE, Hydraulic Up to 01/10/96 For Bin Numbers 180500 and 182884
1 181457 1 TAILGATE, Hydraulic From 01/10/96 For Bin Numbers 182882 and 182887
2 160884 2 BUSH, Bronze
3 161379 2 PIN, Main Pivot
4 100165 4 BOLT, Hex. Head
5 203992 2 NIPPLE, Grease
6 100156 4 SCREW, Hex. Head
7 166411 4 RETAINER, Tailgate
8 230083 2 CYLINDER
9 182695 1 MOUNTING, Cylinder, RH
9 182694 1 MOUNTING, Cylinder, LH
10 182692 1 MOUNTING, Main Pivot, RH
10 182693 1 MOUNTING, Main Pivot, LH
11 260744 1 TAILGATE, Kit (Not illustrated) Up to 01/10/96 For Bin Numbers 180500 and 182884
12 261158 1 TAILGATE, Kit (Not illustrated) From 01/10/96 For Bin Numbers 182882 and 182887

December 9, 1998 B25B061 5-28


BIN HEATER KIT

1
31 2
34 33 32 10

30 3 11
33 19
34
29 12

10 11 12 11 14 11

28
14

26 20 15
2
27 6
21 4
22
18

9 8 7
25
17
23

9 16 25 7 8 9
24
5
22 8
7
8 7
13
9

P004187

June 22, 1998 261667 2-29


BIN HEATER KIT
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 261667 1 KIT, Bin Heating For B# ADT use with Service Bulliten 98/306
2 204196 1 EXHAUST, Stack
3 204035 4 CLAMP, Seal
4 204197 1 EXHAUST, Flex Pipe
5 203574 1 PIPE, Ball Assembly
6 173066 1 BRACKET, Mounting
7 100966 12 NUT, Cleveloc
8 100062 12 WASHER, Flat
9 100731 10 SCREW, Hex. Head
10 100747 6 BOLT, Hex. Head
11 162456 12 WASHER, Spring
12 201666 6 SPRING
13 100320 3 NUT, Cleveloc
14 100966 12 NUT, Cleveloc
15 203565 1 PIPE, Ball Assembly
16 203367 1 SOCKET, Button
17 171686 1 PIPE, Oultlet
18 204198 1 EXHAUST, Flex Pipe, Bottom
19 203368 1 SOCKET, Top
20 100298 3 BOLT, Hex. Head
21 100010 3 WASHER, Flat
22 162457 6 WASHER, Spring
23 201667 3 SPRING
24 183771 1 PLATE, Mounting PART OF KIT 261667, BUT NOT USED ON B30C
25 174581 2 FLANGE, Bin Heating
26 101305 4 WASHER
27 100214 4 SCREW, Hex. Head
28 181211 1 INLET, Bin
29 174161 1 PLATE, Spacer, Bin Ducting Hole
30 174070 2 LINK, Rear Window
31 174583 1 GUARD, Rear Window
32 100090 6 BOLT
33 100147 12 WASHER
34 100314 6 NUT, Nyloc

June 22, 1998 261667 2-30


FRONT FRAME
45 44
43 2
34
42 14 26 35 10
41
28,36
11
38

15 14
39 40
16 13
27
31

3
30
29
24 29
28
5
25 19 17,18

12
37
22 33
23
6
8
20
9
32 1
4

P004756
21
7

December 2, 1998 ADTOO344 5-31


FRONT FRAME
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100147 4 WASHER, Flat
2 183566 1 CHASSIS, Front
3 183022 1 BOX, Battery
4 200389 2 REFLECTOR, White
5 100062 2 WASHER, Flat
6 100214 6 SCREW, Hex. Head
7 173498 1 STEP, Short CE Mark
8 100314 4 NUT, Nyloc
9 100092 4 SCREW, Hex. Head
10 170830 1 BRACKET
11 190524 2 HINGE
12 172942 2 LINK
13 NSI 1 COVER, Battery Box
14 173037 2 HAND RAIL
15 100086 2 SCREW, Hex Head
16 100314 2 NUT, Nyloc
17 204531 1 MOUNTING, Light, LH
18 204530 1 MOUNTING, Light, RH
19 100211 8 SCREW, Hex. Head
20 172512 1 PLATE, Belly
21 201440 2 PIN ASSY
22 100157 2 SCREW, Hex Head
23 100323 2 NUT, Nyloc
24 171212 1 GRILL, Lower
25 100731 4 SCREW, Hex. Head
26 100085 2 SCREW, Hex. Head
27 181299 1 TANK, Fuel
27 182788 1 TANK, Fuel - CE Mark
28 100148 8 WASHER, Flat Used with Tank 182788 Only
29 100316 10 NUT, Nyloc
30 100394 12 NUT, Nyloc
31 100111 2 SCREW, Hex. Head
32 204374 4 REFLECTOR
33 201405 6 WASHER
34 100250 2 SCREW, Cap

December 2, 1998 ADTOO344 5-32


FRONT FRAME
45 44
43 2
34
42 14 26 35 10
41
28,36
11
38

15 14
39 40
16 13
27
31

3
30
29
24 29
28
5
25 19 17,18

12
37
22 33
23
6
8
20
9
32 1
4

P004756
21
7

December 2, 1998 ADTOO344 5-33


FRONT FRAME
ITEM PART NUMBER QTY DESCRIPTION REMARKS
35 174433 1 PLATE, Top From 28.07.97 Used with Tank 182788 Only
36 200725 1 FUEL SENDER UNIT From 28.07.97 Used with Tank 182788 Only
37 171575 2 CABLE
38 210187 3 SIGHT GLASS, Fuel
39 140528 3 WASHER, Dowty
40 100519 3 NUT
41 201503 1 GASKET, Cork - Diesel
42 170739 1 NECK, Filler
43 101312 8 WASHER, Flat
44 100731 8 SCREW, Hex. Head
45 203650 1 CAP, Diesel Filler, Lockable

December 2, 1998 ADTOO344 5-34


ARTICULATION AND OSCILATION ASSEMBLY
4
6 5
8 9 7
11 10
29
32
30
31
3

30
15
16
17

23
21
24
20 25 2
22

10
9
22 1 6 7 14
1
20 27
27 13
18,19
26
3
11
12

28

11

P004195

September 4, 1998 B25B049 5-37


ARTICULATION AND OSCILATION ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 100209 4 SCREW, Hex. Head
2 183098 1 JOINT, Articulation and Oscilation
3 100111 8 SCREW, Hex. Head
4 160368 1 WASHER, Lock
5 160367 1 NUT, Lock
6 140203 2 O RING
7 160365 2 RING, Thrust, Steel
8 900766 A/R TUBING, Bundy
9 140202 2 O RING Factory Fitted
9 910269 2 TUBING Infield Repair - Length 1.1 m
9 161668 1 ADAPTOR, Barbed Infield Repair
10 162523 2 BUSH, Flanged
11 200038 4 GREASE NIPPLE
12 120041 4 ADAPTOR, Swivel
13 240114 1 HOSE ASSY
14 120212 1 ADAPTOR, Swivel
15 100111 4 SCREW, Hex. Head
16 170031 2 TAG, Lock
17 170467 2 PLATE, Retainer
18 160261 1 PLATE, Retainer, Top Pin
19 160309 1 PLATE, Retainer, Bottom Pin
20 140117 4 O RING
21 160383 2 PIN ASSY
22 160382 4 BUSH, Steel
23 160296 4 WASHER, Thrust
24 140162 4 O RING Factory Fitted
24 910269 4 TUBING Infield Repair - Length 0.418 m
24 161668 2 ADAPTOR, Barbed Infield Repair
25 160297 2 BUSH, Bronze
26 172178 2 BAR, Safety
27 160529 2 PIN ASSY
28 240046 2 HOSE ASSY
29 173703 1 PIPE ASSY
30 120106 2 ADAPTOR
31 120401 2 NUT

September 4, 1998 B25B049 5-38


ARTICULATION AND OSCILATION ASSEMBLY
4
6 5
8 9 7
11 10
29
32
30
31
3

30
15
16
17

23
21
24
20 25 2
22

10
9
22 1 6 7 14
1
20 27
27 13
18,19
26
3
11
12

28

11

P004195

September 4, 1998 B25B049 5-39


ARTICULATION AND OSCILATION ASSEMBLY
ITEM PART NUMBER QTY DESCRIPTION REMARKS
32 120790 2 FERRULE
33 900766 A/R TUBING, Bundy

September 4, 1998 B25B049 5-40


STEERING CYLINDER MOUNTINGS (Up To 01.09.97)

10
6 11
6 9

5
5

3
4

4
2 12

7 8
P003376

September 4, 1998 B25B050 5-41


STEERING CYLINDER MOUNTINGS (Up To 01.06.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 230285 1 CYLINDER, Steering, LHS
1 230290 1 CYLINDER, Steering, RHS
2 160446 2 PIN ASSY
3 160393 2 PIN ASSY
4 170467 4 PLATE, Retainer
5 170031 4 TAG, Lock
6 100085 8 SCREW, Hex. Head
7 120041 2 ADAPTER, Swivel
8 240108 2 HOSE ASSY
9 200038 4 GREASE NIPPLE
10 120106 2 CONNECTOR
11 240376 2 HOSE ASSY
12 120148 2 CONNECTOR

September 4, 1998 B25B050 5-42


STEERING CYLINDER MOUNTINGS (From 01.06.97)

12

13
10
14 9

11

6
15

14
1
2
13

12
9 16

8
7 P004593

September 7, 1998 B25B092 5-43


STEERING CYLINDER MOUNTINGS (From 01.06.97)
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 230285 1 CYLINDER, Steering, LHS
1 230290 1 CYLINDER, Steering, RHS
2 160446 2 PIN, Steering Cylinder
3 100714 2 BOLT, Hex Head
4 170467 2 PLATE, Retainer
5 170031 2 TAG, Lock
6 100085 4 SCREW, Hex. Head
7 120041 2 ADAPTER, Swivel
8 240108 2 HOSE ASSY
9 200038 4 GREASE NIPPLE
10 120106 2 CONNECTOR
11 240376 2 HOSE ASSY
12 161537 4 PLATE, End - Expanding, Steering Cylinder
13 140382 4 O - RING
14 161536 4 CONE, Expanding, Steering Cylinder
15 161535 2 PIN, Tapered
16 100320 2 NUT, Cleveloc

September 7, 1998 B25B092 5-44


REAR FRAME
26
28
27
2,51,52 1
23

47

48
46
31

12 50
30
17 16
16 15 13 15

42
14 41
19
4
5 3
21
11

9
6 29 24 25
49 10
43
7
40 8
15
38 20 22

35 18
36 44
39 37
45

33 34
P004594
32

September 7, 1998 B25B093 5-45


REAR FRAME
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 260078 1 KIT, Wear Plate Up To 30.09.96
1 261803 1 KIT, Wear Plate From 01.10.96
2 182882 1 BIN From 01.10.96
2 182884 1 BIN, Ducted Up To 30.09.96
3 183574 1 CHASSIS, Rear
4 200613 8 MAT, Bin Shock
5 100231 32 SCREW, Cap
6 173035 1 SUPPORT, Bin Trailer
7 100211 2 SCREW, Hex. Head From 03.03.97
8 100148 2 WASHER From 03.03.97
9 160540 2 PIN
10 100111 4 SCREW, Hex. Head
11 200036 2 GREASE NIPPLE
12 200387 1 BOARD, Chevron Up To 15.11.96
12 201717 1 BOARD, Chevron From 15.11.96
13 100309 6 RIVET, Pop
14 172732 1 GUSSET, Rubber, Chevron Board
15 100310 13 NUT, Nyloc
16 100063 11 WASHER, Flat
17 100252 6 SCREW, Hex. Head
18 204374 8 REFLECTOR, Amber
19 202590 1 CLIP
20 100061 2 WASHER
21 120181 2 BUSH, Reducing
22 100080 2 SCREW, Hex. Head
23 202563 2 LAMP, Reverse
24 170467 2 PLATE, Retainer
25 170031 2 TAG, Lock
26 100731 2 SCREW, Hex Head
27 173552 1 MOUNTING, Reverse Light
28 100312 2 NUT, Nyloc
29 173578 1 MOUNTING, Switch, Bin Up
30 170972 1 PLATE
31 204373 2 REFLECTOR, Red
32 177271 2 PLATE, Mounting Used With Bin No.182882 Only

September 7, 1998 B25B093 5-46


REAR FRAME
26
28
27
2,51,52 1
23

47

48
46
31

12 50
30
17 16
16 15 13 15

42
14 41
19
4
5 3
21
11

9
6 29 24 25
49 10
43
7
40 8
15
38 20 22

35 18
36 44
39 37
45

33 34
P004594
32

September 7, 1998 B25B093 5-47


REAR FRAME
ITEM PART NUMBER QTY DESCRIPTION REMARKS
33 174908 2 PLATE, Spacer Used With Bin No.182882 Only
34 174907 2 PLATE, Guide, Bin Used With Bin No.182882 Only
35 100320 6 NUT, Cleveloc Used With Bin No.182882 Only
36 100010 6 WASHER, Flat Used With Bin No.182882 Only
37 100487 6 SCREW, Hex Head Used With Bin No.182882 Only
38 201949 1 BLOCK, Rubber Stop From 03.03.97
39 172083 1 BRACKET, Bin Support, Store From 03.03.97
40 100316 2 NUT, Nyloc From 03.03.97
41 182772 1 PIN, Tow Hitch
42 202176 1 LINK, Quick Link
43 100549 4 WASHER, Flat
44 100214 4 SCREW, Hex Head Up to 01/10/96
45 174507 1 PLATE, Mounting, Caliper, Park Brake Up to 01/10/96
46 100080 1 SCREW, Hex Head
47 100381 4 SCREW, Hex Head
48 201333 1 ALARM, Back Up
49 100394 4 NUT, Nyloc
50 190738 1 MOUNTING, Rubber
51 180500 1 BIN Up to 01/10/96
52 182887 BIN, Ducted From 01/10/96

September 7, 1998 B25B093 5-48


TIP CYLINDER MOUNTINGS

9
6 7 8

2
3
1 P003381
5 4
3
2

October 21, 1996 B25B052 5-49


TIP CYLINDER MOUNTINGS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 230054 1 CYLINDER, Tip
2 100301 2 NUT, Nyloc
3 160493 2 WASHER, Retainer
4 161181 1 RING, Spacer
5 160485 2 PIN
6 160384 1 PIN
7 170467 1 PLATE, Retainer
8 170031 1 PLATE, Lock
9 100111 2 SCREW, Hex. Head

October 21, 1996 B25B052 5-50


DECAL LAYOUT
9,10 5
18 21 4 5 6
19
B25B

24

28
7 3 2 1
8 5
1 11,12,13,14,15,16

22 18 18
6 5 4
25

B25B B25B
20 5
26

23

24

2 27 17 7
6
P003385

November 13, 1996 B25B053 5-51


DECAL LAYOUT
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 203152 2 DECAL, Warning, Exterior Condition
2 203153 2 DECAL, Important, Exterior Condition
3 202818 1 DECAL, Propshaft
4 202852 2 DECAL, Warning, Dump Body Prop
5 202855 5 DECAL, Warning, Visibility
6 202721 4 DECAL, Lift Point
7 204837 2 DECAL, Tyre Pressure
8 202857 1 DECAL, Warning, Push Out Window
9 200181 1 PLATE, Name
10 202319 1 PLATE, CE Mark
11 202822 1 PLATE, Warning, Condensed Cab
12 203377 1 PLATE, Bin Up
13 204907 1 PLATE, Power Point
14 204262 1 PLATE, Pull Bonnet Release
15 174515 1 PLATE, Diff Lock Label
16 202828 1 PLATE, Engine Stop
17 202722 2 DECAL, Escape Route
18 203256 3 DECAL, B25B
19 203244 1 DECAL, Bonnet, LH
20 203243 1 DECAL, Bonnet, RH
21 203255 1 DECAL, Bin Stripes, LH
22 203254 1 DECAL, Bin Stripes, RH
23 203248 2 DECAL, Bell
24 203240 2 DECAL, Bell
25 204906 1 DECAL, Exit by Window Instructions
26 204914 1 DECAL, Warning, Emergency Steering
27 203208 1 DECAL, Oscilation Joint Greasing
28 203210 1 DECAL, Maintenance CE MARK

November 13, 1996 B25B053 5-52


DECALS
WARNING
STRUCTURAL DAMAGE, AN OVERTURN, MODIFICATION,
IMPROPER REPAIR OR ALTERATION, CAN IMPAIR THIS
MACHINES CERTIFICATION. CONSULT A BELL
WARNING WARNING WARNING
REPRESENTATIVE TO DETERMINE THIS MACHINES THIS MACHINE IS FITTED WITH A SELF
CERTIFICATION LIMITATIONS.
DIAGNOSTIC TRANSMISSION CONTROL
SUSPENSION SYSTEM MAY DROP MACHINE SUDDENLY IF SYSTEM. IF THE DIGITAL DISPLAY UNIT INSTALL BIN PROP BEFORE
THE LEVELLING VALVE IS TAMPERED WITH. THIS LEAVES
NO CLEARANCE BETWEEN THE AXLE HOUSING,
SHOWS FAULT SYMBOL , STOP THE MACHINE
WORKING UNDER RAISED BIN TO MACHINE OPERATOR HAS LIMITED
MAINFRAME, TYRES, AND MUD GUARDS. AND CONSULT YOUR BELL PRODUCT VISIBILITY. DO NOT REMAIN IN THIS
WORKING IN THESE AREAS CAN RESULT IN PERSONAL
SUPPORT REPRESENTATIVE FOR FURTHER PREVENT IT FROM FALLING WHICH AREA WHEN ENGINE IS RUNNING.
INJURY OR DEATH. ADVICE.
KEEP AREA AROUND EXHAUST SYSTEM AND MANIFOLDS
MAY RESULT IN PERSONAL INJURY PERSONAL INJURY OR DEATH MAY
CLEAR OF COMBUSTIBLE MATERIAL. SHUT DOWN ENGINE
BEFORE CLEANING. DO NOT OR DEATH. RESULT.
MACHINE OPERATOR HAS LIMITED VISIBILITY. DO NOT
REMAIN IN THIS AREA WHEN ENGINE IS RUNNING.
PERSONAL INJURY OR DEATH MAY RESULT.
OPERATE! 202852
P/N 202855

204957
NO CLEARANCE FOR MAN IN THE ARTICULATION AREA.
PERSONAL INJURY OR DEATH MAY RESULT.
2 4 8 5
CHECK ALL WHEEL NUTS AFTER THE FIRST 5 SMR AND 3
THEN AFTER EVERY 50 SMR OF OPERATION.

1
WARNING
INSTALL ARTICULATION LOCK BEFORE LIFTING,
TRANSPORTING THE MACHINE OR PERFORMING ANY
ARTICULATED HAULER
MAINTENANCE IN THIS AREA.
7 MACHINE BUILD No. SERIAL NUMBERS:
203152
9
TYRE PRESSURE B25B 6x6 IN CASE OF EMERGENCY PUSH OUT
MACHINE MODEL
ENGINE MODEL
TRANSMISSION MODEL
MAKE MODEL SIZE
FRONT MIDDLE REAR
kPa PSI kPa PSI kPa PSI
THIS WINDOW FRONT DIFF MODEL
MID DIFF MODEL
6 BRIDGESTONE VKT 20.5R25★★E2 475 69 475 69 475 69 202857 REAR DIFF MODEL
GOODYEAR RL-2+ 20.5R25★★177B 470 68 470 68 470 68
BRIDGESTONE VKT 23.5R25★★E2 375 54 375 54 375 54 AXLE FRONT MID REAR TOTAL
TARE kg
GOODYEAR RL-2+ 23.5R25★★185B 350 51 350 51 350 51
GROSS kg
BRIDGESTONE VKT 23.5R25★E2 375 54 375 54 375 54 PAYLOAD kg
LUBRICATION SCHEDULE - FACTORY FIRST FILL
1. ENGINE CRANKCASE
204837 ADE / CUMMINS - CALTEX DELO SHP SAE 15W/40
PAYLOAD: 23 000 kg (50 600 lbs)
DEUTZ - CALTEX DELO 500 SAE 40
2. HYDRAULIC SYSTEM - CALTEX RANDO Z56
3. TRANSMISSION - CALTEX DELO SHP SAE 15W/40
202721 4. DIFFERENTIAL - CALTEX E.P. PLUS GEAR LUBE 460
12 5. BELL PLANIHUB - CALTEX E.P. PLUS GEAR LUBE 460
6. ALL GREASE POINTS - CALTEX MULTIFAK EP2
CONSULT THE OPERATOR AND MANUFACTURED BY:
MAINTENANCE MANUAL FOR BELL EQUIPMENT CO. (PTY) LTD
LUBRICATION SPECIFICATIONS ALTON, RICHARDS BAY
AND SAFETY PRECAUTIONS. P/N 200181 SOUTH AFRICA

BELL EQUIPMENT CO. S.A. (PTY) LTD.


RICHARDS BAY IMPORTANT
SOUTH AFRICA
Position

Engine
Description Daily 1st 100
Every
250
Every
500
1000/
Annually
Comments
WARNING
YEAR
28 01 Engine oil Level

02 Engine Oil Filter


Note 1, 2 & 3 Consult lube
chart

Note 1 & 2
THIS MAINTENANCE SCHEDULE IS SUPPLEMENTARY TO
AND DOES NOT REPLACE THE MAINTENANCE SCHEDULE
PROVIDED IN THE OPERATORS AND MAINTENANCE MANUAL
MODEL 03 Fuel Filter / Water Trap Note 2

04 Engine Coolant / Coolant Additive Note 1 & 2 Change annually

SERIAL NUMBER 29
05 Fan Drive Belts Note 1 & 2 Check tension

POWER KW 13 06 Air Filter Indicator Note 2


3
3

MASS EMPTY Kg
11 Transmission

07 Transmission Oil Level - Engine idle Note 1, 2 & 3 Consult lube


chart 5 2
POWER POINT 08

09
Oil Filter

Breather
Note 1 & 2
27 27
LOADED Kg 27 35

P/N202319
24V USE ONLY Hydraulics

10 Fluid Level Note 1, 2 & 3 4 1


11 Filters Note 1 & 2 26 34
12 Tip & Steering Cylinders Note 2 & 3
32 6
Driveline and Suspension

Note 1, 2 & 3
24 23
13 Axle & Final Drive Oil Level

14 Walking Beam Pivot Note 2 & 3


13 22
15 Front Cradle Pivot Note 1 & 2 21 33
16 Cradle Restraining Cable
16 19
10 17

18
Oscillation Joint

Oscillation Drive Shaft Bearings


Note 1, 2 & 3

Note 1 & 2
8 20
19 Transmission / Engine Drive Shaft Note 1 & 2
9 31
20 Drive Shafts 15 7
21 Axle breathers 12 15
204907 22 Wheelnuts Check after 1st 5hrs
12 12
23 Tyres & Tyre Pressure Note 1, 2 & 3
11 10
Brakes

24 Service Brake Pads Note 1 & 2


17 12
25 Park Brake Pads / Adjustor Note 1 & 2 18 20
Note 1, 2 & 3 SAE DOT 4
26 Service Brake Fluid
Change ever 4000 hrs 24 18
27 Air Brake reservoirs Note 2
13 12

16 17 General

28

29
Bin Pivot Pins

Lights
Note 2

Note 2
25
20
30 Back-up Alarm Note 2
21 22
31 Cab Ventilation Filter
12
15 X
Time Related Service
32 Vibration Damper 6 000 Hours
14
23
33 Air Filter Change As Required / Indicated 30 26
34 Crankcase Oil Separator 3 000 Hours 24 20
35 Injectors 1 250 Hours
13 22
204262 Note 1:
Note 2:
Refer to SPECIFICATIONS in the OPERATORS AND MAINTENANCE MANUAL
Refer to MAINTENANCE in the OPERATORS AND MAINTENANCE MANUAL 21 23
Note 3: Refer to MACHINE INSTRUCTION DECAL
28 29
29
Key: Drain Check level Check level Check level Check level Check

DI ENGINE Perform full prescribed service as per OMM Replace Lubricate Clean

F F LO CK STOP MAINTENANCE SCHEDULE 6x6 203210

202722
14 202828
P003386

November 13, 1996 B25B053 5-53


DECALS
ITEM PART NUMBER QTY DESCRIPTION REMARKS
1 203152 2 DECAL, Warning, Exterior Condition
2 203153 2 DECAL, Important, Exterior Condition
3 204957 1 DECAL, Warning, Code 10
4 202852 2 DECAL, Warning, Pump Body Prop
5 202855 5 DECAL, Warning, Visibility
6 202721 4 DECAL, Lift Point
7 204837 2 DECAL, Tyre Pressure
8 202857 1 DECAL, Warning, Push Out Window
9 200181 1 PLATE, Name
10 202319 1 PLATE, CE Mark
11 202822 1 PLATE, Warning, Condensed Cab
12 203377 1 PLATE, Bin Up
13 204907 1 PLATE, Power Point
14 204262 1 PLATE, Pull Bonnet Release
15 174515 1 PLATE, Diff Lock Label
16 202828 1 PLATE, Engine Stop
17 202722 2 DECAL, Escape Route
18 203250 3 DECAL, B25B See Decal Layout.
19 203244 1 DECAL, Bonnet, LH See Decal Layout.
20 203243 1 DECAL, Bonnet, RH See Decal Layout.
21 203255 1 DECAL, Bin Stripes, LH See Decal Layout.
22 203254 1 DECAL, Bin Stripes, RH See Decal Layout.
23 203248 2 DECAL, Bell See Decal Layout.
24 203240 2 DECAL, Bell See Decal Layout.
25 202818 1 DECAL, Propshaft See Decal Layout (Upto 31.10.96)
26 204914 1 DECAL, Warning, Emergency Steering
27 203208 1 DECAL, Oscilation Joint Greasing
28 203210 1 DECAL, Maintenance CE MARK

November 13, 1996 B25B053 5-54

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