2377-Enviro-400-Euro-5-Service-Manual-17-05-11 5

SERVICE MANUAL
EURO 5
COVERING:
ENVIRO 400 MODELS
XB16MBRE
XB18SBRF
X318SBRF
XD46MBRE
XB48SBRC
XD48SBRC
XD48SBRF
XD48TBRF
XD49TBRF
Publication Number: 2377 Date: Feb 2009 (10/12)

This manual covers those Enviro 400 models listed on the front cover. It should be regarded as part of the
product and retained with the vehicle. At the time of resale it should be passed on to any subsequent owner.
As the manual lists the specifications for several models, some of the items covered may not apply to your
vehicle. If any doubt exists please do not hesitate to contact Alexander Dennis who will be pleased to offer
technical assistance.
We would like to point out that non-Alexander Dennis parts have not been approved by Alexander Dennis and
we cannot certify the suitability nor the safety of such parts Alexander Dennis is not liable for any damage
caused by the use of non-Alexander Dennis parts.
Any amendments received should be incorporated into the text.
The amendment date appears at the top of the page.
This symbol, next to an item line, indicates that the item has been amended for the current issue of
the page.
Alexander Dennis Ltd

Dennis Way, Guildford,
Surrey GU1 1AF
Tel: + 44 (0) 1483 571271
Fax: + 44 (0) 1483 301696
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted,
in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without prior
written permission of Alexander Dennis.
SERVICE MANUAL
Main Index Amended:15.05.13
PARTS, SERVICE & TECHNICAL CENTRES

TECHNICAL HELP & TRAINING COURSES
SECTION 1:GENERAL
SECTION 5:ELECTRICAL SYSTEM
Health and Safety . . . . . . . . . Page 1.2 - 5
General . . . . . . . . . . . . . . . . Page 5.3
Vehicle Identification . . . . . . . Page 1.6
Batteries . . . . . . . . . . . . . . . Page 5.3 - 6
Servicing Schedule . . . . . . . . Page 1.7 - 15
Starter motor . . . . . . . . . . . . . Page 5.6
Corrosion Protection . . . . . . . Page 1.16 - 17
Multiplex System . . . . . . . . . . Page 5.7 - 50
Lubricants and Fluids . . . . . . Page 1.18
Care points . . . . . . . . . . . . . . Page 5.52 - 54
Maintenance . . . . . . . . . . . . . Page 1.19 - 25 Instrument Panel . . . . . . . . . . Page 5.54 - 56
Towing . . . . . . . . . . . . . . . . . Page 1.26
Front & Rear EDC . . . . . . . . Page 5.59 - 61
Chassis support . . . . . . . . . . Page 1.27
Alternator . . . . . . . . . . . . . . . Page 5.62 - 81
Special Tools . . . . . . . . . . . . . Page 1.28
WIRING DIAGRAMS . . . . . . . Page 5.83 - 160
Standard Torque Figures . . . . Page 1.29
Non Standard Torque Figures Page 1.30 SECTION 6:SUSPENSION, WHEELS
Air Suspension system . . . . . Page 6.2 - 11
SECTION 2:ENGINE
Front suspension . . . . . . . . . Page 6.12 - 15
Air Cleaner . . . . . . . . . . . . . . Page 2.2 - 5
Rear suspension . . . . . . . . . Page 6.16 - 17
Cooling System . . . . . . . . . . . Page 2.6 - 11
Shock absorbers . . . . . . . . . . Page 6.18
EGP Exhaust System . . . . . . Page 2.12 - 15
Wheels and Tyres . . . . . . . . . Page 6.19 - 20
Fuel System . . . . . . . . . . . . . Page 2.16 - 19
Chassis Jacking Points . . . . . Page 6.21
Hydraulic System . . . . . . . . . Page 2.20 - 28
Engine and Mounting . . . . . . Page 2.30 - 52 SECTION 7:STEERING, FRONT AXLE
Automatic Oil Level (Option) . Page 2.53 - 55 Steering . . . . . . . . . . . . . . . . Page 7.2 - 12
Air Conditioning . . . . . . . . . . . Page 2.56 Front Axle - Dana . . . . . . . . . Page 7.13 - 52
Front Axle - ZF . . . . . . . . . . . Page 7.53 - 77
SECTION 3:TRANSMISSION
ZF Gearbox . . . . . . . . . . . . . . Page 3.2 - 7 ALPHABETICAL INDEX
Voith Gearbox . . . . . . . . . . . . Page 3.8 - 11
Propshaft . . . . . . . . . . . . . . . Page 3.12 - 15
Rear Axle . . . . . . . . . . . . . . . Page 3.16 - 72
SECTION 4:BRAKING
Braking System . . . . . . . . . . Page 4.2 - 15
ABS System . . . . . . . . . . . . Page 4.16 - 31
Brake Calipers . . . . . . . . . . . Page 4.32 - 101
Pipe Connectors . . . . . . . . . . Page 4.102 - 104
Enviro 400 Euro 5 Service Manual - Publication Number 2377 - Feb 2009
SERVICE MANUAL
AFTER MARKET SUPPORT LINE Amended:22.05.13
AFTER MARKET SUPPORT LINE
0845 358 9988

FOR ALL ENQUIRIES
including : Part Number Identification

Parts Ordering
Service Support
Warranty Support
Technical Support / Repair & Maintenance Information (RMI)
RMI EC Regulation 595/2009 (as last amended)
On-Line Parts Ordering at www.adl247parts.com

t
FAX numbers : Parts Ordering . . . . . . . . . . . .0845 358 9992

Technical Support . . . . . . . . .01483 451458
Warranty/Service . . . . . . . . . .01483 301696
SERVICE DIRECTOR
BRIAN EVANS E-MAIL : brian.evans@alexander-dennis.com

MOBILE : 07881 825840
TECHNICAL SUPPORT MANAGER
REGIONAL SERVICE MANAGER STEVE HARDY

E-MAIL : steve.hardy@alexander-dennis.com
MOBILE : 07788 717570
Page 4 Enviro 400 Euro 5 Service Manual - Publication Number 2377 - Feb 2009
SERVICE MANUAL
REGIONAL PARTS MANAGERS Amended:
PARTS DIRECTOR
CUSTOMER MANAGEMENT ROB WILLIAMS

E-MAIL : rob.williams@alexander-dennis.com
MOBILE : 07764 922274
LONDON & SOUTH EAST
REGIONAL PARTS MANAGER MARK BOWLEY

E-MAIL : mark.bowley@alexander-dennis.com
MOBILE : 07770 645212
SOUTH WEST & EU
REGIONAL PARTS MANAGER TBC

E-MAIL :
MOBILE :
MIDLANDS
REGIONAL PARTS MANAGER GARY GLOVER

E-MAIL : gary.glover@alexander-dennis.com
MOBILE : 07881 958463
NORTH
REGIONAL PARTS MANAGER LES RIVETT

E-MAIL : les.rivett@alexander-dennis.com
MOBILE : 07843 357228
SCOTLAND & NI
REGIONAL PARTS MANAGER JIM WEBB

E-MAIL : jim.webb@alexander-dennis.com
MOBILE : 07979 703605
Enviro 400 Service Manual - Publication Number 2297 - March 2006 Page 5
SERVICE MANUAL
REGIONAL SERVICE MANAGERS Amended:300610
LONDON, KENT AND EAST & WEST SUSSEX
REGIONAL SERVICE MANAGER STEVE EDMONDS

E-MAIL : steve.edmonds@alexander-dennis.com
MOBILE : 07831 704251
LONDON, SURREY, HAMPSHIRE AND BERKSHIRE
REGIONAL SERVICE MANAGER JOHN CHAVES

E-MAIL : john.chaves@alexander-dennis.com
MOBILE : 07774 108840
CENTRAL
REGIONAL SERVICE MANAGER GLEN WILKIE

E-MAIL : glen.wilkie@alexander-dennis.com
MOBILE : 07736 615459
SCOTLAND
REGIONAL SERVICE MANAGER DAVID ALLEN

E-MAIL : david.allen@alexander-dennis.com
MOBILE : 07770 733779
NORTH EAST & NORTHERN IRELAND & EIRE
REGIONAL SERVICE MANAGER JOHN BRADLEY

E-MAIL : john.bradley@alexander-dennis.com
MOBILE : 07768 921192
NORTH WEST & NORTHERN IRELAND & EIRE
REGIONAL SERVICE MANAGER BEN WAITE

E-MAIL : ben.waite@alexander-dennis.com
MOBILE : 07901 510724
Page 6 Enviro 400 Euro 5 Service Manual - Publication Number 2377 - Feb 2009
SERVICE MANUAL
SERVICE CENTRES & TRAINING Amended:040711
HARLOW
HARLOW SERVICE CENTRE: Unit B, Barrows Road, Pinnacles Industrial

Estate.Harlow. Essex. CM15 5AT
TELEPHONE: 01279 770600 FAX : 01279 419744
COMMERCIAL MANAGER ALAN REYNOLDS
E-MAIL : alan reynolds@alexander-dennis.com
MOBILE : 07799 762070
TRAINING
TRAINING MANAGER PAUL HOPWOOD

E-MAIL : paul.hopwood@alexander-dennis.com
MOBILE : 07831 263246
Enviro 400 Euro 5 Service Manual - Publication Number 2377 - Feb 2009 Page 7
SERVICE MANUAL
General Amended:090311
Contents
Health and Safety Corrosion Protection . . . . . Page 1.16 - 17

Warning and Caution SymbolsPage 1.2
Moving the Vehicle . . . . . . Page 1.2 Maintenance . . . . . . . . . . . . Page 1.18 - 30
Working on the Vehicle . . . Page 1.2 Lubrication Chart . . . . . . . Page 1.18
Hazardous Materials . . . . . Page 1.3 - 4 Checking Engine Oil Level Page 1.19
Enviromental Warnings . . . Page 1.5 Checking Gearbox Oil Level Page 1.20
Remote Fuel Filter . . . . . . Page 1.21
Vehicle Identification Drive Axle . . . . . . . . . . . . . Page 1.21
Vin Plate . . . . . . . . . . . . . Page 1.6 Drive Belt . . . . . . . . . . . . . Page 1.22
Hydraulic System Filter . . . Page 1.23
Servicing Schedule . . . . . . . Page 1.7 - 15 Steering & Fan Drive Reservoirs
Service Intervals . . . . . . . . Page 1.7 level checking . . . . . . . . . . Page 1.23
Servicing Sequence . . . . . Page 1.7 Line Filter - Air Suspension Page 1.24
Air Cleaner . . . . . . . . . . . . Page 1.8 Air Reservoir Draining . . . Page 1.24
Air Conditioning . . . . . . . . Page 1.8 Checking Coolant Level . . Page 1.25
Cooling System . . . . . . . . Page 1.8 Air Cleaner Restriction IndicatorPage 1.25
EGP Exhaust . . . . . . . . . . Page 1.8
Hydraulics . . . . . . . . . . . . Page 1.9
Gearbox - ZF . . . . . . . . . . Page 1.9 Towing . . . . . . . . . . . . . . . . . Page 1.26
Drive Shaft . . . . . . . . . . . . Page 1.9
Rear Axle . . . . . . . . . . . . . Page 1.9
Braking System . . . . . . . . Page 1.10 Chassis Support . . . . . . . . . Page 1.27
Electrical . . . . . . . . . . . . . Page 1.10
Air Suspension . . . . . . . . . Page 1.10
Wheels and Tyres . . . . . . . Page 1.11 Special Tools . . . . . . . . . . . . Page 1.28
Steering Gear . . . . . . . . . . Page 1.11
Front Axle . . . . . . . . . . . . . Page 1.11 Standard Torque Figures . . Page 1.29
Engine and Ancillaries . . . Page 1.12 Non Standard Torque Figures Page 1.30
Body Servicing Schedule . . Page 1.13 - 15

Structure . . . . . . . . . . . . . Page 1.14
Exterior . . . . . . . . . . . . . . Page 1.14
Interior . . . . . . . . . . . . . . . Page 1.14
Doors . . . . . . . . . . . . . . . . Page 1.14
Heating System . . . . . . . . Page 1.15
Ramp . . . . . . . . . . . . . . . . Page 1.15
General . . . . . . . . . . . . . . Page 1.15
Section 1
SERVICE MANUAL
Health and Safety - PLEASE READ Amended:090311
Warning and Caution Symbols

Please take note of the following symbols, used throughout this manual which identify any health hazards or
instructions to prevent any personal injuries or damage to the vehicle.
WARNING
Text with this heading and a shaded background is a reminder of an operation which, if not
carried out with due care, could result in death or serious injury.
CAUTION
Text with this heading and a shaded background is a reminder of a potentially hazardous
situation which, if not avoided, may result in minor or moderate personal injury.
CAUTION
Text with this heading and a shaded background is a reminder of an operation which, if not
carried out with due care, could involve the risk of damage to material.
NOTE
Text with this heading and a shaded background refers to special methods, features or
procedures.
Moving the Vehicle

During movement of the vehicle the hazards involved are those normally associated with all forms of powered
transport.
Before driving the vehicle, operators should familiarise themselves with the vehicle Operation Guide to
ensure understanding of the vehicle controls.
Working on the Vehicle
Before commencing work on the vehicle, take note of all instructions relating to safety and hazardous items.
The following potential hazards should be considered:

Stored Energy
Certain components and systems on the vehicle contain stored energy which must not be released in a non
approved manner.
• Tyre air pressure.
• Braking system air pressure.
• Park brake spring compression.
• Cooling system pressure.
Cooling System Pressure and Temperature
The system will remain hot and under pressure after use. Allow to cool before attempting to remove the filler cap.
Chassis Lifting
Adequate support required during jacking or lifting. Eye and head protection should be worn when working under the
vehicle.
Diesel Injection Pumps
Supply fuel to the engine at very high pressure, care must be taken when working on the injectors or injection pipes as
fuel under high pressure can penetrate the skin.
Braking System
Brake drums or discs will remain at an extremely high temperature for a considerable time after use, caution must be
exercised when handling such items to avoid burns.
Use Common Sense - If in Doubt Ask
Page 1.2 Enviro 400 Euro 5 Service Manual - Publication Number 2377 - Feb 2009
SERVICE MANUAL
Hazardous Materials
Certain components on the vehicle contain, or can produce, material which must be handled cautiously.
These materials are as follows:
Those which must not be taken internally or contact the eyes, skin, or mouth:
Battery acid
Diluted sulphuric acid can cause skin burns, eye damage and internal damage if ingested. Vapour from the
solution can also irritate the respiratory system and the eyes.
Cooling system antifreeze
Based on ethylene glycol, and has significant toxicity if ingested, but can also be absorbed through the skin.
Causes mild eye and skin irritation. Hot fluid can also scald.
Exhaust Emissions
Substances produced are carbon monoxide, hydrocarbons and oxides of nitrogen. Can be highly toxic if
inhaled in sufficient quantity. Emissions in enclosed spaces should be minimised unless adequate extraction
facilities are available.
Friction Material Dust
May consist of a high percentage of white asbestos bonded in a resin. Handling and fitting lined brake shoes
or clutch plates is not regarded as a health risk. The dust produced by worn linings is degraded by the brake
or clutch is not believed to be hazardous. However it is prudent to avoid generating airborne dust
concentration, therefore dust removal should be by the use of approved vacuum cleaner or by the use of a
damp cloth (for occasional exposure).
Fuel
Diesel fuel is a mixture of hydrocarbons largely consisting of paraffinic hydrocarbons, with blended
constituents such as refined vacuum distillants and catalytically cracked oil. Contact with the skin can cause
irritation and dermatitis. Inhalation and ingestion are serious risks and can cause chemical pneumonitis.
Hydraulic Fluids
These are generally made from polyalkylene glycol ethers and can cause mild irritation of the skin and eyes.
The toxicity through ingestion is generally regarded to be low order.
Insulation Materials
Man made fibres which include glass, rock, slag and metal oxides. These may cause skin irritation.
Inhalation of dust from the fibres should be kept below 1 fibre/ml.
Mineral oil (Engine and Transmission)
This type of oil contains small quantities of polycyclic aromatic hydrcarbons, which can cause irritation,
dermatitis and oil acne if allowed persistent contact with the skin. Toxicity through ingestion is of a low order,
however this should be avoided.
Exhaust Emissions
Substances produced are carbon monoxide, hydrocarbons and oxides of nitrogen. Can be highly toxic if
inhaled in sufficient quantity. Emissions in enclosed spaces should be minimised unless adequate extraction
facilities are available.
Enviro 400 Euro 5 Service Manual - Publication Number 2377 - Feb 2009 Page 1.3
SERVICE MANUAL
Hazardous Materials (continued)

Personal Points
Remember to:
Remove rings, watches before working on the vehicle, particularly necessary when working on the electrical
system.
Wear eye and head protection when working underneath the vehicle.
Use barrier cream or wear gloves as necessary to protect hands.
Keep loose clothing and long hair away from moving parts.
These instructions are for your own and others safety and are by no means comprehensive.
Each job and situation should be assessed for its Health, Safety and Environmental Risks as these will
change and vary depending on the task undertaken.
VITON ‘O’ RINGS AND SEALS (fluoro-elastomers)

‘Viton’ material, used in the manufacture of oil seals and ‘O’ rings, produces a highly corrosive acid
(hydroflouric) when subjected to temperatures above 600°F. The resulting contamination can have extreme
consequences on human tissue since it is almost impossible to remove after contact.
The following procedure is recommended when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.
1. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and
sticky.
2. If this is affirmed:- Do not touch.
3. Make enquiries to ascertain material composition.
Any fluoro-elastomer (Viton, Flourel or Tecmoflon) should be considered dangerous but natural rubber
and nitrile are non-hazardous.
4. If fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.
5. Disposable heavy duty gloves (neoprene) MUST be worn and the affected area decontaminated by
washing thoroughly with limewater (calcium hydroxide solution).
6. Any cloths, residue and gloves used MUST be safely discarded after use.
RE-USE OF FASTENERS
Before re-using fasteners they should be inspected for any signs of wear, fatigue of damage, If any is seen
the fastener should be replaced.
If the joint is critical in nature and holds a substantial load or would result in personal harm or equipment
damage upon failure, i.e engine, transmission or suspension fixings, it is recommended the fastener is not re-
used.
Fasteners should be replaced if any corrosion is evident.
Nyloc or Philidas nuts, Spring or shakeproof washers should not be re-used.
IF IN DOUBT THE FASTENER SHOULD BE REPLACED
SERVICE MANUAL
Environmental Warnings - PLEASE READ Amended:090311
Environmental Warnings
WARNING
Burning of discarded items is NOT RECOMMENDED, except in an approved incineration
process where gaseous products are treated by alkaline scrubbing.
Those which may cause noxious fumes if allowed to burn:
Coatings (chassis protection)

Generally inert in the cured state, but should be removed from areas to be welded.
Fuel (diesel)
Not classified as flammable for most purposes.
Hydraulic Fluids
These do not present a fire or explosive hazard under normal circumstances.
Mineral oil (engine and transmission)

These do not present a fire or explosive hazard under normal circumstances.
Rubber and synthetic alternatives (tyres, hoses, bushes, seals, insulation)

Natural and synthetic rubbers are combustible and will produce unpleasant and dangerous fumes.
• Under no circumstances should fingers or any other part of your body be inserted into areas with
moving parts. SERIOUS INJURY MAY RESULT.
• Remove rings, watches before working on the vehicle, particularly necessary when working on the
electrical system.
• Wear eye protection when working underneath the vehicle.
• Use barrier cream or wear gloves as necessary to protect hands.
• Keep loose clothing and long hair away from moving parts.
• Never attempt to lift heavy components unaided.
• Wear hand and eye protection when working with glass.
• Switch off power at master switch before carrying out any electrical maintenance.
WARNING
Used engine oil, hydraulic fluids, transmission fluid, antifreeze, (and their containers) batteries
and tyres can be a hazard to health and the environment.
Fluids and other substances (e.g. used oil) and surplus parts must be disposed of in a safe and
environmentally sound manner.
On no account must any of these items be placed in household refuse bins, or the fluids poured
down drains.
Observe local regulations and laws on environmental protection and disposal of hazardous
materials.
These should be disposed of using authorised waste disposal facilities.
Consult local authority for safe disposal facilities.
SERVICE MANUAL
Vehicle Identification Numbers - Chassis or Body Amended:090311
Sample VIN and Body Plates
LATER ECWVTA ADL CHASSIS ADL BODY
ALEXANDER DENNIS V.I.N

WPO 54123 WPO 54123 TA A
INCOMPLETE VEHICLE
TRIDENT 2 V.I.N SFD18SBRC8GXB1234 B BODY ID NUMBER VEHICLE LENGTH
TYPE TYPE 8414/1
INCOMPLETE ENGINE C 17800 Kg 18000 Kg VEHICLE HEIGHT
CUMMINS ISBE6.7E5250B ADDRESS
MODEL TYPE 91 GLASGOW ROAD
CAB
Kg Kg Body I.D No GLASGOW
FK1 4JB
ENGINE VEHICLE WIDTH
MODEL TYPE
D 6300 Kg 7500 Kg
E 11500 Kg 11500 Kg
Kg Kg
PLATED DESIGN
WEIGHTS WEIGHTS
KEY TO CHASSIS VIN PLATE
SFD World Manufacturers Identity A Type Approval Number

1 Wheelbase B Vehicle Identification Number
8 Engine C Gross Weight
S Transmission D Axle 1 Weight
B Air Conditioning E Axle 2 Weight
R Hand of Drive
C Series / marK
8 Build / Year
G Build Plant
X Model
B Frame Type
1234 Serial Number
The VIN and body plates are sited

inside the front entrance door on the
front bulkhead at floor level.
IMPORTANT
Always quote the Vehicle Identification Number (VIN) and Body number with any
enquiries concerning your vehicle
SERVICE MANUAL
Service Schedule Amended:17.02.10
Service Intervals Recommended Servicing sequence

A-B-A-C
Daily
Daily Daily checks. Advisory Drivers' checks.
Bus Body
Equipment fitted to the body is additional to the chassis
service schedule, and reference should also be made to
First Service
the Body Service Manual.
No later than 1000 miles (1600 km) from new.
CAUTION
Lubricants & Fluids
The first service for a new vehicle must be
carried out no later than 1,000 miles, 1600 km, or
CAUTION
after fitment of a new or reconditioned unit.
Always clean surfaces and components of
As this is the most important service for the any spillage or excess lubricants after
vehicle, it is essential that the service and carrying out maintenance or repair tasks .
inspection instructions in the following
Schedules are followed to the letter.
'A' Service
6,000 miles (10,000 km)/3 months, whichever occurs
first.
NOTE
On stop-start short distance operation the hours
run are more important than the distance.
'B' Service
first.
NOTE
'C' Service
first.
NOTE
SERVICE MANUAL
Air Cleaner NOTE DAILY FIRST A B C

Check security of mountings and pipework. Ensure a good
leak free condition. Renew any damaged parts
Check the restriction indicator

Renew the air cleaner element annually (or if restriction indicator shows red)
Air Conditioning - (option) DAILY FIRST A B C

Check belt tension & condition and pulley faces free from dirt/grease Weekly
If condenser mounted low, check surface for dust & debris build up Monthly
Check condenser for dust & debris build up; check mountings are secure
Check oil level in cooling system compressor (where fitted)
System service by manufacturer
Cooling System DAILY FIRST A B C

Check condition and security of cooling fan
Check cooling system level
Check security of radiator mountings
Check hoses for leaks and signs of deterioration
Check radiator and intercooler matrix for debris.
Clean as necessary Every 7,500 miles (12,000 km) 250hrs or 3 months
) Remove and clean cooling pack flyscreen / (filter where fitted)
Check operation of low coolant alarm
Check strength of antifreeze /engine coolant Every 15,000 miles (24,000 km) 500hrs or 6 months
Check pressure cap spring and seal Yearly
Remove intercooler from vehicle and clean Yearly
and remove debris. Clean radiator
Drain and flush out cooling system and
Refill with the correct engine coolant (Autumn) Every 60,000 miles (96,000 km) 2000hrs or 2 yearly
Check cooling pack alignment and clearances
EGP Exhaust System DAILY FIRST A B C

Check the level of AdBlue in the Urea tank.
Check lagging to ensure no oil contamination
Check Security of all pipe clamps.
Check the anti-vibration rubber mounts for sign of damage or separation.
Check all pipe joints to ensure no exhaust leaks.
Check for security and condition of exhaust system insulation material..
Change doser unit inline air filter Every 38,000 miles (61,000 km) 1500hrs or 1 yearly
Check the doser unit air vent and air regulator
are free from debris and are not restricted in any way.
SERVICE MANUAL
Hydraulics DAILY FIRST A B C

Check hydraulic fluid level
Check security of all components as shown on the hydraulic system diagram
Check all pipework to ensure no chaffing or hose connections leaks
Change hydraulic oil 2-Yearly or 100,000 miles (160,000 km)
Change return line filter 2-Yearly or 100,000 miles (160,000 km)
Change steering reservoir filter 187,500 miles (300,000 km) or (if system is broken into)
Gearbox - Voith DAILY FIRST A B C

Change oil & filter Every 37,500 miles (60,000 km) or 2 years
Change oil & filter - Synthetic Oil Only Every 75,000 miles (120,000 km) or 3 years
Check oil level Monthly
Check for oil leaks and rectify Weekly
Check tightness of all fixings
Check that the gearbox breather is not blocked
Check idling speed of engine
Gearbox - ZF DAILY FIRST A B C

Change the oil and oil filter Every 112,500 miles (180,000 km) or 3 years
Check oil level
Check for oil leaks and rectify
Check idling speed of engine
Check gearbox breather is not blocked
Propshaft DAILY FIRST A B C

Check for wear on the universal and sliding joints
Grease universal and sliding joints Refer to propshaft section page 3.11
Rear Axle DAILY FIRST A B C

Check oil level Monthly, 5,000 miles (8,000 Km)
Check axle breather for cleanliness - axle mounted only Monthly, 5,000 miles (8,000 Km)
Check hub bearing adjustment & satisfactory lubrication 30,000 miles (48,000 Km)
Check hub and pinion seals for leakage
Check security of half shaft and studs for security
Check security of axle
) Drain oil when warm & refill with 93,000 miles, (150,000 km) or 3 years
fresh oil
Repack hubs (Grease filled) 312,500 miles (500,000 Km) or 4 years
SERVICE MANUAL
Braking System (see section Test & Check List) NOTE DAILY FIRST A B C
Check all systems function correctly and correct operating pressures
are being attained and the low pressure buzzer is operating
Check all air line connections and mountings for leakage and security
and all rubber components for signs of cracking or hardening
Check satisfactory operation of parking brake
Check brake lining condition, adjust brakes if necessary
Check function and cleanliness of air dryer
Replace air dryer cartridge Six Monthly
Drain air reservoirs 15,000 Miles (24,000km) or 6 months
Renew all brake actuator diaphragms 2-Yearly
It is advisable to remove all valves from the vehicle, dismantle and
2-Yearly
renew any worn or damaged parts
Disc brake (See Section 4)
Electrical NOTE DAILY FIRST A B C

Check all connections throughout the system for cleanliness,
security and insulation
Check operation of all lights, switches, warning lights,
direction indicators, stop lights, horns
Check that instruments are working correctly
Top up battery with pure distilled water, clean and
protect terminals with petroleum jelly 15,00 miles (24000 Km) or 6 months
Check headlight beams are correctly set
SERVICE MANUAL
Service Schedule Amended:
Air Suspension DAILY FIRST A B C

Check spring mountings, tighten if necessary
Check the front and rear shock absorber mountings
Check shock absorbers for leaks
Check the ride height and set the levelling valves as necessary
Remove dirt and grease deposits from air spring units
and condition of diaphragms
Check air system for leaks (suspension)
Inspect and clean/change air suspension line filter
Test levelling valve operation
Wheels and Tyres DAILY FIRST A B C

Check all wheel nuts and tighten if necessary
Check tyres are free from damage, cuts and foreign matter
Check tyre pressures are correct including spare if fitted
Check tread depth is within legal limit
Check valves are positioned at 180° to each other on twin wheel
Clean wheels frequently to maintain condition
Steering Gear (see also Hydraulics) DAILY FIRST A B C

Check for security - drop arm securing nut, steering box, mounting bolts
track rod clamp bolts and steering lock stops
Check the steering box and bevel box for leakage
Check front axle and wheel alignment adjust if necessary
Check all ball joints and linkages for play
Check bevel box oil level
Lubricate steering relay shaft
Front Axle NOTE DAILY FIRST A B C

Check security of axle
Check for wear/slackness in swivel pins Every 30,000 miles (48,000 Km)
Lubricate top & bottom swivels: Every 30,000 miles, (48,000 km) or 6 months
Check steering ball joints for wear / corrosion
Check hub bearing end play Yearly
SERVICE MANUAL
Service Schedule Amended: 24/05/17
ISB6.7 Engine and Ancillaries NOTE DAILY FIRST A B C

Carry out all service requirements indicated in the engine manufacturer's literature For all engine information
consult the relevant routine maintenance section in the engine manufacturer's service manual.
Check oil level     
Check the security and integrity of silencer and pipes    
Check for leaks in oil, water and fuel systems    
Check charge air piping for leaks, cracks, and loose connection    
Inspect the crankcase breather tube    
Check the security of engine and gearbox in chassis  
Change oil and filter Refer to Engine and Mountings Section
Inspect water in fuel sensor Refer to Engine and Mountings Section
Check alternator drive belt condition & Tensioner Every 30,000 miles (48,000 km) 1000hrs or 1 yearly
Check air compressor carbon build-up Every 30,000 miles (48,000 km) 1000hrs or 1 yearly
Change fuel filters (engine and remote) Every 38,000 miles (60,000 km) 1500hrs or 1 yearly
Change Urea in-line air filter Every 38,000 miles (60,000 km) 1500hrs or 1 yearly
Inspect vibration damper condition Every 60,000 miles (96,000 km) or 2000 hrs or 2 years
1
Adjust valve clearances First adjustment at 150,000 miles (241,401 km) or 5000 hrs 4 years
NOTES:
 1. Initial valve lash adjustment to nominal specification to be performed at this interval and subsequent valve
lash checks to be performed at every 50,000 miles (81,000 km), 2000 hours thereafter.
Chassis NOTE DAILY FIRST A B C

Check for corrosion. Remove and re-apply protection material if necessary.   
SERVICE MANUAL
Body Items First 1,000 miles
A one-time preventative maintenance inspection should be performed after the first 1600 km of service. These
are areas that should receive attention on any new vehicle.
Check operation of all lights, switches, warning lights, direction indicators, stop lights, horns.
Check driver’s seat for security and adjustment.
Check the windshield wipers and washers for correct operation.
Check the security of all fasteners; pivot pins, cylinder mountings and similar components.
Operate the door and observe the movement to see that there is no fouling or chaffing of electrical wiring or
pneumatic pipes.
Check that all hinge fastening bolts are tight and that the door movement is smooth and without tight spots
throughout its range of travel.
Check the setting of the door movement to ensure that the doors are flat and in line when in closed position
and achieve a full 90º opening.
Lightly lubricate hinges and roller bracket, but ensure that roller track is free of grease and that the roller is
running on a dry surface.
Check the supply of pressure to the shelfplate and adjust if necessary to the recommended value at the
pressure regulator.
Operate the doors to ensure that the required opening and closing speeds are achieved and that the
cushioning is satisfactory at both ends of the stroke.
Inspect the underside of the Vehicle or Bodywork and view all the understructure which could hold dirt/road
salts. Also check damaged surfaces for signs of bare metal.
Check the underside of the Bodywork for signs of loose mechanical fixing, cracks or weld failure of joints. On
the exterior and interior, check for bulges or cracks on all joints and body structure intersections. Seats should
also be checked for cracks in pedestals and for security of mountings.
Check the security of pipes, cables, mudflaps, flooring, stepwells, handpoles, plus parts screwed, bolted,
riveted or glued to the Bodywork.
Check all pipe joints for signs of weeping anti-freeze. Ensure heating system gate valves are capable of being
turned on and off and are not leaking.
Inspect wiring for signs of chafing, discoloration of joints or damage to protective covers.
Check the glazing perimeter for signs of deterioration and possible water leaks or failure of joint adhesion.
Inspect the exterior surface for signs of deterioration in the form of blisters, scratching or minor damage, which
if not rectified will result in major problems.
For further information on Body Service details please refer to Body Maintenance Guide,
Publication Number 2409
SERVICE MANUAL
Structure FIRST A B C
Visual check underbody for movement and damage. Repair as necessary
Check all noise and heat insulation material for damage. Replace as necessary
Check insulation supports and fixings
Check for corrosion. Remove and re-apply protection material if necessary.
Ensure compatibility with OE materials.
If panels are removed for repair or body overhaul check all interface joints
and their fixings When applicable
Exterior FIRST A B C
Check roof panels for movement, security, cracks and ingress of dust and
water. Rectify where necessary.
Check side panels for movement, security, cracks and ingress of dust and
water. Rectify where necessary.
Check wheel boxes for water ingress.Reseal if necessary.
Check windows for movement, operation and security
Check windows for ingress of dust and water. Reseal if necessary.
Interior FIRST A B C
Check seats for security and condition
Check partitions are secure and not damaged
Check parcel racks are secure
Check hand rails are secure
Check operation of roof vents/escape hatches
Check roof vent for ingress of dust and water.
Rectify if necessary.
Check floorboards for condition i.e. "prod" check
Check ceiling panels for movement and ingress of water
and dust
Check operation of interior lighting
SERVICE MANUAL
Doors FIRST A B C
Service as instructed in supporting OE supplier literature. .
Heating System FIRST A B C

Ensure heater inlets, outlets, demister and air intakes are not blocked.
Check operation of on/off vents/flaps etc
Check all hose clips and fittings in the heater pipe circuit
Ramp
Service as instructed in supporting OE supplier literature.
General
Check operation of wipers and washer system
Check mirrors for condition and security
Check all exterior lights function correctly
Check operation of passenger information system.
Check all electric controls operate correctly
Wash paintwork regularly either with lukewarm water and soft sponge or
automatic bus wash machine
Check driver's seat for security and adjustment
Check the windscreen washer fluid level
Check security of fuel tank and operation of gauge
Check fuel pipes for leaks and security
Lubricate all linkages with oil or grease as required
Check the windscreen glass for damage
Check operation of doors and emergency exits
Check routing and security of electrical looms
Lubricate wiper moving parts and joints
Check operation of all fuses, bulbs and circuit breakers - replace
as necessary. If persistent failures occur, cause must be investigated
and rectified
When removing access panels these panels have to be replaced correctly to ensure that a secure and water
a tight seal is achieved, if that seal is broken remove seal Clean and replace seal with a new one.
Check seal around emergency door for gaps that may cause water ingress.
For further information on Body Service details please refer to Body Maintenance Guide,
Publication Number 2409
SERVICE MANUAL
Corrosion Protection Amended:
Pre-Primer Preparation
1) Remove all scale and rust by wire brushing or grinding.
Particular attention should be paid to material edges, as they are particularly prone to corrosion.
· All surfaces must be de-greased using thinners.
· Before application of primer, cleaned metal surface will be treated with a phosphoric acid or wash primer
containing zinc chromate to min dry film thickness 15 microns. (See appendix for recommended products).
2) Apply one coat of anti-corrosive primer to a minimum dry thickness (dft) film of 50 microns. Once the
primer has been applied it should be left to allow the primer coat to flash off to allow solvent evaporation.
The time will be dependent on ambient temperature and the air circulation.
NOTE
Random inspection of paint thickness must be carried out to ensure a minimum dft of 50 microns. Airless
spray is the preferred method of achieving high build-up such as dft of 50 micron.
3) Apply single coat of top-coat onto the primer using a different colour as a built in quality measure. This top-
coat will be applied to achieve a total dft of 100 microns.
NOTE
Random inspection of paint thickness must be carried out to ensure a minimum dft of 100 microns. Airless
spray is the preferred method of achieving high build-up such as dft of 50 micron..
4) On surfaces where methods such as grinding or wire brushing have left a rougher surface than shot
blasting to SA 2.5, a second coat of top-coat is recommended to ensure coverage over peaks caused by
cleaning method. If in doubt, consult Alexander Dennis Quality Department.
5) When welding new parts always make sure paint is buffed of to allow a satisfactory weld to be achieved.
Inspect entire component for rust, dirt grease, oil etc. remove any excess before
Carry out pre-primer presentations. As step 2.
It is essential that protection to a dft of 100 micron be achieved to match pre-welding protection. To achieve
this by brush application, a minimum of 3 coats of protection is to be applied as follows.
SERVICE MANUAL
Corrosion Protection Amended:
Apply first coat of primer to a minimum film of 35 micron (this should be achievable by careful brush
application). Once the primer has been applied it should be left to allow the primer to flash off to allow solvent
evaporation. The time will be dependent on ambient temperature and the air circulation.
Apply second and third coats to achieve minimum dft of 100 micron.
After assembly of steel framing to the chassis, drill 8mm holes into the box sections such that the internal box
sections can be coated with a wax product. To do this the wax will be injected using a flexible lance; the
resulting holes will be sealed with a polyurethane sealant.
All non-welded lap joints to be sealed using polyurethane sealant.
6) On completion, prior to use on the road, the complete underside of the vehicle must be thoughly cleaned
to remove any dirt, oil, grease etc.
Mask all necessary areas prior to final chassis treatments i.e. air system blow holes.
All areas with crevices and joints will be sprayed with penetrant sealer.
Complete chassis and underbody to be sprayed with a suitable wax type product.
Power Washing
The following procedure is recommended when power washing surfaces protected with dinol products.
Water temperatures must not exceed 60°C.
Water pressure not to exceed 120 psi.
The use of additives likely to result in softening of the protective coating is prohibited.
Damage to the protective coating to be repaired and make good.
Maintenance Procedure
Apply dinol 3125 penetrant to any surface(s) where loose product coating or surface corrosion has been
removed.
Coat the same area(s) with dinol 4942 underbody wax
Remove all excess wax from the vehicle exterior and entrance exit step prior to the vehicle being returned
to operational duties.
SERVICE MANUAL
Maintenance Amended: 131113
LUBRICATION CHART
7 8 9 6 3 7 2 4
6 5
Ref. Vehicle Capacity in General Recommended

No. Component litres (approx.) Specification Brands*
API CH-4/SJ, API CI-4/SK
1 Engine Cummins ISBe6.7 20.5 ACEA E-5, E-7 Fuchs Titan Truck Plus
CES-20072, 20076, 20077, 20078 15W/40
15W/40
2 Gearbox - ZF EcoLife 42 ZF-Ecofluid Life ZF-Ecofluid Life
Oil change 24 ZF Lubricant class 20F
2a Gearbox - Voith 28 Dexron III Fuch Titan ATF 4000
Oil Change 24.5
3 Drive axle 19.0 API - GL5 ZF Ecofluid X
Oil change 18.5 80W/90
4 Cooling System 55 approx** Cummins CES 14603 Cummins ES Compleat
Ethylene Glycol Prediluted mix -
DO NOT ADD WATER
5 Steering Reservoir 6 Dexron III Fuchs Titan ATF 4000
Fan Drive Reservoir 7 Dexron III Fuchs Titan ATF 4000
6 Rear Axle Hub Compact 0.13 - 0.15kg Lithium Complex Soap Fuchs Renolit LXP EP2
per hub Fuchs Renolit LXN EP2
7 Grease Points: A/R Multi purpose Texaco Multifak EP2

Steering shaft
Propshaft grease points
Battery carrier slide
8 Fuel Tank 275 Ultra Low Sulphur Diesel City Diesel
9 Urea Tank 17 Urea reagent AdBlue® www.air1.info
* When using products other than those listed, confirm compatibility with suppliers.
** This capacity may vary depending on individual customer saloon heater requirements
SERVICE MANUAL
Maintenance Amended:
Preventive maintenance begins with a day to day awareness of the condition of the vehicle.
Engine Oil Level - Checking
DAILY CHECK
The engine oil dipstick and filler is accessed through the rear
right hand side engine compartment door.
CAUTION
Never operate the engine with the oil level below
the 'L' (Low) mark or above the 'H' (High) mark.
Wait at least five minutes after shutting off the
engine to check the oil. This allows time for the
oil to drain back to the oil pan.
OIL GRADE - 15W /40

CAPACITY - 20.5 Litres
Engine Oil Filter

The engine oil filter is mounted under the alternator.
Clean the area around the oil filter head and remove the filter, a
strap wrench may be needed.
The ‘O’ ring may stick to the filter head. Make sure it is
removed.
Apply a light film of oil to the gasket sealing surface and fill /
prime the filter before installing.
Draining The Oil

Drain the oil when it is hot and the contaminants are in
suspension.
CAUTION
Hot lubricating oil may cause personal injury
SERVICE MANUAL
Maintenance Amended:18.11.09
Voith Gearbox Oil Level - Checking
WEEKLY CHECK
The gearbox filler and dipstick are situated in the rear engine compartment.
1. The vehicle should be on level ground with the engine idling, neutral
gear selected and the parking brake applied.
2. The transmission oil should be at an operating temperature of 60°C
(140°F). The temperature is about the same as the engine coolant
temperature.
3. Withdraw the dipstick and wipe it clean, replace the dipstick briefly,
withdraw and read off oil level. The level must be between the MAX
and MIN marks.
Do not leave the dipstick in too long when dipping, as the

reading may become falsified by splash oil.
OIL GRADE - DEXRON III

CAPACITY - 28L - 26 O/C
ZF Gear Oil Level - Checking
WEEKLY CHECK
The gearbox filler and dipstick are situated on the left of the vehicle near the
turbocharger.
ENGINE STOPPED
The oil level can be checked without the engine running and should register
in the engine stopped zone.
COLD RUN
The gearbox should be in neutral and the engine idling for 3 to 5 minutes, the
oil must register in the cold zone or higher. If the oil level registers higher do
not drain any oil.
HOT RUN
With the engine running at idle speed approx 2 minutes and the gearbox in
neutral, the oil level must be at operating temperature (80° - 90°C). The oil
level must register in the hot zone. This check can be carried out immediately
after use of the vehicle.
OIL GRADE - ZF-Ecofluid Life

CAPACITY - 42L - 24 L O/C
SERVICE MANUAL
Maintenance Amended:25.07.12
Remote Fuel Filter
Element Changing
To change the element, disconnect the plug
from the water in fuel sensor located on the
bottom of the filter element. Unscrew the
element and remove it. Refitting is reverse of
removal. Tighten element to 20Nm. After an
element change, slacken bleed screw then
operate the hand primer to purge air from the
system. When air is purged, tighten bleed screw
to 15Nm.
Draining Water and Sediment

Unscrew the drain on the bottom of the filter canister
sufficiently to allow water to drain, tighten when all
traces of water are drained.
Drive Axle
DRAINING - GANTRY
This is best done at the end of a journey when the oil is
warm. Each gantry drive has drain and level plugs and the
housing one drain plug.
Remove plugs and drain, clean and refit plugs using new
‘O’ rings and tighten to 70 Nm.
FILLING - GANTRY
Remove filler plug and fill with the correct grade of oil until
the oil overflows. Wait two minutes until the oil has settled,
recheck and top up if necessary until the level is reached
and remains constant.
) OIL GRADE - 80W / 90

CAPACITY - 18 L
NOTE
On later models the centre drain plug has been
removed, so the the two gantry drain plugs should be
used.
SERVICE MANUAL
Drive Belt Inspection
Daily Checks
Visually inspect the belt. Check the belt for intersecting cracks. Transverse cracks (across the belt width) are
acceptable. Longitudinal cracks (direction of belt length) intersecting with transverse cracks are NOT
acceptable. Renew the belt if it is frayed or has pieces of material missing.
Replacement - Alternator Drive Belt
1. Check that the master switch is

at OFF with the engine stopped.
2. Using a bar from a socket set in
the square hole in the arm, turn
the automatic belt adjuster
clockwise to remove belt
tension.
3. Holding the adjuster in the raised
position, remove the old belt and
fit the new one, ensuring that the
belt seats correctly in the
grooves in the pulleys.
4. Release the adjuster on to the
belt and see that the belt is
adequately tensioned.
ISBe-Euro4
SERVICE MANUAL
Maintenance Amended:300610
Hydraulic System Filter
The filter is situated in the rear engine compartment adjacent

to the gearbox.
The return line filter is of the canister type.
Level Checking - Hydraulic Fan Oil Reservoir

DAILY CHECK
The hydraulic fan oil sight glass and filler is situated in the Left
hand side engine compartment mounted on the end of the
engine. The oil level is visible via a fluid level gauge on the
reservoir. The oil level should be checked with the engine
idling. Maintain the level midway between the High and Low
marks.
1. With the engine switched off, check whether the fluid
is approximately on the uppermost line of the sight
gauge.
MAX
2. Top up as required.
3. Start the engine. MIN
4. With the engine running at idle, the fluid should go

down to approximately the midpoint of the sight
gauge.
Level Checking - Hydraulic Steering Oil Reservoir

DAILY CHECK
1. Thoroughly clean the oil reservoir before removing
the cap to prevent ingress of dirt.
2. Check there is sufficient oil in the reservoir.
3. With the engine idling, top up oil to the upper dipstick
mark.
4. Switch off the engine, if the level rises more than 10
to 20mm, there could be air present in the system.
HIGH
The filter is integral in the reservoir, underneath
filler cap. LOW
SERVICE MANUAL
Line Filter - Air Suspension

A, B, C CHECK
The line filter for the air suspension system is located on the front auxiliary air reservoir (top) situated on the
front, right-hand side of the vehicle beneath the drivers seat area.
The line filter should be checked every 3 to 4 months, depending on the operating conditions. The filter should
be removed and blown through with compressed air. If the filter is damaged the element should be replaced.
Air System Reservoirs - Draining

A, B, C Check
Each reservoir is fitted with a reservoir drain valve. The valve is fitted
with a pull ring.
The pull ring should grasped and pulled to the side to evacuate any
water in the reservoir.
WARNING
Eye protection should be worn when draining the air /
water from the reservoir, as dust or dirt may be blown
around with evacuation of the reservoir.
SERVICE MANUAL
Coolant Level - Sight Glass

Daily Check
The coolant level gauge is sighted on the rear of the vehicle. The coolant level should be checked when the
engine is cold or after 15 minutes if the vehicle has been running. The level should be maintained at the
maximum level. If topping up is required, use the correct premixed coolant. The header tank filler cap is
situated at the rear right hand side of the vehicle.
WARNING
Top up the coolant only when the engine is stopped. Allow the
system to cool until the temperature is below 50°C (120°F)
before removing the pressure cap.
Failure to do so can cause personal injury from pressurised
heated coolant spray.
MAX
CAUTION
Never use a sealing additive to stop leaks in the coolant MIN
system. This can result in coolant system clogging and
inadequate coolant flow. LEVELS
WHEN
COLD
NOTE :
Valvoline HD Extended Life RTU Coolant, to Cummins 14603,
must be used for vehicles fitted with an Aluminium Radiator
Insert.
Air Cleaner Restriction Indicator

The restriction indicator gives a warning that the air cleaner filter is too
clogged for further service. The indicator is operated by the
Restriction
depression between the air cleaner and the engine, and at a preset
figure, the red warning indicator will remain locked up in a visible Indicator
position after the engine has stopped running.
When the red indicator band appears, the air cleaner element must be
removed and renewed. After the element has been renewed, reset the
indicator by pushing on the diaphragm at the top of the instrument.
1. Housing
2. Red panel (service the filter)
1
3. Resetting button
SERVICE MANUAL
Towing Amended:25/09/12
The vehicle should only be towed with the towing eye. The Alternative Procedure:
towing eyes should be screwed into the tapped sockets in When a vehicle with angle drive transmission is towed, the
the front crossmember. A rigid tow bar should be used, propshaft between transmission and powered axle must
utilizing both towing eyes. always be disconnected.
An air coupling is located on the front of the vehicle to
provide a means of supplying air to the braking system Alternatively the axle half shafts must be removed from
while the vehicle is being towed. both sides, if it is safe to do so.
Where there is no means of supplying air to the vehicle
being towed the parking brake (spring brake) must be
WARNING
released. Proper consideration must be given to traffic
conditions and the danger from passing traffic fully
Towing Instructions - ZF Transmission accessed and any necessary precautions taken
before attempting to remove half shafts.
With No Transmission Damage
Engine Running The open axle ends should be temporarily plugged to
Before and during the towing the following conditions prevent loss of oil.
must be fulfilled:
• Ignition ON.
Towing Instructions - Voith Transmission
• Engine running at idle speed.
With No Transmission Damage
• Max. towing time 2 hours.
• Push-button range selector in Neutral position.
• Max. towing speed: 15 mph (25 km/h).
• Unplug the connecting cable between control and
Engine Not Running transmission ECU.
Before and during the towing the following conditions
• Max towing distance 6 miles (10km).
must be fulfilled:
• Max towing speed 18 mph (30 km/h).
Fill the transmission with an extra 10 liters of Ecofluid life
(or an alternative oil approved to ZF Oil Specification TE- With Transmission Damage
ML20) in addition to the normal oil level. Follow Alternative Procedure.
• Max. towing time 2 hours. Releasing Parking Brake
• Max. towing speed: 15 mph (25 km/h).
• Place chocks behind and in front of the wheels.
NOTE • Remove the cap from the end of the drive axle
Before recommisioning the vehicle the extra oil spring actuators.
added to ensure safe towing must be drained out.
• Unscrew the release bolts of both actuators until
the brake shoes release from the drums.
With Suspected Damaged ZF Ecolife Transmission • When resetting release bolts, tighten to 35ft lbs
(47Nm) in a clockwise direction.
If transmission damage is suspected, Follow Alternative • Replace the spring brake actuator caps.
Procedure.
Emergency Exceptions: WARNING

In a dangerous situation, towing without separation of the In this condition the brakes are completely
drive train is permitted until the vehicle has left the danger inoperative. Towing must be carried out using a
area (e.g. intersection, tunnel, etc). In such a case the rigid tow bar.
following conditions apply:
• Ignition ON, if possible

• Engine running at idle speed, if possible.
• Push-button range selector in Neutral position.
• Max towing time 10 minutes.
• Max towing speed: 9 mph (15 km/h) Release Bolt
NOTE: At an ambient temperature below -15°C, the

maximum permitted towing speed is 3 mph (5 km/h). Cap
SERVICE MANUAL
Supporting Vehicle for Maintenance Purposes

When it is necessary to elevate the vehicle to carry out maintenance it is strongly recommended that the wheel type
lifts are used and that they remain in position to provide a stable and safe platform whilst carrying out maintenance /
inspection tasks beneath the vehicle.
Only under certain circumstances such as axle removal / replacement which require the wheel type lifts to be removed
to gain access to components, should the vehicle be supported on stands. Adaptors may be required to support the
chassis from the top of the axle stands, Please contact the axle stand manufacturer for details of stand adaptors. When
supporting the vehicle in this manner it is important that the safety guidelines below are followed in addition to all
normal workshop safety procedures:
• The recommended support stand positions should be used (refer to illustration below for positions).
• On vehicles with air suspension, do not attempt the support the vehicle using suspension components or a
combination of chassis and suspension points.
• Only use stands that are in a safe condition and with a capacity that is rated to support the vehicle.
• Do not use packing between stand tops and the chassis as movement may cause the vehicle to become
unstable.
ADAPTOR REQUIRED ADAPTOR REQUIRED
DISCONNECT LEVELLING VALVE DISCONNECT LEVELLING VALVE
SERVICE MANUAL
Special Tools and Diagnostic Equipment Amended:010812
Enviro 400 Special tools and diagnostic equipment

Engine- Cummins
Insite (Download) https://insite.cummins.com/insite/index.html
In Line 6 Interface 2892092
Gearbox - ZF EcoLife
Testman Pro 6008 208 920
Ecolife application CD 6008 208 838
DPA 05 (interface) 6008 208 003
Gearbox - Voith
Aladin Diagnostics 150.0097802
Connection Lead H59250021
Braking System
Brake tube cutter 610224
Pressure gauges 0 - 10 bar * 4 local supply
Test hoses with ISO test connectors * 4 local supply
ISO test nipple nut -2 off (to make above) SC1006
Rear Axle - ZF AV-132

Oil seal driver 5870 051 040
Driver handle 5870 260 004
Halfshaft Oil seal driver 5870 005 098
Driver handle 5870 260 002
Oil sampling device 5870 286 078
For grease filled hubs:
Pneumatic pump 5870 287 010
50 ton cylinder 5870 287 009
ZF puller 5870 080 071
Front Axle - Dana

Swivel pin dummy nut SL225/19
UNIPAC bearing alignment sleeve E660
Alignment Studs E542
Front Axle - ZF
See axle section
Chassis Electrics
Multiplex Actia MultiAid
Cooling fan motor & ZF Steering

Pressure test point Hose adaptor SMA-3-2000
Hose to gauge adaptor MAV1/4-MA3
Ventura Door
Belt Tension Gauge ST-1138 - (Cummins)
SERVICE MANUAL
Standard Torque Figures Amended:
Standard Torque Figures

Standard Torques For Grade 'S' thread imperial
Torque values quoted are standard figures for bolts and screws, zinc plated
general non-specific applications and assume the
application is generally in line with the test fixture
outlined in BS 7371 : Part 2 : 1993.
Any specific requirements will supersede the
B.S.W. Torque Nm
figures quoted on these tables and will be identified 3/16" 4-6
elsewhere in these manuals. 1/4" 13 - 15
3/8" 47 - 53
Table 1 - Standard torques for Grade 8.8 coarse 7/16" 78 - 86
thread metric bolts and screws, zinc plated 5/8" 233 - 257
Table 2 - Standard torques for Grade 8.8 fine
thread metric bolts and screws, zinc plated
B.S.F Torque Nm
TABLE 1 - METRIC COARSE THREAD
1/4" 8 - 10
Size / Pitch Torque Nm 5/16" 29 - 33
M4 x 0.7 3-5 3/8" 51 - 57
M5 x 0.8 7-9 1/2" 124 - 138
M6 x 1.0 12 - 14
M8 x 1.25 28 - 32
M10 x 1.5 57 - 63 U.N.C. Torque Nm
M12 x 1.75 101 - 111 1/4" 13 - 15
M14 x 2.0 160 - 174 5/16" 26 - 30
M16 x 2.0 249 - 275 3/8" 47 - 53
M18 x 2.5 354 - 392 7/16" 77 - 85
M20 x 2.5 469 - 519 1/2" 119 - 131
M24 x 3.0 869 - 961 5/8" 236 - 260
TABLE 2 - METRIC FINE THREAD

Size / Pitch Torque Nm
M4 x 0.5 3-5 U.N.F. Torque Nm
M5 x 0.5 7-9 1/4" 15 - 17
M6 x 0.75 13 - 15 5/16" 27 - 29
M8 x 1.0 31 - 35 3/8" 48 - 54
M10 x 1.25 61 - 67 7/16" 77 - 85
M12 x 1.25 109 - 121 1/2" 119 - 131
M14 x 1.5 173 - 191 5/8" 236 - 260
M16 x 1.5 265 - 293 3/4" 418 - 462
M18 x 1.5 399 - 441 1" 1007 - 1113
M20 x 1.5 557 - 605
M24 x 2.0 946 - 1046
SERVICE MANUAL
Non Standard Torque Figures Amended:
Non Standard Torque Figures -

Dacromet Bolts
All grade 10.9 bolts specified are coated in

Dacromet. This is a corrosion preventative finish.
(Dacromet 500, Natural Colour, Grade B).
Table 1 - Standard torques for Grade 10.9 coarse

thread metric bolts and screws, Dacromet plated
Table 2 - Standard torques for Grade 10.9 fine

thread metric bolts and screws, Dacromet plated
TABLE 1 - COARSE THREAD TABLE 2 - FINE THREAD
Size / Pitch Torque Nm Size / Pitch Torque Nm

M3 x 0.5 1.4 - 1.9
M4 x 0.7 3.7 - 4.5 M4 x 0.5
M5 x 0.8 7.2 - 9.2 M5 x 0.5
M6 x 1.0 12.1 - 15.6 M6 x 0.75
M8 x 1.25 29 - 35 M8 x 1.0
M10 x 1.5 59 - 72 M10 x 1.25
M12 x 1.75 102 - 132 M12 x 1.25 157 - 173
M14 x 2.0 161 - 201 14 x 1.5 246 - 272
M16 x 2.0 250 - 316 M16 x 1.5 379 - 419
M18 x 2.5 353 - 438 M18 x 1.5 552 - 610
20 x 2.5 491 - 613 M20 x 1.5 770 - 850
M24 x 3.0 857 - 1096 M24 x 2.0 1308 - 1446
M27 x 3.0 1250 - 1565 M27 x 2.0
M30 x 3.5 1700 - 2130 M30 x 2.0
SERVICE MANUAL
Engine Amended: 02.08.12
Contents
Air Cleaner Fuel System

Air Cleaner Diagram . . . . . Page 2.2 Fuel system diagram . . . . . Page 2.16
Description . . . . . . . . . . . . Page 2.3 Fuel system description . . . Page 2.17
Maintenance . . . . . . . . . . . Page 2.3 Fuel tank maintenance . . . . Page 2.17
Vehicle Checks . . . . . . . . . Page 2.3 Filler Cap . . . . . . . . . . . . . . Page 2.17
Restriction Indicator . . . . . . Page 2.3 Priming fuel system . . . . . . Page 2.18
Intake Hoses & Air Leaks . . Page 2.4 Change filter . . . . . . . . . . . Page 2.19
Main Points . . . . . . . . . . . . Page 2.5 Water-in-fuel sensor . . . . . . Page 2.19
Cooling System Hydraulic System

Diagrams . . . . . . . . . . . . . . Page 2.6 System diagram . . . . . . . . . Page 2.20
Description . . . . . . . . . . . . Page 2.7 Description . . . . . . . . . . . . Page 2.21
Specification . . . . . . . . . . . Page 2.7 Specification . . . . . . . . . . . Page 2.21
Maintenance . . . . . . . . . . . Page 2.7 Maintenance . . . . . . . . . . . Page 2.21
Radiator . . . . . . . . . . . . . . Page 2.7 Hydraulic fan system filter . Page 2.22
Coolant . . . . . . . . . . . . . . . Page 2.7 Hydraulic steering reservoir Page 2.22
Draining . . . . . . . . . . . . . . . Page 2.7 Changing reservoir filters . . Page 2.22
Low coolant alarm . . . . . . . Page 2.7 Fan motor . . . . . . . . . . . . . Page 2.24-25
Cooling pack maintenance . Page 2.8 Tandem pump . . . . . . . . . . Page 2.26-27
Radiator and Refitting tandem pump
intercooler Removal . . . . . . Page 2.8 to compressor . . . . Page 2.28
Cooling system drain / fill . . Page 2.8 - 9 Bleeding the system . . . . . Page 2.28
Cooling pack alignment . . . Page 2.9
Filling Heater Circuit . . . . . Page 2.10
Hoses & Leaks . . . . . . . . . Page 2.11 Engine and Mountings
Engine mounting diagram . Page 2.30
Exhaust System & Urea System Description . . . . . . . . . . . . Page 2.31
Diagram . . . . . . . . . . . . . . Page 2.12 Specification . . . . . . . . . . . Page 2.31
Description . . . . . . . . . . . . Page 2.13 Maintenance . . . . . . . . . . . Page 2.32
Exhaust Gas Processor . . . Page 2.13 Compressor Discharge Lines Page 2.33
Dosing Unit . . . . . . . . . . . . Page 2.13 Torque settings . . . . . . . . . Page 2.33
Urea Spray nozzle . . . . . . . Page 2.13 Oil drain interval procedure Page 2.34-35
Urea Storage Tank . . . . . . . Page 2.13 Engine fault code readout . Page 2.36
Urea - Ad Blue . . . . . . . . . . Page 2.14 Cummins fault codes . . . . . Page 2.37-52
Maintenance . . . . . . . . . . . Page 2.14 Automatic Oil Level (Option) Page 2.53-55
Removal & Refitting . . . . . . Page 2.15 Air Conditioning Belt . . . . . Page 2.56
Section 2
SERVICE MANUAL
Air Cleaner Amended:
6 3
1 4
7
8
9
11
10
9
1
12 13
13
14
13
15
AC1511C
1 Air Cleaner
2 Element Assembly
3 Nut & gasket assembly
4 Cover assembly
5 Body assembly
6 Mounting band - air cleaner
7 Clip
8 Hump hose
9 Clip
10 Air intake pipe
11 Restriction indicator
12 Elbow-reducing
13 Clip
14 Air intake pipe - elbow to turbo
15 Elbow - turbo inlet pipe
SERVICE MANUAL
Description Vehicle checks

The air cleaner is fitted in the engine bay of the After reassembly but before restarting engine, the
vehicle. The cleaner encloses a pleated filter following system checks must be carried out.
element which is treated to combat premature
blockage by exhaust carbon. A remote restriction a. Check all cleaner to engine pipe work for
indicator is connected to the outlet to indicate defects to ensure good and leak free
clogging. condition.
b. Check that all rubber hose connections are
Maintenance tight and leak free. Hose clips to be fitted
Access is obtained through the rear engine door. squarely and torqued to 5.6 Nm = 50 lbft-in.
Renew any worn or damaged parts.
The element should be changed on an annual basis
or if the if the restriction indicator (fitted adjacent to c. Check that the cleaner mounting fixtures are
the rear EDC) shows red. secure.
To remove the element, undo the centre hand nut on d. If the cleaner is equipped with a Vacuator
the cleaner casing lid. Remove the lid. Unscrew the valve, visually check and physically squeeze
element retaining nut and pull out the element, avoid to make sure the valve is flexible and not
knocking the filter element against the housing. inverted, damaged or plugged.
Vacuum or use a clean cloth to wipe out the inside of Restriction Indicator
the casing. Ensure that the sealing surface is clean
and free from contaminants. Any dirt residue on the The restriction indicator gives a warning that the air
sealing surface could cause leakage. Make sure cleaner filter is too clogged for further service. The
that all dirt and contaminants are removed from the indicator is operated by the depression between the
housing. Check that the gaskets are in good air cleaner and the engine, and at a preset figure, the
condition and that the casing and lid are red warning indicator will remain locked up in a
undamaged. Before fitting the new element check visible position after the engine has stopped running.
the part number to ensure it is the correct one for the
vehicle. Fit the new element, ensuring that it is
properly seated and tighten the securing nut.
Position the lid and tighten the hand nut. If
necessary reset the restriction indicator by pressing Restriction
down on the top. Indicator
It is not recommended that treated elements should
be washed as this removes the active chemical. In a
case of necessity the element can be cleaned by
blowing through with air at a max 100 p.s.i. (7 bar) in
the reverse direction.
NOTE When the red indicator band appears, the air cleaner
It is strongly recommended that only OE air element must be removed and renewed. After the element
filter elements are used as replacement as the has been renewed, reset the indicator by pushing on the
sealing ring is less susceptible to dirt diaphragm at the top of the instrument.
contamination.
Blank off the connection if the indicator is not fitted.
As “Best Practice” the installation date of the
filter element can be noted on the end face of 1. Transparent panel (no restriction)
the element using a white marker.
2. Red panel (service the filter)
Never fit a damaged element.
3. Resetting button
3
CAUTION
Only a few grams of dirt is sufficient to “dust
2
out” an engine.
SERVICE MANUAL
Intake Hoses & Air Leaks Torque Setting - Tee Bolt Clamp
The air intake hoses should be regularly checked at 5.6 Nm = 50 lbf-in
the appropriate service interval for signs of
deterioration. Any hardened, cracked or leaking
hoses should be renewed. If any hose shows signs
of chafing the cause should be rectified immediately.
If an intake hose shows signs of leaking, firstly the
hose clamp should be torqued to the correct setting. A suitable adjustable single or dual scale torque
If the air leak continues then the hose should be wrench will be needed with a scale of approximately
replaced. 4 - 20Nm and/or 40 - 180 lbf-in.
When fitting tee-bolt clips to the intake hose, pipe

engagement should also be checked.
When securing the hose make sure the clamp is

square and flat to the hose and when tightened.
SERVICE MANUAL
Air Cleaner Maintenance - Main Points
FIG 1 FIG 3
FIG 5
FIG 2 FIG 4
Particular attention should be paid to the following points when carrying out the maintenance on the air cleaner:
Fig 1 - Fitting the incorrect air filter element or failure to seat the element correctly could mean unfiltered air
entering the engine.
Fig 2 - Always check the condition of the element seal and make sure the sealing face is clean
Fig 3 - Check that the gaskets are in good condition and that the casing and lid are undamaged.
Fig 4 - Check the end cover drain hole is clear and not blocked.
Fig 5 - If the cleaner is equipped with a Vacuator valve, visually check and physically squeeze to make
sure the valve is flexible and not inverted, damaged or plugged.
CAUTION
Only a few grams of dirt is sufficient to “dust out” an engine.
SERVICE MANUAL
Cooling System Amended:
Cooling system - ZF Gearbox
HEATER HEATER
SUPPLY RETURN
ENGINE
COOLANT
HEADER
TANK
ZF
GEARBOX
COOLER
LOWER UPPER
RADIATOR SIGHT
GAUGE
TOP
AR8453ZF
SERVICE MANUAL
Cooling System Amended:201011
Cooling System Maintenance

Radiator
Description
The radiator should be flushed out every 60,000
The engine is cooled by water passing through a miles, 2000 hrs or 2 yearly, by passing water through
radiator on the offside beside the engine. The it in the opposite direction to the normal flow.
engine water pump draws water from the bottom of
In very dusty conditions and where insects are
the radiator through a pipe run which includes the
numerous, the radiator matrix should be kept clear
gearbox oil cooler. After circulating through the
by blowing through with compressed air from rear
engine, the water passes back to the the radiator via
face.
the engine thermostat. A header tank, is mounted
above the radiator and connects to the engine feed Coolant
pipe. A pressure cap (50 KPa) is fitted to a remote The recommended premixed coolant will give
filler accessible from the outside of the vehicle. protection down to -37°C (34.6°F) and will also
The radiator cooling fan is driven by a hydraulic fan ensure the correct degree protection against frost,
motor which is powered by the engine driven tandem corrosion and overheating. The radiator header tank
pump. The fan motor is controlled by the Cummins should be topped up to the bottom of the filler neck
engine control module. with the premixed coolant.
For more information refer to the relevant section in
the Engine Operation & Maintenance Manual.
Specification The strength of the solution in the system can be
Cooling system capacity . . . . . . . .approx 50 litres checked with a refractometer. This reading will
measure the freezing point of the coolant accurately.
Recommended Brand
. . . . . . . . . . . . . . . . .Cummins ES Compleat (EG)
Draining
NOTE : A drain plugs is located in the radiator inlet and outlet
Cummins ES Compleat is a Pre-mix coolant. pipes. For engine removal isolate the heater circuit
DO ADD WATER. by closing the heater circuit isolator feed and return
valves.
Coolant Specification . . . . . .Cummins Spec 14603
Thermostat initial opening temperature 82°C - 92°C Low Coolant Alarm - Maintenance
The low level alarm system offers protection against
Maintenance resulting from loss of coolant, by warning the driver
Check coolant level . . . . . . . . . . .Daily, First A,B,C with a light and an audible alarm when the coolant
Check condition & security of cooling fan level in the header tank drops below a
predetermined level.
. . . . . . . . . . . . . . . . . . . . . . . . . .Daily, First A,B,C
It is recommended that a check every 3 months be
Check security of radiator mountings . . .First A,B,C made of the operation of the low level warning
Check for leaks & hose deterioration . . .First A,B,C system by either draining the coolant so that the
level drops below the tip of the probe or by
Check intercooler & radiator matrix for debris, clean disconnecting the wire to the probe. A visual
as necessary . . .Every 7,500 miles 250 hrs or 3 yrs warning should then be given. The probe should
Remove & clean radiator flyscreen/filter . . . . .A,B,C also be examined and if coated with deposits, should
be cleaned using emery paper, wire wool, etc.
Check operation of low coolant alarm . . . . . .A,B,C Examine wiring to ensure there are no frayed areas
Check strength of anti-freeze/engine coolant and all connections are clean and sound.
. . . . . . . .Every 15,000 miles / 2000hrs / 6 months
Check pressure cap spring & seal . . . . . . . . .Yearly
Drain & flush out cooling system & refill with the
correct engine coolant . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .60,000 miles, 2000 hrs or 2 yearly.
SERVICE MANUAL
Cooling System Amended:14.03.12
Cooling Pack Maintenance 4. Carefully remove the intercooler though the

During the normal running of the chassis the vehicle side access aperture, taking care not
radiator, intercooler, hydraulic oil cooler, fly screen to damage the cooler matrix.
and filter (if fitted) are likely to become coated with a 6. To refit the intercooler carry out the reverse
layer of dust, dirt and grime. The amount of dirt that procedure. Check hose connections for
is sucked through these assemblies will vary leaks.
depending on the operating conditions.
Radiator
The coolers/intercooler should NOT be allowed to
1. Carry out drain procedure.
become blocked as this will reduce the cooling
efficiency of the system. It is important to check the 2. Disconnect and remove the hose elbow from
condition of the assemblies at the regular service the bottom of the radiator. Disconnect and
intervals. remove the top hose and bleed connection.
It Is Important when refitting the cooling pack that the 3. Remove the flyscreen. Remove the bottom
pack has the correct alignment and clearances to panel mounting bolts (two on each side). The
reduce the possibility of stress being applied to the radiator must be supported from beneath
cooling pack, to avoid premature failures which can before removing the last mounting bolt.
result when the cooling pack is installed with
4. Lower the radiator carefully, taking care not to
insufficient clearance.
damage the cooling matrix.
Cleaning 5. The radiator can now be cleaned from the
The flyscreen should be cleaned at the specified reverse side. Refer to notes on cleaning.
intervals and is removed easily from the vehicle by
To refit the radiator carry out the reverse
undoing the fixings around the fly screen.
procedure.
The radiator, intercooler and fly screen should be
NOTE - Make sure that the radiator top pads
treated with a suitable water based, soluble cleaner,
are correctly positioned when refitting into the
to the manufacturers instructions and washed off
radiator frame.
using a suitable steam or pressure cleaner.
NOTE - Check the condition of the rubber
pads and replace if necessary (443217-15)
CAUTION
6. Carry out fill procedure.
If a pressure washer is used on these
assemblies extreme care must be used as
the water pressure or proximity of the nozzle
Cooling System Drain /Fill Procedure
may damage the radiator matrix finning and Draining (Engine Circuit)
affect the cooling efficiency of the system.
If it is necessary to break into engine cooling circuit
the saloon heater circuits should be isolated by
Radiator & Intercooler - Removal & turning off the feed and return isolator valves before
Refitting draining down the engine circuit. This will minimize
the loss of coolant from the system. Refer to heater
Intercooler
circuit filling procedure for location of isolator valves.
1. To remove the intercooler undo the fasteners
securing the flyscreen to the radiator frame WARNING
and withdraw the screen. Do not attempt to drain the coolant from a
2. Slacken the hose clips securing the top and hot engine. Heated coolant spray or steam
bottom hoses to the intercooler assembly. can cause personal injury. Wait until the
coolant temperature is below 50°C (122°F).
3. Remove the intercooler to cassette frame
mounting bolts, there are two mounting bolts System drain plugs are located in the bottom of the
located at the bottom and one at the top, care
radiator and the bottom water pipe. Drain the coolant
should be taken to prevent loss of the flat and
spring washers when removing the mounting into a clean, suitably sized container and cover to
bolts. Support the intercooler before prevent contamination, as this may be re-used.
removing the last securing bolt. (Intercooler
weight is approximately 20 kg).
Page 2.8 Enviro 400 Service Manual - Publication Number 2297 - March 2006
SERVICE MANUAL
Cooling System Amended:14.03.12
Filling (Engine Circuit) Cooling Pack alignment

Only use the recommended coolant, never use Premature failures can result when the radiator is
water alone. installed with insufficient clearance. This can
CAUTION contribute to reducing the life of the radiator.
The system must be filled properly to prevent Customers are reminded of the importance of
air locks. During filling air must be vented correct cooling pack installation and maintaining
from the engine coolant passages. During coolant quality.
filling wait 2-3 minutes to allow air to be
To reduce the possibility of stress being applied to
vented, then bring to correct level.
the cooling pack, periodically ensure the correct
Before filling the engine cooling circuit ensure that installation clearances are present. In addition,
the radiator drain plug has been refitted and that all
whenever a radiator or charge cooler is replaced, or
cooling hoses and clips are in good condition and
secure. accident damage occurs to this area of the vehicle, it
is important that the following checks are also
Fill the system through the header tank until the
correct level has been reached. Install the filler cap. carried out:-
Operate the engine until it reaches a temperature of The Cooling Packing must have a MINIMUM of
80°C (176°F) and check for coolant leaks. Check 6mm air gap to the chassis sole plate.
coolant level, top up if necessary. Open the saloon
heater valves, run engine again to circulate, check
the coolant level again to ensure that the level is NOTE
correct. Failure to have the correct clearance may
Note: See Heater Circuit Coolant Filling result in the transfer of load or any stress to
the radiator and may result in radiator or
Procedure
intercooler failure.
Fan Motor 1. Radiator

2. Hydraulic Oil Cooler
3. Charge Cooler Top Panel
4. Flyscreen
Fan
T
ON
FR Side
Fan Cowl
Panel
Rubber
Pad
Hose
Adapter
Rubber
Pad
3 Seal
Fan Hub Seal
2 Seal
Flexible
Mounting Mount 4
Stay
Seal
Side
Panel Seal
Rubber
Pad Bottom Seal
Panel 443217
SERVICE MANUAL
Heater Circuit Filling Procedure

To ensure that the heating system is filled and to to
avoid air locks in the heater matrices, on manual
control systems the heating must be switched on
and all heating valves must be open, follow steps 4
to 12 inclusive. For vehicles with the automatic
heating system it must be activated in ‘Override
Mode’. Follow steps 1 to 12 inclusive. (see page
2.10).
A B C
For ‘Override Mode’ follow sequence below:
1. With Battery Master switch "A" on and Ignition/
Engine Stop switch "B" off, press and hold both
Demist Temperature Control switches "C" then press
Ignition/ Engine Stop switch "B" to activate Ignition
Phase.
2. Saloon Heating Override Mode takes over control
of the Ambient Temperature display "D" on the driver
screen which is used instead to display the
overridden saloon temperature value. An initial D
setting of 10°C is adopted which affords the operator
a means of acknowledging override mode has been
successfully activated.
3. Simulated saloon temperature can be set using
the Demist Temperature Control switches "C",
demist heat control to increment, demist cool control
to decrement.
Proceed to open chassis isolator valves as
described in following sequence.
4. Open L.H. Side Radiator Access door for access
to coolant system ‘Take Off’ valve. Check gate valve
is in an open position.
5. Enter service pit to access the system ‘Return’
gate valve. Check gate valve is in an open position.
Fill system with the coolant in the following
sequence.
6. Open Coolant filler cover and remove filler cap.
7.Top up system with an initial amount of pre-mixed
coolant.
8. Start engine and run for a period of time, check
Coolant Level display periodically.
If level is low top up with pre-mixed coolant.
9. Check level again on display and if green light
illuminates/ level on sight glass ok stop filling.
10. Replace nozzle cap and close filler cover.
11. Leave all gate valves in the open position.
12. Run System and observe for leaks.
If any leaks are detected shut system down fix leak
and repeat valve open and coolant fill operation.
SERVICE MANUAL
Hoses & Coolant Leaks When fitting new clips, pipes should be checked for
The coolant and heater hoses should be regularly score marks and hoses should be checked for any
checked at the appropriate service interval for signs damage which may have been caused by removing
of deterioration. Any hardened, cracked, swollen or the clip.
restricted hoses should be renewed. If any hose
shows signs of chafing the cause should be rectified
Hose Clip Torque Settings
immediately.
5 +0.5 Nm = 44 +4.5 lbft-in
If a hose connection is leaking, firstly the hose clip
should be torqued to the correct setting. If the leak NOTE
continues then the hose should be replaced. Top up the cooling system and re-check for leaks.
It is recommended that when fitting a new hose
that a torque setting of 53 lbft-in (6Nm) is used to
compensate for hose settling / bedding in.
656818 Series
661990 Series
See Section 1 in the Parts Manual for Part Numbers.
When fitting clips to hose, pipe engagement should

also be checked. When securing the hose make sure A suitable adjustable single or dual scale torque
the clamp is square and when tightened, that it is flat wrench will be needed with a scale of approximately
to the hose and pipe and not secured over the pipe 4 - 20Nm and/or 40 - 180 lbft-in.
flare.
9
8
SERVICE MANUAL
Exhaust Gas Processor System - EGP Amended: 230910
High Temperature
Mounts
Urea Injection
Nozzle
Heat
Shield
Thermister (inlet)
Thermister (outlet)
EGP1510F
Insulation
Jacket
NOX Sensor
OUT
IN
AIR
Air IN
UREA
Filter OUT
Dosing Unit
MIX
FROM REAR OUT
AUXILIARY & UREA
IN
SUSPENSION
RESERVOIR
Urea Injection
Nozzle
Exhaust
Gas
Processor
Urea Tank
NOX Sensor
AR8509
SERVICE MANUAL
Exhaust Gas Processor System - EGP Amended:
General Decription
The vehicle is fitted with an integrated engine and NOTE
exhaust after treatment system for Euro 5 emissions Road debris may collect around the Urea
legislation. The system has a NOX sensor fitted. The Doser unit. It is IMPORTANT that no debris
system optimizes the engine for particulate enters the doser if the urea lines are
emissions and to deal with the oxides of nitrogen disconnected for any reason. The unit
(NOx) using selective catalytic reduction (SCR) should be thoroughly cleared and cleaned of
exhaust system after-treatment. road debris before any servicing activity
Exhaust Gas Processer (EGP) takes place.
The exhaust gas processor (EGP) is an integrated
catalyst and acoustic unit in one sealed stainless
steel housing or ‘can’. The three, in series, distinct The dosing unit and the EGP are protected from
elements in the EGP are ammonia diffuser, catalyst contamination by the compressed air system. A
and acoustic unit. The diffuser acts to evenly dedicated 5 micron filter/oil separator is fitted on all
distribute the ammonia over the catalyst face. The vehicles equipped with an EGP.
catalyst performs the chemical process of NOx
conversion and the acoustic unit muffles the exhaust Urea Spray Nozzle
system noise. The chemical process in the catalyst The Doser Unit uses compressed air supplied from
is temperature dependant (200 oC min.) the vehicle system to atomize the AdBlue® and by
means of a very accurate metering and pumping
There are two catalyst temperature sensors in the system, supplies a spray nozzle in the engine’s
EGP, one for the inlet and one for the outlet. The exhaust system.
catalyst temperature sensors are used to determine Urea Storage Tank
when the catalyst has reached the required
temperature to support the SCR chemical reactions
and hence to allow dosing of AdBlue®.
Dosing Unit
CAUTION
This component should be handled with
care. It may be damaged if dropped.
Dosing Unit (DU) is mounted under the rear left-hand

suspension cross member.
The dosing unit (DU) is a high accuracy unit for The AdBlue is stored in a chassis mounted tank next
injecting the required AdBlue® quantity into the to the main fuel tank. The tank supplies the solution
exhaust after-treatment system (EGP). to a Dosing Unit.
A 24v electronically operated pump and metering A continuous fluid level sensor is fitted for system
system, electronically controlled by the engine diagnostics, empty indication, monitoring AdBlue®
control module (ECM), work in combination with air usage rates, and instrument panel low level warning.
from the vehicle compressed air system to propel the If the tank level falls below a minimum point, a low
atomized AdBlue® charge through a nozzle into the level warning will be indicated. If the tank is empty,
exhaust system upstream of the catalyst. an empty warning will be indicated.
AIR REGULATOR
VENT
(REAR COVER)
SERVICE MANUAL
Urea - AdBlue
AdBlue® is a clear liquid with a weak ammonia CAUTION
odour. If spilled, the water evaporates and crystals Cleanliness of the system must be
are formed. maintained when any repairs are being
carried out to system.
The agreed industry generic trade name for this
solution is AdBlue®. Urea as a solid, or in solution Brass in-line connections must not be used
to repair damaged pipes. Brass when
with water as AdBlue®, is classified as non-
immersed in urea can attack the dosing unit.
hazardous.
The amount of AdBlue® injected into the exhaust is
Maintenance
controlled by the ECM and matched to the NOx Check security of all pipe clamps
output of the engine at any given speed and load A, B & C Service Intervals
condition. Water evaporates quickly and the urea
Inspect anti-vibration rubber mounts for sign of
turns into ammonia when in contact with hot exhaust
damage or separation
gases. The ammonia reacts with NOx over the
A, B & C Service Intervals
catalyst and the resultant tailpipe emission from this
process is harmless nitrogen (N2) and water (H20). Check for signs of exhaust leaks at all pipe joints
Check the urea injection system pipework
WARNING
When using or handling AdBlue® the proper

Health and Safety precautions should be
WARNING
taken. Please refer to your Adblue supplier Drain down the vehicle air system before
for the correct Material Safety Data Sheet. removing this filter.
AdBlue® www.air1.info
Wear appropriate eye and face protection
when using compressed air. Flying debris
and dirt can cause personal injury.
WARNING
CAUTION: MAY CAUSE IRRITATION TO SKIN AND Change urea in-line air filter
EYES. AVOID CONTACT WITH SKIN, EYES, AND Every 38,000 miles (60,000 km) 1500hrs or 1 yearly
CLOTHING. AVOID PROLONGED OR REPEATED
BREATHING OF VAPOR. USE WITH ADEQUATE Check the doser unit air vent & air regulator are
VENTILATION. DO NOT TAKE INTERNALLY. free from debris and are not restricted in any way
EMPTY CONTAINERS MAY CONTAIN RESIDUAL A, B & C Service Intervals.
PRODUCT. DO NOT REUSE CONTAINER UNLESS
PROPERLY RECONDITIONED
CAUTION
It may be a criminal offence to use a vehicle
that does not consume reagent (Urea) if it is
required for the reduction of pollutant
emissions.
The use of a reagent (Urea) is mandatory for
this vehicle in order to comply with the
certificate of conformity.
Emissions-Diesel Engines 2005/55/EC/6.5.2.5/6
SERVICE MANUAL
WARNING NOTE
Ensure that the flexible pipe is not fully
Care must be taken when removing the compressed or extended in the installed
exhaust gas processor (EGP) as it is condition, as this may lead to premature failure.
significantly heavier than a conventional
silencer.
Spiralwound Flexible Section
Recommended installation is for the flex to be
NOTE
installed straight, and at a length half way between
Any restriction or damage to the silencer or fully compressed and fully extended. Incorrect
pipework must be rectified as this will impair installation may affect service life/warranty.
engine performance.
Urea Pipework
Removal It is highly critical that the internals of the urea
1. Disconnect the Exhaust Gas Processor system are kept free from contamination. If lines are
(EGP) inlet pipe at the EGP. disconnected for any reason, dust caps must be
fitted. When new lines are supplied they are fitted
2. Disconnect the two sensor wire from the
with dust caps, these should not be removed until
EGP.
the moment of connection. failure to do so creates a
3. Remove the pipe clamp securing the down high risk of contamination, which creates a serious
pipe to the exhaust manifold. risk to the dosing unit.
4. Support the exhaust system and then
disconnect the EGP mountings. Injector/Nozzle
Care must be taken not to contaminate the internals.
5. Remove the pipe clamps. The step on the injector creates a metal-metal seal
6. Remove the components from the vehicle. with the step on the boss, so these surfaces must be
completely free from dirt/swarf.
Refitting
Guidelines For Assembling Exhaust Checks
To ensure a correct installation, components (EGP, After fitting and exhaust component, check the
pipework sections, clamps, supports) should firstly system for any sign of exhaust leakage. If any leaks
be assembled in a loose fashion, so that are found they must be rectified before returning the
adjustments may be made to the precise orientation vehicle to service.
of components before a final tightening up. This is
necessary to ensure a good fit of all components nd
reduces the risk of stresses being placed on Torque Values
components during assembly. Urea nozzle retaining nut . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Stepped Band Clamps
Exhaust gas temperature sensors . . . . . . . . . . . . .
Firstly, the clamp should be loosely assembled to the
. . . . . . . . . . . . . . . . . . . . . . .. . . . . 24 - 36 Nm
inner (unslotted) pipe, with the wider part facing the
Catalyst solution supply to injector nut . . . . . . . . .
joint. The inner pipe should be inserted past the
. . . . . . . . . . . . . . . . . .. . . . . 89 in. lb. (10 Nm)
length of the slots (70mm overlap is an optimum, but
this is not achievable for all joints). Once the whole
system is satisfactorily aligned, the clamp can be
tightened. Firstly, ensure that the clamp is aligned so
that bolts are easily accessible, and the outer pipe
extends to the step in the clamp but not past it –
failure to do so can deform the clamp and will
compromise its sealing ability.
V-Clamps
It is critical that the correct clamp is used on the
correct joint – care should be taken to ensure this is
so.
SERVICE MANUAL
Fuel System Amended:
SEAL - 2 OFF FUEL TANK

ADAPTOR RETURN PORT
Fuel System NON -RETURN VALVE

(NOTE DIRECTION FLOW TOWARDS TANK)
ELBOW
SLEEVE - 2 OFF
A
10mm BLACK NYLON TUBE A
CONNECTOR
*
View A
RETURN HOSE
* CONNECTOR
ENGINE FUEL PUMP FUEL TANK
FEED PORT
BULKHEAD RETURN
*
ELBOW
* SWIVEL CONN
SOLENOID VALVE
(NOTE DIRECTION FLOW - VIEW B)
FUEL FEED HOSE REDUCER
SLEEVE - 2 OFF
CONN CONNECTOR
BULKHEAD CONN. FEED

PIPE - FUEL RETURN
REDUCER - 7/8" TO 3/4" JIC
PIPE - FUEL FEED
ENGINE FUEL MANIFOLD
QUICK CONNECTOR
'O' RING
HAND PRIMER
FUEL PRE-FILTER
TO PRE-FILTER
CONNECTOR
CONNECTOR View B
BALL VALVE
ELBOW SWIVEL CONN SWIVEL
FROM TANK
Fuel Tank Mounting

AR7717-440766
SERVICE MANUAL
Fuel tank maintenance

WARNING Maintenance should be confined to repairing leaks,
The fuel pump, high-pressure fuel lines, or, if the fuel has become contaminated, cleaning the
and fuel rail contain very high pressure fuel tank internally.
fuel. Do not loosen any fittings while the
If contaminated fuel is detected, contents of the tank
engine is running. Wait at least 10
should be drained and the tank flushed to remove
minutes after shutting down the engine
any sludge or debris.
before loosening any fittings in the high-
pressure fuel system to allow pressure to Filler Cap
decrease to a lower level.
If a new filler cap has to be fitted, ensure that Loctite
572 sealant is applied to the threads on the filler cap
and collar, prior to the filler cap being screwed on for
Description assembly.
Fuel is carried in a 275 litre tank within the staircase
Specification
area of the vehicle. Fuel is drawn through a remote
filter mounted on the rear frame below the engine oil Fuel pressure at filter
filter. From the remote filter the fuel travels through
. . . . . . . . . . . . . .300-1100 kpa - engine cranking
the engine fuel distrinbution point before entering
the engine fuel filter Excess fuel from the engine Fuel pressure at filter
pump is returned directly to the tank.
. . . . . . . . . . . . . . .500-1300 kpa - engine running
The remote fuel filter incorporates a water-in-fuel
Fuel rail pressure
sensor in the base of the filter element which is
linked to a dashboard mounted warning light. . . . . . . . . . . .25000-140000 kpa - engine running
Fuel is carried in flexible pipes with quick release Minimum cranking speed . . . . . . . . . . . .150 RPM
connections. Engine idle speed . . . . . .Min.600 - max 800 RPM
Firing order - 6cyl. . . . . . . . . . . . . . . . .1-5-3-6-2-4
IMPORTANT
The engine has fuel pipe quick release locking
devices.
SERVICE MANUAL
Non start / stopped troubleshooting tree Priming the Fuel System
Check power supply After the fuel filter has been changed or the system
has been opened for any other reason the fuel
Do the engine warning lights come on and go system will need to be primed. Open the bleed screw
out in sequence? two turns. Unscrew the knob on the hand pump.
NO Pump until fuel passes though the bleed screw.
Check emergency stop. Tighten bleed screw to 15Nm. Tighten pump knob.
Check ECM fuses. DO NOT over-pressurise the system as this can
cause a failure of the ECM sealing gasket.
Check power supply from Aladin.
YES
Check fuel supply from tank.
Check pressure at hand priming pump (resistance
when pumping, do not over pump)
YES
Connect Insite and check fault codes.
Flash out fault codes with diagnostic switch. Bleed Screw
Is there smoke from the exhaust?

NO
Check fuel supply. Check battery voltage.
YES
Check engine crank speed too slow.
Air heater not working in cold weather.
Engine speed / position sensor not working.
Fuel leak at high pressure connector
Runs rough / misfires / stalls troubleshooting

tree.
Is there pressure at the priming pump?
NO
Air in fuel. Fuel leak before high pressure pump.
YES
Fuel filter blocked. Supply line from tank blocked.
Return line to tank blocked. Pipes connected
Hand Pump
incorrectly. Check for moisture in wiring harness
connectors.
NOTE
For ECM fault codes refer to Engine and
Mountings section.
SERVICE MANUAL
Changing the Element Water-in-Fuel Sensor

To change the element , disconnect the plug from the The water-in-fuel sensor is located in the base of the
water-in-fuel sensor located on the bottom of the fuel filter element, if it becomes necessary to replace
filter element. Unscrew and remove the element. it, remove the sensor connection and unscrew the
Refitting is reverse of removal. Tighten element to sensor from the filter element, use a suitable
20Nm. After an element change, slacken bleed container to catch the contents of the filter element.
screw then operate the hand primer to purge air from To drain the filter of accumulated water and
the system. When air is purged, tighten bleed screw sediment. Slacken the drain slightly by unscrewing
to 15 Nm. until water/sediment flows from the drain. A pipe can
be connected to the drain to prevent spilage. When
all water/sediment is drained and the fuel flow is
clear, remove pipe and retighten the drain.
Drain
Water in Fuel
Sensor Connection
. for Pipe
Engine Mounted Filter Fuel Quality

Detailed recommendations on fuel properties are
The engine mounted filter is a spin a cartridge type.
contained in Cummins Bulletin 3379001.
Install the filter on the filter head. Tighten the filter
until the gasket contacts the filter head surface.
Tighten the fuel filter an additional ¾ turn after
contact. Torque 23 Nm. NOTE:
For removal of fuel injector and injector
supply lines see Engine and Mountings
section.
SERVICE MANUAL
Hydraulic System Amended:041109
TEST
POINT
AR8519/E
STEERING
BOX
TEST
POINT
FAN
MOTOR
FAN
RESERVOIR
STEERING
RESERVOIR
COOLER
OIL
OIL
FILTER
RETURN
RETURN
FEED
FEED
RETURN
FEED
STEER FAN
PUMP PUMP
FEED
FEED
AR8519/E
SERVICE MANUAL
Hydraulic System Amended:
Description
The hydraulic system provides the power for the NOTE
steering system and the radiator cooling fan. An The fan motor has a 'Trim Speed' which is reached
engine driven tandem pump draws oil for the fan and before the engine reaches its maximum rated
steering systems from each respective reservoir speed. Once this speed is reached any increase in
mounted on the engine and the right hand rear side engine revolutions will have no further effect on
of the vehicle. The pump nearest the compressor the fan. The trim speed will only vary with
supplies the cooling fan motor and returns to the hydraulic oil temperature and may reduce by up to
reservoir via the oil cooler and system filter. The 10% as the oil heats up.
outer pump supplies the steering system. The fan speed is to be checked with the engine at
A canister type oil filter is fitted in the cooling fan working temperature or with the plug removed
return line, and an internal filter is fitted inside the from the solenoid valve on the fan motor.
steering oil reservoir.
Pressure test points, are fitted on the fan motor inlet
connections for testing system working pressures. Fan Trim Speeds
Specification Typical Hydraulic Fluid at 45°C / 115°F
1044 rpm . . . . . . . . . . . at engine speed 700 rpm
Engine Idle Speed . . . . . . . . . . . . . . . . . .700 rpm
Governed Engine Speed . . . . . . . . . . . . .2500 rpm
Engine No Load/High Speed Idle . . . . . .2750 rpm
TANDEM PUMP - 661123
Rotation . . . . . . . . . . . . . . . . . . . . . . . .Clockwise
Maximum speed . . . . . . . . . . . . . . . . . . .2850 rpm
Fan pump (front)
Nominal displacement . . . . . . .23.1 litres/1000 rpm Maintenance
Outlet pressure . . . . . . . . . . . . . . . . . . . . .210 bar Check hydraulic oil level . . . . . . . . . . . . . . . .Daily
Steering pump (rear) Change hydraulic oil . . . . . . . . . . . . . . . . .2 yearly
Nominal displacement . . . . . . .18.5 litres/1000 rpm Change steering reservoir filter . . . . . . .300,000 km
Maximum pressure . . . . . . . . . . . . . . . . . .165 bar Change return line filters . . . . . . . . . . . . . . . . . . . .
Controlled flow . . . . . . . . . . . .16 litres per minute. . . . . .Every 60,000 miles (100,000 km) or 2 years
Check all pipes, hoses and connections for leaks
FAN MOTOR
. . . . . . . . . . . . . . . . . . . . . . . . .Service interval B
Relief Valve Setting . . . . . . . . . . . .210 bar 3.5±bar
Check security of all hydraulic system components
Fan cut in . . . . . . . . . . . . . . . . . . . . . . . .89°C±3°C . . . . . . . . . . . . . . . . . . . . . . . . . .Service interval B
Fan cut out . . . . . . . . . . . . . . . . . . . . . . .83°C±3°C
Maximum speed . . . . . . . . . . . . . . . . . . .3500 rpm First Service = 1,000 miles (1,600 km).
Steering box
'A' Service = 6,000 miles (10,000 km) or 3 months
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ZF8098 whichever occurs first.
Pressure Relief Valve Setting . . . . .150Bar +15 bar
SYSTEM 'B' Service = 12,000 miles (20,000 km) or 6 months
whichever occurs first.
Fluid capacity . . . . . . . . . . . . . . . . . . . . . .17 litres
Fluid type . . . . . . . . . . . . . . . . . . .Dexron lID or Ill 'C' Service = 24,000 miles (40,000 km) or 12 months
whichever occurs first.
SERVICE MANUAL
Hydraulic System Amended:300610
Hydraulic Fan System Filter
Maintenance
The filter indicator should be checked at each
service interval and the filter should be changed,
along with the hydraulic oil, 2 yearly or at 100,000
miles whichever is sooner.
The return line filter is of the canister type
The filter situated in the rear engine compartment
near the rear bulkhead, to the left of the hydraulic
reservoir.
Hydraulic Steering Oil Reservoir

The Steering Oil reservoir is situated at the rear right
hand side of the vehicle and incorporates a filler and
dipstick. Do not overfill reservoir. Check level with
engine on tick-over.
Changing the Filter
The filter element in the oil reservoir should be
changed at the intervals given in the servicing
schedule or if the system has been broken into to
carry out repairs.
To remove the filter first remove the filler cap, release

the filter locking handle by pressing down and
turning through 90°. Withdraw the filter. Replace with
new filter and refit locking handle.
IMPORTANT
When withdrawing the old filter hold the
lower bore closed to prevent old oil flowing
out of the element into the reservoir and oil
circuit. Lubricate the filter carrier with oil
before fitting.
SERVICE MANUAL
Hydraulic System Amended:
Oil Level
The oil level should be checked at normal

operating temperature.
Thoroughly clean the oil reservoir and area around it

before removing its cap. This precaution is
necessary to prevent dirt getting into the hydraulic
oil.
A high engine speed or powerful suction would
cause small air bubbles to be sucked into the pump
and these would be broken down into microscopic
bubbles as they pass through the pump; this can
result in frothing and would make the time required
for bleeding unacceptably long.
The oil level should be checked with the engine at
idle speed. The level must be maintained mid way
between the upper and lower marks on the sight
glass.
CAUTION
Too low an oil level can cause the system to
malfunction. If the system is losing oil,
locate the leak and rectify it immediately.
Repairs to the steering gear should be
carried out at a Alexander Dennis Service
Centre.
Fault Finding
If the cooling fan fails to operate at the present
temperature; proceed as follows:
1. Check that the hydraulic oil level is correct.

2. Remove and bridge the temperature switch
connections.
3. Start the engine. If the fan runs at maximum
speed - check the temperature switch.
4. If the fan fails to operate - check the fan
motor.
SERVICE MANUAL
Hydraulic System - Fan Motor Amended:
1. Bearing 10. Circlip

2. Drive shaft 11. Backing washer
3. Cover 12. Shaft seal
4. Body 13. Bolt
5. Gear 14. Key
6. Sealing ring 15. Dowel
7. Mounting flange 16. Solenoid valve
8. Backing ring 17. Cover
9. Pressure loading ring
SERVICE MANUAL
Hydraulic System - Fan Motor Amended:
Fan Motor 11. Fit the cover (3), ensuring that the inlet side is
in the correct position.
The two shafts carrying the gears are supported in
pressure loaded bearings, enclosed in a machined 12. The threads on the bolts (13) should be
body. The drive end is closed by a mounting flange cleaned and flange (7) and apply Loctite
while the opposite end is closed by a cover which adhesive to the end 3 or 4 threads of the bolts
encloses a relief valve. A solenoid valve is fitted to before assembly.
the inlet. 13. Screw solenoid valve stem (16) into cover
(17) and tighten.
Maintenance
The only maintenance permitted is the replacement
of the seals at each end of the body and the shaft
seal on the fan spindle. The number of the
appropriate seal kit will be found in the Parts Manual.
Fitting new seals to fan motor

1. Remove bolts (13).
2. Separate the flange (7) and the cover (3) from
the body (4), gears (2 and 5) and bearings
(1).
3. Remove the circlip (10), the backing washer
(11) and the shaft seal (12).
4. Remove the pressure loading rings (9) and
their backing rings (8).
5. Remove the sealing ring (6).
6. Fit the shaft seal (12) with the spring side
innermost. Pack with grease, insert backing
washer (11) and fit circlip (10).
7. Fit the pressure loading rings (9), backing
rings (8) and sealing rings (6) to the flange (7)
and cover (3), using a little grease to retain
them in the grooves.
8. Hold the flange (7) in a soft-jawed vice, with
the sealing rings facing upwards, and
assemble the body (4). Ensure that the body
cut in track corresponds to the inlet side of the
flange.
9. Assemble the gears (2 and 5) and bearings
(1) separately into a pack. It is important that
the flange end bearing goes next to the
flange, otherwise internal leakage can occur
due to bedding in. Ensure the bearing face
recesses are adjacent to the gear faces.
10. Fit a protective sleeve over the gear shaft (2)
or cover the key way sharp edges with a thin
tape. Lightly lubricate the body bore and the
gear lobes. Push the assembled pack into
the body and the flange. Remove the tape or
sleeve.
SERVICE MANUAL
Hydraulic System - Tandem Hydraulic Pump Amended:
SECTION A - A
SECTION B - B
SECTION C - C
SERVICE MANUAL
Tandem Pump Fitting new seals to the twin pump

1. Carefully mark all parts to ensure that they
Key to Diagram are refitted in exactly the place from which
1. Shaft coupling they were removed.
2. Flange 2. Remove the drive coupling (1).
3. 'O' ring 3. Remove the four bolts (26) and separate the
4. Pressure loading ring (1 off) inner and outer pumps. The outer cover (13)
and the sandwich plate (15) will also
5. Sealing ring (4 off) separate.
6. Bearing (4 off)
4. The cover (9) is held by the dowels (23) and
7. Driven gear (2 off) can be tapped off.
8. Cover, inner pump 5. Remove gears and bearings.
9. Inner cover, outer pump 6. Remove the circlip (18) and the shaft seal
10. Pressure loading ring (3 off) (17).
11. Body, outer 7. Remove all 'O' rings and seals and pressure
loading rings.
12. 'O' ring
13. Outer cover, outer pump 8. Repeat Step 4 to Step 7 for the inner pump.
14. 'O' ring 9. Fit the pressure loading ring (4) and its back
up ring (27) into the flange (2) noting that it
15. Sandwich plate differs from the other three rings (10).
16. Driving gear outer pump
10. Fit the pressure loading rings (10) and back
17. Oil seal, outer pump up rings (28).
18. Circlip 11. Fit the rings (3), (5), (12), (14) and (19). A
19. 'O' ring little grease in the grooves will help to retain
the seals.
20. Drive couple
12. Pack the shaft seals (17) and (23) with
21. Driving gear, inner pump
grease and fit. Fit circlip (18).
22. Body, inner
13. Hold the flange (2), face up, in a soft, jawed
23. Shaft seal vice and assemble the body (22).
24. Hollow dowel 14. Fit a protective sleeve over the gear shaft
25. Spring washer (21) or cover the sharp edges with a thin
tape.With the gears (7 and 21) and bearings
26. Bolt
(6) assembled into a pack, lubricate lightly
27. Backing ring and place in the body (22). It is important that
28. Backing ring the flange end bearing goes next to the
flange, otherwise internal leakage can occur
Tandem hydraulic pump due to bedding in. Ensure that the bearing
face recesses are adjacent to the gear faces.
The twin pump consists of two gear pumps each Remove the tape or sleeve.
consisting of a body and end covers enclosing
meshing gears supported in bearings. The inner 15. Fit the cover (8).
pump, driven by the engine is connected to the outer 16. Assemble the outer pump in a similar fashion,
pump by a coupling sleeve. The outer end cover position the coupling (20) and place on the
incorporates a pressure relief valve. inner pump.
Maintenance 17. Position the sandwich plate (15) and the
cover (13).
The only maintenance permitted is the replacement
of body seals and the seals on the gear shafts. The 18. Fit the bolts (26) and washers (25). Tighten
number of the appropriate seal kit will be found in the to 34 - 41 Nm.
Parts Manual.
SERVICE MANUAL
Refitting Tandem Pump to Compressor Torque Setting - TandemPump & Fan

It is recommended that the following procedures are Motor Fittings
followed if it is found necessary to remove and refit The torque value table lists the fittings into the pump
the hydraulic tandem pump.
body.
1. It must be ensured that the lubrication hole
The port torque values, for the fittings, are lower than
between the compressor and the tandem
pump is clear from sludge or debris. the hose connection values, it is necessary that a
second tightening device is used to hold the fittings
2. Renew the gasket between tandem pump in its torqued position while the hose is tightened to
and compressor the required value.
Failure to adhere to these recommendations may CAUTION
result in premature failure of the tandem pump drive.
Failure to observe this requirement may
Occasionally these bolts have been found to loosen
render a unit scrap due to the distortion of
and require re-tightening. The recommended
procedure when changing the tandem pump is to the sealing seat, port threads or cracking of
thoroughly degrease the bolts and the thread of the the body through port.
holes to which they go in. Apply Loctite 242 to the
thread and tighten bolts to 43 ± 3 Nm.
Leak invesigation should be centred on ‘O’ rings and
/ or sealing faces and NOT by further tightening of
the fittings or hoses beyond the values stated below
Bleeding the System
Once the steering system has been filled to a point
where the oil level does not drop below the upper Tightening Procedure
mark on the dipstick, allow engine to run for a short 1. Ensure that the area around the ‘O’ ring chamfer
while at low rpm. This enables most of the air to be is clean.
expelled from the cylinder spaces. Observe the oil
level during this process and add oil immediately if 2. Check that adaptor ‘O’ ring seal is clean and
the level drops. The bleeding process can be correctly fitted. carefully screw fitting into pump
accelerated by turning the steering wheel from lock body and tighten to the correct torque.
to lock several times with the steering axle jacked
up. Do not apply any more effort than necessary to 3. When fitting hoses on the gear pump ensure that
turn the steering wheel in its end positions. Add oil the fitting in the pump is locked by a spanner
as necessary until level remains constant at the before tightening the hose
upper mark on the dipstick and no further air bubbles
can be seen in the reservoir when the steering wheel
is turned.
SERVICE MANUAL
Hydraulic System - Torque settings Amended:01.09.10
NOTE
These torque valves are for use with Tandem Pump Part Number 661123 and Fan Motor Part Number
661124.
TORQUE 115-126 Nm
656612-2 CONNECTOR
TORQUE 55-65 Nm*
Return
445483 ASSY HOSE

FAN DRAIN 440988 ASSY SUCTION
TORQUE 25-40Nm PIPE STRG
TORQUE 155-165 Nm
659322 ADAPTOR
656732 ELBOW
TORQUE 25-40Nm TORQUE 80-90Nm*
447281 ASSY HOSE 440987 ASSY SUCTION

FAN FEED PIPE FAN
TORQUE 50-60Nm TORQUE 155-165Nm
659323 TEE
TORQUE 35-45 Nm* Feed
657444 SWVL ADAPTOR

603680 SEAL 661123 TANDEM PUMP
TORQUE 79Nm* 445545 ASSY PIPE
FAN FEED
TORQUE 80-88Nm*
Out 656944-1 ELBOW 661664 ELBOW
TORQUE 55-65Nm TORQUE 35-45Nm*
In
659763-3 CONN
FILTER MALE/MALE
TORQUE 79Nm*
Feed 445549 ASSY PIPE

STRG FD BH
TORQUE 80-88Nm*
659632 ADAPTOR Return

658379 DOWTY SEAL
TORQUE 30-45Nm
NOTE: FITTINGS WITH TORQUE FIGURES MARKED WITH * INDICATE

VALUES THAT ARE LOWER THAN THE TORQUE FOR THE PART
FITTED TO THEM. TO AVOID OVER-TIGHTENING THESE FITTINGS IT
IS IMPERATIVE THAT THE FITTING IS HELD, IN ITS SET POSITION,
WITH A SECOND SPANNER WHILE TORQUING THE PART TO THE
VALUE INDICATED. FAILURE TO OBSERVE THIS PROCEEDURE MAY
RESULT IN DAMAGE TO PORT SEALING SEAT &/OR BODY
RENDERING THE UNIT BEYOND REPAIR!
SERVICE MANUAL
Engine and Mountings Amended:
VISUALLY CHECK EVEN GAP ALL AROUND IN SIDE &

FRONT PLANES BETWEEN REBOUND WASHER &
ENGINE MOUNTING OF APPROX 5mm ON BOTH MOUNTS.
THIS IS TO ENSURE MOUNTING HARDWARE
I S SQUARE AND SYMETRICAL TO ENGINE & FRAME
CHASSIS JIB MEMBER
APPLY 607139
PBC LUBRICANT (M22)
TO SHANK ONLY OF TORQUE 400-410 Nm
425867 ENGINE STAY &
MFB-124-190P BOLT.
(STAY MOUNTING)
DO NOT LUBRICATE THREADS
TORQUE M24 NUTS
250 Nm
CHASSIS CROSS MEMBER (M16 x 60) 6 on each side

TORQUE 225 Nm
APPLY 606152 LOCTITE TO

THREADS & TORQUE 50 Nm
(ENGINE BELLHOUSING)
TORQUE 77 Nm
(Bolt M12 x 90)
TORQUE 77 Nm
(Bolt M12 x 30)
TORQUE 190-210 Nm
(Screw M16 x 55)
SERVICE MANUAL
Description Maintenance
The vehicle is powered by a Cummins ISBe 6.7 Euro Carry out all service and routine maintenance
5 250B, electronically controlled six cylinder, turbo- requirements according to the engine
manufacturer's operator's manual.
charged diesel engine developing 184kw (250 PS)
with urea injection. It drives the rear axle through a
Engine data plate
Voith or ZF automatic gearbox.
The engine is mounted at 3 points. Two brackets are The engine data plate is attached to the top of the
mounted with bolts at the sides of the gearbox valve rocker cover on top of the engine.
housing. Anti-vibration mounts are bolted to
brackets on the main frame members and rear
(Located on Top of Valve Cover)
engine stay . On the gearbox sides bolts pass down
through the bracket and mount with a rebound
washer on top of the mount and a rebound washer
below it. The whole assembly is clamped by a nut .
At the rear, an anti-vibration mount is bolted to the
rear engine crossmember, which in turn is bolted to
the chassis frame
Specification
Power . . . . . . . . . . . . . . . . . . . . . .184kw (250 PS)
Idle speed Speed (rpm) . . . . . . . . . . .600-800rpm
No load governed speed (rpm) . . . . . . . .2850rpm
Capacity . . . . . . . . . . . . . . . . . . . . . . . . .6.7 litres
Bore and Stroke .114mm (4.49 in) x 135mm (5.32)
Valve clearances (cold)
- inlet . . . . . . . . . . . . . . . . .0.010 inch (0.254 mm)
- exhaust . . . . . . . . . . . . . .0.020 inch (0.508 mm)
Oil pressure at idle (min) . . . . . .10 p.s.i. (70 KPa)
Oil pressure at rated (min) . . . .30 p.s.i. (207 KPa)
Oil capacity . . . . . . . . . . . . . . . . . . . . . .20.5 litres
Oil grade . . . . . . . . . . . . . . . . : ACEA E5 15W/40
Cooling system capacity . . . . . . . . . . . . . .55 litres
For engine tappet valve clearance see engine

data plate.
SERVICE MANUAL
WARNING
Fuel is flammable. Keep all cigarettes, flame, pilot lights, arcing equipment, and switches out of the
work area and areas sharing ventilation to avoid severe personal injury or death when working with
the fuel system.
WARNING
The pressure of the fuel line is sufficient to penetrate the skin and cause serious bodily harm.
WARNING
Do not bleed a hot engine as this could cause fuel to spill onto the hot exhaust manifold creating a
danger of fire.
WARNING
Before starting the engine, ensure that all spilt fuel is completely removed and the area cleaned.
ISB6.7 Engine and Ancillaries NOTE DAILY FIRST A B C
Carry out all service requirements indicated in the engine manufacturer's literature For all engine information
consult the relevant routine maintenance section in the engine manufacturer's service manual.
Check oil level
Check the security and integrity of silencer and pipes
Check for leaks in oil, water and fuel systems
Check charge air piping for leaks, cracks, and loose connection
Inspect the crankcase breather tube
Check the security of engine and gearbox in chassis
Change oil and filter Refer to Engine and Mountings Section
Inspect water in fuel sensor Refer to Engine and Mountings Section
Check alternator drive belt condition & Tensioner Every 30,000 miles (48,000 km) 1000hrs or 1 yearly
Check air compressor carbon build-up Every 30,000 miles (48,000 km) 1000hrs or 1 yearly
Change fuel filters (engine and remote) Every 38,000 miles (60,000 km) 1500hrs or 1 yearly
Change Urea in-line air filter Every 38,000 miles (60,000 km) 1500hrs or 1 yearly
Inspect vibration damper condition Every 60,000 miles (96,000 km) or 2000 hrs or 2 years
Adjust valve clearances First adjustment at 150,000 miles (241,401 Km) or I5000 hrs 4 years
SERVICE MANUAL
Engine and Mountings Amended:28.10.09
Compressor Discharge Lines Torque Settings

Remove the air compressor discharge line from the
air compressor. Bolt - starter motor . . . . . .. . . . 40 - 46 Nm (29-33 lbf.ft)
Measure the total carbon deposit thickness inside Bolt - alternator mounting . . . . . .. . . . 40 Nm (29 lbf.ft)
the air discharge line as shown. If the total carbon
deposit exceeds 2 mm [1/16 in], clean and inspect Bolt - tandem pump to compressor. . . .
the compressor cylinder head, the valve assembly, . . . . . . . . . . . . . . . . . . . . . .43 ± 3 Nm (31 ± 2.2 lbf.ft)
and the discharge line. Replace if necessary.
Bolt- gearbox to bellhousing - ZF . . . . . . . . . .. (50 Nm)
ID of Discharge Line
Then a ring of bolts is to be torqued up the
sequence as shown in diagram should be
followed.
X X
Refer to Gearbox section for flexplate
fixing details.
ID of Carbon Build up
OK
If the total carbon deposit exceeds specifications,

continue checking the air discharge line connections
up to the first tank until total carbon deposit is less
than 2 mm [1/16 in]. Clean or replace any lines or
connections that exceed this specification.
SERVICE MANUAL
Oil & Filter Drain Interval Procedure

CAUTION
Maintaining the correct oil and filter change intervals
is a vital factor in preserving the integrity of an Fuel sulphur content to be less than or equal to
0.05 mass percent sulphur. If the fuel sulphur
engine. Oil filters must be changed when the oil is content is greater than 0.05 mass percent
changed. The appropriate Operation and sulphur, seek advice from your local Cummins
Maintenance manual must be consulted for detailed distributor.
instructions and specific tables or charts on oil and Extending the oil and filter change interval
filter change intervals. beyond the recommendations will decrease
engine life due to factors such as corrosion,
The maximum recommended oil and filter change deposits and wear.
intervals for ISBe Euro 4 engine powered Buses can The use of ACEA,API & CES formulation oils,
be determined by carrying out the following which do not attain one or more of the following
procedure: lubricant qualifications: A.P.I.CH-4,CH-I A.C.E.A.
E5, E7. C.E.S. 20071, C.E.S. 20072, C.E.S. 20076,
1. Determine the appropriate oil drain interval, C.E.S. 20077 and C.E.S 20078 .
refer to the table on the following page,
Oils which do not comply with the specification
Table 1.
listed above, are used in Cummins automotive
2. Determine the vehicle(s) average speed engines, problems such as wear to overhead,
category(s), representative of the vehicles(s) sliding tappets, camshaft and crankshaft
operation, determined within the appropriate bearings may be experienced. Cylinder bore
table. glazing may also be experienced.
3. If the operation of the vehicle(s) encroaches The responsibility is with the owner if the
recommendations are ignored, and warranty
across the specified average speed category
could be affected.
boundaries, then the lesser vehicle speed
category should be used. Any Warranty claims which could be oil related,
must be accompanied by complete service
4. Ensure lubricant selection (ACEA, API, or
history details of the following, prior to any
CES) conforms to the specifications detailed in warranty assessment being undertaken:
the table.
1. The oil type, specification and supplier.
5. Determine the appropriate drain interval,
2. Oil drain intervals.
defined by your selection of oil quality and
vehicle average operational speed. 3. Injector, valves, and engine brake, lash
adjustments.
4. Oil filter type and supplier.
5. Application duty cycle.
NOTE
A change in vehicle application/duty
cycle will require a reassessment of the
established oil drain interval.
SERVICE MANUAL
Engine and Mountings Amended:28.11.13
OIL DRAIN INTERVAL PROCEDURE (Continued)
TABLE 1
Maximum Oil Drain Intervals for
 ISB6.7- 6 Cylinder (GVW up to 18 tonne)

Vehicle Speed Category
Oil Type Drain Interval < 10 kph 10 - 15 kph 15 - 20 kph 20 - 25 kph 25 - 30 kph
whichever (6.2 mph) (6.2 - 9.3 mph) (9.3 - 12.5 mph)(12.5 - 15.5mph) (15.5-18.6 mph)
occurs first
ACEA E5 km 11,000 km 15,000 km 22,500 km 30,000 km 37,500 km
ACEA E7 Miles 6835 miles 9320 miles 13980 miles 18641 miles 23301 miles
API CH4, CI4 hours 1500 hrs 1500 hrs 1500 hrs 1500 hrs 1500 hrs
CES 20071 months 6 6 6 6 6
CES 20072 Oil filters MUST be changed when the oil is changed.
CES 20076 The inline air and fuel filters MUST also be changed at the relevant intervals.
CES 20077
CES 20078
NOTE 1
If CG4/SH oil is used within a vehicle, with a GVW in excess of the tabulation limit, then the oil change
interval must be reduced to one quarter of the interval given in the maintenance schedule.
NOTE 2
CG4/SH oils can be used in areas where none of the recommended oils are available, but the oil
change interval must be reduced to one half the interval given in the maintenance schedule.
NOTE 3
If the vehicle GVW is in excess of the tabulation limit, the oil change interval must be reduced to one
half of the interval given in the maintenance schedule.
NOTE 4
A.C.E.A = Association des Constructeurs Européen d’Automobiles.
A.P.I. = American Petroleum Institute.
C.E.S. = Cummins Engineering Standard.
SERVICE MANUAL
Engine and Mounting - Cummins ISB6.7 Fault Codes Amended:18.11.09
Cummins Engine - Fault Code Readout

Should the engine management warning lamps (Red or
Yellow) on the instrument panel fail to go out on start up or
come on whilst driving, the ECU has detected an ACTIVE
fault in the engine management system and logged an
appropriate fault code in its fault memory.
Viewing INACTIVE (non current) codes and erasing the fault
memory can only be performed using the Cummins 'INSITE'
diagnostic tool.
Engine Fault (Red)

This light illuminates to indicate a major engine
fault has occurred. The vehicle should be stopped
as soon as it is safe to do so and the engine
switched off until the fault is rectified.
Engine Fault (Yellow)

If the yellow warning light adjacent to the engine symbol
illuminates, a minor engine fault has occurred. The vehicle
can still be driven but the fault must be rectified as soon as
possible.
15
10 20
r/min
x100
5 25
0 30
10 bar
0 2
Types of Fault
There are two types of fault codes stored by the system:
Engine electronic fuel system codes
Maintenance system codes
The Engine electronic fuel system faults codes use both the
YELLOW WARNING and RED STOP lamps
If the RED STOP lamp lights the vehicle must be driven
safely to the side of the road, handbrake applied and the
engine stopped. The vehicle must not be driven until the
fault is rectified.
If the YELLOW WARNING lamp lights the vehicle can be
driven safely; with the fault corrected as soon as possible
NOTE
This can be accompanied by rough running or a
gradual reduction in engine power and speed.
SERVICE MANUAL
Engine and Mounting - Cummins ISB6.7 Fault Codes Amended:
FAULT CODE: 111 Lamp: Red

Reason: Internal hardware error.
Effect on Engine: Possible no effect or engine will die or hard starting

Reason: Engine speed & backup speed sensor, signals reversed.
Effect on Engine: Fuelling to injectors disabled - no start
FAULT CODE: 122 Lamp: Yellow

Reason: High voltage detected at the intake manifold pressure circuit
Effect on Engine: Engine power derate.
Reason: Low voltage or open circuit detected at the intake manifold pressure circuit
Reason: High voltage detected at the accelerator position signal circuit .
Effect on Engine: Severe derate in power output - Limp home power only.

Reason: Low voltage detected at the accelerator position signal circuit .
Effect on Engine: Severe derate in power output - Limp home power only.

Reason: High voltage detected at the remote accelerator position circuit.
Effect on Engine: Remote accelerator will not operate. position set to 0.

Reason: Low voltage detected at the remote accelerator position circuit.
Effect on Engine: Remote accelerator will not operate. position set to 0.

Reason: High voltage detected at oil pressure circuit.
Effect on Engine: None on performance. No engine protection for oil pressure.

Reason: High signal voltage or open circuit detected at engine coolant temperature circuit.
Effect on Engine: Possible white smoke.Fan will stay on if ECM controlled. No engine protection for
coolant temperature.

Reason: Low signal voltage or open circuit detected at engine coolant temperature circuit.

Reason: Coolant temperature signal indicates coolant temperature above engine protection
critical limit.
Effect on Engine: Power and/or speed derate. If engine shutdown feature is enabled, engine will
shutdown in 30 seconds after red stop light stops flashing.

Reason: High voltage or open circuit detected at the intake manifold air temperature circuit.
intake manifold air temperature.
SERVICE MANUAL

Reason: Low voltage or shorted to low source detected at the intake manifold air temperature
circuit.
intake manifold air temperature.

Reason: Intake manifold air temperature signal indicates intake manifold air temperatures
above the engine protection critical limit .
Effect on Engine: Progressive power derate increasing from time of alert. If engine shutdown feature is
enabled, engine will shutdown in 30 seconds after red stop light stops flashing.
Reason: Low voltage detected at thesupply number 2 circuit.


Reason: High signal voltage detected at engine coolant level circuit.
Effect on Engine: None on performance

Reason: Low signal voltage detected at engine coolant level circuit.

Reason: Coolant temperature signal indicates coolant level is at a moderately severe low level.
Reason: High signal voltage detected at the barimetric pressure circuit.


Reason: Low signal voltage detected at the barimetric pressure circuit.

Reason: High voltage detected at sensor supply number 2 circuit.

Reason: Engine speed signal indicates engine speed has exceeded the overspeed limit.
Effect on Engine: Fuel injection disabled until engine speed falls below the overspeed limit.

Reason: Coolant level signal indicates coolant level is low.
Effect on Engine: Progressive power derate. If engine shutdown feature is enabled, engine will
shutdown in 30 seconds after red stop light stops flashing.
Reason: Low voltage detected on the +5 sensor supply circuit line to the engine harness.
Effect on Engine: Default value used for oil pressure sensor connected to this + 5 VDC supply and no
engine speed sensor.
SERVICE MANUAL

Reason: The vehicle speed signal has been lost.
Effect on Engine: Engine speed limited to "Max Engine Speed without VSS", Cruise control, gear-down
protection and the road speed governor will not work.

Reason: The vehicle speed signal is intermittent.
Effect on Engine: Engine speed limited to "Max Engine Speed without VSS", Cruise control, gear-down
protection and the road speed governor will not work.

Reason: Error detected on one or more of the lamp circuits. Error could be open circuits, or
short circuits to battery or ground on any lamp except diagnostic lamp.
Effect on Engine: Lamp will not come on during the key on bulb test if there is an open circuit or short
circuit to battery. Lamp will stay on if shorted to ground.

Reason: Low signal voltage detected at the fan control circuit when commanded on.
Effect on Engine: Fan may stay on continuously or may not run at all.

Reason: Very low oil level has been detected by the oil level sensor. Most severe level.
. Effect on Engine: The engine may derate possible low oil pressure, possible severe engine damage.

Reason: Engine ignition attempt when the vehicle anti-theft feature is active.
Effect on Engine: The engine will not start.
Reason: Low voltage or short circuit detected on the electronic fuel control actuator circuit.
Effect on Engine: Runs poor at idle, low power. higher fuel presure than commanded.

Reason: Open circuit detected on the electronic fuel control actuator circuit
Effect on Engine: Power derate to calibrated value.

Reason: A pumping imbalance between the front & rear pumping plungers has been detected.
Effect on Engine: Engine will not run or possible low power.

Reason: SAE J1939 Multiplexing PGN time out error. Multiplexed device did not receive
information soon enough or did not receive it at all
Effect on Engine: At least one multiplexed device will not operate properly.

Reason: SAE J1939 Multiplexing accelerator pedal of lever sensor error. Multiplexed device
only received a portion of the necessary information.
Effect on Engine: At least one multiplexed device will not operate properly.

Reason: SAE J1939 Multiplexing configuration error. VECU has detected a fault with the
accelerator pedal.
Effect on Engine: Engine may only idle or engine will not accelerate to full speed.
SERVICE MANUAL

Reason: The OEM vehile ECU has detected a fault with the remote accelerator.
Effect on Engine: The engine will not respond to the remote throttle. Engine may only idle.

Reason: The ECM cannot communicate with the immobilizer anti-theft system.
Effect on Engine: Immobilizer anti-theft system will not operate properly. The engine may not start

Reason: The ambient air pressure sensor is reading erratic value at initial key-on.
FAULT CODE: 319 Lamp: Maintenance

Reason: Real Time Clock lost power. Unswitched battery power to the electronic control
module (ECM) has been interrupted.
Effect on Engine: None on performance. Data in ECM may not have accurate time and date
information.

Reason: Injector solenoid driver cylinder 1 circuit - current below normal or open circuit. High
resistance or no current detected at number 1 injector driver or return pin.
Effect on Engine: Engine can possibly misfire or run rough

AULT CODE: 332 Lamp: Yellow
Reason: The engine coolant temperature is not changing with engine operating conditions.
Effect on Engine: The ECM will estimate the engine coolant temperature.

Reason: Internal ECM failure.
Effect on Engine: None on performance or severe derate.
SERVICE MANUAL

Reason: The ECM measured injector boost voltage is low.
Effect on Engine: Possible smoke, low power, engine misfire, and/or engine will not start.

Reason: Sensor supply circuit 1 - voltage below normal or shorted to low source. Low voltage
detected at sensor supply number 1.

Reason: Sensor supply circuit 1 - voltage above normal or shorted to high source. High voltage
detected at sensor supply number 1.

Reason: Oil pressure signal indicates oil pressure below the very low engine protection limit.
Most Severe level
Effect on Engine: Progressive power derate increasing from time of alert. If engine shutdown feature is
enabled, engine will shutdown in 30 seconds after red stop light stops flashing.

Reason: Water-in-fuel signal. Water has been detected in the fuel system.
Effect on Engine: Possible white smoke loss of power or hard starting.
FAULT CODE: 427 Lamp: None

Reason: Communication between the ECM and another device on the J1939 datalinkhas been
lost.
Effect on Engine: Engine will ramp down and remain at idle.

Reason: Error detected in the water-in-fuel signal. Voltage above normal or shorted to high
source. High voltage detected in water in fuel circuit.
Effect on Engine: None on performance. No detection capability for water-in-fuel.

Reason: Error detected in the water-in-fuel signal. Voltage below normal or shorted to low
source. Low voltage detected in water in fuel circuit.
Effect on Engine: None on performance.No detection capability for water-in-fuel.

Reason: Accelerator pedal or lever Idle validation switch. Data erratic, intermittent or incorrect.
Voltage detected simultaneously on both idle & off-idle validation switches.
Effect on Engine: Engine will only idle.

Reason: Idle validation signal indicates the accelerator is at the idle position when the
accelerator position signal indicates the accelerator is not at the idle position. OR idle
validation signal indicates the accelerator is not at the idle position when the
accelerator is at the idle position.

Reason: Power supply lost with ignition on. Data erratic, intermittent or incorrect Supply voltage
to ECM fell below 6.2 volts momentarily. ECM was not allowed to power down
correctly.
Effect on Engine: None on performance. possible dying or hard starting. Fault & trip information data
and maintenance monitor data can be inaccurate.
SERVICE MANUAL

Reason: An error in the engine oil pressure switch was detected by the ECM.
Effect on Engine: None on performance. No protection for engine oil pressure .

Reason: Th engine intake manifold temperature sensor is reading an erratic value at key-on.
Effect on Engine: The ECM will estimate the the engine intake manifold temperature .

Reason: Battery 1 Voltage. Moderately Severe level.ECM supply voltage is below the minimum
system voltage.
Effect on Engine: Engine may stop running or be difficult to start.

Reason: Battery 1 Voltage. Moderately Severe level. ECM supply voltage is above the
maximum system voltage.
Effect on Engine: Possible damage to all electrical components.

Reason: High voltage detected at fuel pressure sensor signal pin 12 of the engine harness.
Effect on Engine: Power and/or speed derate.

Reason: Low oil level has been detected. by the oil level sensor.
Effect on Engine: The engine may derate. possible low oil pressure. Possible Severe engine damage.

Reason: Engine oil level sensor circuit. Voltage above normal or shorted to high source. High
voltage detected at engine oil sensor circuit.
Effect on Engine: No protection for low engine oil level.

Reason: Engine oil level sensor circuit. Voltage below normal or shorted to low source. Low
voltage detected at engine oil sensor circuit.
Effect on Engine: No protection for low engine oil level.

Reason: Intake manifold pressure has exceeded the maximum limit for the given engine rating.

Reason: No voltage detected simultaneously on both the idle validation off-idle and on-idle
circuits.
Reason: The ECM has detected a fuel pressure higher than the commmanded pressure.
Effect on Engine: Engine noise associated with high injection pressure. Engine power reduced.
Reason: The ECM has detected a fuel pressure lower than the commmanded pressure.
Effect on Engine: Possibly hard to start, low power or engine smoke.
Reason: Open circuit or high voltage detected at starter lockout circuit.
Effect on Engine: Engine will not start or will not have starter lock out protection.
SERVICE MANUAL

Reason: Low voltage detected at starter lockout circuit.
Effect on Engine: The engine will have no starter lockout protection.

Reason: High battery voltage detected by the battery voltage monitor feature.
Effect on Engine: Yellow lamp will light until high battery voltage condition is corrected.

Reason: Low battery voltage detected by the battery voltage monitor feature.
Effect on Engine: Yellow lamp will light until low battery voltage condition is corrected.

Reason: Very low battery voltage detected by the battery voltage monitor feature.
Effect on Engine: Red lamp will light until very low battery voltage condition is corrected.

Reason: Engine oil change interval Change engine oil and filter.
Effect on Engine: None on perfomance.

Reason: Most severe level. High oil level has been detected by the oil level sensor.
Effect on Engine: Possible low power, excessive smoke, oil dilution, contamination or svere engine
damage. The engine may derate.

Reason: Loss of signal for the crankshaft level sensor.
Effect on Engine: Rough running, possible poor starting. Engine runs using back up speed sensor.
Engine power reduced.

Reason: Mechanical misalignment of the camshaft and the crankshaft engine speed sensors.
Effect on Engine: Engine will run derated. excessive back smoke. Hard start and rough idle.

Reason: The ECM has detected an error in the camshaft position sensor signal.
Effect on Engine: Possible poor starting. Engine power derate.

Reason: Power Supply Lost With Ignition On -Data Erratic intermittent or incorrect.
Effect on Engine: Possible no effect or engine dying or hard starting. Fault & Trip information and
maintenance data maybe in accurate..

Reason: Injector Solenoid Driver Cylinder 1. Mechanical System Not Responding Properly or
Out of Adjustment. Unintended fueling detected in cylinder number 1
Effect on Engine: Engine will shutdown.


SERVICE MANUAL




Reason: Engine Misfire Cylinder 1 - Condition Exists. Engine misfire has been detected in
cylinder number 1.
Effect on Engine: Possible low power, rough idle, or misfire.

cylinder number 1.

cylinder number 2.

cylinder number 3.

cylinder number 3.

cylinder number 4.

cylinder number 5.

Reason: Catalyst Inlet Temperature Sensor Swapped with The inlet and outlet cataIyst
temperature sensor connections are swapped.
Effect on Engine: Catalyst solution injection into the aftertreatment.system is disabled
SERVICE MANUAL

Reason: Catalyst Sensor Swapped with outlet condition exists. The inlet and outlet. The inlet
and outlet cataIyst temperature sensors connections are swapped.
Effect on Engine: Catalyst solution injection into the aftertreatment system is disabled.

Reason: Catalyst missing. Condition exists. The inlet and outlet cataIyst temperature sensor
connections are swapped.
Effect on Engine: Catalyst solution injection into the aftertreatment system is disabled

Reason: Exhaust Gas Temperature 1 Circuit . Voltage Below Normal, or Shorted to Low
Source. Low signal voltage detected at the catalyst inlet temperature sensor circuit
Effect on Engine: Possible emissions non-compliance. Default temperature used for catalyst inlet
temperature.

Reason: Exhaust Gas Temperature 1 Circuit . Voltage above Normal, or Shorted to high
Source. High signal voltage detected at the catalyst inlet temperature sensor circuit
Effect on Engine: Possible emissions non-compliance. Default temperature used for catalyst inlet
temperature.

Reason: Exhaust Gas Temperature 1 Circuit. Data Erratic, Possible Intermittent, or Incorrect.
The catalyst inlet temperature sensor is not changing with engine operating con-
ditions.
Effect on Engine: Possible emissions non-compliance. Default temperature value used for catalyst inlet
temperature.
Reason: Catalyst Tank Level Sensor Circuit Voltage Below Normal, or Shorted to Low
Source.Low signal voltage detected at the catalyst tank level sensor circuit.
Reason: Catalyst Tank Level Sensor Circuit Voltage above Normal, or Shorted to high Source.
High signal voltage detected at the catalyst tank level sensor circuit.
Reason: Catalyst Tank Level . Data Valid but Below Normal Operational Range -Moderately
Severe Level. Low catalyst solution level has been detected in the catalyst solution
tank.
Effect on Engine: None on performance.
Reason: Catalyst Tank Level . Data Valid but Below Normal Operational Range -most severe
Level. No catalyst solution has been detected in the catalyst solution tank.
Reason: Exhaust Gas Temperature 2 Circuit -Voltage Below Normal, or Shorted to Low
Source. Low signal voltage detected at the catalyst exhaust temperature sensor
circuit.
Effect on Engine: Possible emissions non-compliance. Default temperature used for catalyst exhaust
temperature sensor circuit.
SERVICE MANUAL

Reason: Exhaust Gas Temperature 2 Circuit - Voltage above Normal, or Shorted to high
Source. High signal voltage detected at the catalyst outlet temperature sensor circuit.
Effect on Engine: Possible emissions non-compliance. Default temperature used for catalyst outlet
temperature sensor circuit.
Reason: Exhaust Gas Temperature 2 Circuit - Data Erratic, Possible Intermittent, or Incorrect.
The catalyst outlet temperature sensor is not changing with engine operating
conditions.
Effect on Engine: Possible emissions non-compliance. Default temperature value used for catalyst
outlet temperature.
Reason: Catalyst tank Temperature - Voltage below Normal, or Shorted to low Source. Low
signal voltage detected at the catalyst tank temperature circuit.
Effect on Engine: Default temperature value used for catalyst outlet temperature.
Reason: Catalyst tank Temperature - Voltage above Normal, or Shorted to high Source. High
signal voltage or open circuit detected at the catalyst tank temperature sensor circuit.
Reason: Catalyst tank Temperature - Data Erratic, Possible Intermittent, or Incorrect. The
catalyst tank temperature sensor is not changing with engine operating conditions.
Reason: Catalyst Dosing Control Unit -Bad Intelligent Device or Component. An internal error
has been detected in the catalyst dosing control unit. .
Reason: Catalyst Reagent Dosing Unit Input Lines -Condition Exists. An error has been
detected by the cataIyst dosing control unit.
Reason: Catalyst Tank Heater Circuit -Voltage Above Normal, or Shorted to High Source. High
signal voltage or open circuit has been detected at the catalyst tank heater relay
sensor circuit.
Effect on Engine: Catalyst tank heater will be disabled.
Reason: Catalyst Over Temperature -Data Valid but Above Normal Operational Range -Most
Severe Level. Very high temperatures have been detected in the aftertreatment
system.
Reason: Real Time Clock Power Interrupt -Data Erratic, Intermittent, or Incorrect. The real time
clock power has been interrupted.
Effect on Engine: None on performance. Data in the ECM will not have accurate time and date
information.
SERVICE MANUAL

Reason: Air Supply Actuator -Voltage above Normal, or Shorted to high Source. Hogh signal
voltage has system detected at the dosing control unit air solenoid circuit.
Reason: Air Supply Actuator -Voltage below Normal, or Shorted to low Source. Low signal
voltage has system detected at the dosing control unit air solenoid circuit.
Reason: Catalyst Tank Level Sensor -Data Erratic, Intermittent, or Incorrect. Catalyst solution
level is not changing with engine operating conditions.
Reason: Dosing Control Unit Datalink -Abnormal Update Rate. Datalink communications
between the ECMand the catalyst dosing unit has been interrupted.
Reason: Catalyst Tank Heater Circuit -Data Valid but Below Normal Operating Range -
Moderately Severe Level. The catalyst solution temperature did not increase when
the catalyst tank heater was commanded ON.
Effect on Engine: None on performance. Catalyst solution injection into the aftertreatment system may
be disabled if the catalyst solution is frozen.
Reason: Catalyst Tank Heater Circuit -Data Valid but Above Normal Operating Range -
Moderately Severe Level. The catalyst tank heater is continuously in the ON position.
Effect on Engine: None on performance.
Reason: Auxiliary Temperature Sensor Input 1 Circuit - Root Cause Not Known. High
temperature detected by the OEM temperature sensor.
Effect on Engine: Possible engine power derate.
Reason: Exhaust Gas Temperature 1 - Data Valid but Above Normal Operational Range - Least
Severe Level.
Effect on Engine: Possible engine derate.
Reason: Engine Misfire for Multiple Cylinders -Condition. Engine misfire has been detected in
multiple cylinders.
Reason: Intake Manifold 1 Temperature -Abnormal Rate of Change. The intake manifold
temperature sensor is not responding to a change in engine operating conditions
Effect on Engine: The ECM will estimate engine intake manifold temperature.
Reason: Exhaust Gas Temperature 1 -Abnormal Rate Change. The catalyst inlet temperature
sensor is not responding to a change in engine operating conditions.
Effect on Engine: Possible emissions non-compliance. Default temperature value used for catalyst inlet
temperature.
Reason: Exhaust Gas Temperature 2 -Abnormal Rate of Change. The catalyst outlet
temperature sensor is not responding to a change in engine operating conditions
Effect on Engine: Possible emissions non-compliance. Default temperature value used for catalyst
outlet temperature.
SERVICE MANUAL

Reason: Wheel-Based Vehicle Speed -Data Valid but Below Normal Operational Range -
Moderately Severe Level. The ECM lost the vehicle speed signal.
Effect on Engine: Engine speed limited to Maximum Engine Speed without VSS parameter value.
Cruise control, gear down protection, and road speed governor will not work.

Reason: Injector Metering Rail 1 Pressure -Data Valid but Above Normal Operational Range -
Most Severe Level. Fuel pressure signal indicates that fuel pressure has exceeded
the maximum limit for the given engine rating.
Effect on Engine: None or possible engine noise associated with higher injection pressures (especially
at idle or light load). Engine power is reduced.
Reason: Engine Brake Actuator Driver 1 Circuit -Voltage Below Normal, or Shorted to Low
Source. Low voltage detected at the engine brake solenoid number 1 signal circuit.
Effect on Engine: The exhaust brake will not operate.

Reason: Sensor Supply 4 Circuit -Voltage Above Normal or Shorted to High Source. High
voltage detected at + 5 volt sensor supply circuit to the accelerator pedal position
sensor
Reason: Sensor Supply 4 Circuit -Voltage below Normal or Shorted to low Source. Low voltage
detected at + 5 volt sensor supply circuit to the accelerator pedal position sensor
Reason: Engine Control Module Calibration Program Memory (RAM) Corruption - Condition
Exists. Severe loss of data from the ECM.
Effect on Engine: Possible no performance effects or engine dying or hard starting. Fault & Trip
information and maintenance monitor data maybe in accurate.

Reason: Engine Crankshaft Speed/Position Sensor -Data Erratic, Intermittent, or incorrect.
Crankshaft engine speed sensor Intermittent synchronization.
Effect on Engine: Possible low power.
Reason: Engine Camshaft Speed/Position Sensor -Data Erratic, Intermittent, or incorrect.
Camshaft engine speed sensor Intermittent synchronization.
Effect on Engine: Possible low power.
Reason: Fan Control Circuit -Voltage Above Normal,Shorted to High Source. Open circuit or
high voltage detected at the fan control circuit. Open circuit or high voltage detected
at the fan control circuit.
Effect on Engine: The fan may stay on continuously or not at all.

Reason: Intake Air Heater 1 Circuit -Voltage Above Normal, or Shorted to High Source. High
voltage detected at the intake air heater signal circuit.
Effect on Engine: The intake air heaters may be ON or OFF all the time.

Reason: Intake Air Heater 1 Circuit -Voltage below Normal, or Shorted to low Source. Low
voltage detected at the intake air heater signal circuit.
Effect on Engine: The intake air heaters may be ON or OFF all the time.
SERVICE MANUAL

Reason: Auxiliary PWM Driver 1 Circuit -Voltage Above Normal, or Shorted to High Source.
High signal voltage detected at the analog torque circuit.
Effect on Engine: Can not control transmission.

Reason: Auxiliary PWM Driver 1 Circuit -Voltage below Normal, or Shorted to Low Source. Low
signal voltage detected at the analog torque circuit.
Effect on Engine: Can not control transmission.

Reason: Engine Coolant Temperature -Data Valid but Above Normal Operational Range -Least
Severe Level. Engine coolant temperature signal indicates engine coolant
temperature is above engine protection warning limit.
Effect on Engine: Power derate and possible engine shutdown if Engine Protection Shutdown feature is
enabled.
Reason: Intake Manifold 1 Temperature -Data Valid but Above Normal Operational Range -
Lease Severe Level. Intake manifold air temperature signal indicates intake manifold
air temperature is above the engine protection warning limit.
Effect on Engine: Progressive power derate increasing in severity from time of alert.
Reason: Intake Manifold 1 Pressure -Data Erratic, Intermittent, or Incorrect. The ECM has
detected an intake manifold pressure signal that is too high or low for current engine
operating conditions.

Reason: Engine Coolant Temperature - Condition Exists. Engine coolant signal indicates
coolant temperature is above the engine coolant temperature engine protection
warning limit.

Reason: Aftertreatment Outlet NOx Sensor - Abnormal Update Rate. No communications or
valid data transfer rate detected on the J1939 datalink between the ECM and the
aftertreatment outlet NOx sensor.
Effect on Engine: Aftertreatment outlet NOx sensor operation will be disabled. Engine will derate after
running 50 hours with the fault active.

Reason: Aftertreatment Outlet NOx - Data Valid but Above Normal Operational Range - Least
Severe Level. The engine NOx output is higher than recommended levels.
Effect on Engine: Aftertreatment Outlet NOx Sensor operation will be disabled.

Reason: Aftertreatment Outlet NOx - Data Valid but Above Normal Operational Range - Most
Severe Level. The engine NOx output is higher than recommended levels.
Effect on Engine: Aftertreatment outlet NOx sensor operation will be disabled. Engine will derate the
next time that the vehicle sees zero vehicle speed.
SERVICE MANUAL

Reason: Exhaust Gas Recirculation (EGR) temperature - Data Valid but Above Normal
Operating Range, Least Severe Level.
Effect on Engine: Engine power derate until the EGR temperature is under the maximum limit.

Reason: Exhaust Gas Recirculation (EGR) temperature - data valid but above normal
operating range, moderately severe level.
Effect on Engine: Severe fueling derate to bring EGR temperature under the maximum limit.

Reason: Engine Coolant Temperature High - Data Valid but Above Normal Operational Range
- Least Severe Level. Engine coolant temperature signal indicates coolant
temperature is above the engine coolant temperature engine protection warning limit.

Reason: Intake Manifold Temperature High - Data Valid but Above Normal Operational Range
- Least Severe Level. Intake manifold air temperature signal indicates intake manifold
air temperature above engine protection warning limit.
Effect on Engine: Automotive application: Progressive power derate increasing in severity from time of
alert.

Reason: Intake Manifold Pressure Sensor Circuit - Data Erratic, Intermittent or Incorrect. The
ECM has detected an intake manifold pressure signal that is too high or low for
current engine operating conditions.

Reason: Dosing Control Unit Temperature — Data Erratic, Intermittent, or Incorrect. An internal
error has been detected in the catalyst dosing control unit.
Effect on Engine: Catalyst solution injection into the aftertreatment system in disabled.
FAULT CODE: 3142 Lamp: Amber

Reason: Aftertreatment SCR Intake Temperature Sensor Circuit - Voltage Above Normal or
Shorted to High Source. High signal voltage detected at the SCR intake temperature
sensor circuit.
Effect on Engine: Default temperature value used for SCR intake temperature.
Reason: Aftertreatment SCR Intake Temperature Sensor Circuit - Voltage Below Normal or
Shorted to Low Source. Low signal voltage detected at the SCR intake temperature
sensor circuit.
Reason: Aftertreatment SCR Intake Temperature - Data Erratic, Intermiitent, or Incorrect.. The
SCR intake temperature sensor is not changing with engine operating conditions.
Reason: Aftertreatment SCR Intake Temperature Sensor - Abnormal Rate of Change. The
SCR catalyst intake temperature sensor is not responding to a change in engine
Effect on Engine: Default temperature value used for SCR catalyst intake temperature.
SERVICE MANUAL

Reason: Aftertreatment SCR Outlet Temperature Sensor Circuit - Voltage Above Normal or
Shorted to High Source. High signal voltage detected at the SCR outlet temperature
sensor circuit.
Effect on Engine: Default temperature value used for SCR outlet temperature.

Reason: Aftertreatment SCR Outlet Temperature Sensor Circuit - Voltage Below Normal or
Shorted to Low Source. Low signal voltage detected at the SCR outlet temperature
sensor circuit.
Effect on Engine: Default temperature used for SCR exhaust temperature.
Reason: Aftertreatment SCR Outlet Temperature Sensor - Data erratic, intermittent or
incorrect. The SCR outlet temperature sensor is not changing with engine operating
conditions.
Effect on Engine: Default temperature value used for SCR outlet temperature.
Reason: Aftertreatment SCR Outlet Temperature Sensor - Abnormal Rate of Change. The
SCR catalyst outlet temperature sensor is not responding to a change in engine
Effect on Engine: Default temperature value used for SCR catalyst outlet temperature.
Reason: Aftertreatment SCR Catalyst System Missing - Condition Exists. The aftertreatment
SCR catalyst in the exhaust system is not present.
Effect on Engine: Diesel exhaust fluid solution injection into the aftertreatment system is disabled.
Reason: Aftertreatment SCR Intake Temperature Sensor Swapped - Out of Calibration. The
SCR intake and outlet temperature sensor connections are swapped.
Effect on Engine: Diesel exhaust fluid injection into the SCR aftertreatment system is disabled.
Reason: Aftertreatment SCR Intake Temperature - Data Valid But Above Normal Operating
Range - Least Severe Level. High SCR intake temperature has been detected.
Effect on Engine: Possible engine derate.
Reason: Aftertreatment SCR Intake Temperature - Data Valid But Above Normal Operating
Range - Moderately Severe Level. High SCR intake temperature has been detected.
Reason: Aftertreatment SCR Outlet Temperature - Data Valid But Above Normal Operating
Range - Least Severe Level. High SCR outlet temperature has been detected.
Reason: Aftertreatment SCR Outlet Temperature - Data Valid But Above Normal Operating
Range - Moderately Severe Level. High SCR outlet temperature has been detected.
Reason: Aftertreatment Diesel Exhaust Fluid Line Heater 1 Circuit - Voltage Above Normal or
Shorted to High Source. High signal voltage detected at the diesel exhaust fluid line
heater 1 relay circuit.
Effect on Engine: Diesel exhaust fluid line heater 1 will be disabled.
SERVICE MANUAL

Reason: Aftertreatment Diesel Exhaust Fluid Line Heater 1 Circuit - Voltage Below Normal or
Shorted to Low. Low signal voltage detected at the diesel exhaust fluid line heater 1
relay circuit.
Effect on Engine: Diesel exhaust fluid line heater 1 will be disabled.
Reason: SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System - Abnormal
Update Rate. The ECM expected information from a multiplexed accelerator pedal or
lever sensor but did not receive it soon enough or did not receive it at all.
SERVICE MANUAL
Automatic Oil Level System (Option) Amended:24.04.12
Automatic Oil Level Control System "Oil Master"

Key to Diagram
1. Control Unit
2. Non return valve
3. Metering chamber
4. Level float switch
5. Gear pump
6. Non return valve
7. Level float switch
8. Signal light harness
Description
This system monitors the oil level in the
engine sump and automatically
replenishes the oil, when required.
The system comprises of an oil storage
reservoir (12.5 litres) with an integrated
pump unit. The systems digital control has
been integrated with the pump unit. The
pump unit comprises of an oil metering
chamber, which it uses to accurately
measure out the quantity of oil it adds to
the engine.
The system measures the oil level in the engine by means of sump mounted sensor. The control unit maintains an
electronic log of all errors and other events concerning the system.
When the driver switches the vehicles ignition on, the electronics of the system performs a self-test. During that test, the
control units checks whether the pump, the electrical connections and the sensors are in order. Subsequently, the system
measures the oil level in the sump of the engine and the oil level in the storage reservoir.
If the oil level in the sump is too low, the system will pump a quantity of oil from the reservoir, via the metering chamber,
to the engine. The amount of oil added to the engine is specified in the control unit, expressed as a number of pump
cycles. During one pump cycle the whole contents of the metering chamber (0.5 litre) will be added to the oil in the engine.
The quantity of oil added during a single pump cycle is always the same.
NOTE
The engine oil level must still be checked according to the service schedule
System Activation
The system will be activated each time the ignition is switched on, after being switched off for at least 30 minutes.
SERVICE MANUAL
Fill
Point
Oil
Reservoir
Breather
Level
Sensor
Sump
Coupling
SERVICE MANUAL
Replenishing Procedure
As soon as the control unit (1) receives a signal, it measures the oil level
in the engine with the oil level sensor(4). The pump cycle starts with
filling the metering chamber. The gear pump (5) transfers oil from the
storage reservoir via a non-return valve (2), to the metering chamber (3)
until the level float switch (4) in the chamber signals it is full.
Subsequently, the direction of the pump is reversed. The pump now

transfers the oil, via a second non return valve (6), in the metering
chamber to the sump of the engine. Because the float switch in the
metering chamber cannot detect whether the chamber has been
emptied, the pump will continue running longer than usually necessary
to empty the metering chamber.
Filling the Metering Chamber
The storage reservoir is also fitted with a level float switch. If the Storage
reservoir becomes (nearly) empty, this switch will indicate that fact to
the control unit, which in turn will warn the driver by means of the signal
light on the instrument panel.
Pump Cycle Test (only for vehicles with test button

mounted on dash)
• Fill the storage reservoir with oil
• Check all the oil pipes and connections for leakage.
Test
After switching the vehicles ignition on a pump cycle test can be
performed regardless of the oil level in the sump of the engine.
Replenishing the Engine Oil
Use this test carefully. Each time you execute this test oil will be added
to the engine, probably without this being necessary
• Turn the vehicles ignition to on.
• Depress the test push button on the instrument panel for at least 5 seconds. The pump cycle test will then be
executed.
NOTE
If you switch the ignition off during the pump cycle, and subsequently switch it on again, the
interrupted pump cycle will automatically be completed.
Determining the Oil Level in the Sump (Only for variants with dash switch)
• Turn on the ignition.
• Press the push button three times within 5 seconds.
• If the signal light flashes slowly (2.5 seconds on - 2.5 seconds off), three times, the oil level sensor reports the oil
level is.correct
• If the signal light flashes slowly (1 seconds on - 1 seconds off), three times, the oil level sensor reports the oil level
in the sump is too low.
NOTE
For further information please refer to Greoneveld General Manual Publication Number : GE0214.
SERVICE MANUAL
Air Conditioning (Option) Amended:010812
Air Conditioning Compressor Belt Tension

The A/C drive belt the tension should be set to 380N using belt tensioning gauge as shown below:
This is equivalent to a Frequency reading of 109 Hz.
Measuring Air Conditioning Compressor Belt Tension
SERVICE MANUAL
Transmission Amended:18.11.09
Contents
ZF Gearbox Rear Axle

Diagram . . . . . . . . . . . . . . . . Page 3.2 Introduction . . . . . . . . . . . . . . Page 3.16
Maintenance . . . . . . . . . . . . . Page 3.3 Towing . . . . . . . . . . . . . . . . . Page 3.16
Checking oil level . . . . . . . . . Page 3.3 Maintenance . . . . . . . . . . . . . Page 3.16 -17
Oil & filter change . . . . . . . . . Page 3.4 General working practices . . . Page 3.18
Oil fill . . . . . . . . . . . . . . . . . . Page 3.4
Examples of tooth contact . . . Page 3.19 - 20
Push button illumination . . . . Page 3.5
Adjustment values . . . . . . . . . Page 3.21
Display of errors . . . . . . . . . . Page 3.5
Output Disassembly . . . . . . . Page 3.22 - 26
Diagnostic equipment . . . . . . Page 3.5
Drop Centre Drive . . . . . . . . . Page 3.27 - 29
Flexplate . . . . . . . . . . . . . . . . Page 3.6
Fastener torque . . . . . . . . . . . Page 3.7 Differential . . . . . . . . . . . . . . Page 3.30 - 47
Troubleshooting . . . . . . . . . . Page 3.7 Drop Centre Drive refitting . . . Page 3.48 - 58

Hub . . . . . . . . . . . . . . . . . . . . Page 3.59 - 65
Voith Gearbox Caliper & Spring Carrier . . . . Page 3.66
Description . . . . . . . . . . . . . . Page 3.9 Special Tools . . . . . . . . . . . . . Page 3.67 - 72
Transmission function . . . . . . Page 3.9
Maintenance . . . . . . . . . . . . . Page 3.10
Checking oil level . . . . . . . . . Page 3.10
Oil and filter change . . . . . . . Page 3.10 - 11
Propshaft
Diagram . . . . . . . . . . . . . . . . Page 3.12
Description . . . . . . . . . . . . . . Page 3.13
Inspection . . . . . . . . . . . . . . . Page 3.13
Removal . . . . . . . . . . . . . . . . Page 3.14
Bearing removal . . . . . . . . . . Page 3.14
Assembly and refitting . . . . . . Page 3.14
Troubleshooting . . . . . . . . . . Page 3.15
Torque settings . . . . . . . . . . . Page 3.15
Section 3
SERVICE MANUAL
Transmission - ZF EcoLife Gearbox Amended:
SERVICE MANUAL
Maintenance Check After Starting the Engine

Check oil level . . . . . . . . . .Weekly, First, A, B & C Oil-level check with cold transmission oil (30°C):
Change the oil and oil filter . . . . . . . . . . . . . . . . . . • Vehicle stationary on level ground.
. . . . . .Every 112,500 miles (180,000 km) or 3 years
• The speed range selector (push-button selector)
Check for oil leaks and rectify Weekly First, A, B & C must be in Neutral.
Check idling speed of engine . . . . . . . . . . . .B & C • Let engine run for 15 - 20 seconds at 1200 - 1500 rpm.
Check the tightness of all fixings . . . . . . .A, B & C • Let engine run at idle speed.
Ensure the breather is not blocked . . . . . .A, B & C • Oil must be in the “30°C (COLD)” range.
SERVICE INTERVALS
First Service = 1,000 miles (1,600 km)
'A' Service = 6,000miles (10,000km) or 3 months *
'B'Service = 12,000miles (20,000km) or 6 months *
'C' Service = 24,000miles (40,000km) or 12 months *
* whichever occurs first
CAUTION
90°
Always ensure the correct oil level is 30°
maintained. Too little oil may cause

malfunction or failure of the gearbox. Too
much oil may cause the gearbox to overheat.
Check at Operating Temperature

Check The Oil Level
Oil-level check with hot transmission oil (90 °C):
The following general rules apply:
• Vehicle stationary on level ground.
• Oil-level check at operating temperature (90°C) is
crucial. • The speed range selector (push-button selector)
must be in Neutral.
• The oil level must be checked with the vehicle on
level ground. • Let engine run for 15 - 20 seconds at 1200 - 1500
rpm.
• The speed range selector (push-button selector)
must be in Neutral. • Let engine run at idle speed.
• Let engine run at idle speed.
CAUTION
• Carry out oil-level checks at least quarterly.
The idle speed should be set to between 500 and
• Conduct regular visual inspections of the 700 rpm. It must never drop below 400 rpm.
transmission for signs of leakage. • Oil must be in the “90°C (HOT)” range.
• In exceptional cases, the oil level may need to be
NOTE
checked while the transmission oil is cold.
The oil level can rise and reach the “120°C mark”
Then always check the oil again at operating when the oil sump temperature is 120°C.
temperature.
SERVICE MANUAL
Oil Change Oil Fill

WARNING • Tighten filter cover (3), tightening torque: 23 Nm
Risk of scalding due to hot oil. When NOTE
unscrewing the oil filter cover, a small
Be aware of different screw lengths.
quantity of transmission oil escapes that can
be very hot. The hot oil can cause severe • Screw screw plug (2) into the filter cover (3).
scalding if it comes in direct contact with the Tightening torque: 25 Nm
skin. Take suitable precautions for handling
• Screw in oil drain plug (1):Tightening torque: 35 Nm
hot oil.
Oil Quantities
For oil Change (drain last approx 10 mins) 24 litres.
NOTE
For initial fill (dry transmissions) 42 liters.
Only drain oil at operating temperature and for at
least 10 minutes: Note
• Engine standstill These values are reference values! The definitive oil
quantity is the one determined by oil-level check at
• Unscrew oil drain plug (1) and drain oil. operating temperature (90°C).
• Unscrew screw plug (2) on filter cover (3) and drain CAUTION
oil from filter space. Always use genuine ZF oil drain plugs. The
• Unscrew filter cover (3). converter drain valve is activated via the ZF oil drain
plug.
• Replace filter cartridge (pressure filter) and O-ring
on filter cover and on th oil drain plug. • Fill in oil through oil filler pipe (4).
ZF 80° angle drive
• Check oil level on oil dipstick (5).
The angle drive does not have its own oil drain plug.
Drain oil through main transmission’s oil drain plug.
SERVICE MANUAL
Push Button Ilumination • Depressed push button flashes
When the vehicle ignition is switched on the system - Push button selection is not accepted by the ECU.
will perform an automatic check. All push buttons will
be illuminated for approximately 1.2s at brightness
level 2 (high) before reverting to brightness level 1 • All push buttons flash
(low). - Serious internal fault of push-button selector
After depression of a push button it will be - Malfunction of CAN communication
illuminated at level 2 as soon as the selection is
accepted by the ECU.
Diagnostic Equipment
Display of Errors
The diagnostics system of the electronic control unit
• Illumination level 1 is retained despite
monitors the transmission status every time the
depressed push button
vehicle system voltage is switched on and
Possible causes: continuously while the vehicle is in motion.
- Information needed for illumination is not provided Fault finding can be carried out using the “Testman
by the ECU. In such a case, normal driving is still Pro” diagnostic tool and software.
possible.
The connection plug for connection of the diagnostic
- Hardware defect on push-button selector tool is located on the front EDC.
VOITH
D
N
R
Diagnostic Connector
on EDC
SERVICE MANUAL

Flexplate
ADAPTER FLY RING GEAR

TORQUE 83 Nm 10 OFF 88,97 ±0.66
WASHER - 10 OFF Check Dmn
FLEX PLATES - 4 OFF
A 2
RING - CLAMPING
CAPSCREW - 8 OFF
B B
Refer to diagram
for tightening
sequence and
A A-A
Torque instructions
ADAPTER
CRANK
M8 x 20 CUP HD SCREW - 2 OFF
FLEX PLATES TO STARTER RING

B-B
& TRANSMISSION COUPLING
WASHER & SCREW ACCESS
Assembly Order:
1. FIX FLEX PLATES TO ENGINE CRANKSHAFT
2. FIX STARTER RING ADAPTER TO TRANSMISSION
3. JOIN TRANSMISSION TO ENGINE BELLHOUSING
4. FIX FLEX PLATES TO TRANSMISSION
SERVICE MANUAL

Fastener Torque Sequence
1
8 5
Flywheel or Flexplate
4 mounting bolts to 3
crankshaft
6 7
Fasteners to crankshaft to be torqued up in a

sequence where diametrically opposite bolts
are tighten in pairs to the instruction opposite.
That is, do all the bolts up to instruction 'A'
then 'B' next 'C' and finally 'D'. The marks on
the bolt heads at 'C' & 'D' are pictorial
representation only.
A. Torque to 30Nm ± 4Nm C. Torque to 30Nm ± 4Nm

& mark head position
60
°
B. Back off 180° D. Torque a further 60° ± 5°
Troubleshooting
SERVICE MANUAL
Transmission - Voith Gearbox Amended:18.11.09
Breather
Harness
Dipstick
Filler Cap Dipstick
Oil Cooler
Coupling
Hydrodamp
Oil Filter
Element
Washer Oil Filter

Cover
Drain Plug
GB1520
SERVICE MANUAL
Description The shift frequency is quite low. This is achieved by

the differential converter and by down-shifts, which
The Voith gearbox combines the advantages of an take place at a lower speed than up-shifts, even at
automatic transmission and an efficient full throttle.
hydrodynamic brake.
As well as for purposes of acceleration in first gear,
The integral brake has a three stage mode of
the torque converter is used as a wear-free brake;
operation.
for this reason, it is also termed the converter-brake.
The hydrodynamic brake is activated from the
vehicle footbrake and therefore require no extra The full braking torque is already available at a
effort on the part of the driver. The effect of this relatively low speed. It is automatically maintained
three-stage brake, whose response time constant with increasing speed to prevent too great
corresponds to that of a pneumatic brake, is such loading of driveline components to the rear of the
that the loading of the normal vehicle braking is transmission.
reduced decisively, with the result that the service
The size of this constant torque can be varied by the
life of brake linings and drums is considerably
driver via the brake pedal.
increased.
The transmission has an internal oil filter. As in the third stage via the foot pedal the air brakes
are also applied to a pressure of 0.5 bar (7 psi), there
Transmission Function is always a smooth transition from hydraulic braking
to normal vehicle braking.
The power of the engine is transmitted in first gear
via a “differential torque converter” (torque converter The transmission has an electronic control.
with pre-mounted differential torque unit) and in
The inductive pick-up (the rev. - counter on
second, third and fourth gear (4-speed only) purely
transmission output drive) and the accelerator pedal,
mechanically.
according to position, govern the speed at which the
The differential torque converter produces a transmission shifts (with electronic controls having
considerably higher efficiency in the lower speed fixed shift points, the inductive pick-up only).
range than a transmission in which the full torque is
The brake pedal - via which the three stages of the
transmitted via a torque converter without
converter brake are engaged - the push button
differential.
switch unit for drive selection, the accelerator pedal,
In this way it is possible to operate the transmission and the inductive pick-up are connected up to an
in first gear up to 40% of the top vehicle speed electronic control unit which picks up the incoming
without any impairment of economy. electric pulses.
The flow of power in forward gears and reverse is The electronic control processes these pulses and
controlled by friction disc clutches and brakes which transmits them to the solenoid valves for the
are activated by oil pressure. hydraulic activation of the friction disc clutches and
brakes.
The automatic shifting is dependent upon road
speed and accelerator pedal position, whereby the
transmission shifts into the next higher gear earlier
when less than full throttle is given.
By depressing the accelerator pedal past the full

throttle position into “kick-down”, the up-shifts take at
place at a 10% higher speed.
The automatic shifts can also be inhibited by the

driver according to requirement. In spite of its fully
automatic mode of operation, the gear shift can
therefore be influenced to a large degree.
Overspeeding of the engine is automatically

prevented by the transmission in every operating
condition.
SERVICE MANUAL
Maintenance
NOTE
Change the oil and oil filter - mineral oil . . . . . . . . . . . . .
If the oil level is checked with the engine stopped
37,500 miles (60,000km) or 2 years whichever sooner and the oil temperature at 20 deg C, the oil level
should be approx 20mm above the MAX mark.
Change the oil and oil filter - synthetic oil . . . . . . . . . . .
75,000 miles (120,000km) or 3 years whichever sooner
Check oil level . . . . . . . . . . . . . . . . . . . . . . . . . .Monthly
If the oil level is too low, the transmission will
not function properly and there may be
Check for hoses for oil leaks and rectify . .First, A, B & C damage to the friction plates.
Ensure that breather is not blocked . . . . . . . . . . . .B & C If the oil level is too high there will be loss of
Check idling speed of engine . . . . . . . . . . . . . . . .B & C power and increase in fuel consumption and
Oil may also escape through the breather .
Check the tightness of all fixings . . . . . . . . . . .A, B & C
Gearbox Oil Flushing Procedure - Mineral to
Synthetic oil
SERVICE INTERVALS
1. Fill the transmission with up to 28 litres of
First Service = 1,000 miles (1,600 km) Shell Donax TX (Pt No 656450) - check the
dipstick
'A' Service = 6,000miles (10,000km) or 3 months *
'B'Service = 12,000miles (20,000km) or 6 months * 2. Drive the vehicle to fully circulate the fluid.
'C' Service = 24,000miles (40,000km) or 12 months * 3. Ensure the oil is at normal operating
temperature (60 deg C min) and drain the
* whichever occurs first fluid from the transmission.
Checking Oil Level 4. Undo drain plug for sump oil.

1. The vehicle should be on level ground with 5. Undo.drain plug for the torque convertor oil,
the engine idling, neutral gear selected and accessible through the drain hole of the
the parking brake applied.
sump.
2. The transmission oil should be at an
operating temperature (60°C/140°F). The 6. Refit drain plugs with new copper seals and
temperature is about the same as the engine tighten to 50Nm.
7. Undo the drain plug for the oil filter ,drain oil.
8 . Refit drain plug with the new sealing ring and
tighten to 25 Nm
9. Refill the transmission with 28 litre of fresh
Shell Donax TX oil - check the dipstick
10. Check the fluid level is correct with the
transmission at the correct operating
temperature and check for leaks
3. Withdraw the dipstick and wipe it clean,

replace the dipstick briefly, withdraw and read
off oil level. The level must be between the
MAX and MIN marks.
The difference between the two levels is
approx 2.5L.
SERVICE MANUAL
7. Install new oil filter element and sealing ring

WARNING
and tighten to the correct torque.
Risk of scalding due to hot oil. When
unscrewing the oil filter cover, a small
quantity of transmission oil escapes that can CAUTION
be very hot. The hot oil can cause severe If filter element is badly clogged, remove oil
scalding if it comes in direct contact with the sump and check friction discs.
skin. Take suitable precautions for handling
hot oil.
Oil And Filter Change
1. Stop the engine
2. With the oil at normal operating temperature,
remove the plug and drain off the oil, taking
precautions to avoid contact with the hot oil.
Undo and remove the plug (2) from the oil
pan (allen wrench 12mm) and drain the oil.
8. Install access cover with a new sealing ring

and tighten to the correct torque and tighten
to the correct torque.
3. Remove the drain plug in the torque

convertor. This is accessible through the
drain hole of the sump). 9. Refill with oil, about 23 - 26 litres will be
4. When the oil is drained, refit both drain plugs required. (Initial fill - 25 28 litres).
with new copper washers and tighten to the 10. Check oil level as described on Page 3.4 of
correct torque. this section.
11. Check oil filter cover, sump, sump plug and
hoses for leaks.
Torque Values
Drain plug . . . . . . . . . . . . . . . . 73 lb. ft. (100 Nm)
Convertor plug . . . . . . . . . . . . . . 37 lb. ft. (50 Nm)
Oil filter cover . . . . . . . . . . . . . . 18 lb. ft. (25 Nm)
5. Unscrew and remove the oil filter cover of the

oil pan (36mm A/F)
SERVICE MANUAL
Transmission - Propshaft Amended:
SERVICE MANUAL
Transmission - Propshaft Amended:17.02.10
Description 5. Check the shaft for damage such as bending.
The propshaft connecting the gearbox to the back axle 6. Check that the plug is in position at the bearing
consists of two sections each incorporating a universal end of the forward section.
joint. One section has internal splines into which the
external splines of the other section engages, both Removal
sections having a non-metallic coating to reduce sliding
friction and to improve spline life. To disconnect the propshaft, remove the four nuts and
bolts at each end and then remove the propshaft.
Each universal joint consists of a forged steel spider on
which each spigot is fitted with a needle race. These
locate in bores in the yoke ends welded to the spline
sections and the yoke ends secured to the gearbox output
shaft and to the axle input shaft. The bearings are located
CAUTION
by thrust pads and internal circlips. The propshaft is heavy - ensure that it is
adequately supported if removing.
Inspection
The shaft should be checked periodically as follows:
1. Check that the yokes on the gearbox and the axle
are tightly secured.
2. Check that there is no play in the bearings
CAUTION
supporting the gearbox output shaft and the axle Always clean excess lubricant from yoke
input shaft. bearing housing external surfaces after
3. Check the end float in the spider bearings. This
carrying out maintenance to prevent it from
should not exceed 0.006 in. being thrown inside the engine
compartment.
4. Check the radial play between the two splined
sections. This should not exceed 0.007 in.
Maintenance
City Traffic
Grease universal and sliding joint : 15500 miles (25000 km) 3 months
Check the tightness of all fixings 31000 miles (50000 km) 6 months
Visual check for damage 31000 miles (50000 km) 6 months
Check for missing balance weights 31000 miles (50000 km) 6 months
Inspect for damage to seals 31000 miles (50000 km) 6 months
Remove shaft - check backlash. 124000 miles (200000 km) 2 years
Check grease escape past seals
No evidence of water or contamination 124000 miles (200000 km) 2 years
Long Distance Traffic
Grease universal and sliding joint 31000 miles (50000 km) 6 months
Check the tightness of all fixings 62000 miles (100000 km) 12 months
Visual check for damage 62000 miles (100000 km) 12 months
Check for missing balance weights 62000 miles (100000 km) 12 months
Inspect for damage to seals 62000 miles (100000 km) 12 months
Remove shaft - check backlash. 186000 miles (300000 km) 3 years
Check grease escape past seals
No evidence of water or contamination 186000 miles (300000 km) 3 years
SERVICE MANUAL
Transmission - Propshaft Amended:17.02.10
Bearing Removal 13. Repeat steps 10 to 13 to fit the other two

bearings on the spider.
With the shaft removed, proceed as follows:
14. Repeat steps 10 to 14 to fit the bearings to
1. Using a soft drift, tap the outside of the the second universal joint on the shaft.
bearing assembly to loosen the circlips. Do Ensure that the grease nipples are in the
not use excessive force, just sufficient to same line at each end of the shaft.
break the assembly away from the ring.
Assembly and Refitting
2 Using circlip pliers, remove the circlip.
Repeat for the circlip at the other side of the Before assembling the shaft, check that the two
yoke. yokes at the ends of sections are in alignment. Out-
of-phase bearings can cause rough running. If
3. Seat the yoke in a suitable press with a short necessary separate the two sections and re-engage
length of tube underneath into which the the splines. Mating engagement arrows should be
bearing can be ejected. The yoke should be stamped on the two sections.
positioned with the grease nipple upwards to
prevent interference during dismantling. 1. Fully degrease the securing bolts and the
holes they engage.
4. Place a solid plug on the upper bearing and
operate the press to eject the lower bearing. (Degreaser agent - Loctite 7070 Cleaner -
If the bearing will not pull out by hand after Dennis Part No 658103).
pressing, tap the base of the lug near the 2. Apply threadlock to bolts (Loctite 648 high
bearing to dislodge it. temperature retainer).
5. Turn the yoke over so that the second 3. Tighten bolts - see Torque settings Page
bearing is against the tube. Apply press force 3.13.
to the upper end of the spider ensuring that it
remains central in the hole in the yoke. If the 4. Using a grease gun, pump in more grease at
spider is misaligned, the lower bearing will each end until grease exudes from all eight
score the hole as it it ejected and ruin the bearings. (Grease: Texaco Hytex EP2).
yoke assembly. 5. Clean off excess grease from bearing
6. Repeat the procedure to free the other two housing external surfaces.
bearings and remove the spider.
7. Pack the four grease cavities on the spider
with grease recommended in the Lubrication
Chart. Also pack each bearing assembly
about ¼ full with grease.
8. Position the spider in the yoke with the
grease nipple on the inboard side.
9. Move the spider so that one trunnion projects
through a hole in the yoke. Fit a bearing on
this trunnion and align with the hole in the
yoke.
10. Place a plug of smaller diameter on the
bearing and place the assembly in a suitable
press. Holding the bearing and yoke in
alignment, press the bearing in far enough to
fit a circlip. Fit the circlip.
11. Repeat steps 10 and 11 to install the opposite
bearing. If the joint is stiff, strike the yoke
ears with a hide faced hammer to seat the
needle bearings.
12. Ensure that both circlips are correctly
engaged.
SERVICE MANUAL
Transmission - Propshaft Amended:
Trouble Shooting
Fault Cause Remedy
Vibration such as shudder in Sections out of phase. Re-assemble correctly.

low gear, under light load or Wear in U.J. Fit Bearing Kits.
at critical speeds. Shaft bent. Renew.
Premature wear Improper lubrication. Lubricate correctly.

Contamination. Clean and relubricate.
Worn or damaged seals. Renew.
Spline wear. Improper lubrication. Lubricate correctly.
Torque settings
Nm Lbf ft
Propshaft Bolts 105 77
SERVICE MANUAL
Rear Axle Amended:260712
Introduction
The repair instructions in this section regarding the
disassembly and reassembly are general to the ZF-
Portal axle (AV-132). Differing steps of other
versions can be easily identified by qualified
personnel. References may be the illustrations in the
parts list.
Due to technical developments of the axle, the actual
unit filled to the vehicle may differ from that covered
in this section and may require different steps as well
as other adjustments and testing specification.
It is recommended that repairs on the unit are
referred to a ZF qualified technician.
Towing
It is possible to tow the vehicle, but to prevent
damage to the differential and Gantry drive both stub
shafts must be removed. To do this, remove the hub
IMPORTANT
end caps and separate the shaft by using an M10 After an axle has had repairs carried out with
screw to withdraw the shaft. Replace the hub end components such as portal drives or torso
cap. axles, it is recommended that the oil is
changed after a running in period of
The maximum towing distance is 30 miles (50 km). approximately 3100 miles (5000 km)
To tow for a greater distance the wheel bearings
must be lubricated.
Maintenance
Check axle oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monthly
Check security of axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First A, B & C Service intervals
Check adjustment and lubrication of hub bearings . . . . . . . . . . . . . . . . . . .First A, B & C Service intervals
Check hubs for signs of leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First A, B & C Service intervals
) Change the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93,000 miles (150,000 km) or every 3 years
) OiI Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80W/90 API GL5
Recommended brand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ZF Ecolfluid X
Repack compact bearing hubs . . . . . . . . . . . . . . . . . . . . . . .312,500 miles (500,000 km) or every 4 years
(For further information please refer to ZF doument - list of lubricants TE-ML 12)
Do not mix lubricant of differing grades
Check and clean, if required, the axle breather at each oil level check.
SERVICE MANUAL
Rear Axle Amended:250712
DRIVE AXLE
Draining
The oil in the axle housing and gantry drive is
common but each gantry drive has a drain plug.
Remove both the drain plugs and drain oil into
suitable container. when oil has stopped draining, Drain Plug LH Gantry
clean and refit both plugs using new ‘O’ rings and
tighten to 130 Nm.
Drain Plug RH Gantry
Filling
Remove filler plug on left hand gantry and the level
plug on the right hand gantry, fill through the filler on
left hand gantry with the correct grade of oil until the Filler Plug in LH Gantry
oil flows out of the level hole on the right hand gantry.
Wait until the oil has settled, recheck and top up if
necessary until the level is reached and remains
constant.
Refit filler and level plugs and tighten to 70Nm.
) OIL GRADE - 80W/90

CAPACITY - 19.0 L
Level Plug in RH Gantry
SERVICE MANUAL
Rear Axle Amended:
General Working Practices After the repair, ZF-Units are filled with oil.
During all operations, pay attention to cleanliness After the oil filling, the oil level plugs and oil drain
and skilled working. plugs must be tightened to the specified torque
limits.
Transmissions, removed from the vehicle, must be
cleaned prior to open them.
We assume that the Special Tools, specified by ZF

and listed, will be used.
After the disassembly, all components must be

cleaned, especially corners, cavities and recesses of
housing and covers.
The old sealing compound must be carefully

removed.
Check lubricating holes, grooves and pipes for free

passage. They must be free of residues, foreign
material or protective compounds.
The latter refers especially to new parts.
Parts which have been inevitably damaged in a

disassembly operation, must be generally replaced
by new ones; for example: rotary seal rings, 'O' rings,
U-section rings, cap boots, protective caps etc.
Components such as roller bearings, thrust washers,

synchronising parts which are subject to normal
wear in automotive operation, must be checked by
skilled Service person, they will decide if the parts
may be reused.
For the heating of bearings etc., hot plates, rod

heaters or heating furnaces must be used.
Never heat parts directly with a naked flame. An

auxiliary solution would be to immerse the bearing in
a vessel filled with oil, which is then heated by a
flame. In this way, damage to the bearings could be
avoided.
Ball bearings, covers, flanges and parts like that

must be heated to 90° to 100°C.
Hot-mounted parts must be reset after cooling in

order to assure a proper contact.
Before pressing shafts, bearings etc. in position,

both parts must be lubricated.
During the reassembly, all specified adjustments

values, testing specifications and torque limits must
be respected.
SERVICE MANUAL
Rear Axle Amended:
EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS
Ideal tooth-contact pattern i.e. pinion distance is correct is shown in Figure 1 and Figure 2.
Coast Side
Drive Side
SERVICE MANUAL
Rear Axle Amended:
Contact pattern when distance must be Contact pattern when distance must be
increased is shown in Fig 3 and Fig 4. decreased is shown in Fig 5 and Fig 6.
Coast Side
Drive Side
SERVICE MANUAL
Rear Axle Amended:
Adjustment Values - Input

Rolling moment Drive pinion bearing . . . . . . . . . . .T = 1.5... 3 Nm (without shaft seals)
Rolling moment Differential bearing . . . . . . .T = 3.5 ... 5.5 Nm ( ^ of a bearing preload
= 0.20 mm)
Backlash Crown-wheel set . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.25 ... 0.30 mm
Torque limit Slotted nut (Drive flange) . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 Nm
Adjustment Values - Output

End play Drive gear (Gantry drive) . . . . . . . . . . . . . . . . . . . . . . 0.0 ... 0.03 mm
End play Idler gear bearing (Gantry drive) . . . . . . . . . . . . . . .: 0.05 ... 0.08 mm
End play Output gear bearing (Gantry drive) . . . . . . . . . . . . . . . 0.0 ... 0.03 mm
End play Wheel bearing (Hub) . . . . . . . . . . . . . . . . . . . . . . . .: 0.01 ... 0.05 mm
Torque limit of the outer slotted nut (wheel bearing) . . . . . . . . . . . . . . . . . . . .MA = 580 Nm
Drive Axle
Disassembly/Reassembly
The illustrations and text in the following Part Numbers
section describe the disassembly and Assembly Car
reassembly of the axle. 5870 350 000
The disassembly and assembly process Supports
described presumes the axle has been removed 5870 350 077
from the vehicle and is supported on an axle
assembly car. Clamping Brackets
5870 350 075
Tools
Where special tools are referred to, they are shown
Marked (S).
A list of special tools is shown at the end of this
section.
SERVICE MANUAL
Rear Axle Amended:
Fasten axle on the assembly car.
(S) Assembly car 5870 350

000
(S) Supports 5870 350
1 093
SERVICE MANUAL
Rear Axle Amended:
OUTPUT
DISASSEMBLY
Wheel head-Version with pneumatic disk brake.
If necessary, separate spring carriers (4x) from the
axle.
2 Note or mark the installation positions of the
carriers.
Separate Brake caliper from the Axle (Figure 3- 7):
Remove brake pad retaining clip (Arrow).
3 For pad wear sensors remove cable

guide plate and separate sensor from
brake-pad plate.
Remove protection cap and back off hexagon

(WAF 8) of the adjuster by means of ring spanner
anticlockwise until the brake pads are free.
Due to the slipping moment of the

4 overload clutch, a "Clicking noise” is
created!
ATTENTION
Do not create an overstressing on the
hexagon (WAF 8).
Do not use an open end wrench.
SERVICE MANUAL
Rear Axle Amended:
Pull both brake pads out of the brake pad slot.
Loosen mounting bolts - brake caliper.

(S) Insert WAF - 27 5870 656 068
(S) Inserting head 14 x 18 5870 656 069
(S) Torque spanner 5870 203 023
6
Separate complete brake caliper from the axle,

using lifting device.
(S) Lifting bracket 5870 281 046
(S) Lifting strap 5870 281 026
7
Output
Loosen hexagon screws and separate flange shaft

from the axle.
Some residual oil may leak.
8
SERVICE MANUAL
Rear Axle Amended:
Unlock and loosen outer slotted nut.
(S) slotted nut wrench 5870 401 146
Fasten hook spanner again on the hub and loosen

inner slotted nut.
Separate hub/brake disk form the hub carrier.

(S) lifting bracket 5870 281 043
10
Loosen bolts and separate hub from the brake disk.

Locate hub/brake disk by using a press.
11
Remove O-ring (arrow).
12
SERVICE MANUAL
Rear Axle Amended:
Remove shaft seal of the brake disk
13
Pry outer shaft seal out of the hub carrier bore.

(S) Pry bar 5870 345 071
14
Remove Compact Bearing

Check the compact bearing grease: as part of
lubrication interval. In case of grease leakage of
shaft seals or in case of overheated brake parts.
1 = Hub
15 2 = Compact bearing
3 = O-ring
4 = Retaining ring
5 = Hub carrier
Unsnap retaining ring (arrow).
16
SERVICE MANUAL
Rear Axle Amended:
Remove both bearing inner races.

If necessary remove both bearing outer races.
17
SERVICE MANUAL
Rear Axle Amended:
Drop Centre Drive
Locate hub carrier by means of lifting device.

Loosen screw connection and separate hub carrier
from drop centre housing.
18
(S) Lifting strap 5870 281 026
Pull bearing outer ring out of hole with striker.

Take note: release shim.
(S) Striker 5870 650 004

19
Remove output gear.
20
Remove both bearing inner rings from the output

gear.
21 (S) Rapid grip 873 012 013

(S) Basic device 5873 002 001
SERVICE MANUAL
Rear Axle Amended:
Locate drop center housing by means of lifting

device. Loosen threaded connection and separate
drop centerdrive from the axle housing.
Pay attention to releasing differential and plug
shaft! Watch out for residual oil quantity which may
leak out.
22 (S) Lifting chain 5870 281 047
Fix drop center drive to the assembly truck.

For the subsequent removal of the two
intermediate gears (figures 20 to 22), it is
necessary to mark the installation position and
positions of the components.
23 Loosen hexagon screw and assemble adjusting
screw. Drive out bearing bolt. Remove second
bearing bolt accordingly.
(S) Assembly truck 5870 350 000
(S) Clamping plate 5870 350 119
(S) Adjusting screws 5870 204 022
Shift drive gear diagonally (see arrow/figure 24)

and remove releasing intermediate gear (figure
25).
Remove second intermediate gear accordingly.
24
Now remove the complete drive gear.
25
SERVICE MANUAL
Rear Axle Amended:
Pry bearing outer ring – differential bearing out of

the housinghole.
Pay attention to releasing adjusting screw.
If necessary, drive bearing outer ring - output gear
26 bearing (arrow) out of the housing hole.
Pull plug shaft out of the differential.
Differential is not fixed!
27
SERVICE MANUAL
Rear Axle Amended:
DIFFERENTIAL
The following illustrations provide a description of
thedifferential disassembly: Version I, Type “C”
Version II / Type “D” (new differential), only
available as complete component.
28
Lift differential out of the axle housing by means of
anappropriate assembly mandrel.
Remove both bearing inner rings.
(S) Rapid grip 5873 011 012

(S) Rapid grip 5873 002 025
29 (S) Basic tool 5873 002 001
(S) Back off insert 5870 026 100
Loosen hexagon screws.

Remove both differential carrier halves and single
components.
If necessary, loosen threaded connection and
30 press crown wheelout of the differential carrier.
Pull plug shaft out of the axle.
31
SERVICE MANUAL
Rear Axle Amended:
Drive bearing outer ring out of the housing hole by

means of striker.
Pay attention to releasing adjusting screw!
32 (S) Striker 5870 650 004
SERVICE MANUAL
Rear Axle Amended:
INPUT
Loosen slotted nut (figure 30 and 31).
Heat grooved nut before loosening it (secured
with Loctite)
(S) Hot air blower 230 V 5870 221 500
33 (S) Hot air blower 115 V 5870 221 501
(S) Clamping yoke 5870 240 002
(S) Slotted nut wrench Ø 86 5870 401 093
(S) Slotted nut wrench Ø 81 5870 401 139
(S) Centering disk 5870 912 015
34
Pull out input flange and remove shaft seal.

(S) Pry bar 5870 345 071
35
Press drive pinion out of the bearing hole.

(S) Press off tool 5870 080 044
36
SERVICE MANUAL
Rear Axle Amended:
Remove adjusting ring.
37
Remove bearing inner ring from the drive pinion.

Version 1 (Type C)
bearing dimension 70 x150 x 41.27 mm
(S) Gripping insert 5873 003 022
38 (S) Reduction 5873 003 011
(S) Basic tool 5873 002 001
Version 2 (Type D)
bearing dimension 70 x150 x 50.0 mm
(S) Gripping insert 5873 002 052
(S) Basic tool 5873 002 001
Pull outer bearing outer ring out of the hole.

39
(S) Internal extractor 5870 300 019

(S) Counter support 5870 300 020
40
Drive inner bearing outer ring out of the hole.
Pay attention to releasing adjusting disk.
SERVICE MANUAL
Rear Axle Amended:
ASSEMBLY
INPUT - DIFFERENTIAL
General: If crown wheel or drive pinion are damaged, both parts (bevel gear set) must be replaced.
Make sure that mating numbers are identical.

The following pages describe the setting of the assemblies being listed below.
A - Contact pattern - bevel gear set
B - Backlash - bevel gear set
C - Rolling torque – drive pinion bearing
D - Rolling torque – differential bearing
Legend:
A1 - Shim-contact pattern
B1 - Shim-backlash
C1 - Adjusting ring-drive pinion bearing
D1 - Shim-differential bearing
When reusing the shims that were removed during disassembly, the required setting values are obtained.
However, it is indispensable to check the values.
SERVICE MANUAL
Rear Axle Amended:
Contact pattern – adjustment of bevel gear set

(fig. 41 to 47):
Read the installation dimension A on the axle
housing (arrow).
Dimension A e.g. ……………………….. 195.42 mm
42
The figure left shows the drive pinion.

The following information is stamped or marked
manually into the pinion head:
1 = Mating number (marked manually)
43
2 = Pinion basic dimension (stamped)
3 = Pinion distance deviation + or – (marked
manually)
NOTE:
Distance deviation is indicated in 1/100 mm.
Pinion dimension „X“ e.g.:
Dimension X 153 - 5 ( 5/100 = 0.05 ) = 152.95 mm
If no distance deviation is indicated, pinion basic
dimension equals pinion dimension „X“!
Determine bearing height.

Dimension Y e.g. ……………………….. 41.25 mm
44 (S) Straightedge 5870 200 022

(S) Gauge block 5870 200 066
(S) Digital depth gauge 5870 200 072
SERVICE MANUAL
Rear Axle Amended:
Calculation example A1:

Dimension X (pinion dimension) e.g.…. 152.95 mm
Dimension Y (bearing height) e.g. …. + 41.25 mm
Equals dimension Z = 194.20 mm
Calculation example A 2:
Dimension A e.g. ……………………. 195.42 mm
Dimension Z e.g. ……………………. - 194.20 mm
Difference = shim s = 1.22 mm
The individual shims are available in 0.03 mm size
intervals. Use the next available shim size
e.g. s = 1.23.
Supercool outer bearing outer ring and insert it until

contact isobtained.
45
Mount shim (according to calculation example s =

1.23 mm).
46 Supercool bearing outer ring and insert it with the

fixture into the bearing hole until contact is
obtained. (Figure 46 and 47).
(S) Assembly fixture 5870 345 080
47
SERVICE MANUAL
Rear Axle Amended:
Press bearing inner ring until contact is obtained.
48
Adjust rolling torque of the input pinion bearing

1.5 to 4.5Nm (figures 49 to 53):
When reusing the shims being removed during
disassembly, we know from experience that the
required setting dimension is obtained.
49
However, it is indispensable to check the rolling
torque afterwards.
Mount adjusting ring e.g. s = 10.32 mm.
Set the rolling torque of the input pinion

bearing
(Sketch … figure 53):
The two versions of the pinion head bearing have
different /setting values. (arrow)!
Version I: Bearing dimension 70 x 150 x 41.27
mm.
Required rolling torque 3.0 … 7.0 Nm
Version II: Bearing dimension 70 x 150 x 50.0 mm.

Required rolling torque 4.0 … 10.0 Nm
When mounting new bearings, try to achieve the

respective average value.
With used bearings try to achieve the lower value.
If reusing the setting ring that was removed during
disassembly, from experience the required rolling
torque is reached.
However, a check of the rolling torque is still
necessary.
SERVICE MANUAL
Rear Axle Amended:
Position drive pinion and mount the heated bearing

inner ring until contact is obtained.
Before mounting the input flange and tightening the
slotted nut (figures 51 and 52 ), let bearing inner
ring cool down to ambient temperature.
50
Mount input flange.
51
Mount shim and tighten slotted nut.

Tightening torque ………… MA = 1000....1700 Nm
First tighten the slotted nut to 1000 Nm and check
the rolling torque (figure 13). Increase the
tightening torque step by step until the requested
rolling torque is reached, the max torque is MA =
1700 Nm, .
While tightening, rotate the input pinion several
52
times in both directions.
If the necessary rolling torque within the tolerance
area of the tightening torque is not reached, please
correct with the corresponding setting ring (figure
9) as specified below:
Insufficient rolling torque – mount a thinner ring
Excessive rolling torque – mount a thicker ring
After completion of the setting, note the tightening
torque of the slotted nut and the rolling torque of
the pinion bearing.
Secure the slotted nut (Loctite-locking) and mount
the shaft seal ring after ensuring the contact pattern
is OK.
53 (S) Slotted nut wrench Ø 86 mm 5870 401 093
(S) Slotted nut wrench Ø 84 mm 5870 401 173
(S) Clamping fork 5870 240 002
(S) Torque wrench 5870 203 031
(S) Reduction 1/2” - 1/4” 5870 656 056
SERVICE MANUAL
Rear Axle Amended:
Differential (figures 54 to 63)

the differential assembly: Version I, type “C”
Version II / type “D” (new differential), is only
available as complete component.
54 Heat crown wheel and install it at the mounting face

of the differential until contact is obtained.
Pay attention to radial installation position.
Use protective gloves.
Fix differential carrier by means of press.

Bolt crown wheel and differential carrier.
Permitted temperature for crown wheel and
differential carrier when bolting max. + 30° C.
55
Only new locking screws may be used.
Tightening torque ……………….. MA = 250 Nm
Insert thrust washer.

Pay attention to installation position – lubricating
groove showing upwards (to the axle bevel gear).
56
Radial fixation of thrust washer by means of

grooved pins (2 x).
Pay attention to the installation depth of the
grooved pins.
The front face of the grooved pins must be slightly
57 below the contact face/thrust washer (approx. 1.0
mm).
Pre-assemble differential carrier 2nd half
accordingly.
SERVICE MANUAL
Rear Axle Amended:
Install axle bevel gear.

Oil all internal components of the differential
according to ZF –List of lubricants TE ML 12.
58
Mount complete differential spider.

Pay attention to radial installation position of the
thrust washers – torsional stop in vertical position,
see arrow.
59
Mount second side gear.
60
Mount pre-assembled differential carrier half II.

Pay attention to radial installation position, see
ZF-No. .… … … (arrow).
61
SERVICE MANUAL
Rear Axle Amended:
Fix differential carrier halves by means of hexagon

screws and washers (s = 3.0 mm).
Tightening torque (M12x1.5/10.9) … MA = 120 Nm
62
Press both bearing outer rings until contact is

obtained.
63
Adjust backlash– bevel gear set and bearing rolling

torque – differential 2.5 to 5.5 Nm
64 Necessary backlash, see crown wheel (arrow).
Insert adjusting shim and bearing outer ring into the

bearing hole until contact is obtained.
If re using the shims that were removed during
disassembly, the required setting values should be
65 obtained. However, it is indispensable to check the
values afterwards.
(S) Driver 5870 058 078
(S) Handle 5870 260 002
SERVICE MANUAL
Rear Axle Amended:
Insert pre-assembled differential into the axle

housing.
Then pivot axle housing into vertical position.
66
Install bearing outer ring.
67
Insert measuring cover evenly until contact is

obtained by means of hexagon screws (4 x).
(S) Measuring cover 5870 200 121
68
To ensure that the individual components are

centered precisely, rotate bevel gear set several
times in both directions.
69
SERVICE MANUAL
Rear Axle Amended:
Check backlash
Due to the installation situation, the acceptance of
the backlash is not possible on the outer diameter
of the crown wheel. therfore backlash must be
measured on the crown wheel threaded
connection(screw head), the necessary backlash
70 (see manually marked value on the crown wheel).
Permitted tolerance deviation ± 0.04 mm
When measuring the backlash, the position of the
screw head lateral face to the center axis of the
differential should be parallel to each other.
If backlash corrections are necessary:
1. Insufficient backlash - mount thicker adjusting
shim.
2. Excessive backlash - mount thinner adjusting
shim.
Position dial indicator to the crown wheel back and

check max. axial runout 0.08 mm.
In case of deviations from the permitted axial
runout, check the accurate contact between crown
wheel and differential carrier and correct, if
necessary.
71
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057
SERVICE MANUAL
Rear Axle Amended:
Adjust rolling torque of the differential bearing

between 2.5 and 5.5 Nm
(figures 72 to 75):
Calculate dimension I, between the front face of the
bearing outer ring and the mounting face of the
axle housing (figures 72 and 73).
72
Dimension I is based on the measuring processes
of figure 72 and figure 73.
Measurement I (figure 72):
Insert digital caliper gauge until bearing outer ring
and balance to 0.00 mm.
Then separate the measuring cover from the axle
housing.
Measurement II (figure 33):

Insert caliper gauge until straightedge and read
73
dimension I.
Dimension I e.g.………………………… 26.68 mm
(S) Straightedge 5870 200 022
Calculate dimension II, between the mounting face

of the drop center housing and the locating
face/bearing outer ring (figure 74).
Measurement I:
Position digital caliper gauge between straightedge
and mounting face and balance to 0.00 mm.
74
Measurement II:
Now insert caliper gauge to the mounting
face/bearing outer ring and read dimension II.
Dimension II e.g.…………………………. 27.69 mm
Calculation example B:
Dimension II……………………………… 27.69 mm
Dimension I…. ………………………… - 26.68 mm
Difference = 1.21 mm
Difference ∧ installation dimension of the adjusting
shim. The individual shims are available in 0.05
mm size intervals.
When using the next available shim size, e.g.
s = 1.20 mm, the necessary rolling torque of the
differential bearing is between 2.5 and 5.5 Nm.
SERVICE MANUAL
Rear Axle Amended:
Insert the calculated adjusting shim (e.g. s = 1.20

mm) and install the bearing outer ring until contact
is obtained.
75
Contact pattern – check bevel gear set.

Cover some drive and coast flanks of the crown
wheel with marking ink.
76
Insert differential into the axle housing.
77
Position the drop center housing on the axle

housing and locate it provisionally with hexagon
nuts as well as with cylindrical screws.
Tightening torque ………………….. MA = 200 Nm
(S) Lifting chain 5870 281 047
78
SERVICE MANUAL
Rear Axle Amended:
Roll drive pinion several times in both directions

over the crown gear.
79
Check total rolling torque (pinion and

differential bearing).
Total rolling torque must be approx. 2 – 3 Nm
above the previously measured rolling torque of the
pinion bearing.
80
If a completely preassembled drop center drive is
mounted, it is necessary to increase the rolling
torque by 3- 4 Nm.
(S) Torque spanner 5870 203 031
(S) Reducer 1/2 “ - 1/4 “ 5870 656 056
Now disassemble the differential again and

compare the contact pattern result with the contact
pattern examples shown at the beginging of the
section.
If the contact pattern is not correct, it is imperative
to correct the measuring fault which has occurred
during the calculation of the adjusting shim.
SERVICE MANUAL
Rear Axle Amended:
Pivot axle housing into horizontal position.

Loosen slotted nut and remove input flange.
Assemble shaft seal with the seal lip towards the oil
chamber (figure 71).
Wet the outer diameter with spirit.
81 The use of the specified special tool (S) ensures
the precise installation position!
(S) Driver 5870 048 216
Press the protective shield over the collar of the

input flange until contact is obtained.
(S) Driver 5870 056 008
(S) Handle 5870 260 002
82
Carefully clean and degrease the thread of the

input pinion and the slotted nut.
Then wet some threads of the slotted nut and of the
pinion with Loctite locking compound (product no.:
262).
Mount the input flange.
83 Finally tighten the input flange by using a disk and

a slotted nut.The required tightening torque of the
slotted nut was determined/noted at stages on
page 3.33.
If the pinion bearing was not dismantled, but only
the shaft seal was replaced, tighten the slotted nut
as follows:
- lift the axle to allow the wheels to freely rotate
- pretighten slotted nut with MA = 500 Nm and
rotate the input flange10 to 15 times.
- finally tighten the slotted nut with MA = 1700 Nm
(S) Clamping yoke 5870 240 002
SERVICE MANUAL
Rear Axle Amended:
DROP CENTER DRIVE

Fix the longitudinal rod bracket (arrow) using
cylindrical screws and washers on the drop center
housing as specified below:
Secure screws with Loctite 243
84 1. Position the bracket on the housing.

Provisionally tighten the cylindrical screws (pos. 1)
on the side of the rod connection finger-tight (3 …
5 Nm).
2. Now mount cylindrical screws (pos.2) and
tighten them with the necessary tightening torque
MA = 440 Nm.
3. Finally tighten cylindrical screws (pos. 1) with the
necessary tightening torque MA = 440 Nm.
Mount studs, see arrows

Tightening torque ………………….. MA = 33 Nm
Wet thread with Loctite 262.
Mount studs only on the drop center housing of the
85 differential.
SERVICE MANUAL
Rear Axle Amended:
Mount Gear Drive
1 = housing
2 = cup spring (67.5 x 50.5 x 0.7)
3 = housing shim (68 x 42 x 5)
4 = axial bearing (68 x 40 x 9)
5 = plate (68 x 30 x 5)
6 = retaining ring
7 = drive gear
8 = plate (42 x 65 x 4)
9 = axial bearing (65 x 45 x 6)
10 = housing disk (47 x 65 x 4)
11 = cup spring (63.8 x 50.5 x 0.7)
Pay attention to the installation position of the cup springs (pos. 2 and pos. 11), refer to sketch diagram.
Mount plates (pos. 5 and pos. 8) with the larger chamfer or radius showing to the drive gear.
Mount housing disks (pos. 3 and pos. 10) with the larger chamfer or radius towards the housing.
SERVICE MANUAL
Rear Axle Amended:
Position individual components pos. 2 to 5 and pos.

8 to 11 using assembly fixture (figure 87) in the
drop center housing (arrow/figure 88).
(S) Assembly fixture 5870 345 103
The cup springs are pre-stressed with the fixture,
until the drive gear can be assembled (figure 90).
87
Ensure the individual components are assembled
in the correct positions, refer to figure 86.
88
Engage retaining ring (arrow) into the groove of the

drive gear.
89
Position the drive gear in the housing (arrow) and

thereby remove the assembly fixture again.
When in position - retaining ring shows upwards,
see figure 86.
90
SERVICE MANUAL
Rear Axle Amended:
Preassemble intermediate gears and check axial

play 0.01 to 0.05 mm (figures 91 and 92):
When reusing already run intermediate gears,
ensure to retain original installation positions of the
individual components.
When reusing the shims that were removed during
disassembly, the required axial play of the
intermediate gear bearing should be maintained.
However, it is indispensable to check the values
afterwards.
Assemble individual components and insert

adjusting shim.
91
Insert plug gauge (S) and fix intermediate gear

bearing by means of press. Contact pressure
approx. 10 000 N (1 to.).
Check axial play
If the necessary axial play is not correct, adjust with
the relevant adjusting shim (figure 51).
92
(S) Plug gauge 5870 200 094
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057
(S) Pry bar 5870 345 071
Then disassemble bearing bolt again.
SERVICE MANUAL
Rear Axle Amended:
Install intermediate gears (figures 94 to 99):

In order to enable the assembly of both
intermediate gears, move drive gear preliminarily in
direction of arrow.
When putting back the drive gear, make sure that
the installation position of the components is
93 maintained.
Position both intermediate gears (arrows) in the

drop center housing.
Then align intermediate gears and side gear
centrally to the bearing holes.
94
Insert O-rings (arrows) in both annular grooves of

the bearing bolt and grease them.
95
Use assembly grease to glue the calculated

adjusting shim and mount the adjusting screw.
(S) Adjusting screws 5870 204 022
96
SERVICE MANUAL
Rear Axle Amended:
Locate both intermediate gears by means of bolts.
97
Pivot drop center housing 180°.

Locate both bearing bolts by means of hexagon
screws.
Tightening torque (M14/10.9) ……… MA = 185 Nm
98
Pre-assemble and install output gear (figures 100

to 112).
Heat impulse disk and press it until contact is
obtained.
99
Press both bearing inner rings until contact is

obtained.
100
SERVICE MANUAL
Rear Axle Amended:
Adjust axial play – output bearing 0.00 to 0.03 mm

(figures 102 to 106):
Determine the total height of the output gear
bearing, figure 102 and 103.
(S) Measuring ring (2x) 0730 161 832
101 (S) Digital depth gauge 5870 200 072
(S) Measuring bar 5870 200 127
(S) Straightedge 5870 200 022
Dimension X e.g. ………………………. 135.12 mm

Roll bearing several times in both directions in
order to ensure that the individual components are
centered precisely.
102
Drop center housing:

Measure dimension I between the mounting
face/flange and the locating face of the bearing
outer ring.
103 Dimension I e.g. ……………………….. 136.48 mm
Hub carrier:
Measure dimension II, between the mounting face
of the flange and the locating face of the bearing
outer ring.
104
Dimension II e.g. ………………………... + 0.02 mm
Dimension II, can be + or –
(S) Gauge blocks 5870 200 066
SERVICE MANUAL
Rear Axle Amended:
Calculation example C:
Dimension I ………………………… 136.48 mm
Dimension II ……………………....... + 0.02 mm
Equals dimension Y = 136.50 mm
Dimension Y.…………………………… 136.50 mm

Dimension X.…………......………….. - 135.12 mm
Difference s = 1.38 mm
The individual shims are available in 0.03 mm size

intervals. When using the next available thinner
adjusting shim, e.g. 1.37 mm, the axial play is 0.01
mm.
Insert the calculated adjusting shim and mount

bearing outer ring until contact is obtained.
105
Insert bearing outer ring (arrow) into the bearing

hole until contact is obtained.
106
SERVICE MANUAL
Rear Axle Amended:
Insert output gear.

Pay attention to installation position – impulse disk
shows downwards.
107
Mount protective shield.

(S) Press device 5870 506 162
Wet the contact surface hub/screen shield with
Loctite (type no.574).
108 Pay attention to installation dimension 4 +1 mm ,
refer to figure 110.
The use of the specified special tool ensures that
the installation position is precise.
109
Assemble and grease O-ring (arrow).
110
SERVICE MANUAL
Rear Axle Amended:
Fix hub carrier on the drop center housing.

Assemble washers s = 3.0 mm.
For the Torx screw version the assembly of
washers is not applicable.
Secure screws with Loctite 243.
111 Tightening torque (cylindrical screws) MA = 200 Nm
or (depending on individual version)
Tightening torque (Torx screws) MA = 185 Nm
Insert plug shaft until contact is obtained (figure 72

and 73).
An installation dimension between 109 and 112
mm (see figure 114) ensures that all individual
112 components of the drive gear bearing are being
assembled and centered.
113
Put sealing agent DREI-BOND SILIKON 1207 onto

the mounting face of the section without holes.
Mount and grease O-ring (arrow).
114
SERVICE MANUAL
Rear Axle Amended:
Mount drop center housing by means of lifting

device onto the axle housing until contact is
obtained and fix it.
Assemble washers s = 3.0 mm.
For the Torx screw version the assembly of
washers is not applicable.
115
Secure screws with Loctite 243.
Tightening torque
Hexagon screws MA = 200 Nm
Cylindrical screws MA = 200 Nm
or
Torx screws MA = 185 Nm
(S) Lifting chain 5870 281 047
116
Assemble speed sensor (arrow).
Tightening torque MA = 9,5 Nm
SERVICE MANUAL
Rear Axle Amended:
OUTPUT
Assemble wheel bolt.
Pay attention to radial installation position.
(S) Wheel stud puller basic tool 5870 610 010
(S) Insert 7/8 – 11 5870 610 008
117
(S) Insert M22x1.5 5870 610 002
Mount compact bearing

When replacing the compact bearing or when
changing grease as part of the maintenance
interval, make sure that hub and compact bearing
are cleaned thoroughly.
118
Figures 119 and 120 show the individual
components of the compact bearing and the
installation position.
Legend to figure 119 and 120:
1 = Hub
2 = Compact bearing
3 = O-ring Complete component
4 = Retaining ring
5 = Hub carrier
119 Items 3 and 4 are provided with the compact

bearing as loose parts.
Press in both bearing outer rings until contact is

obtained.
(S) Driver 5870 050 007
(S) Handle 5870 260 004
120
SERVICE MANUAL
Rear Axle Amended:
Grease compact bearing in the marked area - -

Total grease quantity of each output side: 130 gram
(max.150 g).
Apply plenty of grease onto the bearing rolls,
inside, outside and on the front sides.
Only use grease types which have been approved
121 by ZF (e.g. Renolit LX-PEP 2, ZF order no.: 0671
190 122).
Ref to ZF List of lubricants TE-ML 12.
The latest update of the List of Lubricants is
available at internet site www.zf.com
Service/Techn. Information
Mount bearing inner ring on brake disk side.

To ensure that the position of the bearing rollers in
the bearing outer ring is precisely aligned, press
bearing inner ring firmly and rotate it several times
122 (roll in)).
The bearing inner ring of the brake disk side is
visible on the ring nut for the O-ring (arrow).
Turn hub.
Support the bearing inner ring on the brake disk
side by means of an appropriate mandrel (arrow) to
maintain the contact of the bearing inner ring.
123
Mount outer bearing inner ring.

To ensure that the position of the bearing rollers in
the bearing outer ring is precisely aligned, press
bearing inner ring firmly and rotate it several times
124 (roll in).
Clearance free contact of both bearing inner rings
must be ensured.
SERVICE MANUAL
Rear Axle Amended:
Locate both bearing inner rings by means of

retaining ring.
Pay attention that the installation position of the
retaining ring is correct, see arrow/figure 127.
In case of incorrect location the reference
dimension is = 140 +/- 0,4 mm , see figure 127.
125
It is not possible to lift the outer bearing inner ring.
126
Mount shaft seal on the flange shaft side.

(S) Driver 5870 051 053
The use of the specified special tool (S) ensures
that the installation depth is precise.
Make sure that the OILSIDE shows upwards.
127
Mount the shaft seal on the side of the brake disk.

(S) Driver 5870 051 053
The use of the specified special tool (S) ensures
that the installation position is correct.
128 When installing ensure – sensor ring or designation
“OUTSIDE“ shows upwards (outside).
Insert O-ring into the ring nut of the bearing inner
ring (arrow).
SERVICE MANUAL
Rear Axle Amended:
Bolt hub/brake disk.

Tightening torque
Version with hexagon screw (M16x1.5/10.9) MA =
300 Nm
Version with torx screw (M14x1.5/10.9) MA = 190
129 Nm.
Put lubricant “MOLYKOTE DX“ onto the bearing.
130
Insert inner installer into the hub carrier until

contact is obtained.
(S) Inner installer 5870 651 085
131
Mount preassembled hub carefully using lifting

device until contact is obtained.
Then remove inner installer again.
132
SERVICE MANUAL
Rear Axle Amended:
Mount internal slotted nut.

When installing the slotted nut – ensure the
chamfer shows outwards.
While tightening rotate the hub several times in
both directions.
133 Tightening torque (inner slotted nut)......MA = 850 Nm

(S) Slotted nut wrench 5870 401 146
If no increase of the bearing rolling torque or axial
play of the wheel bearing is noticeable (figure 135)
while tightening the slotted nut (figure 134), it is
possible that this is caused by the unsnapping of
the retaining ring (figure 126 and 127).
If necessary, correct assembly fault.
134
Insert locking plate and assemble outer slotted nut.

Pay attention to the installation position of the
locking plate – securing clip shows inside.
slotted nut – chamfer shows inside.
135 Tightening torque (outer slotted nut) .. MA = 1200 Nm
Secure slotted nut by fixing the locking plate to the outer

slotted nut.
136
SERVICE MANUAL
Rear Axle Amended:
Insert O-ring into the ring nut of the flange shaft

(arrow) and grease it.
137
Insert flange shaft until contact is obtained and fix it

with hexagon screws.
Tightening torque (M18x1.5/10.9) .. MA = 440 Nm
138
Check if the function of the sealing elements is correct.

Test medium : air
Test pressure : 0.5 bar
Test period: 10 minutes
139 Lock the mounting hole for the breather valve
provisionally (arrow).
Lock the stop valve during the 10 minutes test period.
(S) Air connection 5870 286 079
(S) Reducer 5870 286 080
SERVICE MANUAL
Rear Axle Amended:

the mounting of various peripherical parts and
assemblies.
Different versions may require different operating
processes.
In this context please also refer to other relevant
140 sections of the manual.
Mount breather valve, see arrow (if fitted).
Tightening torque ………….. MA = 6 Nm
Brake Reassembly
Tightening torque (M16x1,5 / 10.9)….. MA = 270 Nm
or (depending on individual version).
Tightening torque (M18x1,5 / 10.9)) . MA = 440 Nm
141
When working on the brake system, the instructions
and specifications of the respective brake
manufacturer must be used. The relevant information
is included in the repair and maintenance instructions
of the component manufacturer.
The latest updates of the individual instructions can
be ordered by the brake manufacturer or looked up
at the available internet site.
Brake manufacturer and brake type can be taken from
the identification plate of the brake caliper.
Figure 142 shows the position of the identification plate
(arrow) with the example of a KNORR – brake.
142
With this version it is necessary to pay attention to the
installation position of the fitting screw (arrow / figure
143). The fitting screw must always be mounted on the
left and right output side in driving direction (front side).
Fix the spring carriers (4x) with screws and washers to

the axle housing.
Tightening torque (M20x1.5/10.9) …….. MA = 620 Nm
Pay attention to the installation position – see the
143 markings which have been applied during the
disassembly process.
Before commissioning the unit, carry out oil filling
according to the specifications provided in the
lubrication and maintenance instructions
(ZF-order no.: 5871 214 902).
SERVICE MANUAL
Rear Axle Amended:
LIST OF SPECIAL TOOLS FOR THE DISASSEMBLY AND REASSEMBLY

DIFFERENTIAL - OUTPUT
DISASSEMBLY REASSEMBLY APPLICATION SPECIAL TOOL(S) PART NO
Figure 1 Assembly truck cpl. with tilting device 5870 350 000
Support Universal use. 5870 350 093
For clamping the cpl. axle on the
assembly truck.
Figure 9 Figure 133 Slotted nut wrench#

To loosen and tighten the slotted nut 5870 401 146
M105x1.5 0637 504 083 on the hub carrier.
Figure 10 Figure 132 Lifting device#

Universal use. 5870 281 043
Facilitates disassembly and reassembly of the
preassembled hub on the hub carrier.
Figure 12 Pry bar 2 pieces necessary

Figure 35 Universal use. 5870 345 071
To separate components, disassembly of seal rings,
bearings etc.
Figure 18 Lifting strap

Facilitates the disassembly and reassembly of the hub or of
the complete hub carrier.
Figure 19 Striker#
To remove the bearing outer rings from the hub carrier or
the housing hole.
Figure 21 Rapid grip

To pull off the bearing inner ring 27695= 0750 117 141
from the output gear. 5873 012 013
Can be used together with: 5873 002 001
Basic device
SERVICE MANUAL
Rear Axle Amended:

Figure 21 Figure 78 Lifting chain 3 parts

For various lifting works.
Figure 23 Assembly truck cpl. with tilting device

Clamping plate 5870 350 000
For clamping the complete portal drive onto the assembly
truck.
Figure 23 Figure 96 Adjusting screws 1 set = 2 pieces

To position and align the bearing bolts in the drop center
housing / intermediate gear bearing.
Figure 25 Rapid grip

To pull bearing inner ring JLM710949 = 0750 117 210 off
from the differential carrier. 5873 011 012
Can be used together with : Back-off insert 5870 026 100
Figure 25 Pry bar

To pull bearing inner ring 32213 = 0635 373 018 off from
the differential carrier. Crown gear side. 5873 002 025
Can be used together with : Basic device 5873 002 001
Figure 33 Hot air blower 230 V 5870 221 500

Hot air blower 115 V 5870 221 501
Universal use.
To warm housing and bearings as well as connections
fixed with LOCTITE.
SERVICE MANUAL
Rear Axle Amended:

Figure 33 Figure 52 Slotted nut wrench # ø 86 mm 5870 401 093

Figure 83 Slotted nut wrench # ø 81 mm 5870 401 139
To loosen and tighten the slotted nut 0737 502 146
on the pinion shaft.
Attention: Differing flange diameters
4460 305 255 / 441 / 468 / 477 = ø 86 mm
necessitate different tools.
Can be used together with:
Clamping yoke 5870 240 002
Centering flange 5870 912 015
Figure 36 Press off tool# 5870 080 044

To press off the bevel gear shaft from the axle housing.
Figure 38 Gripping insert 5873 003 022

To pull the bearing inner ring JH913848 = 0750 117 619
off from the bevel gear shaft.
Reducer Size 3/ Size 2 5873 003 011
Basic device 5873 002 001
Figure 39 Internal extractor 5870 300 019

Universal use.
To remove the bearing outer ring JW6010 = 0750 117 003
from the axle housing input pinion.
Counter support 5870 300 020
Figure 44 Straightedge # 5870 200 022

Figure 104 Universal use.
Figure 113 For various measuring processes.
Digital depth gauge # 200 mm 5870 200 072
Gauge blocks# 70mm 1 set of 2 5870 200 066
SERVICE MANUAL
Rear Axle Amended:

Figure 47 Assembly fixture# 5870 345 080

To pull the bearing outer ring JH913848 = 0750 117 619
into the axle housing.
Figure 53 Slotted nut wrench 1 – 12 Nm 5870 203 031

Figure 80 Reducer ½“ – ¼“ 5870 656 056
Universal use.
To calculate and check rolling resistance in the pinion
bearing.
Figure 45 Driver 5870 058 078

To insert bearing outer ring JLM710949 = 0750 117 210
into the axle housing (differential bearing).
Can be used with : Handle 5870 260 002
Figure 68 Measuring cover # 5870 200 121

Figure 70 To preclamp the differential in the axle housing.
Figure 71 Calculate backlash as well as bearing preload = rolling
torque in the differential bearing.
Figure 71 Magnetic stand # 5870 200 055

Figure 73 Dial indicator # 5870 200 057
Universal use.
To calculate and measure the backlash in the bevel gear
set.
Figure 81 Driver # 5870 048 216

To insert the shaft seal 90x125x12/19 = 0734 319 589 into
the axle housing hole (input).
Figure 82 Driver 5870 056 008

To press the protective shield 4460 311 206 onto input
flange 4460 305 477 .
Can be used with: Handle 5870 260 004
SERVICE MANUAL
Rear Axle Amended:

DIFFERENTIAL - INPUT
Figure 87 Assembly fixture# 5870 345 103

To preclamp cup spring 0750 106 080 to facilitate the
assembly of the drive wheel.
Figure 92 Plug gauge# 5870 200 094

Magnetic stand # 5870 200 055
Dial indicator # 5870 200 057
Pry bar# 2 pieces 5870 345 071
To calculate and adjust the backlash in the intermediate
gear bearing.
Figure 96 Adjusting screws 1 set = 2 pcs 5870 204 022

Universal use.
to position and align the bearing bolt in the drop center
housing / intermediate gear bearing.
Figure 101 Measuring ring# 0730 161 832

Figure 103 Digital depth gauge # 5870 200 072
Figure 104 Measuring bar# 5870 200 127
To calculate and adjust the output gear bearing.
Figure 108 Pressing fixture# 5870 506 162

To press protective shield 4472 335 730 onto the hub
carrier.
Figure 117 Wheel bolt puller 5870 610 010

In connection with :
Insert M22x1.5 5870 610 002
Insert 7/8 – 11 BSF 5870 610 008
to insert the wheel bolts
4474 306 180 M22x1,5
4472 335 281 / 461 7/8 – 11 BSF
into the hub hole. Repair solution.
SERVICE MANUAL
Rear Axle Amended:

DIFFERENTIAL - INPUT
Figure 120 Driver# 5870 050 007

To insert bearing outer ring 0735 371 966 into the hub
hole.
Can be used together with: Handle 5870 260 004
Figure 127 Driver # 5870 051 053

Figure 128 To insert shaft seals 0734 319 643 and 0734 319 644
into the hub hole.
Can be used with: Handle 5870 260 004
Figure 131 Inner installer 5870 651 085

To align and position the preassembled hub onto the hub
carrier.
Figure 139 Air connection# with reducer valve 5870 286 079
Reducer # M24 x 1.5 5870 286 080
for leakage test of the complete output.
Plastic hammer . 60 mm 5870 280 004

Universal use.
For careful disassembly and reassembly of sensitive parts.
# = tools of particular importance.
SERVICE MANUAL
Braking System Amended:10.12.09
Contents
Braking System Replacing Tappet & Boot . . . . Page 4.46 - 49

Braking system diagram . . . . Page 4.2 Adjuster Thread Inspection . . Page 4.47
Description . . . . . . . . . . . . . . Page 4.3 Replacing Inner Seals . . . . . . Page 4.47
Braking system component Caliper Replacement . . . . . . . Page 4.49
locations diagram . . . . . . . Page 4.4
Caliper Removal . . . . . . . . . . Page 4.50
Braking system components . Page 4.5
Caliper fitting . . . . . . . . . . . . . Page 4.51 - 52
Data sheet . . . . . . . . . . . . . . Page 4.6
Fitting outer boot . . . . . . . . . . Page 4.52 - 53
Test and check list . . . . . . . . . Page 4.7 - 9
Fitting Cap . . . . . . . . . . . . . . Page 4.53
Hand Brake valve . . . . . . . . . Page 4.10
Replacement of Inner boot . . Page 4.54 - 55
Foot Brake valve . . . . . . . . . . Page 4.11 - 13
Guide Pin Bush Replacement Page 4.56
Air dryer . . . . . . . . . . . . . . . . Page 4.14 - 15
Rubber Bush Replacement . . Page 4.57 - 58
Carrier Replacement . . . . . . . Page 4.59
ABS braking System
Brake Actuator Replacement . Page 4.60
ABS braking system schematic Page 4.16
Brake Chamber Fitting . . . . . Page 4.60
Description - ABS . . . . . . . . . Page 4.17
Spring Brake Removal . . . . . Page 4.61
Sensor Adjustment . . . . . . . . Page 4.17
Brake Caliper (SN)
System Components . . . . . . . Page 4.18 - 19
Brake Caliper Description . . . Page 4.63
Wheel Sensing . . . . . . . . . . . Page 4.20
Inspection Points . . . . . . . . . . Page 4.64
ABS Solenoid Valve . . . . . . . Page 4.20 - 21
Wear Limits . . . . . . . . . . . . . . Page 4.64 - 69
Warning Light Function . . . . . Page 4.22
Adjuster Check . . . . . . . . . . . Page 4.70
Failure Mode . . . . . . . . . . . . . Page 4.23
Caliper Checks . . . . . . . . . . . Page 4.72
Displaying Fault Codes . . . . . Page 4.24 - 26
Pad Replacement . . . . . . . . . Page 4.74
Dynotester Function . . . . . . . Page 4.26
Pad Fitting . . . . . . . . . . . . . . Page 4.75
Fault Code List . . . . . . . . . . . Page 4.27
Wear indicator . . . . . . . . . . . . Page 4.77
Fault codes / repair instructions Page 4.28 - 31
Tappet & Boot Assy . . . . . . . . Page 4.79
Caliper Replacement . . . . . . . Page 4.83
Brake Caliper (SB)
Guide Pin Bush Replacement Page 4.89
Brake Caliper Description . . . Page 4.32 - 33
Actuator Replacement . . . . . . Page 4.96
Inspection Points . . . . . . . . . . Page 4.34
Spring Brake Actuators . . . . . Page 4.97
Wear Limits . . . . . . . . . . . . . . Page 4.34 - 37
Special Tools
Adjuster Check . . . . . . . . . . . Page 4.38
& Torque Requirments . . . . . . Page 4.101
Caliper Running Clearance . . Page 4.39
Pipe connectors
Rubber Bush to Guide Pin . . . Page 4.39 - 40
Plastic pipe fitting type PA . . . Page 4.102
Seal Checks . . . . . . . . . . . . . Page 4.41
Pipe removal . . . . . . . . . . . . . Page 4.102
Tappet & Boot Assy . . . . . . . . Page 4.41
Pipe assembly . . . . . . . . . . . Page 4.102
Pad Replacement . . . . . . . . . Page 4.42
Nylon tube repair . . . . . . . . . . Page 4.103
Pad Fitting . . . . . . . . . . . . . . Page 4.43
Metal pipe fitings . . . . . . . . . . Page 4.104
Wear Indicator . . . . . . . . . . . Page 4.44
Cable Guide . . . . . . . . . . . . . Page 4.45 Section 4
SERVICE MANUAL
Braking System Amended:
STRG
2
PILOT
VALVE 1 3 HANDBRAKE
CHARGE
VALVE
COUPLING
1
3
L HANDBRAKE
INTERLOCK
21 1
LOW PRESSURE SOLENOID
SWITCH
KEY TO PIPE SIZES
ZF ONLY
GEARBOX SECTION
RETARDER - REFER
TP TP
SERVICE 1
FOOT
BRAKE
16mm Red BRAKE BRAKE VALVE
CHAMBER CHAMBER
STOP TP
s
LIGHT
ABS ABS SWITCH
VALVE
10mm Red VALVE
13
23 PRESSURE
21 11
TRANSDUCER
22 12
12mm Red
FRONT AXLE
FRONT LOCATION
STOP
LIGHT s
SWITCH
10mm Orange
SOLENOID VALVE
FRONT SUSP'N
TP
ABS
VALVE
BODYBUILDER
12mm Orange
SUPPLY
SUSPENSION
AUXILIARY &
ABS
BRAKE
ACTUATOR
REAR AXLE VALVE
6mm Orange BRAKE

ACTUATOR
24
23
TP
21
22
12
12
11
11
6mm Yellow QUAD

1
VALVE
TP
12mm Yellow ONE WAY

TP VALVE
10mm Yellow
TO UREA DOSER
TO UREA DOSER
16mm Yellow
FRONT KNEEL
6mm Green
OR
4 1
1
4
FULL KNEEL
4 2 4
2 2 11 12 2 2
12mm Green
RELAY RELAY
SOLENOID VALVE
VALVE VALVE
FRONT SUSP'N
PRESSURE LINE
FILTER TP
4mm Black TRANSDUCER AIR AUXILIARY &
DRYER SUSPENSION
TP = Test Point SERVICE 2

22
PARK
21
1
TP
L
TP
LOW
PRESSURE
SWITCH
REAR
LOCATION FROM
AIR
CLEANER
REAR
LOCATION
PING
TANK
COMPRESSOR
SAFETY
AR8302 - E400 E5 VALVE
SERVICE MANUAL
General Description
The braking system is fully air operated, the front
wheel brakes being applied by diaphragm actuators
while the rear actuators can be spring-applied in
addition to pneumatic operation.
A compressor, driven by the engine, connects to a
cartridge-type air drier. In addition to drying and
filtering the air, the dryer purge cycle is used as an
unloading device, diverting the compressor output to
atmosphere when the pressure in the reservoirs in
high. When the pressure falls again, the dryer
unloader valve closes the purge valve and connects
the compressor output to the multi-circuit protection
valve.
This valve gives priority to charge the Service 1 and
Service 2 reservoirs. It also ensures that
downstream failure in any of the four circuits will lead
to isolating that circuit. Service 1 reservoir feeds the
front brakes through a load sensing valve to give the
correct ratio between the front and rear braking
effort. Service 2 reservoir connects directly to the
rear brakes, both front and rear systems being
controlled simultaneously through separate sections
of the footbrake valve.
The park reservoir supplies the hand brake system.
This connects the rear brake actuators via the hand
brake valve and quick release valve. When the
control valve is at OFF an air supply is connected to
the brake actuators to compress a spring and hold
the brakes off. When the valve is at PARK, the air
supply is cut off and the pressure exhausted through
the quick release valve to allow the springs in the
actuators to apply the brakes.
There are two auxiliary reservoirs supplying the air
suspension system. Another tapping of this supply
line supplies the coachwork system (such as doors).
The system pressure in Service 1 and 2 systems is
displayed on the dashboard screen control unit. Low
pressure switches sound a buzzer and bringing up a
warning light if the pressure in any of the three brake
systems is below a safe figure.
An external charging connection is provided on the

front chassis crossmember.
SERVICE MANUAL
Solenoid
Valve - ZF
Charge
Coupling
ABS Footbrake
Modulator Valve
Valve
Levelling Levelling
Valve Valve
Front Brake
Chamber Front Brake
Chamber
Double Check
Multi Circuit Valve
Protection Valve
Relay
Relay
Valve
Valve
Levelling Valve Levelling Valve

Pressure
Pressure
Modulation
Modulation
Valve
Valve
Spring Brake Spring Brake

Actuator Actuator
Air Dryer
Compressor
SERVICE MANUAL
Braking System Components Amended:
Compressor Speed Sensors - (SS)

This compressor is an engine driven two cylinder These are located at the wheels to sense the
unit, with a balanced crankshaft and reed type instantaneous movement of individual wheels and
valves. The cylinder head is cooled by water from send an electronic signal directly proportional to the
the vehicle cooling system. and is lubricated by oil rotational velocity of the sensed wheel to the
from the engine lubrication system. electronic control unit.
Air Dryer Electronic Control Unit - (ECU)
This type of air dryer operate on the principle of cold- This monitors the speed sensor signals and
regenerated absorbtion drying in which very low determines when the ABS intervention is required
pressure dew points are achieved. A dual fine and actuates the appropriate pressure modulation
filtering system protects th braking system against valves to optimize the brake pressure. The ECU
impurities. continually monitors the system to detect and warn
the driver of any malfunctions. Failure specific codes
Multi Circuit Protection Valve are stored in the ECU and can be recalled to
This valve is of the type which allows air to flow back diagnose a failure.
(bleed back) from the system to the air dryer. The
main function of this valve is to isolate a failed circuit Pressure Modulator Valves - (PMV)
whilst allowing the remaining circuits to be charged These are located near the brake chambers and are
from zero if necessary and function as normal. controlled electronically by the ECU to decrease,
hold or allow the full applied brake pressure into the
Relay Valve brake chamber to control the braking torque at the
These valves respond rapidly and precisely to the wheels.
incoming signal pressure and deliver air of equal
pressure, but in greater volume to its destination.
They are a remote type of control valve where a
signal replaces the usual mechanical operation.
Spring Brake Actuator
These brakes are a dual type actuator, the front or
service portion working in exactly the same way as a
single diaphragm brake chamber. The rear portion is
a cylinder containing a powerful coiled spring, which
is held compressed by introducing air behind the
piston or diaphragm. Releasing the air will allow the
spring to expand and this movement is used to
actuate the parking brake.
Double Check Valve
These valves are also described as change over
valves or shuttle valves, they allow air from two
different controls to be supplied to one destination.
Hand Brake Valve
In the OFF position, air is delivered to hold off the
spring brakes and in the PARK position the air is
exhausted to apply the spring/Park brake.
Footbrake Valve - Dual
This valve has two supply ports and two delivery
ports supplied from two reservoirs.Should one circuit
fail then there is a second separate back up system.
Relay Valve
This valve supplies air to operate the brake actuators
when signalled by a control valve (Footbrake or
Hand control valve), to which it reacts immediately
and precisely.
SERVICE MANUAL
Braking System - Data Sheet Amended:
ITEM DESCRIPTION PART NO DETAILS
Brake Assemblies
Front brake assembly LH 660364-10 Rationalised Caliper
Front brake assembly RH 660364-9 Rationalised Caliper
Rear brake assembly LH 660426-25 Rationalised Caliper
Rear brake assembly RH 660426-24 Rationalised Caliper
Special Tools
Brake tubing cutter
Spanner 24mm Spring brake release
Brake Actuators
Front 659387-1 &2 Type 22
Rear 658517-38 Type 24/24
Air Pressure Settings Bar P.S.I.
Air Dryer Cut Out Pressure 657516 10 (+ 0.2) 145 (+5.8)

Safety Pressure 13 191
Colour Coding of Pipes

Compressor Supply Red
Service Brake Circuit Yellow
Parking Brake Circuit Orange
Auxiliary Circuit Green
Signal Lines Black
SERVICE MANUAL
Test and Check List Before you begin testing the air brake
system, perform the following checks:
WARNING 1. Examine all tubing for signs of kinks or dents-
Before working on or around air brake systems 2. Examine all hoses for signs of wear, drying out or
and components, the following precautions overheating.
should be observed. 3. Check suspension of all tubing. It should be
supported and not vibrate.
• Stop the engine before working under a vehicle. 4. Check suspension of all hoses. Position so that
• Always chock the wheels because depleting hoses will not abrade or be subject to excessive
vehicle air system pressure may cause the vehicle heat.
to roll.
• Keep hands away from actuator push rods and
slack adjusters; they may apply as system Test Procedure for Vehicle Braking
pressure drops. System
• Never connect or disconnect a hose or line
containing air pressure, it may whip as air Test 1
escapes.
Govemor/Unloader Cut-Out
• Never remove suspension components without
first releasing stored pressure held in the air Low pressure Warning
springs Pressure Build-Up
• Never remove a component or pipe plug unless 1. Drain all reservoirs to 'O' bar.
you are sure that all system pressure has been
depleted. 2. Start engine (run at fast idle). Low pressure
warning light should be on, buzzer should sound.
• Never exceed recommended air pressure and
always wear safety glasses when working with air 3. Low pressure warning light should go off and
pressure. buzzer should stop at approximately 5.8 bar.
• Never look into air jets or direct them at anyone. 4. Governor/unloader should cut-out at
recommended pressure (see Data Sheet).
• Never attempt to dismantle a component until you
have read and understood recommended 5. Build up time. Pressure should rise from 6 bar to 7
procedures. Some units contain powerful springs bar within 40 seconds.
and injury can result if not properly dismantled.
Make all necessary repairs before proceeding to
Use only correct tools and observe all precautions
relative to the use of these tools. Test 2 - see Check List 1 for common
corrections.
Description If governor/unloader does not cut-out at pressure specified

on Data Sheet:
The five tests outlined in this programme have been
designed to discover the presence of air leaks and/or 1. Adjust governor/unloader using a gauge of known
sluggish performance in a Dual Air Brake System. The accuracy.
entire system, from the compressor through to the 2. Where compressor has an integral unloader check
actuators can easily be diagnosed in a short period of time function and repair or replace as necessary.
by performing these tests.
3. Repair or replace governor/unloader as required.
After completion, you will know whether or not the system
is building pressure rapidly enough, if there is any leakage 4. If compressor unloads through air dryer, check
and if the emergency components are functioning properly. operation of the air dryer purge valve.
In some cases you may find that corrections will need to

be made. Each test is followed by a check list that gives a
guide to the more common causes for the vehicle failing
the test. Please note that these are static tests only. They
must not be interpreted as overruling the importance and
necessity of functional, dynamic controllability tests and
other tests required to assure vehicle safety and
performance.
SERVICE MANUAL
If the low pressure warning occurs below 5.8 bars: • Hand control valve(s).
1. Check dash gauge against gauge of known • Safety valve.
accuracy.
• Governor/unloader
2. Repair or replace low pressure switch. (L.P. switch
• Compressor delivery valve(s).
integral with air gauge)
Retest to check out all items repaired or replaced.
If pressure build-up time exceeds 40 seconds or greatly
exceeds previously recorded figures:
Test 3
1. Examine compressor air intake filter and clean or
replace. Leakage (Service Air Delivery)
2. Ensure that inlet line and engine intake filter are (Full Pressure, Engine Stopped)
not restricted, delivery pipes that are 'carboned up'
1. Make and hold a brake application. (A block of
are extremely difficult to clean.
wood can be used to hold down the foot valve).
3. Clean any excessive carbon from discharge port
2. Allow pressure to stabilise for 1 minute, then begin
and delivery line.
timing for 2 minutes whilst watching the dash
4. If compressor is belt driven check for drive gauges for a pressure drop.
slippage.
0.030 bar maximum for each reservoir.
5. Check for compressor inlet or discharge valve
leakage.
Make all necessary repairs before proceeding to
6. Check for leakage from air dryer purge valve.
Test 4 - see check list 3 for common
corrections.
Test 2 Check List 3

Leakage (Reservoir Air Supply) If there is excessive leakage in the service side of the
system, One or more of the following devices could be
(Full pressure Engine stopped) causing the problem:
1. Allow pressure to stabilise for at least 1 minute.
NOTE
2. Observe dash gauge pressures for 2 minutes and
note any pressure drop. A leak detector or soap solution will aid in
locating the faulty component.
0. 15 bar maximum for each reservoir.
Make all necessary repairs before proceeding to • Service lines and fittings (tighten).
Test 3 - see Check List 2 for common • Stoplight switch(es).
corrections.
• Quick release valve(s).
• Dual brake valve.
Check List 2 • Test point.
If there is excessive leakage in the supply side of the
pneumatic system, one or more of the following devices
could be causing the problem: Retest to check out all items repaired or replaced.
NOTE
A leak detector or soap solution will aid in
locating the faulty component.
• Supply lines and fittings (tighten).

• Low pressure indicators.
• Reservoir protection valve(s).
• Relay valve(s).
• Dual brake valve.
SERVICE MANUAL
Test 4 5. Re-charge the rear axle reservoir, drain the

reservoir feeding the spring brakes.
Handbrake (Secondary/Parking System)
The remaining reservoir pressures should not fall
(Full Pressure, Engine Idling 600 - 900 rpm) below the closing setting of the reservoir protection
valve(s).
1. Operate hand control valve. Spring brakes should
apply brakes promptly. The spring brake actuators should apply.
2. Move hand control valve to park position. Handle The spring brake cab warning light, if fitted and
should lock securely. stop lights should come on.
3. Move hand control valve to off position. Brakes 6. Re-charge the spring brake reservoir.
should release promptly.
Make all necessary repairs before proceeding to Check List 5

Test 5; see Check list 4 for common If the vehicle fails to pass any of the prescribed tests,
corrections. check the following components for leakage and correct
operation:
Check List 4 • Fittings.
If defective performance is noted in either test, check for: • Kinked hose or tubing.
• Dented or kinked lines. • Reservoir protection valve.
• Improperly installed hose fittings. • Double check valve(s).
• A faulty relay emergency valve. • Relay emergency valve.
• Faulty quick release valve(s). • Hand control valve.
• A faulty hand control valve. • Non-return valve(s).
NOTE
Test 5 Other possible fault - Failure of one reservoir to
Secondary/Emergency System charge.
(Full Pressure, Engine Stopped) • Possible problem with MCPV.
1. Drain front axle reservoir to 'O' bar. • Kinked or crushed pipework.
Remaining reservoir pressures should not fall

below the close setting of the reservoir protection
valve(s). (See Data Sheet).
2. Without recharging front reservoir make a brake
application.
Rear axle brakes should apply and release.
The stop lights should come on.
3. Recharge the front axle reservoir and drain the
rear axle reservoir to '0' bar.
The remaining reservoir pressures should not fall
below the closing setting of the reservoir protection
valve(s). (See Data Sheet)
4. With no pressure in the rear axle reservoir make a
brake application.
The front axle brakes should apply and release.
The stop lights should come on.
SERVICE MANUAL
Braking System - Hand Brake Valve Amended:
Introduction At vehicle service intervals check the valve for any

damage, defects or air leaks. Check the operation of
The valve controls the flow of air which releases the the valve as follows:
parking brake The control lever is spring loaded in
the OFF position but will lock in the PARK position.
1. Ensure that the vehicle air reservoirs are kept
fully charged during testing. Chock the
Operation vehicle wheels to prevent it rolling away.
When the valve handle is in the brake ‘OFF’ position 2. Ensure that the handle torsion springs are
the vehicle spring brakes are held off by the effective and that they hold the handle in the
maintenance of air pressure in the spring brake brakes ‘OFF’ position.
actuators. When the valve handle is moved towards
3. Ensure that the handle locks securely in the
the ‘PARK’ position the air pressure in the spring
vehicle ‘PARK’ position.
brake actuators commences to exhaust to
atmosphere through the exhaust port of the Park 4. There must be no air pressure in the delivery
relay valve. lines when the handle is at vehicle ‘PARK’.
If handle movement is halted between brakes ‘OFF’ 5. Release the handle and gradually move it
and vehicle ‘PARK’ position, the valve is again towards the brakes ‘OFF’ position. Confirm
lapped, although with a lower pressure in the spring that the delivered air pressure rises in
brake actuators. proportion to the amount of handle
movement. At ‘OFF’, the delivered pressure
If handle movement is fully to the ‘PARK’ position the
should be at the specified maximum setting.
air pressure in the spring brake actuators is
completely exhausted to atmosphere. As no air 6. Apply soap solution to the valve bodies and
pressure is allowed to pass through the valve, the exhaust ports. There must be no air leakage
vehicle parking brakes are held on by powerful when the valve handle is at either end of its
springs in the actuators. movement.
When the handle is moved from the vehicle ‘PARK’
towards brake ‘OFF’ position, an increasing air
Should a valve be found defective or leaking, it must
pressure is admitted to the delivery port off the
be removed from the vehicle and a new item fitted as
spring brake actuators to act against the force of the
the valve is not repairable.
powerful springs and release the vehicle brakes.
Maintenance
WARNING
Before working on or around the brake
systems and components always observe the
safety precautions given under
BRAKING SYSTEM.
SERVICE MANUAL
Braking System - Foot Brake Valve Amended:
WARNING
Before working on or around the brake
systems and components always observe
the safety precautions given under BRAKING
SYSTEM..
Pedal General
The pedal functionalilty, voltage output, retarder
torque and air application points are as follows:
1. Pedal position at idle - the output will be

0.5 - 1.5v but no more - No retarder and no air.
2. Pedal angle at approx 42 degrees - Output is
1.7v - Retarder starts with a torque of
1200Nm, no air.
3. Pedal at the end of free play, approx 6 degrees -
output is approx 2v - retarder Torque approx 1750
Nm, no air
4. Pedal at 7-8 degree angle - air starts.
5. Pedal at 10 degree angle - Output is 2.7v -
retarder torque is 2000 Nm - Air is .7bar.
TREADLE
TREADLE
PIVOT PIN
TREADLE
BASEPLATE
POTENTIOMETER
ASSEMBLY
BAYONET PLUG
BASIC VALVE CONNECTION
ASSEMBLY
SERVICE MANUAL
Footbrake Valve - ZF (Retarder Valve Type) Retarder Valve
Footbrake Valve - Voith (Microswitch Type) Valve - Basic
SERVICE MANUAL
Footbrake Valve - ZF - (Retarder Valve

WARNING
Type)
Before dismantling, mark all parts in relation to
Pedal Assembly - Dismantling each other to ensure correct re-assembly.
1. Remove the four nuts (3) and separate the
upper and lower (1) section of the valve
2. Remove the two screws (4) to free the
.retarder valve (2). (where fitted)
3. Remove the screw (5) to free the shim (6)
Basic Valve - Dismantling
4. Depress the foot pedal (27) and remove the
adjuster screw (20) 1. Grip the clamping square in a vice and screw
5. Hinge back the foot pedal (27) and remove the transfer pie into the double connector on
the circlip (24). Withdraw the pin (18) to free the square. Screw the brake valve on to the
the two pressure pieces (23 & 25) and the transfer pipe and tighten.
roller (22) 2. Remove the circlip (22) and lift out the boot
6. Remove the Gaiter (21) (21) and the locating ring (20).
7. Hold the plunger down against the spring 3. Connect an air line to the port marked 11 on
(11). Remove the pin (7) and allow the the body and carefully increase the air
plunger to rise and release the components pressure until the piston (16) is ejected from
of the assembly. the body. Take out the spring
8. Remove the adjuster screws (13 & 14) to 4. Remove the guide rings (18) and the “O”
release the operating plate. rings (17) from the piston.
5. Remove the screws (23) to free the lower
body (8).
Footbrale Valve - VOITH- (Microswitch
6. Remove the circlip (7) to free components
Type)
(2,3,4,5 & 6) and “O” ring (15)
Pedal Assembly - Dismantling 7. Lift the piston (13) out of the body (8).
1. Remove the four nuts (20) and separate and Remove the “O” rings (14 & 10).
remove the upper and lower section (1) and 8. Remove the circlip (12) to free components
the micro switch assembly and remove large (2,3,4,5 ,6,9,10 & 11)
seal (18) from the valve
2. Depress the foot pedal (35) and remove the
adjuster screw (26)
Inspection
3. Hinge back the foot pedal (35) and remove Clean all metal parts in an approved solvent and dry.
the roll pin (36). Withdraw the pivot pin (23) to check for wear and damage and renew all faulty
free the bushes (30 & 38) and the spring (31) parts. It is recommended the parts
4. Remove the Gaiter (29) and withdraw plunger 3,5,6,7,10,11,12,14,15,17,18,21 and 22 are renewed
(28). Check condition of the bush (27) as a matter of course.
Assembly
Assembly is a reversal of the dismantling procedure.
Grease all the parts with Lubricant RHF 1 (Dennis
657186-6)
SERVICE MANUAL
Braking System - Air Dryer Amended:020210
22
20
18
27
19
21
13 14
9
15 1
12
16 11 10
8
4
6 26
7
2
5
17
23 3
1-25 Repair kit 26 Heater plug 27 Filter cartridge
Maintenance
Check function and cleanliness of air dryer . . . . . . . . . . . . . . . . . .A,B,&C Service intervals
Change air dryer cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yearly
Specification
Inlet from compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Port 1
Air outlet to multicircuit protection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Port 21
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Port 3
Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 bar + - 0.2 bar
Operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 bar + - 0.5
Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 bar
Ambient temperature range- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-40° C to + 65° C
Resistant to heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max +80° C
Electrical connection for heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24V 100W
Switching temperatures for heating . . . . . . . . . . . . . . . . . . . . . . . . . .ON +7°C OFF +29°C
Tightening torque M12 x 1.5 connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Nm
Tightening torque M22 x 1.5 connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Nm
SERVICE MANUAL
Braking System - Air Dryer Amended:020210
WARNING
The cartridge air dryer contains compressed
air at brake system pressure. It is possible
for this pressure to still be present even
when the rest of the system appears to be
drained. Always relieve this pressure before
attempting to renew the cartridge,
dismantling any part of the dryer, or
• The pull ring should be grasped and pulled to the
removing the dryer from the vehicle.
side to evacuate any remaining air in the reservoir.
WARNING
Air Dryer Eye protection should be worn when
The air dryer removes any water vapour which draining the air / water from the reservoir, as
passes through the condenser unit, controls the dust or dirt may be blown around with
unloading pressure of the twin compressor and evacuation of the reservoir.
provides a safety valve.
• Unscrew the filter cartridge (with the aid of a
A non-serviceable dessicant cartridge, which screws
suitable tool e.g. oil filter wrench).
into the top of the dryer body, is filled with micro-
crystalline pellets, each having many minute pores to
give a very large surface area. This dessicant has a WARNING
high affinity for water but does not change Note the direction – clockwise or counter-
chemically as it absorbs and releases water. Air clockwise.
enters the body at port 1 and passes through the
cartridge and emerges at port 21 via a non-return • Clean the housing as well as the inside and
valve, on to an unloader valve. An exhaust valve in outside sealing areas thoroughly, making sure
the bottom of the body allows accumulated that dirt does not enter the clean air chamber.
condensate to be discharged to atmosphere.
• Only use a new filter cartridge and sealing ring.
The dryer body contains an electric heating element
• Lightly grease (General purpose) the sealing ring.
which is energised by the operation of the vehicle
engine control or ignition switch. The body also • Hand-tighten the new filter cartridge (tightening
contains a thermostat which restricts the heater torque 15Nm approx.).
operation to within preset temperature limits.
WARNING
Maintenance Note the direction – clockwise or counter-
clockwise.
Cartridge Replacement
The following points should be observed when • Record the replacement date of the filter
replacing the filter cartridge: cartridge.
• Clean the general installation area and the • Re-charge the air pressure system and check for
surfaces of the air dryer to avoid any ingress of any leakage.
dirt or road grit into the vehicle air system when
changing the cartridge. NOTE
Dispose of the filter cartridge in accordance with
• Before removing the old filter cartridge, the air any national regulations that may apply -
dryer should not be under pressure. noting that the product may contain oil or oil
deposits.
The braking system should be drained of all air
pressure by depleting the air reservoirs: Please refer to the Health & Safety and the
Environmental Warnings on pages 1.1 - 1.3 of this
• Repeated application of the footbrake valve will manual.
exhaust the air system.
Please refer to the Test and Check Warning on page
• Each reservoir is fitted with a reservoir drain valve. 4.7 of this manual
The valve is fitted with a pull ring.
SERVICE MANUAL
Wabco A.B.S. (E) Braking System Amended:26.06.09
Wheel Wheel
Sensor Sensor
Solenoid Valve
Front Brake Front Brake

Chamber Chamber
Footbrake
Valve
A.B.S. ECU
Primary Secondary
Reservoir Reservoir
Diagnostic Warning Lamp
Socket
Relay
Wheel Valve Wheel
Sensor Sensor
Solenoid
Rear Brake Valves Rear Brake
Actuator Actuator
SERVICE MANUAL
Braking System - ABS System Amended:26.06.09
Description
A.B.S. Braking system Maintenance

The task of the anti-lock brake system (ABS) is to The A.B.S. system is designed to be maintenance
prevent the wheels of the vehicle locking, especially free, however the following guidelines should be
on slippery roads, due to the brakes being applied observed.
to hard. This enables lateral traction to be
maintained on the wheels being decelerated, even • Check sensor adjustment when inspecting
during full brake application. This in turn guarantees brake pads or linings and also whenever
driving stability and steering control of the vehicle. hubs are removed.
within the physical limits. At the same time, the
• Check the electrical control unit and relays
available braking friction between tyre and road, and
are securely mounted and the E.C.U. plug is
thus vehicle deceleration and stopping distance, are
secure and clipped. Check the area around
optimized. During braking, electronic sensors on
the E.C.U. free from moisture.
each wheel evaluate wheel speeds. Wheel
performance is fed to a microprocessor which • Check the modulator and proportioning
senses when a wheel is about to lock. Brake valves are securely mounted and that the air
pressure is then adjusted, both to prevent the wheel and electrical connections are secure.
from sliding and to maintain optimum braking. • Check the wiring harness is secure and free
from damage. In particular check sensor and
Safety Instructions modulator cables for abrasions especially
While the ABS increases the vehicle safety, it is not where they are close to moving parts of the
able to overcome natural physical laws. ABS can vehicle. Any damaged components found
only optimise the utilisation of the available traction should be replaced.
between the tyres and the road. ABS is not able to
compensate for poor driving to avoid the
Sensor Adjustment
consequences of driving too close to the preceeding
Clean and regrease sensors . . . . . . . . .
vehicle and/or driving into a bend with excessive
Every 12 months or 100,000 miles (160,000km)
speed.
Grease . . . . . . . . . . . . . . .Anti corrosive
Reposition the sensor at every convenient

opportunity, especially when the hubs are removed
or the bearings have been adjusted. Push the
sensor fully home with the thumb or flat faced
implement. Once the wheel is rotated the sensor will
automatically back off to create an air gap.
CAUTION
Do not strike the sensor or push with a
pointed implement.
SERVICE MANUAL
The ABS intervenes during braking whenever the Pressure Modulation Valves - (PMV)
available friction between the road and the tyre of a These are located near the brake chambers and are
monitoring wheel is less than the braking force controlled electronically by the ECU to decrease,
applied to the wheel causing the wheel to decelerate hold or allow the full applied brake pressure into the
(impending wheel to lock) quickly. brake chamber to control the braking torque at the
wheels.
The Anti Lock Braking System consists of:
Four Wheel speed sensors, sensor clamping

bushes and polewheel (toothed wheel).
Four pressure modulator valves.
Electronic Control Unit (ECU).
Warning lamp, diagnostic interface, relay or
data interface for Retarder control and a
pushbutton.
Speed Sensors - (SS)
These are located at the wheels to sense the
instantaneous movement of individual wheels and
send an electronic signal directly proportional to the
rotational velocity of the sensed wheel to the
electronic control unit.
Electronic Control Unit - (ECU)

The E-version is not compatible to any of the A, B, or C
versions because the harness and plugs of the ECU are
different.
The four-sensor system uses an ECU with four

connectors. One connector is dedicated to supply
diagnostics and dashboard connections, the others for
frame harness components.
The ECU has two permanent power supplies for the valve
current from the battery positive, and one from ignition to
start the internal 5 Volt stabilisation. Continuous 5 Volt
supply is one of the permanent ‘valve’ supplies. Through
this method it is possible to control the end of the power on
session for i.e. writing to the EPROM. Switch off is
accepted if the vehicle is stationary and all signal lamp
outputs including pin 7 of the 18 pin plug are without
voltage. The time delay is 400 ms. The output to the
auxiliary brake (DBR) is excluded because it can be
connected directly to the other ECU’s.
Standard application is a relay connected to ‘Ignition’.

Interfaces to other ECU’s work at voltages higher than 8
Volts. ECU plus or ground problems result in total shut
down.
SERVICE MANUAL
ABS Braking System Amended:26.06.09
Kl.15: Voltage after the ignition switch of the

vehicle
15A UB
2,5 mm²
*
8
KL.30 (Batt.) Kl.30: Battery voltage of the vehicle
10 K
Diagnosis acc. ISO 9141
11 L
A1: Front axle of commercial vehicles
1 L
3 H SAE J1939
A1l = axle 1 left
6 ATC Traction
A1r = axle 1 right
5 ABS OFF-ROAD
A2: Drive axle of commercial vehicles
2
PRESSURE SENSOR
p A2l = axle 2 left
DBR
(X1)
14 A2r = axle 2 right

5A
U ECU
ABS: Anti-lock Brake System
7
KL.15 (IGN.) ABS OFF ROAD: Input to activate Off-road mode
2
ATC-L
(temporarily locked wheels)
13
WL
ATC: Automatic Traction Control
15
9
***
ATC-L: Output for ATC-control lamp (option ATC)
4
AV: Output to the outlet valve, which reduces
the pressure in the wheel brake when
EV
ABS-E Basic
3
A1l switched on.
**
6
AV CAN-H: High speed data link according SAE
12 CENTRAL J1939
twisted
A1l GROUND
15 CAN-L: High speed data link according SAE
10
13
twisted A1r J1939
EV
1
A1r
DBR: Relay disables an endurance brake such
**
AV
as a retarder or engine brake and may be
4
used to disable an inter axle lock (front /
EV
2 rear axles).
(X2)
A2l
**
5 AV DIF: Output for the pressure control valve of the
11
differential brake function (option ATC)
14
twisted
A2l EBL: Electronic brake force limitation
17
twisted A2r EV: Output to the inlet valve, which prevents
18
8 EV
further pressure rise when switched on
A2r (current flows).
**
AV
9 IG: Sensor input
16
DIF IGM: Sensor ground. The voltage generated by
7
the inductive sensors is measured
between IG and IGM. The designation
"sensor ground" does not mean, that this
point is directly connected to electronic
ground).
l r K: Diagnostic Output / input in accordance
A1 with JED 677 (ISO 9141)
A2 L: Diagnostic input according to JED 677
(ISO 9141)
TRACTION: Input to activate traction mode for
*: voltage drop less than 0.5V.
deep snow etc.
**: modulator wire resistance UECU: power supply for the ECU
< 0,28 Ohm. 1,5mm²
UB: supply voltage for the A1 and A2 valves
***: unplugged: short circuit
Warning lamp: ON WL: Warning lamp, which lights if the output
non marked wires
0,75 to 1,5 mm²
switches to ground
bladetype fuses
acc. ISO/DIS 8820
SERVICE MANUAL
Wheel Sensing
2
The rotation of the wheels is registered by a signal-
1
generating sensor and a toothed wheel moving with the
wheel hub. Because the vehicle reference speed is
derived from diagonally opposite wheel speeds, the
relationship between tooth number and tyre
circumference must be equal front to rear, within a defined Hub
percentage.
The inductive sensor comprises of a permanent magnet,
core and coil. The magnetic flux surrounding the coil is cut
by the rotating motion of the toothed wheel induction an
A.C. voltage whose frequency is directly proportional to Stub 3
the wheel speed. Axle
The WABCO sensor has been specifically developed for
the arduous conditions of commercial vehicle use. The
sensor is held in position by a special clamping bush made A.B.S. Sensor Installation
from corrosion resistant spring material. This allows the
sensor to be pushed up against the pole wheel during
assembly and allows the sensor to achieve its own
clearance once the wheel has been rotated for the first Operation - Pressure Increase
time. The action of the bush also provides tolerance for
axle elasticity. etc. e.g. allowing A.B.S. / A.S.R. operation When not activated by the ABS system electronics the
with increased clearance down to low speeds. diaphragm control chamber (2) of the inlet valve is open to
atmosphere. The brake pressure at port (1) lifts
The figure shows a typical installation of toothed wheel (1), diaphragm (3) and reaches the brake chamber through
clamping bush (2), and sensor (3) in a front wheel. In such port connection (4) unhindered. Simultaneously, the brake
an arrangement the clamping bush should be mounted pressure flows passed the non-energised armature (8) into
with a temperature-stable and waterproof grease the diaphragm control chamber (6) and prevents the outlet
(e.g.silicone grease) to protect the bore from corrosion and valve from opening. If the driver reduces the braking
to keep the dirt out. The toothed wheel is installed in a pressure, air flows out of the brake chamber and back
similar fashion on the hub of the rear wheel. The sensor through port (1). Under certain conditions the outlet
is securely mounted on the axle beam with a special diaphragm is also opened which effects a fast release of
retainer. the foundation brake.
The sensor / polewheel combinations generate signals
with a frequency proportional to the wheel speed. A.B.S.
2
computes wheel speed and vehicle speed from these
signals. 3
1
4
A.B.S. Solenoid Valve
11
Without an active control the input pressure is just passed
on unrestricted. During an active control, the pressure is
modulated according to wheel behaviour.
The electropneumatic control valve provides the precise, 5
graduated brake pressure modulation for ABS brake 10
control. The valves are mounted on the frame. They
comprise a double solenoid arrangement and two
diaphragm valves. The extremely fast-acting solenoid
valves only influence pressure in the relay control 9
6
chambers of the diaphragms.
8
These control the pressure in the brake chamber by virtue 7
of the valve geometry.
Pressure Increase
SERVICE MANUAL
Pressure Hold Pressure Reduction

When the solenoid at (10) is energised, brake pressure is Both solenoids are energised in the pressure reduction
admitted into control chamber (2) via the closing seal of phase. The activation of the solenoid (10), as described in
armature (11). This causes the diaphragm valve to close, ‘pressure hold’ leads to a cut off of the air supply.
separating connection (4) from port (1) preventing further Simultaneously, solenoid (9) is energised so that the
pressure increase in the brake cylinder. diaphragm control area of the outlet valve is vented to
atmosphere past the seal of armature (6). Now, the brake
pressure still in the brake chamber reaches the seal of
2 diaphragm (5) and is vented.
3 The principles of design and function of the solenoid

control valve remain practically unchanged in all three
1 generations of WABCO ABS systems.
4
11
2
3
1
5
10 4
11
9
6
8
5
7
10
Pressure Hold
9
6
8
7
Pressure Reduction
SERVICE MANUAL
ABS Warning Light Function A push-button (blinkcode switch) located on the EDC
can be used to display ACTIVE (current) or
The warning lamp informs the driver of system
INACTIVE stored fault codes from the ECU fault
condition and to transmit blink codes for system and
memory.
diagnostic information.
If the warning lamp fails to go out when the vehicle

is driven off, or if it comes on shortly after drive off,
this is an indication that the ABS system is either
disabled or partially disabled due to a fault. If the
system is disabled the driver still has full use of the
conventional braking system. When the warning
lamp lights up this indicates increased danger of
wheel lock-up. The driver should exercise caution
when braking to avoid loss of control due to wheel
skid.
The warning lamp is switched on (bulb check) after

“ignition on”. If a wheel speed sensor fault was not
stored in the fault memory before the last “ignition Blinkcode Switch & Diagnostic Socket on FEDC
off”, the warning lamp will be switched off about 2
seconds after “ignition on”, provided the static
system test was successfully completed. The Blink code description
warning lamp the remains switched off when the For blink code activation ABS indicator lamp WL
dynamic system test has successfully concluded respectively the ASR-L has to be grounded for a
given time by the push button switch. After release
If a wheel speed sensor fault was stored before the of the switch the signal light will be on for further 0,5
last “ignition off”, the warning lamp remains on until sec. to confirm that the grounding was detected and
the static and dynamic system test was successfully accepted by the Electronic Control Unit, ECU.
been completed - a stored fault If a fault occurs or signal lamp is grounded for longer
than 6.3 sec. blink code will be terminated. If
• NOTE The driver is responsible for taking grounding is detected for more than 15 sec., fault
note of the warning lamp. If the warning detection of warning lamp open circuit can be
lamp fails to light up immediately after detected and stored in ECU EPROM (non-volatile
“ignition on” this indicates that the lamp bulb memory). Blink code activation on ASR-lamp do not
is defective. It MUST be replaced without cause fault memorizing because open circuit is not
delay. detected.
• When a fault occurs, it is essential that the

ABS is checked immediately in an
authorised workshop in order to repair the
fault and return the system to normal
operation. Failure to do so may result in
unforseen consequences.
SERVICE MANUAL
Warning Light Operation Faults in the system are recognised by the integrated
safety circuit, stored and remain so even if the electrical
Warning light operation for ‘E’ generation electronics differ supply is switched off.
from ‘B’ and ‘C’ versions in that:
• The lamp comes on and goes out when the
ignition is turned on. Diagnostics
• The lamp will stay on when the system has been
Using WABCO tools listed below:
interrogated by either the blinkcode switch or the
diagnostic socket until the vehicle first exceeds Diagnostic Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7kph then goes out. Part No - 446 301 022 0
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Failure Modes Part No - 246-301-246-0
The detection of failures within the system results in a Connection lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
progressive shut-down of the corresponding section of the Part No - 894 604 303 2
system dependent on the severity of the failure.
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No - WA-08/500
Individual Wheel Channel Shut-down
Individual wheels will be shut down if any of the following Diagnostic Socket is located on Front EDC.
failures are detected:
• Sensor/toothed-wheel air gap becomes too large.
After each service on the ABS system, fault free operation
• Break in sensor wiring. should be verified by a test -drive.
• Break in solenoid valve wiring.
• Short-circuit in solenoid valve wiring.
General Advice
Diagonal Shut-down
• If erasure of a fault is not possible, it means the
A diagonal (a wheel and the one diagonally opposite) will fault is actually present and must first be repaired.
be shut down if any of the following failures are detected:
• Low voltage.
• Short circuit in power supply to solenoid valves.
• Amplifier failure within the ECU (each supplies two
valves).
• Diagonal control fault within the ECU.
Total Shut-down
A total shut-down will result following detection of any of
the following failures;
• Overvoltage.
• Supply voltage falls below 15 volts (or more than 5
volts outside tolerance).
• Internal ECU faults occur in both diagonals
simultaneously.
In the event of a fault being detected by the ECU a
warning light in the cab is illuminated. At this stage, the
faulty section of the system has been shut down and the
brake in that section has reverted to normal operation.
Testing the ABS system once a fault is indicated is carried
out using diagnostic software.
SERVICE MANUAL
To Display Fault Codes Inactive Fault Codes

If the ABS warning lamp illuminates during driving an If INACTIVE faults are stored the last occurred fault is
ACTIVE (current) fault has been detected by the ECU. blinked out followed by other stored faults (in no order). All
stored faults will be displayed until the fault memory is
A push-button (blinkcode switch) located in the front EDC
empty, in order of last in first out for first four stored faults
can be used to display ACTIVE (current) or INACTIVE
then any order.
stored faults from the ECU fault memory. The blinkcode
switch on the ‘E’ generation ECU is wired in parallel with The fault code comprises of two blocks. Following the
the ABS dashboard warning light. initial 0.5 sec confirmation and a pause of 1.5 sec. the first
fault code is blinked out, the second fault code follows
To enter fault diagnosis mode and display (blinkout) an
after a pause os 1.5 secs.
ACTIVE fault or to display INACTIVE stored faults the
switch is closed for 0.5 sec to 3.0 secs, on release of the If the fault is ACTIVE the faultcode is repeated after a paus
switch the lamp will illuminate for 0.5 sec to confirm eof 4 secs.
operation of the switch.
If iNACTIVE stored faults are being accessed the next
If an ACTIVE fault is present the ECU will blinkout and stored fault will be displayed after a pause of 4 secs and
repeat the faultcode until terminated by turning the ignition so on.
off/on.
If one fault was detected during current “IGNITION ON”
(actual fault) the ECU blinks out that fault. If more faults
were detected during that period blinkcode shows just the
latest detected fault. For termination ignition must be
switched off / on or vehicle has to move (measured speed
of more than one axle).
Diagnostic Mode
Inactive Faults
SERVICE MANUAL
Blink Code Timing
System mode, CLEAR ALL MEMORIZED FAULTS:

System mode is activated if the signal lamp is grounded
for a time of 3 to 6.3 sec. All stored faults are erased, if no Two seconds after system mode activation further
fault is actual. functions are available:
For termination ignition has to be switched off / on or 1. ASR (ATC) engine control function can be tested by two
vehicle has to move (measured speed of more than one times extra grounding of a time of > 0.5 sec [ASR (ATC)
axle). commands idle torque for 10 sec.].
System code (one number) represents the expected 2. ASR (ATC) respectively retarder control system can be
system and should be used to check correct ECU Type. reconfigured by three times extra grounding of a time of >
0.5 sec (missing components can be confirmed).
After activating system mode ASR (ATC) is disabled for Reconfiguration is confirmed by four short flashes.
dyno tests. With WL blinkode ECU’s
ASR (ATC) lamp is permanently on indicating ASR(ATC)
disabling.
SERVICE MANUAL
With Actual Fault
Dynotester function:
For certain dynotester it is necessary to disable ASR to
allow higher speed difference between driven and steering
axle. By activating system mode ASR can be disabled.
With WL Blink code ECU’s ASR (ATC) lamp is
permanently on indicating ASR disabling.
To prevent dangerous situations caused by brake force in
case of ignition off/on or powersupply interrupts, ASR is
disabled as long as there are speed differences after ECU
reset. For indication the ASR lamp is permanently on until
ignition is switched off/on.
SERVICE MANUAL
Braking System - ABS Amended:26.06.09
FAULTCODE LIST
FIRST FAULTCODE SECOND FAULTCODE

1 NO FAULTS 1 NO FAULTS
2 ABS MODULATOR 1 RIGHT FRONT
3 SENSOR AIR GAP 2 LEFT FRONT
4 SENSOR SHORT / OPEN 3 RIGHT REAR
5 SENSOR ERRATIC / TIRE SIZE 4 LEFT REAR
6 SENSOR TONE RING 5 RIGHT THIRD
6 LEFT THIRD
7 SYSTEM FUNCTION 1 DATA LINK
2 ASR (ATC) VALVE
3 ENDURANCE BRAKE
(THIRD BRAKE) RELAY
4 WARNING LAMP
5 ASR (ATC) CONFIGURATION
6 ASR (ATC) PROP/DIF LOCK/STOP VALVE
8 ECU 1 POWER SUPPLY LOW
2 POWER SUPPLY HIGH
3 INTERNAL FAULT
4 CONFIGURATION ERROR
5 GROUND
SERVICE MANUAL
Fault Codes / Repair Instructions
2.n Check modulator wires. Inlet (EV) or outlet (AV) or common wire is permanently or
temporarily broken or shorted to plus respectively ground.
3.n Amplitude of Sensor signal is to low. Check bearing play, polewheel run out, push sensor to
polewheel. Check sensor wiring and connections for intermittent contact. Other possible
reason: gear engaged at slippery conditions. 16 sec. slip duration.
4.n Check sensor wiring. Open circuit, short circuit to plus respectively ground or between sensor
wires IG/IGM is detected.
5.n Check sensor wiring and connectors for intermittent contact. Check toothed wheel for damage.
Check for mismatch-fault of another sensor or number of polewheel teeth are different.
6.n Check polewheel for damage / missing teeth / run out. Use Wabco sensor probe. Replace
polewheel if damaged. If additional air gap fault are stored, adjust airgap.
7-1 ECU with PROP: check wire and speedometer signal. C3/B7 signal calibration.
check tyre sizes.
gear switch signals neutral or is manipulated
Electronic engine control: Check wiring respectively other ECU’s.
Excessive slip / dynotester, One axle was much faster than the other.
7-2 Check wire. Output wire is interrupted or grounded or shorted to battery supply.
7-3 Check wire. Output wire is interrupted or grounded or shorted to battery supply.
ECU with SAE J1922 resp. SAE J1939: Check other ECU’s. No access to the link.
7-4 Check wire and bulb. Was blinkcode switch activated longer than 16sec.
7-5 Check wires resp. parameter setting. Diff-brake valve without engine control is detected or
CAN, PWM, PROP are detected while self parameterizing is disabled.
7-6 Check wire. Output wire is interrupted or shorted to ground or battery supply.
8-1 Check supply wire and fuse. Supply voltage is temporarily too low.
8-2 Check alternator and battery. Supply voltage too high for more than 5 sec.
8-3 Replace ABS (ASR) electronic if fault detection repeats.
8-4 Modulators connected or wrong ECU or wrong parameterized.
8-5 Check ECU ground wires and common modulator wires.
SERVICE MANUAL
Faultcode S.l.D F.M.l Location Fault condition

2_1 8 1 Front Right Modulator Open circuit - inlet/outlet
2_1 8 5 Front Right Modulator Open circuit
2_1 8 6 Front Right Modulator Short to ground
2_1 8 3 Front Right Modulator Short to battery
2_1 254 9 Modulator Excessive activation time
2_2 7 1 Front Left Modulator Open circuit - inlet/outlet
2_2 7 5 Front Left Modulator Open circuit
2_2 7 6 Front Left Modulator Short to ground
2_2 7 3 Front Left Modulator Short to battery
2_3 10 1 Rear Right Modulator Open circuit - inlet/outlet
2_3 10 5 Rear Right Modulator Open circuit
2_3 10 6 Rear Right Modulator Short to ground
2_3 10 3 Rear Right Modulator Short to battery
2_4 9 1 Rear Left Modulator Open circuit - inlet/outlet
2_4 9 5 Rear Left Modulator Open circuit
2_4 9 6 Rear Left Modulator Short to ground
2_4 9 3 Rear Left Modulator Short to battery
3_1 2 1 Front Right Sensor Sensor air gap
3_1 2 8 Front Right Sensor Slip condition
3_1 2 10 Front Right Sensor Speed drop out
3_2 1 1 Front Left Sensor Sensor air gap
3_2 1 8 Front Left Sensor Slip condition
3_2 1 10 Front Left Sensor Speed drop out
3_3 4 1 Rear Right Sensor Sensor air gap
3_3 4 8 Rear Right Sensor Slip condition
3_3 4 10 Rear Right Sensor Speed drop out
3_4 3 1 Rear Left Sensor Sensor air gap
3_4 3 8 Rear Left Sensor Slip condition
3_4 3 10 Rear Left Sensor Speed drop out
SERVICE MANUAL

4_1 2 3 Front Right Sensor Short to battery
4_1 2 4 Front Right Sensor Short to ground
4_1 2 5 Front Right Sensor Open circuit
4_1 2 6 Front Right Sensor Short circuit
4_2 1 3 Front Left Sensor Short to battery
4_2 1 4 Front Left Sensor Short to ground
4_2 1 5 Front Left Sensor Open circuit
4_2 1 6 Front Left Sensor Short circuit
4_3 4 3 Rear Right Sensor Short to battery
4_3 4 4 Rear Right Sensor Short to ground
4_3 4 5 Rear Right Sensor Open circuit
4_3 4 6 Rear Right Sensor Short circuit
4_4 3 3 Rear Left Sensor Short to battery
4_4 3 4 Rear Left Sensor Short to ground
4_4 3 5 Rear Left Sensor Open circuit
4_4 3 6 Rear Left Sensor Short circuit
5_1 2 2 Front Right Sensor Incorrect tyre size
5_1 2 9 Front Right Sensor Mismatched wires
5_1 2 11 Front Right Sensor Abnormal speed
5_2 1 2 Front Left Sensor Incorrect tyre size
5_2 1 9 Front Left Sensor Mismatched wires
5_2 1 11 Front Left Sensor Abnormal speed
5_2 1 12 Front Left Sensor High frequency
5_2 2 12 Front Right Sensor High frequency
5_3 4 2 Rear Right Sensor Incorrect tyre size
5_3 4 9 Rear Right Sensor Mismatched wires
5_3 4 11 Rear Right Sensor Abnormal speed
5_3 4 12 Rear Right Sensor High frequency
5_4 3 2 Rear Left Sensor Incorrect tyre size
5_4 3 9 Rear Left Sensor Mismatched wires
5_4 3 11 Rear Left Sensor Abnormal speed
5_4 3 12 Rear Left Sensor High frequency
6_1 2 7 Front Right Sensor Incorrect polewheel size
6_2 1 7 Front Left Sensor Incorrect polewheel size
6_3 4 7 Rear Right Sensor Incorrect polewheel size
6_4 3 7 Rear Left Sensor Incorrect polewheel size
SERVICE MANUAL

7_1 248 2 J 1939 Plausibility
7_1 248 5 J 1939 Open circuit
7_1 248 6 J 1939 Grounded circuit
7_1 248 9 J 1939 Timeout
7_1 249 5 J 1922 Open circuit
7_1 249 6 J 1922 Grounded circuit
7_1 249 10 J 1922 Bus not free
7_1 254 8 Axle speeds Excessive slip
7_2 18 3 ASR valve Short to battery
7_2 18 5 ASR valve Open circuit
7_2 18 6 ASR valve Short to ground
7_3 13 3 Retarder Short to battery
7_3 13 5 Retarder Open circuit
7_3 13 6 Retarder Short to ground
7_4 23 5 Warning lamp Lamp on
7_5 253 1 ASR configuration ASR disabled
7_6 19 3 DIFF lock Short to battery
7_6 19 6 DIFF lock Short to ground
8_1 14 4 Diagonal I Low voltage
8_1 15 4 Diagonal2 Low voltage
8_2 251 3 Diagonal 1 or 2 Overvoltage
8_3 248 12 J 1939 Internal error
8_3 254 2 ECU Internal error
8_3 254 12 ECU Internal error
8_4 253 2 EEPROM Incorrect parameter
8_4 253 12 EEPROM Checksum
8_4 254 5 ECU Excessive loads
8_5 14 3 Diagonal 1 Short to battery
8_5 14 5 Diagonal 1 Open circuit
8_5 14 6 Diagonal 1 Short to low
8_5 15 3 Diagonal 2 Short to battery
8_5 15 5 Diagonal 2 Open circuit
8_5 15 6 Diagonal 2 Short to low
SERVICE MANUAL
Braking System - SB Caliper Amended:10.12.09
11 44
26
45
12/2
18/1 18/2 4d*)
White assembly grease
4c*)
4b*) 12/1
12
4a*)
Green assembly grease
6d*)
1
13
6b*)
39d*)
6c*)
37
39c*)
61*)
68*) 6a*)
37a*) 7 161
39b*)
39a*)
5 22
5a*) 9 58

40 40a*)
31*) 10*)
31a *)
pre-applied adhesive
10a *) 2
1 Caliper
2 Carrier 18/1 Spring Brake
4a*) Guide Pin 18/2 Brake Chamber
22 Inner Seal
26 Spring Clip
31 Outer Boot Clip
31a*) O-Ring
37 Adjuster Cap
37a*) Adjuster Cap
39a*) Caliper Bolt
39b*) Caliper Bolt
39c*) Caliper Bolt
39d*) Caliper Bolt
40 Caliper Bolt
40a*) Caliper Bolt
*) Variants
44 Pad Retainer Pin
See also contents leaflet in the Service Kit
45 Washer
58 Ring
61*) Shear Adapter
68*) Cap
161 Tappet Bush
SERVICE MANUAL
Description of Operation (Floating Please follow repair manual instructions and adhere
Caliper principle) to the wear limits of the Pads and the Discs.
Use only recommended tools.
Brake Actuation Tighten bolts and nuts to the recommended torque
During actuation, the Push Rod of the Actuator (18/1 values.
or 18/2) moves the Lever (19). The input forces are After re-fitting the wheel according to the Vehicle
transferred via the Eccentric Bearing (20) to the Manufacturer’s recommendations, please ensure
Bridge (17). The force is then distributed by the that there is sufficient clearance between the Tyre
Bridge (17) and the two Threaded Tubes (16) to the Inflation Valve, the Caliper and the wheel rim, to
Tappets (13) and finally to the inboard Pad (12). avoid damage to the Valve.
After overcoming the running clearance between the
Pads and Disc, the reaction forces are transmitted to
the outboard Pad (12). The clamping forces on the After service work:
Pads (12) and the Disc (46) generate the braking Check the brake performance and the system
force for the wheel. behaviour on a rolling road or by actual road test.
Brake release
After releasing the air pressure, the two Return
Springs (27/28) push the Bridge (17) and Lever (19)
back to the start position; this ensures a running
clearance between Pads and Disc is maintained.
Brake adjustment (automatic)
To ensure a constant running clearance between
Disc and Pads, the brake is equipped with a low
wearing, automatic adjuster mechanism. The
Adjuster (23) operates with every cycle of actuation
due to the mechanical connection with Lever (19).
As the Pads and Disc wear, the running clearance
increases. The Adjuster (23) and Turning Device
(24) turn the Threaded Tubes (16) by an amount
necessary to compensate for this wear. The total
running clearance (sum of clearance both sides of
Disc) should be between 0.6 and 0.9 mm.; smaller
clearances may lead to overheating problems.
Safety Instructions for service work (for

"Axial- and Radial Disc Brake")
Please also refer to the relevant safety instructions
for repair work on commercial vehicles, especially
for jacking up and securing the vehicle.
Use only original Knorr-Bremse parts.
WARNING
Before starting repair work, ensure the
service brake and parking brake are not
applied and that the vehicle cannot roll away.
SERVICE MANUAL
Inspection Points for the Axial and Radial Disc Adjuster Cap (37 or 37a) and the sealing elements
Brake (6c, 9, 10, 10a, 31, 58, 68) for correct fitting and
condition.
Despite the use of long-life materials, it is necessary
to check some of the components regularly for their
Wear Limits of Pads and Discs
general condition. The following points ensure a
long-life and trouble-free operation of the disc brake. The thickness of the Pads must be checked regularly
The dependent on the usage of the vehicle.
inspection frequencies specified are minimum The Pads should be checked corresponding to any
values. Depending on the vehicle application a more legal requirements that may apply.
frequent
If no Wear Indicator has been connected this should
check of the components may be necessary. be at least every 3 months.
The brake pad wear must be checked visually on a If friction material is less than 2mm, the Pads must
regular basis, e.g. each time the tyre pressures are be replaced.
checked, or at least every three months.
Minor damage at the edges is permitted.
At least annually inspect the pad to disc running
Major damage on the surface of the pad is not
clearance and the correct fitting and condition of the
permitted. (See figures)
Outer Boot (10) or Steel Cap (10a) and the Adjuster
Cap (37 or 37a). WARNING
With each Pad change check for the correct
For optimum safety, stay within the Disc and
functioning of the Adjuster and the smooth operation
Pad Wear Limits.
of the caliper over its full range of movement. Also
inspect the Tappet and Boot Assemblies (13), the
11 44
26
45
12/2
18/1 18/2 4d*)
4c*)
4b*) 12/1
12
4a*)
Green assembly grease
6d*)
1
13
6b*)
39d*)
6c*)
37
39c*)
61*)
68*) 6a*)
37a*) 7 161
39b*)
39a*)
5 22
5a*) 9 58

40 40a*)
31*) 10*)
31a *)
pre-applied adhesive
10a *) 2
SERVICE MANUAL
PAD WEAR
The thickness of the Pads must be checked regularly dependent on the usage of the vehicle.
The Pads should be checked corresponding to any legal requirements that may apply.
If a Wear Indicator has not been fitted or is not connected this should be checked at least every 3 months.
If friction material is less than 2mm (see E, sketch 3), the Pads must be replaced.
Minor Damage on Edges (Permitted) Major Damage on Surface (Not Premitted)
WEAR LIMITS - BRAKE DISCS

Measure thickness at thinnest point. Avoid measuring near the edge of the disc as a burr may be present.
A = Disc thickness (new condition) 45mm

Sketch 3
B = Disc thickness (worn) 37 mm, Disc must be replaced
C = Overall thickness of Pad (new condition) 30mm
D = Backplate 9mm
E = Minimum thickness of friction material 2mm
F = Minimum allowed thickness in worn condition for backplate
and friction material 11mm (replacement of Pads
necessary).
If the Disc thickness is less than 37mm, the Disc must be replaced.
WARNING
If these recommendations are ignored, there is a danger of brake failure.
CAUTION
When replacing brake discs, they should be only replaced in pairs.
SERVICE MANUAL
Check Disc at each change of Pads for grooves and

cracks. In case of surface conditions A1 - C1, the Disc
can continue to be used until the minimum
The diagram shows possible conditions of the thickness of 37mm is reached.
surface.
Knorr-Bremse Discs are normally service-
free and grinding when changing Pads is not
necessary.
However, grinding could be useful, e.g. to
increase the load-bearing surface of the Pads
after severe grooving on the entire friction
surface has occurred.
Brake discs should always be replaced in
pairs.
To meet safety requirements, the minimum
thickness after regrinding is 39-40 mm.
In addition, the recommendation of the
Vehicle Manufacturer MUST be followed.
A1 = Small cracks spread over the surface are

allowed.
B1 = Cracks less than 1.5mm deep or wide,
running in a Radial direction, are allowed. WARNING
C1 = Grooves (circumferencial) less than 1.5mm If these recommendations are ignored, there is
a danger of brake failure. If the Pads are worn
wide are allowed.
down to the backplate or if Disc wear is
D1 = Cracks in the vanes are not allowed and the excessive, brake performance will be severely
Disc MUST BE REPLACED. affected and may be lost completely.
a = Pad contact area
SERVICE MANUAL
Brake Wear Check using Axially Ribbed Rubber

Bush
The condition of the Pads can be visually determined
without removing the road wheel by viewing the
position of the wear Indicator (G).
1
1
4c
4c
G
6c 6c
FD00190/1Äi02
"X" G "Z"
New Condition (see X)
The position of Wear Indicator (G) on the rubber
Bush (6c) in new condition.
Wear Limit (see Z)
When the rubber Bush (6c) is retracted to the level
(G) of the wear Indicator as shown, the wheel must
be removed so that the wear of teh pads and disc
can be checked.
If necessary change the pads and disc.
Pad Wear Indicator
In-pad normally closed indicator is fitted. Circuit is

broken when pad wear reaches limit.
SERVICE MANUAL
Adjuster Check - With Shear Adaptor
WARNING
Before starting service work, ensure the service brake
and parking brake as well as the bus stop brake with
buses are not applied and that the vehicle cannot roll
61 37a
away.
Remove wheel.
The caliper assemply should be pushed inboard on its
Guide Pins. Using a suitable tool, press the inboard pad
(12) away from the Tappets and check the gap between
Tappet and inboard pad backplate - it should be between
0.5mm & 1.0mm. If the running clearance is too small or
large, the adjuster may not be functioning correctly and
should be checked as follows.
Pull off the Adjuster Cap (37a) using the tag, taking care
not to lose the Shear Adapter (61). 23
61 37a
The Adjuster (23) must be turned with the Shear Adapter
(61) anti-clockwise for 2 or 3 clicks (increasing running
clearance).
CAUTION
Never turn Adjuster (23) without Shear Adapter (61) 1
being fitted. If the shear torque of the Shear
Adapter is exceeded, then it is designed to fail. Try
again with a new (unused) Shear Adapter a second
time. With a second failure of the Shear Adapter the
Caliper must be exchanged since internal damage
is present. Do not use an open ended spaner,
because it may damage the Shear Adaptor.
CAUTION
Make sure that the Ring Spanner or Socket can turn
freely anti-clockwise during following procedure.
By applying the brake (about 2 Bar) 5 - 10 times the

Spanner or Socket should turn clockwise in small
increments if the Adjuster is functioning correctly (see
notes below) 37a
NOTE
As the number of applications increases,
incremental movement will decrease.
NOTE
If the Spanner or Socket does not turn or turns only
with the first application or turns forward and
backward with every application, the automatic
Adjuster has failed and the Caliper must be
replaced. NOTE
The tag of the Adjuster Cap (37a) should be
positioned as shown by the arrow in the adjacent
Even if Pads are not being changed, a new Adjuster Cap diagram. This ensures access is maintained for
(37a) should be fitted having lightly greased it with white subsequent removal. Removal of the Adjuster Cap
grease. with e.g. a screwdriver is not recommended since
the seal may be damaged.
SERVICE MANUAL
Caliper Checks
Caliper Running Clearance
WARNING 31a* )
Before starting service work, ensure the service
brake and parking brake as well as the bus stop
brake with buses are not applied and that the
vehicle cannot roll away. 10a* )
9 5*) 7
By pushing and pulling the Caliper in an axial direction by 10
hand (see arrow A in adjacent sketch), a movement of 0,5
- 1.0 mm must possible.
If using hand pressure only (no tools) the Caliper is not
movable, the Caliper guidance must be further examined.
Caliper Movement along Guide Pins

Remove Pads.
Clean dirt from Guide Pin (4a, 4b, 4c, 4d) (see arrows in
illustration).
Using hand pressure only (no tools), the Caliper (1) must
slide freely along the whole length of the Guide Pin
arrangement. This should be greater than 25mm.
4b* )6b* )
1
68*)
A
*) Pay attention to the variants 6c*)
Rubber Bush to Guide Pin Clearance
NOTE
Before removing the wheel, note that there is no
contact between Caliper and axle, vehicle, chassis
sections or Carrier. If necessary the Rubber Bush
(6a, 6b, 6c, 6d), must be replaced.
To measure the clearance, the following steps must be

taken:
Remove the wheel.
Remove Pads.
Fully wind-back the Tappet and Boot Assemblies (13) by
rotating the Adjuster (23) in an anti-clockwise direction.
Slide Caliper as far as possible towards the outside of the
vehicle (see sketch 1). Sketch 1
SERVICE MANUAL
Rubber Bush to Guide Pin Clearance

Push the Caliper in the direction of the arrow. (see
illustration).
NOTE
Before removing the wheel, note that there is
no contact between Caliper and axle, vehicle,
chassis sections or Carrier. If necessary the
X
Rubber Bush (6a, 6b, 6c, 6d), must be
replaced.
Sketch 2
Whilst maintaining pressure on the Caliper, measure
the distance ‘x’ (see sketch 2).
Pull the Caliper away from the Carrier and measure

distance ‘y’ (see sketch 3).
Y
If the distance (y-x) is greater than 3mm, the
Rubber Bush (6a, 6b, 6c, 6d) must be replaced.
Fit Pads. Sketch 3
Fit the wheel.
SERVICE MANUAL
Seal Checks
31a* )
Caliper Guide Pin Seals
The Guide Pin (5, 5a ) is sealed with the Inner Boot
(9) and the Adjuster Cap (10) or the Steel Cap (10a)
and the O-Ring (31a). The items (9) and (10) or 9 5*) 7
10a*)
(10a) must not show signs of cracking or damage.
10
On versions with Rubber Bush (6c) this is also to be
checked for damage.
Check for correct location and fitment.
NOTE
It may be necessary to remove the Pads to
inspect the Inner Boot (9) - dependant on the
amount of pad wear.
If necessary repair Caliper with suitable Service Kit
4b*) 6b*)
1
68*)
Check of Tappet and Boot Assembly (13)

*) Pay attention to the variants 6c*)
If necessary remove Pads (12) and screw the
Adjuster (23) clockwise until the boots are clearly
visible.
NOTE
The tappet should not extend more than 30
mm (see sketch). 13
The Tappet and Boot Assemblies (13) must
not show any signs of damage.
M+P-KN-012/Äi01
Check for correct location and fitment.

30
NOTE
The penetration of dirt and humidity into the
brake will lead to corrosion and impair the
function of the Disc Brake.
If necessary replace Tappet and Boot
Assemblies.
If necessary replace Tappet and Boot assemblies.
SERVICE MANUAL
Pad Replacement
WARNING
Before starting repair work, ensure the
service brake and parking brake are not
applied and that the vehicle cannot roll away.
Pad Removal (with shear adaptor)

Take the wheel off.
NOTE :
Before removing pads it is strongly
recommended that the Adjuster mechanism is
checked for correct operation.
Remove clip (26) and washer (45), depress the pad

retainer (11) and remove pin (44).
If necessary remove any in -pad wear sensor

componants and discard.
If pad retainer (11) is corroded or damaged, it should
be replaced.
Remove adjuster cap (37a) using the tab, taking

care not to loose the shear adaptor (61).
Fully wind-back the tappet and boot assembly (13)
by rotating the adjuster (23) in an anti-clockwise
direction.
NOTE : 23
23
6137
Never turn the adjuster (23) without shear 37a
adjuster (61) being fitted. If the given shear
torque of the shear adaptor is exceeded, then
it will be destroyed. Try with a new (unused)
shear adaptor a second time. If the shear
adaptor fails for a second time, then the 12
caliper must be exchanged as internal 12
damage is present. Do not use an open ended
spanner, because it may damage the shear
adaptor.
Push inboard pad (12) towards actuator and pull out

both pads
SERVICE MANUAL
Pad Fitting
WARNING WARNING
Pads must be changed as an axle set and New pads need bedding in. Heavy or long
NOT individually. duration braking should initially be avoided.
Use only Pads which are permitted by the

vehicle manufacturer, axle manufacturer and
brake manufacturer.
Failure to comply with this may invalidate the
vehicle manufacturer’s warranty.
NOTE :
Fully wind back the tappet and boot assemblies
(13) by rotating the adjuster (23) in a anti-
clockwise direction - Do Not overload the
adjuster.
Clean the Pad abutments.

Push Caliper (1) outboard and fit the outboard Pad
(12).
Push Caliper (1) inboard and fit inboard pad (12).
Fit new in-pad wear indicator, if appropriate. Install
the cable so that it cannot be damaged.
Rotate the Adjuster clockwise until the Pads come 37a
into contact with the Disc. Do Not overload the
adjuster (23).
Then turn back the Adjuster 2 clicks.
The hub should turn easily by hand after having
applied and released the brake.
The adjuster cap (37 or 37a) must then be replaced
having lightly greased it with white grease.
After setting the Pad Retainer (11) into the groove of
NOTE :
The tag of the Adjuster Cap (37a) should be
positioned as shown by the arrow in the
adjacent sketch. This ensures access is
maintained for subsequent removal. Removal of
the adjuster cap with e.g. screwdriver is not
recommended since the seal may be damaged.
the Caliper (1), it must be depressed to enable the

positioning of Pad Retainer Pin (44).
Fit washer (45) and Spring Clip (26) to the Pad
Retainer Pin (44).(use only new parts).
It is recommended that the Pad Retaining Pin (44) is
installed pointing downwards. (see sketch)
Re-fit the wheels.
SERVICE MANUAL
Wear Indicator Fitting

(Normally Closed or Normally Open Type)
101
Remove Pads (12).
Wear Indicator Kits (for SB7...) consist of items as
shown in Section 1.2.1 and 1.4.1. outer Pad
Insert the Wear Indicator Cables (101) into the

groove of the Pads. The Wear Indicators snap into
place in the holes in the Pad material. 12/1 12/1
The longer end of the Wear Indicator cable (see
arrow) must be fitted in the outer Pad.
Insert Pads (12/1) into the Pad abutments.
12/1
12/2
Fit Pad Holder Springs (12/2) onto the Pads (12/1).
Pay attention to correct installation of Wear Indicator
Cable (101) (see arrows).
12/2
101
12/1
44
11
45
Fit Pad Retainer (11), Pad Retainer Pin (44), Washer 26
(45) and Spring Clip (26).
Pay attention to correct installation of the Wear
101
Indicator Cable (101) (see arrows).
SERVICE MANUAL
Cable Guide Type 105

Fit Cable Guide (105) onto the Pad Retainer (11).
105
In the right position, the Cable Guide (105) snaps
into place by pressing it lightly onto the Pad Retainer
(11).
101
Press Wear Indicator Cable (101) into the locating
tabs of the Cable Guide (105) (see arrows A). B
A
The short cable end of the Wear Indicator Cable
(101) must not be secured by locating tabs of the short cable end
Cable Guide (105).
According to vehicle type, install the cable loom that B
leads to the electrical supply of the vehicle, in one of
the two locating tabs (see arrows B). A
FD00237/6
Cable Guide Type (105a)
Install Indicator Cable (101) in the middle of the Pad
101 105a
Retainer (11).
Insert Cable Guide (105a) at one side of the Pad
Retainer (11) (see arrow B). C
A A
Slightly press in on the other side of the Pad
Retainer (11) (see arrows A). The Cable Guide
(105a) snaps into place.
According to vehicle type, install the cable loom that C
leads to the electric supply of the vehicle, in one of
FD00305
the wire loop (see arrows C). B

The short end of the Wear Indicator Cable (101)
must not be secured by a wire loop of the Cable
Guide (105a) (see arrows C).
104
Protection Plate 11
Fit the Cable Protection Plate (104).
Pay attention to the correct position of the Cable
Protection Plate’s catch (see arrows).
Exert hand pressure to the Cable Protection Plate
(104); it will snap into place.
FD00237/7
SERVICE MANUAL
Replacement of Tappet and Boot & Inner Seals

Assemblies (13) as well as Inner Seals (22) . (for
Axial and Radial Disc Brakes).
The components of the tools are referred to by item

number for ease of reference.
To remove the Tappet and Boot Assembly (13) use
 the Wedge Fork (A) (Part No. II32202).
To fit the Tappet and Boot Assembly (13) use the
Press-in Tool (B) (Part No. II19252).
To fit the Inner Seal (22), use the Press-in Tool (L)
(Part No. Z004361).
Tappet and Boot Assemblies (13) Removal

NOTE :
It may be easier to remove the Caliper from the axle
to replace the Tappet and Boot Assemblies (13).
The Adjuster (23) must be screwed clockwise until

the Boots can be reached (max. 30 mm).
To remove the Tappet Boot from the Caliper bore, a
Screwdriver should be used to deform the Boot
location ring - see diagram.
CAUTION
Great care must be taken not to damage the Sealing 13
Seat of the tappet Boot since it is not a replaceable
13
item. See arrow X in adjacent diagram.
The Tappet and Boot Assemblies (13) can be removed

from the Threaded Tubes (16) by using Wedge Fork (A)
(Part No. II32202). 30
Remove the old Tappet Bush (161).
Check Inner Seal (arrow X) and if damaged, the Caliper
must be replaced.
NOTE :
If the sealing seat of the Tappet Boot has been
damaged the caliper must be replaced. The Inner
Seal (22) must also be replaced if Tappet and Boot
Assemblies (13) have been removed.
SERVICE MANUAL
Adjuster Thread Inspection

Place an unworn Pad (12) into the outboard gap to
avoid overrunning of the Threaded Tubes.
IMPORTANT
Threaded Tubes should not overrun the inner
thread of the Bridge.
The Caliper must be changed if
synchronisation is lost.
For the inspection of the threads, the tubes must be

screwed out (max. 30mm) by turning the Adjuster
clockwise.
If Caliper is not installed on axle, put a spacer E
(length 70mm) into the Caliper (1) to avoid
overrunning of the Threaded Tubes (16) when
screwing them out (see illustration). During
screwing, the threads can be checked for corrosion
damage.
In case of water ingress or corrosion, the Caliper
must be replaced.
Iner Seals (22) Replacement
Fully wind back the Threaded Tubes (16) by turning

the Shear Adapter (61) anti- clockwise.
Clean area of the Inner Seal (22).
A
To remove the Inner Seal (22) a Screwdriver (A)
should be used - see adjacent diagram.
CAUTION
The sealing face (X) for the inner seal (22), as well
as teh threaded tubes (16) must not be damaged. A
they cannot be replaced.
22
FD00297
Clean sealing face (X) .

Fit each Inner Seal (22) onto a Threaded Tube (16).
With Caliper installed on axle
Remove the Tappet Bush (161). Position Tool (L)
(Part No. Z004361) with the short strut in the position
shown.
The Tool (L) is guided over the spigot of the
Threaded Tube (16).
Fully press in the Inner Seal (22) by rotating Tool
(T3) using a spanner - see adjacent diagram.
SERVICE MANUAL
To check the correct fit of the inner seal (22), screw

out the treaded tube (16) about 4-5 threads by
turning the shear adaptor (61) clockwise.
The inner seal must not turn.
With Caliper not installed on axle
The fitting sequence of inner seal (22) does not

change.
When pressing in the inner seal (22) however, use

teh long strut (T3 + T4) for tool (L) (Part No
Z004361)
Fittting Tappet And Boot Assemlies with Caliper

fixed to axle:
Grease threads with White grease (Part Number.

II14525 or II32868).
Screw back Threaded Tubes (16), by turning the
Adjuster (61) counter-clockwise.
The sealing seat in the caliper for tappet and boot
assemblies (13) must be clean and free of grease.
Place new Tappet Bush (161) onto the head of the
Tube (16).
Place Tappet with Boot assembly (13) onto the
Tappet Bush.
Use Push-In Tool (B) with the short strut (T3) (Part
Number II19252) for positioning and pressing-in the
Boot.
Using Tool B in reverse, the Tappet can be pressed
on to the tappet bush.
SERVICE MANUAL
With Caliper not installed on axle

Grease threads with White grease (Order No.
II14525).
Screw back Threaded Tubes (16), by turning the
shear Adaptor (61) counter-clockwise.
The sealing seat in the caliper for tappet and boot
assemblies (13) must be clean and free of grease.
Place new Tappet Bush (161) onto the spigot of the
Threaded Tube (16).
Place Tappet with Boot (13) onto the Tappet Bush.
Use Push-In Tool (B) with the long strut (Part No
II19252) for positioning and pressing-in the boot
Using the Tool (B) in reverse, the Tappet can be
pressed onto the Tappet Bush.
SERVICE MANUAL
Caliper Replacement
(for Axial and Radial Disc Brakes)
To remove and to fit the Steel Cap (10a) use the
Press-in Tool (G) (Part No. Z001105).
To fit the Cap (68) the Press-in Tool (K) (Part No.
Z003934) must be used.
Caliper Removal
Remove Pads.
Remove Actuator.
NOTE :
It may be necessary to remove the Caliper (1)
and the Carrier (2) as a single unit.
10
31
39
Proceed as follows if the Caliper (1) is to be removed 10a 31a
from the Carrier (2), with the Carrier remaining on
the vehicle. 31
Remove Outer Boot Clip (31) and take off Outer Boot 40
(10), or on Calipers with Steel Cap (10a) and O-Ring 10
(31a), place tool (G) (Part No. Z001105) onto the
Steel Cap and tighten the threaded pins. Then use
hammer as shown.
On Calipers with Rubber Bush (6c) pull the Cap (68)
from the Guide Pin (4c) using a suitable tool (see
diagram).
Remove Caliper Bolts (39a, 39b, 39c or 39d) and
(40 or 40a).
CAUTION
Before removing the Caliper Bolts (39 and 40) ensure
that the Caliper (1) cannot move or fall when the
Caliper Bolts are removed causing damage or injury.
CAUTION
Do not damage Rubber Bush (6c). If necessary
replace it using a Rubber bush and Guide Pin Kit.
CAUTION
Hold Caliper only at its outer side. Never get your
fingers between Caliper and Carrier. Do not fasten any
lifting device to the Pad Retainer (11 or 11a), since this
can be damaged.
Remove Caliper from Carrier.
SERVICE MANUAL
Caliper Fitting
NOTE
Dismantling of the Caliper is not authorised.
Only use Genuine replacement Calipers.
The correct choice of Caliper must be ensured by

checking the part number on the identification label
(see arrow in sketch 1).
The replacement Caliper may have a plastic cap or
adhesive tape in the area of the actuator attachment
(see arrow in sketch 2). Remove the cap or tape
after installing the caliper on the vehicle.
Alternatively,
if the replacement Caliper has a breakthrough
diaphragm, it should be left in place (see arrow in
sketch 3).
NOTE
The service exchange Caliper includes seals
and Guide Pins. The Pads are not included.
CAUTION
Hold Caliper only at its outer side. Never get
your fingers between Caliper and Carrier.
Do not fasten any lifting device to the Pad
Retainer (11 or 11a), since this can be
damaged.
Fitting of Caliper (1) to Carrier (2)
NOTE
It may be necessary for reasons of
10a 31a
accessibility to fit the Caliper and Carrier 39
assembly as a single unit to the vehicle.
31
NOTE
Screw threads and tapped holes must be clean 40
and dry (free of lubrication). 10
NOTE
The guide pins (4 & 5) as well as the Caliper
Bolts (39 & 40) are highly stressed items. They
must be replaced whenever the Caliper (1) is
removed from the Carrier.
9
Screw in Caliper Bolts (39a, 39b, 39c, 39d) and (40,
40a) and tighten to 180 Nm + 90°.
Check that the Caliper slides easily on the Guide
Pins.
Check the position of the Inner Boot (9) on the Guide
Pin (5, 5a). 5
58
Check Adjuster function.
SERVICE MANUAL
Caliper Fitting (continued) Clamping device

9
When the Caliper and Carrier Assembly with Steel
Cap (10a) is not fitted to the vehicle, move the
Caliper against the Carrier and retain using a
suitable clamping device so that the Inner Boot (9) is Direction
in a compressed condition. This is to prevent air of pr essure
being trapped when Steel Cap (10a) is fitted.
Fit new Outer Boot (10) or Steel Cap (10a).
Fit the Pads, if not already fitted.

If the Caliper and Carrier Assembly is to be fitted as
a single unit to the vehicle.
Attach Brake Chamber or Spring Brake.
Fitting of Outer Boot (10) 39 31

Check that the seat for the Outer Boot (10) on the
Caliper (1) is free of grease and fit the Outer Boot.
Tighten Outer Boot Clip (31).
Pay attention to correct fitment of the Outer Boot Clip 31
(31) and check Outer Boot (10) for damage.
Fitting of Steel Cap (10a)
NOTE
Replacing the outer boot (10) with steel cap
(10a)
This is only allowed if Guide Pin (5) and Caliper
Bolt (40) are also replaced with the Guide Pin
(5a) and Caliper Bolt (40a).
10
NOTE
The guide pins (4 & 5) as well as the Caliper
Bolts (39 & 40) are highly stressed items. They 5a
must be replaced whenever the Caliper (1) is
31
removed from the Carrier.
40a
NOTE
31a
The stell cap (10a) and the ‘O’ Ring (31a) must
only be used once.
10a
SERVICE MANUAL
Fitting of Outer Boot (continued)
31a
When the Caliper is on the vehicle the fitting of the
Steel Cap (10a) must be carried out with the Pads
installed.
- Clean area.
- Using the white Grease supplied (II14525), lightly
lubricate the O-Ring (31a) and place it over the cast
spigot (see Sketch).
- Remove threaded pins from assembly tool G (Part 2mm
No. Z001105) to avoid damaging the Steel Cap.
-Hold the new Steel Cap on the end of the spigot.
By using a suitable press or assembly tool (G) and
a hammer, press the Steel Cap fully on the spigot
making sure not to deform the Cap.
After removal, the Steel Cap and the O-Ring must
never be re-used.
68 K
Fitting Of Cap (68)
Fit the Cap (68) using Tool K (Part No. Z003934)

6c
and a hammer. Force the Cap (68) into the Guide 4c
Pin (4c) until it contacts the Caliper Bolt. The seal
is achieved by the compression of the lip of the "Y"
Rubber Bush (6c) between the Guide Pin (4c) and 68
Cap (68) (see view “Y”).
SERVICE MANUAL
Replacement of Inner Boot

To fit the inner boot (9) use the Pull in Tool (C) (part
no II19253).
Remove Caliper.
Remove Ring (58).
Pull out Guide Pin (5 or 5a).
Push out Inner Boot (9) with screwdriver.
5, 5a
NOTE 58
The Sealing Seat of Inner Boot (9) in the Caliper
9
must not be damaged (see arrow A in adjacent
Sketch).
7 A
Inspect and clean contact area of Inner Boot (9).

Check for corrosion (see arrow A in adjacent
Sketch). 9 9
C
Check Brass Bush (7) for dirt and replace if
damaged.
Put new Boot (9) into the Sleeve of the Tool C (Part
No. II19253). See arrow B in adjacent Sketch. B
Pay attention that the Bellow-folds of Inner Boot (9)
are positioned within the tool.
Position Sleeve with Inner Boot (9) into the Caliper
bore and pull in.
NOTE
Pay attention to the correct position of Inner
Boot (9).
Carry out a pulling check (see adjacent Sketch).
SERVICE MANUAL
Grease Brass Bush (7) with white grease (Part No.

II14525 or II32868).
Fit Guide Pin (5 or 5a).
The Boot end must engage in the groove of the
Guide Pin (5 or 5a) (see arrow).
Fit Ring (58) by pushing until it engages.
Fit Caliper.
58
5, 5a 9
SERVICE MANUAL
Guide Pin Bush Replacement

In order to remove and fit Brass Bush (7) use the
Pull-in/Pull-out Tool (D) (Part No. II19254).
To groove Brass Bush (7), Grooving Tool (F) (Part
No.II36797) must be used.
Remove Caliper.
Remove Guide Pin (5 or 5a) and Inner Boot (9).
Brass Bush (7) Replacement
Pull out Brass Bush (7) with Tool (D) (Part
No.II19254) - see Sketch 1.
If Caliper has a groove (see arrow A):
Pull in new Brass Bush (7) with Tool (D) - see
Sketch 2.
Remove Tool (D).
To prevent longitudinal displacement of the new
Brass Bush (7) it must be grooved (see arrow B).
Before insertion of the Grooving Tool (F) (Part No.
II36797), its hexagon screw must be wound out so
that the head of the screw is approximately 20mm Sketch 1
from the tool face Insert the Grooving Tool (F) fully
into the Brass Bush (7).
Wind in the hexagon screw of the Grooving Tool (F)
to its stop.
Slacken the screw and rotate the Grooving Tool (F) A D
in the Brass Bush (7) by approximately 60 degrees.
Again wind in the hexagon screw of the Grooving
Tool (F) to its stop.
The new Brass Bush (7) is now firmly retained in
the Caliper (see arrow B).
Before removing the Grooving Tool (F), its hexagon
screw should be wound out approximately 20 mm. Sketch 2 7
If Caliper has no groove:
(Note: Groove is always located on the inboard
side).
Pull in new Brass Bush (7) with Tool (D) - see
Sketch 2.
Check contact area of Brass Bush (7) for burrs and
remove any burrs.
Grease Bush with white Grease (Part No. II14525
or II32868).
Sketch 3
SERVICE MANUAL
Rubber Bush Replacement

NOTE:
There are two different types of Rubber
Bush (6a or 6b) ,Short and long. The two
versions are not interchangeable.
If necessary remove the caliper.

Remove guide pin (4a or 4b)
Pull Rubber Bush (6a or 6b) out of bore.
Check bore for corrosion, clean and if necessary.
use a corrosion protection paint (eg zinc spray)
CAUTION
Under no circumstances must the White Grease
(mineral oil) be used for lubricating the Rubber
Bush (6a or 6b) and Guide Pin (4a or 4b). Use
only synthetic based green Grease.
(Part Number II32793 or Z000046)
Deform new Rubber Bush (6a or 6b) and push from

the inside of the caliper into the bore.
Push Rubber Bush (6a or 6b) so that the external
positioning ring(s) locates in the groove(s) (see
arrows).
Assemble Guide Pin (4a or 4b).
CAUTION
The Guide Pins (4 & 5) as well as the Caliper
Bolts are highly stressed items. They must be
replaced whenever the Caliper (1) is removed
from the caliper.
Re-fit Caliper.
NOTE:
Torque Caliper Bolts (39a) and (39b) to 180
Nm plus 90 degrees. Check that the Caliper
slides easily.
CAUTION
Screw threads and tapped holes must be clean
and dry (free of lubrication).
Rubber Bush Replacement (6c or 6d)

If necessary remove Caliper
Use tool H (Part No. Z004198) for the assembly of
the Rubber Bush (6c or 6d), (see adjacent picture).
NOTE:
Depending on the shape of the Rubber Bush
(6c or 6d) the appropriate disc must be
selected, for pressing out..
SERVICE MANUAL
Removal of Rubber Bush (6c or 6d)

Remove guide pin (4c or 4d).
Clean caliper in area of the rubber bush.
Select appropriate disc for pressing out the Rubber
Bush (6c or 6d). The disc locks into the Rubber
Bush.
Position the Tool (H) (Part No. Z004198) as shown in
the adjacent picture. Lightly screw on the nut by Pay attention to the size of the Disc
hand.
Hold the nut with a ring spanner and with a suitable
socket or ring spanner tighten to remove the Rubber
Bush.
Unscrew Threaded Pin in the Tool (H), so that there
is no projection at the contact surface.
Push Rubber Bush (6c or 6d) into the Tool (H).
Position Tool (H) with Rubber Bush (6c or 6d) as

shown in adjacent picture - see sketch 1 on page 46.
Fitting of Rubber Bush (6c or 6d)
Check bore for corrosion and clean.
There are two versions of Rubber Bush (6c).
Make sure, that the diameter (ø) of the Metal Ring is
the same as the diameter (ø) of the Rubber Bush
Stopper.
CAUTION
If the wrong Rubber Bush (6c) is fitted, it can
become loose, affect the Caliper Movement
along the Guide Pins and reduce the braking
force.
Insert Metal Ring of the Rubber Bush (6c or 6d) into
the caliper bore.
CAUTION
The Metallic Sleeve of the Rubber Bush (6c or
6d) must not enter the caliper bore by more than
4 mm.
If the Metallic Sleeve of the Rubber Bush (6c or
6d) enters the caliper bore by more than 4 mm
then the caliper bore is worn and the Caliper
must be replaced.
Unscrew Threaded Pin in the Tool (H), so that there

is no projection at the contact surface.
Push Rubber Bush (6c or 6d) into the Tool (H).
Position Tool (H) with Rubber Bush (6c or 6d) as
shown in adjacent picture.
SERVICE MANUAL
Lightly screw on the nut by hand.

Screw in Threaded Pin until it contacts the Caliper
inorder to adjust possible unevenness at the
contactsurface - see sketch 2.
Rubber Bush (6c or 6d)
Using Torque Wrench pull in Rubber Bush (6c or
6d) (min. 8 Nm up to max. 45 Nm).Note:Do not tilt Contact Surface
the Rubber Bush (6c) or (6d) whenpulling-in.

Remove the Tool.
CAUTION
Threaded pin
If the torque is< 8 Nm or > 45 Nm,then the Caliper
must be replaced.Failure to replace the Caliper
could leadto a guidance failure.
CAUTION
The Metal Ring (see arrows in sketch 3)must not
move. When checking for movement, then the
Sealing Elements of the Rubber Bush (6c or 6d)
must not bedamaged.
Grease the interior of the Rubber Bush (6c or 6d)
with White Grease (Part No. Il14525 or II32868).
CAUTION
The Guide Pins (4 and 5) as well as theCaliper
Bolts (39 and 40) are highly stressed items. They
must be replacedwhenever the Caliper (1) is
removedfrom the Carrier (2).
Push Guide Pin (4c or 4d) from the inside of

theCaliper into the Rubber Bush (6c or 6d). 4c 6c
Carrier Replacement
If necessary remove Caliper.
NOTE:
FD00198
Do not fasten any lifting device to the Pad

Retainer(11), since this can be damaged.
Remove Carrier (2) from axle.

Clean axle contact area.
Fit new Carrier (2) with new bolts.
It may be necessary, to firstly attach the Caliper.
CAUTION 2
Before removing Caliper / Carrier boltsensure
that the Caliper / Carrier cannotmove or fall
when the bolts are removedcausing damage or
injury.
SERVICE MANUAL
Brake Actuator Replacement

Brake Chamber Removal B
Disconnect air hose from Brake Chamber (18/2)
Unscrew Brake Chamber Mounting Nuts (see arrow A
B). They must not be re-used.
Remove Brake Chamber
18/2
B
Brake Chamber Fitting
NOTE:
New Brake Chambers (18/2) have drain plugs
installed (see arrows A). Remove lowest plug
(as viewed when Brake Chamber is installed).
All otherdrain holes should be plugged.
Before fitting the new Brake Chamber, the

sealingsurface (see arrow C) must be cleaned, and
theSpherical Cup (19) in the Lever must be greased
C
withwhiteGrease (Part No. II14525 or II32868). 19
The surface area of the flange must be damage
freeand clean.
The Seal, as well as the piston area - see arrow
inadjacent picture - must be clean and dry.
CAUTION
Do not use Grease containing molybdenum
disulphate. Use only genuine OE Actuators.
Attach Brake Chamber using new Nuts (self-locking

EN ISO 10513).In order not to tilt the Brake
Chamber, screw Nuts stepby step alternately with a
suitable tool and torque tighten to 180 +30 Nm.
Connect air hose and check for leakage.
Make sure that hose is not twisted and that

chafingis not possible.
CAUTION
Check function and effectiveness of the brake.
SERVICE MANUAL
Spring Brake Removal
CAUTION
Chock wheels before releasing Spring Brake.
Release parking brake, move Hand Control Valve

to‘run’ position.
Screw-out Release Bolt (arrow D) with a
maximumtorque of 35 Nm.
Release air from brake, move Hand Control Valve
to‘park’ position.
Disconnect air hoses from Spring Brake (18/1).
Unscrew Spring Brake Mounting Nuts (see arrow
B). They must not be re-used.
Remove Spring Brake.
Spring Brake Fitting

NOTE:
New Spring Brakes (18/2) have drain plugs
installed (see arrows A). Remove lowest plug (as
viewed when Spring Brake is installed). All other
drainholes should be plugged.
CAUTION
On Radial Disc Brakes the drain holes inthe
Actuator mounting face must be open (see arrow
E).
Before fitting the new Spring Brake, the sealing

surface (see arrow C) must be cleaned, and
theSpherical Cup (19) in the Lever must be greased
with white Grease (Part No. II14525 or II32868).
The surface area of the flange must be damage

freeand clean.
The Seal, as well as the push rod area - see
adjacent picture - must be clean and dry.
CAUTION
Do not use grease containing molybdenum
disulphate. Use only genuine OE Actuators.
SERVICE MANUAL
Braking System - SN Caliper Amended:10.12.09
1 Caliper
2 Carrier
4a* Guide Pin
4b* Guide Pin
4c* Guide Pin
5 Guide Pin
6a*) Rubber Bush
6b*) Rubber Bush
6c*) Guide Sleeve
7 Brass Bush
9 Inner Boot
10 Cover
11 Pad Retainer
12 Pad (complete)
13 Tappet and Boot Assembly
16 Threaded Tube
17 Bridge
18/1 Spring Brake
18/2 Brake Chamber
19 Lever
20 Eccentric Bearing
22 Inner Seal
23 Adjuster Unit
24 Turning Device
26 Spring Clip
27 Spring
30 Chain
32 Chain Wheel
33 Wear Sensor
37 Adjuster Cap
39a*) Caliper Bolt
39b*) Caliper Bolt
39c*) Caliper Bolt
40 Caliper Bolt
43 Bolt
44 Pad Retainer Pin
45 Washer
46 Disc
58 Ring
61 Shear Adapter
68a*) Cap
68b*) Cover
161 Tappet Bush
SERVICE MANUAL
Description of operation (Floating Caliper principle)
Brake actuation
During actuation, the Push Rod of the Actuator (18/1 or 18/2) moves the Lever (19). The input forces are transferred via
the Eccentric Bearing (2) to the Bridge (17). The force is then distributed by the Bridge (17) and the two Threaded Tubes
(16) to the Tappet and Boot Assemblies (13) and finally to the inboard Pad (12).
After overcoming the running clearance between the Pads and the Disc, the reaction forces are transmitted to the
outboard Pad (12). The clamping forces on the Pads (12) and the Disc (46) generate the braking force for the wheel.
Brake release
After releasing the air pressure, the Return Spring (27) pushes the Bridge (17) and Lever (19) back to the start position;
this ensures a running clearance between Pads and Disc is maintained.
Brake adjustment (automatic)

To ensure a constant running clearance between Pads and Disc, the brake is equipped with a low wearing, automatic
adjuster mechanism.
The Adjuster (23) operates with every cycle of actuation due to the mechanical connection with Lever (19). As the Pads
and Disc wear, the running clearance increases. The Adjuster (23) and Turning Device (24) turn the Threaded Tubes (16)
by an amount necessary to compensate for this wear. The total running clearance (sum of clearance both sides of Disc)
should be between 0.6 and 1.1 mm; smaller clearances may lead to overheating problems.
Safety Instructions for service work

Please also refer to the relevant safety instructions for repair work on commercial vehicles, especially for jacking up and
securing the vehicle.
Use only original Knorr-Bremse parts.
WARNING
Before starting repair work, ensure the service brake and parking brake are not applied and that the
vehicle cannot roll away.
Please follow repair manual instructions and adhere to the wear limits of the Pads and the Discs.
Use only recommended tools.
Tighten bolts and nuts to the recommended torque values.
After re-fitting the wheel, please ensure that there is sufficient clearance between the Tyre Inflation Valve, the Caliper and
the wheel rim, to avoid damage to the Valve.
NOTE
Screw threads and tapped holes must be clean and dry (free from lubrication).
After service work:

Check the brake performance and the system behaviour on a rolling road or by actual road test.
SERVICE MANUAL
Inspection Points for the Axial and Radial Disc Brake

Despite the use of long-life materials, it is necessary to check some of the components regularly for their general
condition. The following points ensure a long-life and trouble-free operation of the disc brake. The inspection frequencies
specified are minimum values. Depending on the vehicle application a more frequent
check of the components may be necessary.
The brake pad wear must be checked visually on a regular basis, e.g. each time the tyre pressures are checked, or at
least every three months.
At least annually inspect the pad to disc running clearance and the correct fitting and condition of the Cover (10) the Cap
(68a), the Cover (68c) and the Adjuster Cap (37).
With each Pad change check for the correct functioning of the Adjuster and the smooth operation of the caliper over its
full range of movement. Also inspect the Tappet and Boot Assemblies (13), the Adjuster Cap (37) and the sealing elements
(6a, 9, 10, 58, 68a, or 68c) for correct fitting and condition.
Wear Limits of Pads and Discs

Pads
WARNING
For optimum safety, stay within the Disc and Pad Wear Limits.
The thickness of the Pads must be checked regularly dependent on the usage of the vehicle.
The Pads should be checked corresponding to any legal requirements that may apply.
If no Wear Indicator has been connected this should be at least every 3 months.
If friction material is less than 2mm, the Pads must be replaced.
Minor damage at the edges is permitted. (see arrow sketch 1).
Major damage on the surface of the pad is not permitted. (See sketch 2).
SERVICE MANUAL
Pad Wear
Minor Damage on Edges (Permitted) Major Damage on Surface (Not Premitted)
Wear Limit Discs

Measure thickness at thinnest point. Avoid measuring near the edge of the disc as a burr may be present.
A = Disc thickness (new condition) 45mm

Disc thickness (worn) 37 mm, Disc must be replaced
C = Overall thickness of Pad (new condition) 30mm
D = Backplate 9mm
E = Minimum thickness of friction material 2mm
F = Minimum allowed thickness in worn condition for backplate and friction material 11 mm (replacement of Pads
necessary).
If the Disc dimension < 39 mm,it is recommended that the Disc should be renewed together with the Pads. If the disc
thickness is less than 37mm, the Disc must be replaced.
SERVICE MANUAL
Check Disc at each change of Pads for grooves and cracks.

The diagram shows possible conditions of the surface.
A1 = Small cracks spread over the surface are allowed.

B1 = Cracks less than 1.5mm deep or wide, running in a Radial direction, are allowed.
C1 = Grooves (circumferencial) less than 1.5mm wide are allowed.
D1 = Cracks going through to the cooling duct or from inner to outer edge of the pad contact area (a) are not allowed.
The Disc MUST BE REPLACED.
a = Pad contact area
In case of surface conditions A1,B1 and C1, the Disc can continue to be used until the minimum
thickness of 37mm is reached.
The Discs are normally service-free and grinding when changing Pads is not necessary.
However, grinding could be useful, e.g. to increase the load-bearing surface of the Pads after severe
grooving on the entire friction surface has occurred.
To meet safety requirements, the minimum thickness after regrinding is 39 mm.
WARNING
If these recommendations are ignored, there is a danger of brake failure. If the Pads are worn down to
the backplate or if Disc wear is excessive, brake performance will be severely affected and may be lost
completely.
SERVICE MANUAL
Brake Wear Check using rubber Bush (6a)

For all Disc Brakes which are equiped with a Rubber Bush that is axially ribbed.
The condition of the Pads can be visually determined without removing the road wheel, by viewing the position of the
Caliper (1) against the fixed guide(4).
New Condition (see “X”).

The position of Wear Indicator “G” on the Rubber Bush (6a) in new condition.
Wear Limit (see “Z”)

When the Rubber Bush (6a) is retracted to the level “G” of the wear indicator as shown, the wheel must be removed so
that the wear of the pads and disc can be checked. If necessary change the pads and /or the disc.
SERVICE MANUAL
Brake Wear Check using rubber Bush (6b)

For all Disc Brakes which are equiped with a open Rubber Bush version.
Guide pin (4) in the caliper (1).
If the dimension ‘C’ is less than 1mm, a more accurate check of the pads and disc must be made.
If necessary change the pads and / or the disc.
C = pin protrusion - shown in new condition.

D = minimal pin protrusion - pads and disc must be checked with road wheel removed.
SERVICE MANUAL
Brake Wear Check using Carrier to Caliper position (6c)

For all Disc Brakes which are equiped with Caliper to Carrier marking
Caliper position (P) against the Carrier marking (R).
If the condition ‘D’ is reached the wheel must be removed so that the wear of teh pads and disc can be checked.
If necessary change the pads and / or the disc.
C = Shown in new condition.

D = Pads and disc must be checked with road wheel removed.
Wear Indicators
There are several types of Pad Wear Indicator used.
1. In - Pad Normally Closed Indicator - Circuit

is broken when Pad Wear reaches limit.
2. In - Pad Normally Open Indicator - Circuit is
made when Pad Wear reaches limit.
SERVICE MANUAL
Adjuster Check
WARNING
Before starting service work, ensure the service brake and parking brake as well as the bus stop brake with
buses are not applied and that the vehicle cannot roll away.
Remove wheel.
The caliper assemply should be pushed inboard on its
Guide Pins. Using a suitable tool, press the inboard pad
(12) away from the Tappets and check the gap between
Tappet and inboard pad backplate - it should be between
0.6mm & 1.1mm. If the running clearance is too small there
is a danger of overheating. That may lead to consequential
damage. If the running clearance is too small or too large,
the adjuster may not be functioning correctly and should be
checked as follws.
Pull off the Adjuster Cap (37a) using the tag, taking care not
to lose the Shear Adapter (61). The Adjuster (23) must be
turned with the Shear Adapter (61) anti-clockwise for 2 or 3
clicks (increasing running clearance).
CAUTION
Never turn Adjuster (23) without Shear Adapter (61)
being fitted. If the shear torque of the Shear Adapter
is exceeded, then it is designed to fail. Try again with
a new (unused) Shear Adapter. With a second failure
of the Shear Adapter the Caliper must be exchanged
since internal damage is present. Do not use an open
ended spanner as this may damage the adapter.
By applying the brake (about 2 Bar) 5 - 10 times the

Spanner or Socket should turn clockwise in small
increments if the Adjuster is functioning correctly (see notes
below).
CAUTION
Make sure that the Ring Spanner or Socket can
turn freely anti-clockwise during following
procedure.
NOTE
As the number of applications increases, incremental movement will decrease.
NOTE
If the Spanner or Socket does not turn or turns only with the first application or turns forward and
backward with every application, the automatic Adjuster has failed and the Caliper must be replaced.
SERVICE MANUAL
Even if Pads are not being changed, a new Adjuster Cap (37) should be fitted having lightly greased it with white
grease.
NOTE
The tag of the Adjuster Cap (37) should be positioned as shown by the arrow in the above diagram. This
ensures access is maintained for subsequent removal. Removal of the Adjuster Cap with a screwdriver, for
example is not recommended since the seal may be damaged.
SERVICE MANUAL
Caliper Checks
WARNING
Before starting service work, ensure the service brake and parking brake as well as the bus stop brake with
buses are not applied and that the vehicle cannot roll away.
Caliper Running Clearance

By pushing and pulling the Caliper in an axial direction by
hand (see arrow A in adjacent sketch), a movement of 0,6 -
1.1 mm must possible.
If using hand pressure only (no tools) the Caliper is not
movable, the Caliper guidance must be further examined.
Caliper Movement along Guide Pins

Remove Pads.
Clean dirt from Guide Pin (4a, 4b, 4c, 4d) (see arrows in
illustration).
Using hand pressure only (no tools), the Caliper (1) must
slide freely along the whole length of the Guide Pin
arrangement. This should be greater than 30mm.
Rubber Bush (6a, 6b) or Guide Sleeve (6c) to Guide Pin Clearance
NOTE
Before removing the wheel, note that there is no contact between Caliper and axle, vehicle, chassis sections or
Carrier. If necessary the Rubber Bush (6a, 6b), or Guide sleeve (6c) must be replaced.
To measure the clearance, the following steps must be taken:

Remove the wheel.
Remove the pad retainer (11) but leave the pads (12) in the abutment.
SERVICE MANUAL
Checking of Tappet and Boot Assmblies
NOTE
The tappet should not extend more than 30 mm (see
diagram). The tappet and boot assemblies (13) must
not show and signs of damage. Check for correct
location and fitment.
The penetration of dirt and moisture into the brake

will lead to corrosion and impair the function of the
disc brake.
If necessary replace tappet and boot assemblies.
SERVICE MANUAL
Pad Replacement
WARNING
Before starting service work, ensure the service brake and parking brake as well as the bus stop temporary
hold brake, if fitted, are not applied and that the vehicle cannot roll away.
Pad Removal
Remove wheel.
Remove Clip (26) and Washer (45), depress the Pad
Retainer (11) and remove Pin (44). If necessary remove
any in-pad wear sensor components and discard.
If the Pad Retainer (11) is corroded or damaged, it should
be replaced.
NOTE
Before removing Pads it is strongly recommended
that the Adjuster mechanism is checked for correct
operation.
If the pad retainer (11) is corroded or damaged, it should be

replaced. Pull off the Adjuster Cap (37a) using the tab,
taking care not to lose the Shear Adapter (61).
Fully wind-back the Tappet and Boot Assembly (13) by
rotating the Adjuster (61) in an anti-clockwise direction.
NOTE
since internal damage is present.
Do not use an open-ended spanner as this may
damage the adapter.
Push inboard Pad (12) toward Actuator.

Pull out both Pads (12).
SERVICE MANUAL
Pad Fitting
CAUTION
Pads must be changed as an axle set and NOT individually. Use only Pads which are permitted by the vehicle
manufacturer, axle manufacturer and disc brake manufacturer. Failure to comply with this may invalidate the
vehicle warranty
NOTE
Fully wind-back the Tappet and Boot Assemplies
(13) by rotating the shear adapter (61) in an anti-
clockwise direction.
NOTE
since internal damage is present.
Do not use an open-ended spanner as this may
damage the adapter.
Clean the Pad abutments.
Slide Caliper (1) outboard and fit the outboard Pad (12).
For fitting the inboard Pad (12) push Caliper (1) inboard
and fit the inboard pad.
Fit new In-pad Wear Indicator kit, if appropriate.
Install the cable so that it can not be damaged.
Turn the shear adapter (61) clockwise until the pads come
into contact with the disc..
Then turn back the Adjuster 2 clicks.
The hub should turn easily by hand after having applied
and released the brake.
SERVICE MANUAL
Pad Fitting
After setting the Pad Retainer (11) into the groove of the
Caliper (1), it must be depressed to enable the positioning
of Pad Retainer Pin (44).
Fit washer (45) and Spring Clip (26) to the Pad Retainer Pin
(44) (use only new parts).
It is recommended that Pad Retainer Pin (44) is installed
pointing downwards (see Sketch).
The Adjuster Cap (37) must then be replaced (use only a

new Cap) having lightly greased it with white grease.
NOTE
The tag of the Adjuster Cap (37) should be
positioned as shown by the arrow in the adjacent
Sketch. This ensures access is maintained for
subsequent removal.
NOTE
After every servicing: Check the brake performance
and the system behaviour on a rolling road. check
function and effectiveness. During teh bedding-in
period there may be reduced braking effort..
Wear indicator fitting

Remove Pads (12).
Insert the wear indicator cables into the groove of teh pads.
the wear indicators snap into place in the holes in the pad
material.
The longer end of the wear indicator cable (see arrow) must
be fitted in the outer pad
CAUTION
New Pads need bedding in. Heavy or long duration braking should initially be avoided
SERVICE MANUAL
Wear indicator fitting

Insert pads (12/1) into the pad abutments.
Fit pad holder springs (12/2) onto the pads (12/1). Pay
attension tot he correct installation of wear indication
cable (101) (see arrows)
Fir pad retainer (11), Pad retainer pin (44), washer (45)
and spring clip (26). Pay attension to correct installation of
teh wear indication cable (101) (see arrows).
Cable Guide
Fit cable guide (105) onto the pad retainer 9110. In the
right position, the cable guide (105) snaps into place by
pressing it lightly onto the pad retainer (11).
SERVICE MANUAL
Wear Indicator Fitting

Press wear indicator cable (101) into the locating tabs of
teh cable guide (105) (see arrows A).
The short cable end of the wear.indicator cable (101) must
not be secured by locating tabs of teh cable guide (105).
Install the cable that leads to the electrical supply of the
vehicle, in one of the two locating tabs (see arrows B).
Cable Guides
Install indicator cable (101) in the middle of the pad retainer
(11).
Insert cable guide (105a) under one side of the pad retainer
(11) (see arrow B).
Slightly press on the other side of the pad retainer (11) (see
arrows A). The cable guide snaps into place.
Install the cable that leads to the electrical supply of the
vehicle, in one of the wir loop (see arrows C).
The short end of the wear indicator cable guide (101) must
not be secured by a wire loop of the cable guide (105a)
(see arrows C).
Protection Plate
Fit the cable protection plate (104).

Pay attention to the correct position of the cable protection
plate’s catch (see arrows).
Exert hand pressure to the cable protection plate (104); it

will snap into place.
SERVICE MANUAL
Tappet and Boot Assembly Replacement and

Inner seal
The tools are referred to by item number fro ease of
reference.
To remove the tappet and boot assembly (13) use the

wedge fork (A).
To fit the tappet and boot assembly (13) use the press-in
tool (B).
To fit the inner seal (22), use the press-in tool (l).
Tappet and Boot Assembly (13) Removal
NOTE
It may be easier to remove the Caliper from the axle
to replace the Tappet and Boot Assemblies (13).
The shear adapter (61) must be screwed clockwise until the

Boots can be reached (max. 30mm).
To remove the Tappet Boot from the Caliper bore, a
Screwdriver (B) should be used to deform the Boot location
ring - see diagram.
CAUTION
Great care must be taken not to damage the Inner
Seal since it is not a replacement item.
The Tappet and Boot Assemblies (13) can be removed from

the Threaded Tubes (16) by using Wedge Fork (A) by
driveing it between the tappet and the caliper.
Remove the old Tappet Bush (161).
Check Inner Seal (arrow X).
When replacing tappet and boot assemblies (13), the inner
seals (22) must also be replaced.
SERVICE MANUAL
Threaded Tubes (16) Inspection

Place an unworn Pad (12) into the outboard gap to avoid
overrunning of the Threaded Tubes.
CAUTION
Threaded Tubes should not lose engagement with
the inner thread of the Bridge. The Caliper must be
replaced if thread engagement is lost.
If Caliper is not installed on axle, put a spacer E (length =

70mm) into the Caliper (1) to avoid loss of thread
engagement of the Threaded Tubes (16) when screwing
them out (see adjacent Sketch). check the threads for
corrosion damage.
In case of water ingress or corrosion, the Caliper must be
replaced.
Inner Seals (22) - Replacement

Fully wind back the treaded tubes (16) by turning the
shear adapter (61) anti-clockwise.
Clean area of the inner seal (22).
To remove the inner seal (22) a screwdriver (A) should be
used - see sketch.
CAUTION
The sealing face (X) for the inner seal (22), as well as
the threaded tube (16) must not be damaged. They
cannot be replaced.
Clean sealing face (X).

For teh inspection of the threads, the tubes must be
screwed out (max 30mm) by turning the shear adapter
(61) clockwise.
Grease threads with white grease.
Fit each inner seal (22) onto a treaded tube (16).
With Caliper installed on axle
Remove the tappet bush (161).
Position tool (L) with the short strut in th position shown.
The tool (L) is guided over the spigot of teh threaded tube (16).
Fully press in the inner seal (22) by rotating Tool T3 using a spanner - see sketch.
SERVICE MANUAL
To check the correct fit of the inner seal (22), screw out the
threaded tubes (16) about 4-5 threads by turning the shear
adapter (61) clockwise.
The inner seal (22) must not turn.
With Caliper Installed on The Axle

The fitting sequence of inner seal (22) does not change..
Tappet and Boot Assemblies (13) - Fitting

The threaded tubes (16) must be wound back.
The seal seat in the caliper for tappet and boot
assemblies (13) must be clean and free from grease.
Fit a new tappet bush (161) onto the spigot of each

threaded tube (16).
Position a tappet and boot assembly (13) onto each
tappet bush.
Use Push-in tool (B) with the short strut (T3) for
positioning and pressing in the boot - see sketch 1.
Using tool (B) in reverse, with the short strut (T3), each
tappet can be pressed onto its tappet bush - see sketch 2.
After assembly the tappet (13) must be free to turn in both

directions.
SERVICE MANUAL
With Caliper Not Installed on The Axle

The threaded tubes (16) must be fully wound back.
The sealing seat in the caliper for the tappet and boot
assemblies (13) must be clean and free from grease.
Fit a new tappet bush (161) onto the spigot of each treaded
tube (16).
Position a tappet and boot assembly (13) onto each tappet

bush.
Use Push-in tool (B) with the long strut (T3+T4) for
positioning and pressing in the boot - sketch 3.
Using tool (B) in reverse, with the long strut (T3+T4), each
tappet can be pressed onto its tappet bush - see sketch 4.
After assembly the tappet (13) must be free to turn in both

directions.
SERVICE MANUAL
Caliper Replacement
The tools are referred to by item number for reference
To fit the cap (68a), use the press-in tool (K).
To fit the cover (68c), use the Press-in tool (M).
To fit the cover (10), use Press-in tool (H).
Caliper Removal
Remove Pads.
Remove Actuator.
If fitted remove wear indicator cable.
NOTE
Do not touch electrical contact poits because of
static discharge.
NOTE
It may be necessary to remove the Caliper and the
Carrier from the axle or remove only the caliper.
Removal of the Cover (10)

Use a suitable tool (e.g. screwdriver) to penetrate the cover
(10).
During penetration, the cover may move approximately
10mm inwards.
Remove cover (10).
NOTE
Cover should be penetrated in the middle. Do not
drive the tool between the caliper bore and cover
(10) since caliper bore may be damaged.
Removal of the Cover (68c)

Because of the protruding cover (68c) it must be
dissasembled a sshown in sketch. use a screwdriver or
another suitable tool.
Do not dissasemble the cover (68c) in direction of the
caliper since in may be damaged.
Check the caliper bore for the cover (68c), as well as the
inner bearing bore for dirt and corrosion. If necessary the
caliper must be replaced
SERVICE MANUAL
Removal of Cap (68a)
On Calipers with Rubber Bush (6a) pull the Cap (68a) from
the Guide Pin (4) using a suitable tool (see Sketch).
CAUTION
Take care not to damage Rubber Bush (6a). If
necessary replace it by means of a Guide Pins and
Seal.
Remove Caliper from Carrier
CAUTION
Before removing the Caliper Bolts (39 and 40)
ensure that the Caliper (1) cannot move or fall when
the Caliper Bolts are removed causing damage or
injury.
Remove Caliper Bolts (39) and (40) and discard. They must
not be reused.
CAUTION
Never hold the Caliper with your fingers between
Caliper and Carrier - there is a risk of injury! Do not
fasten any lifting device to the Pad Retainer (11),
since this could be damaged.
CAUTION
Opening or dismantling of the caliper is not
authorised. use only genuine replacement calipers..
Remove caliper from carrier.
Caliper Fitting
(Carrier is fitted on the axle)
The correct choise of caliper must be ensured by checking
the part number on the identification label.
The replacement caliper may have a plastic cap or
adhesive tape in the area of the actuator attachment (see
arrow B in sketch 1). Remove the cap or tape after installing
the caliper on the vehicle. alternatively, if the replacement
caliper has a breakthrough diaphragm, it should be left in
place (see arrow on sketch).
Note:
The replacement caliper includes seals and guide pins. The
pads are not included.
SERVICE MANUAL
CAUTION
The guide pins (4 and 5) as well as the caliper bolts
(39 and 40) are highly stressed items. they must be
replaced whenever the caliper (1) is removed from
the caliper.
Fit the caliper to the carrier.

Screw in new Caliper Bolts (39) and (40) and tighten to
180Nm, then tighten by a further 90 deg.
CAUTION
Screw threads and tapped holes must be clean and
dry (free form lubricant and resduals of pre-applied
adhesive).
Check that the caliper slides easily on the guide pins.

Check the position of the inner boot (9) on the guide pin (5).
According to the caliper variant check also the position on
the guide pin (4) as well as the position of Ring (58).
Fit the pads.
Check adjuster function.
Attach brake chamber or spring brake.
Remove caliper from carrier.
Fitting of Cover
Caliper bores and covers (10) and (68c) must be clean and
free from lubrication.
Clean the new cover (10) and (68c) thoroughly and check
that the face and the chamfer are clean and not damaged -
see arrows in figure.
Clean the interior of the press-in tool (H) or (M) and place
the cover (10) or (68c) inside - see figures.
Position the Press-in tool (H) or (M) including the cover (10)
or (68c) in the start of teh caliper bore. Press on the
mandrel of the Press-in tool (H) or (M) by hannd until
resistance is felt.
Note:
Do not tilt the tools when assembling the covers (10) and
(68c) - see figures.
SERVICE MANUAL
CAUTION
The inner boot (9) must be in a compressed
condition - see adjacent figure. since the caliper’s
freedom of movement may be limited if air is trapped
in the inner boot..
Use a hammer on the mandrel to insert the cover to the end

stop.
Note:
After fitting the new cover (10), it should protrude 2mm from
the caliper’s face - see figure.
Note:
After fitting the new cover (68c) it should protrude 15.5 nn
from the caliper’s face - see figure.
Fitting of Cap
Fit the cap (68a) using tool (K) and a hammer. Force the
cap (68a) into the guide pin (4) until it contacts the caliper
bolt. The seal is achieved by the compression of the lip of
the rubber bush (6a) between the guide pin (4) and cap
(68a) (see view ‘Y’).
If the caliper and carrier assembly is not fitted to

the vehicle
CAUTION
Move the caliper against the carrier and hold so that
the inner boot (9) is in a compressed condition to
prevent air being trapped while cover (10) or cover
(68c) and cap (68a) is fitted.
Fit new cover (10), cover (68c) or cap (68a) as described

above.
Fit the pads, if not already fitted.
Check adjuster function.
Attach brake chamber or spring brake.
SERVICE MANUAL
Replacement of Inner Boot (9)

The tools are referred to by item number for ease of
reference.
To fit the inner boot (9) use the Pull-in tool (C).
Remove the caliper.
Remove ring (58).

Pull out Guide Pin (5).
Push out inner boot (9) with screwdriver.
Note:
If teh inner boot (9) is installed with guide pin (4c):
Remove ring (58).
Pull out guide pin (4c).
Push out inner boot (9) with screwdriver.
CAUTION
The sealing face of inner boot (9) in the caliper must
not be damaged (see arrow in sketch)
Inspect and clean contact area of inner boot (9).

Check for corrosion (see arrow A in sketch).
Check brass bush (7) and if installed guide sleeve (6c) for
dirt and replace if damaged.
Fit new boot (9) into the sleeve of the tool (C). See arrow in
sketch.
Pay attention that the bellow-folds of the inner boot (9) are
positioned within the tool.
Position sleeve with inner boot (9) into the caliper bore and
pull in by hand.
Then pull in with a maximum torque 8 Nm.
Note:
Pay attention to the correct postion of inner boot (9).
Carry out a pulling check (see adjacent sketch)
SERVICE MANUAL
Grease brass bush (7) and if installed guide sleeve (6c)

with white grease.
Insert guide pin (5) and also guide pin (4c) if guide sleeve
(6c) is installed.
The lip in the end of the inner boot must engage in the
groove of the guide pin (5) and if installed in the groove of
the guide pin (4c) (see arrow).
Pushing on the ring (58) ensures that the boot (9) is
engaged in the groove of the guide pin (5) or if installed in
the groove of the guide pin (4c).
Fit caliper.
SERVICE MANUAL
Replacement of Guide Pin Bushes

The tools are referred to by item numnber for ease of
reference.
In order to remove, fit and groove the brass bush (7) use
the Pull-out/Pull-in and grooving tool (D).
Remove Caliper.
Remove Guide Pin (5 or 5a) and Inner Boot (9).
Brass Bush (7) Replacement

Remove guide pin (5) and inner boot (9). Clean surface (X),
surface (Y) and brass bush (7) (see sketch 2).
Removal of Brass Bush

Position toll combination (D) for pulling out brass bush (7)
(see sketch 2).
Note:
Ensure that nut (T14) is located in brass bush (7) and the
end of tube (12) is is firmly located - see sketch 2.
Pull out brass bush (7) by means of a spanner or socket -

see sketch 2.
Fitting of Brass Bush
Fully wind brass nut (T14) on to spindle (T13).
Place new brass bush (7) on the groover (T16) and insert
into caliper bore - see sketch 3a.
Screw spindle (T13) by hand up to stop.

Note:
Pay attention to the groover (T16) - see sketch 3a. It must
be able to move freely.
The flange (T8) must be located in the caliper recess.
Pull in brass bush (7) using brass nut (T14) up to stop - see
sketch 3b.
To prevent longitudinal dispacement of brass bush (7) it
must be ‘grooved’ - see sketch 3c.
To do so the groover (T16) must be screwed in upto the
stop.
Wind back the groover (T16) approximately 20mm.
Slacken the brass nut (T14) and rotate the groover (T16)
through approximately 60deg.
Report the process of ‘grooving’.
The new brass bush (7) is now grooved with the caliper.
Before removing the tool (D), the hexagon screw of the groover
(T16) should be wound out approximately 20mm.
SERVICE MANUAL
Check contact area of Brass Bush (7) and remove any

burrs.
Grease bush (7) with white grease..
Rubber Bush and Guide Sleeve (6c) -

Replacement
The tools are referred to by item numnber for ease of
reference.
Use tool (R) for the assembly of the rubber bush (6a or 6b).
(see sketch)
Note:
Do not use the disc T5 dia 39 with SN type.
use tool (N) for the assembly of the sleeve guide (6c). (see
sketch).
Removal of Rubber Bush
Remove guide pin (4a or 4b).
Clean caliper in the area of the rubber bush.
Select disc T6 dia39.
Position the tool (R) as shown in the adjacent picture.

Screw on the nut (T22) by hand.
Hold the nut (T22) with a ring spaner and with a suitable
socket or ring spanner tighten spindle (T20) to remove the
rubber bush.
SERVICE MANUAL
Removal of Guide Sleeve (6c)

Remove guie pin (4c).
In order to separate the tab from the guide sleeve (6c) use
the screwdriver or similar tool whose width is smaller than
the tab.
Place the screwdriver as close as possible to the base of
the tab (see adjacent sketch).
Then separate the tab from the guide sleeve (6c) by means
of the screwdriver and a hammer (see adjacent sketch).
Clean caliper in the are of the guide sleeve (6c) and the pad
abutement.
Note:
Caliper groove can be on left side or right side of teh caliper
bore.
position tool (N) as shown in adjacent sketch.
Screw on the nut (T14) by hand.
Hold the nut (T14) with a ring spanner and with a suitable
socket or ring spanner tighten spindle (T20) to remove the
guide sleeve (6c).
Fitting of Rubber Bush

Ensure that the threaded pin in the tool (R) is unscrewed,
so that there is no protection at the contact surface.
Push rubber bush (6a or 6b) into the tool (R).
Position tool (R) with rubber bush (6a or 6b).
Lightly screw on the nut (T22) by hand.
Note:
Do not tilt the rubber bush (6a or 6b) when pulling-in.
Using torque wrench pull in rubber bush (6a or 6b) (min.

8Nm up to max 45Nm) to its stop.
Remove the tool.
CAUTION
If the torque is < 8Nm or > 45Nm, then the caliper
must be replaced.
Failure to replace the caliper could lead to a
guidance failure.
SERVICE MANUAL
CAUTION
The metal ring (see arrows adjacent sketch) must
not move. When checking for movement, then the
sealing elements of the rubber bush (6a or 6b) must
not be damaged.
Grease the interior of the rubber bush (6a or 6b) with white
grease.
CAUTION
The guide pins (4 and 5) as well as the caliper bolts
(39 and 40) are highly stressed items. They must be
replaced whenever the caliper (1) is removed from
the carrier (2).
Fit guide pins (4a or 4b) via the pad abutement in the
rubber bush (6a or 6b).
Fitting of Guide Sleeve

Position the guide sleeve (6c) (see adjacent sketch).
CAUTION
Before pressing in guide sleeve (6c) the tab must be
in the correct position. The tab must snap in caliper
groove when guide sleeve (6c) is reaching its final
position.
Note:
Caliper groove can be on left side or right side of the caliper
bore.
Slightly press in the guide sleeve (6c) by means of the nut
(t14) and a hammer. The guide sleeve 96c) is now
adjusted.
Insert tool (N) and position (see sketch).
Tighten spindle (T20) slightly by hand.
Hold nut (T14) by means of a ring spanner and with a
suitable socket or other suitable tool tighten spindle (T20)
up to stop.
CAUTION
Do not turn nut (T14) because guide sleeve (6c) may
lose its correct position.
SERVICE MANUAL
Remove Tool (N)

In order to press in the tab use a screwdriver or similar tool
whose width is smaller than the tab. Place teh screwdriver
as close as possible to the top of the tab (see adjacent
sketch). then press in the tab by means of the screwdriver
and a hammer.
The guide sleeve (6c) is now secured against rotaing and
axial movement.
Grease the interior of the guide sleeve (6) with white
grease.
SERVICE MANUAL
Carrier Replacement
If necessary remove caliper.
Remove carrier (2) from axle.
Note:
Do not fasten any lifting devise to the pad retainer (11),
since this can be damaged.
Clean axle conact area.
Fit new carrier (2) with new bolts.
SERVICE MANUAL
Brake Actuator Replacement

Brake Camber Removal
Disconnect air hose from brake chamber (18/2) (air hose
must be free of air pressure).
Unscrew brake cahmber mounting nuts (see arrow B).They

must not be reused.
Brake Chamber Fitting

Note:
New brake cambers (18/2) have drain plugs installed.
(see arrows A).
Remove lowest plug (as viewed when brake chamber is
installed). All other drain holes should be plugged.
Before fitting the new brake chamber, the sealing surface
(see arrow C) must be cleaned, and the spherical cup (19)
in the lever must be greased with white grease.
The surface are of the flange must be drained free and
clean.
The seal, as well as the push rod area - see adjacent

sketch must be clean and dry.
If the thickness of the seal is less than 3mm the brake
chamber must be replaced.
CAUTION
Do not use grease containing molybdenum
disulphate. Use only genuine acuators.
Attach brake chamber using new nuts (self locking EN ISO

10513).
In order not to tilt the brake chamber , tighten nuts
alternately with a suitable tool and torque tighten.
Connect air line and check for leakage.
Make sure that the hose is not twisted and that it is not
chafing.
CAUTION
Check function and effectiveness of Brakes.
SERVICE MANUAL
Attach brake chamber using new nuts (self locking EN ISO 10513).
In order not to tilt the brake chamber , tighten nuts alternately with a suitable tool and torque tighten.
Connect air line and check for leakage.
Make sure that the hose is not twisted and that it is not chafing.
CAUTION
Check function and effectiveness of Brakes.
SERVICE MANUAL
WARNING
Do not attampt to service or disassemble the spring chamber or any spring brake actuator. A large spring in
the chamber, having extreme force, could cause serious bodily injury if it were suddenly released due to
inadvertent removal of the clamp band or tamper-resistant head.
NOTE
Unlike double diaphragm spring brakes, the
unscrewing or removal of the release bolt does not
cage the power spring, but only removes the power
spring force from the slack adjuster. The “MG-T”
model will fully retract to the zero stroke position.
NOTE
For easier turning of the release bolt, apply 85-100
psi air pressure to the spring port. After removal of
the release bolt, completely exhaust air from the
spring chamber.
Removal and Installation Instructions

The removal and installation of single/piggyback spring
brake chambers (withoutremoval of the service brake
chamber) can be made easier by “locking off” the service
chamber push-rod. To do this, apply air to service brake by
holding down driver’s foot brake treadle valve and, while
applied, clamp vise-grip pliers onto push-rod to prevent rod
from retracting when air pressure is released (see
illustration).
1. Manually release the spring brake as described earlier.
2. Remove both air lines from the chamber.
NOTE
Be sure to mark air line from air-inlet port marked
“SPRING BRAKE” for later re-installation reference.
3. On actuators fitted with external breather tubes,

disconnect the tube and elbow from the service chamber
housing (see illustration opposite).
4. Using a 9/16-inch wrench or socket, remove hex nuts on
service clampband. Then, while holding the
single/piggyback spring brake securely in place, remove
clampband, and separate piggyback from service chamber.
NOTE
At this time take the opportunity to inspect all parts
in service chamber (especially the diaphragm) and
replace any parts which may be damaged or worn.
Use only genuine replacement parts.
SERVICE MANUAL
Spring Brake Actuators
Inspection
1.The plastic end cap requires no positioning or
maintenance, but must be snapped tightly into place. 1
Inspect the cap for damage and replace as necessary.
Operating these units without the end cap securely in
place will void the brakes warranty without remedy.
Remove the end cap and check to ensure that the
release bolt is tightened to 35-45 Lbs.-Ft. of torque. The
release bolt must be properly installed for the brake to 2
function properly. Be sure to replace the end cap
properly. 5
2. Ensure the breather tube is securely engaged a

minimum of 1/2 inch into the rubber elbows and glued
together with a high quality rubber cement. These units 3
must be mounted with the breather tube in the upper half
of the non-pressure chamber facing away from the road
surface. Failure to comply with these installation
4
instructions will void the brakes warranty without remedy.
6 7
Visually inspect the exterior surfaces of the unit for signs Model “MG-T” Series
of damage from outside sources.
3. Check to ensure the service chamber clampband is evenly seated and the clampband hex nuts are tightened to 34-41
Nm (25-30 Lbs.-Ft.) of torque.
4. Check to ensure the mounting stud nuts are tightened to 135-156 Nm (100-115 Lbs.-Ft.) of torque (clockwise) and
washers are in place between the nuts and bracket.
5. Inspect air lines, hoses and fittings attached to the chamber. Replace any damaged or leaking parts.it’s recommended
the fittings be tightened to 34Nm (25 Lbs.-Ft.) of torque into the chamber air-inlet ports.
6. Inspect the push rod to be sure it is working free, not bent, not binding and is square to the chamber bottom within ±3°
in any direction at any point in the stroke of the chamber. If the push rod is not square, make corrections by repositioning
the chamber on the mounting bracket and/or by shimming the slack adjuster to the right or left on the camshaft.
7. Inspect the yoke assembly being sure the yoke pin is installed and locked into place with a cotter pin. Replace any
damaged, worn or missing parts. it’s recommended the yoke locknut be tightened to 34-47 Nm (25-35 Lbs.-Ft.) of torque.
On units equipped with a dust boot, check the boot for tears and replace as necessary.
Manual Release
CAUTION
The actuators must only be wound off with the Handbrake in the “ON” position or with the air pressure
exhausted from the system. If the actuators are wound off with air pressure in the system and Handbrake is
released, the protruding release bolts will impact and damage the shock absorber.
WARNING
Before releasing brakes, chock wheels of the vehicle
to prevent a runaway. SE
T
RE
Remove the plastic end cap from the spring chamber. Manually
release the spring brake by turning the release bolt counter-
clockwise using a 3/4-inch deep socket wrench until the bolt is SE
LEA
RE
completely removed from the unit.
SERVICE MANUAL
5. Make sure new single/piggyback spring brake is fully

released as outlined in previously of this manual.
Position diaphragm in bottom recess of chamber (see
illustration opposite) and, with very close attention taken
to assure all mating parts are aligned straight and the air
lines are positioned to mate with vehicle air supply lines
, replace service clampband.
6. Re-install clampband bolts and nuts. Alternately

tighten each hex nut in 7-13 Nm (5-10 Lbs.-Ft.) of torque
increments while constantly rechecking mating parts
alignment.
If realignment is required, loosen clampband nuts and
repeat Steps (above).
Firmly tap around the circumference of clampband with
hammer to assure full seating of clampband (see
illustration opposite) and tighten nuts to 34-40 Nm (25-30
Lbs.-Ft.) of torque.
7. Apply Teflon® tape or sealing compound to hose

fittings and re-install both air lines to chamber, making
sure each is mated to the correct air-inlet port according
to markings made earlier. it’s recommended the fittings
be tightened to 33 Nm (25 Lbs.-Ft.) of torque into the
chamber’s air-inlet ports.
8. Using vehicle system air, charge parking brake with

full line pressure (minimum 100 psi). Using only soapy
water (NEVER ANY TYPE OF OIL!), inspect for air leaks
at air lines and fittings. If bubbles appear, tighten fittings
slightly, but not over 33 Nm (25 Lbs.-Ft.) of torque.
9. With spring brake still fully charged with full line

pressure, apply and hold foot brake treadle valve down
to charge service brake chamber.
NOTE
At this time, remove vise-grip pliers from the service
push-rod so it returns to a normal position inside
chamber. Now test for air leaks around
circumference of service clampband. If bubbles
appear, firmly tap circumference of clampband with
a hammer and retighten clarnp nuts until leaks Apply
cease. MGM Brakes recommends 33-40 NM (25-30 Adhesive
Here
Lbs.-Ft.) of torque on the clampband hex nuts.
10. On Models fitted with external breather tubes, wipe

open end of connector tube clean to be sure no oil is
present, apply a good quality rubber cement to the tube
and re-insert tube into flexible elbow with a minimum 1/2- 1/2-inch
inch engagement into elbow. Minimum
Engagement
SERVICE MANUAL
NOTE
These units must be operated with the breather tube
in the upper half of the non-pressure chamber facing
away from the road surface, and the tube must be
securely glued into the rubber elbows. Failure to
T
comply with these installation instructions will void SE
RE
the warranty without remedy.
SE
11. With air pressure exhausted from service chamber, LEA
RE
but with line pressure still on the spring brake, install the
release bolt completely into chamber and tighten to 47-
61 (35-45 Lbs.-Ft.) of torque.
12. Replace the end cap properly. Operating these units

without the end cap securely in place will void the brakes
warranty without remedy.
WARNING
Release bolt must be properly installed for the
correct function of the spring brake..
Removal and Installation of Service Brake

Diaphragm
Follow the previous instructions on removal of brake
chamber up to instruction 5. Only use genuine
replacement diaphragms. Replace the diaphragm with a
new one at this point and then complete the re-assembly
process as previously described.
NOTE
It may not be necessary to disconnect air lines from
spring brake during this procedure as long as
correct parts are used and alignment can be
obtained during re-assembly operation.
SERVICE MANUAL
Attach Spring Brake using new Nuts (self-locking

EN ISO 10513).
In order not to tilt the Spring Brake, screw
Nutsstepby step alternately with a suitable tool and
torque tighten to 180 +30 Nm.
Connect air hoses, ensuring that they are replaced
inthe correct ports.
Make sure that hoses are not twisted and that
chafing is not possible.
Release parking brake, move Hand Control Valve
to‘run’ position, and check for leakage.
Screw in Spring Brake Release bolt to maximum 70
Nm.
CAUTION
Check function and effectiveness of the brake
Special Tools
Part Number Description

II 19252 Press-In Tool for Tappet and Boot (13)
II 19253 Pull-In Tool for Inner Boot (19)
II 19254 Pull In/Out Tool for Brass Bush
II 32202 Wedged Fork for removal of Tappet and Boot (13)
II 36797 Grooving Tool for Brass Bush (7)
Z001105 Press-in tool for steel cap
Z004198 press in/ pull out for rubber bush (6c) & (6d)
Z003934 Press-in tool for cap
Z004361 Press-in tool for Inner Seal
Torque Requirements
Pos. Number Pos. No Spanner Size

[ Nm ] ( mm)
39a,39b,39c Caliper Bolts
180 plus 90 degrees 14
39d, 40, 40a M16 x 1.5 - 10.9
Brake chamber, spring
180+30 24
brake. Hexagon nuts
M16 x 1..5 (x2) EN ISO 7042
SERVICE MANUAL
Braking System - Pipe Connectors Amended:
Introduction Once the sleeve is pushed in, the pipe can be

withdrawn.
This section describes the pipe connectors used on
the Trident bus chassis. Pipe assembly
NOTE NOTE
No modification may be made, nor may any air In order to avoid any abnormal strain on the
piping be relocated without the express fitting and consequently guarantee a better
permission of Dennis. performance, it is important to follow the
minimum bend radius and the minimum
straight length indicated in the table below.
CAUTION
Before working on any piping, ensure that any
Diameter R minimum L minimum
internal pressure has been released.
Metric (mm) (mm)
4 x 6 60 6
Plastic Pipe Fitting Type PA 6 x 8 80 8
In this type of fitting, the pipe pushes on to an 7.5 x 10 100 10
internal spigot where it is locked in position by a
9 x 12 120 12
toothed grab ring. It is sealed by a square section
seal in the outer part of the fitting. A sliding release 12 x 16 160 16
sleeve is provided to enable the pipe to be removed.
Removal
Because the pipe can rotate in the fitting, the pipe
need not be disconnected before unscrewing the The pipe should be assembled to the fitting as
fitting. To disconnect the pipe, place an open-ended follows
spanner to fit over the tube, push the tube into the
1. Cut the end of pipe square. A cutter
fitting and push on the spanner to depress the
(610224) is available (see Tube Repair, Page
release sleeve. As the seal has to be moved to
4.55).
release the grab ring, strong pressure will be
required but the following pressures should not be 2. Mark the insertion distance on the pipe
exceeded. according to its diameter.
Pipe size (mm) Force (kg.) 3. Push the pipe into the fitting until it bottoms
6 3.0 and check that the insertion mark is just
visible outside the release sleeve.
8 4.0
4. Pull on the pipe to check that it is securely
10 5.1
retained in the fitting.
12 8.2
16 9.2
SERVICE MANUAL
Nylon Braking Tube Repair

Should damage occur to the nylon brake tubing it is
permissible to carry out a repair using a in line Unmarked Tubing
double connector. Suitable in line connectors are When fitting a in line double connector to unmarked
available from Dennis. tubing it is important that the length of tube
penetration should be marked indelibly on the tubing
according to the dimension indicated on the table
below.
Metric tube diameter L (mm)

4 x 6 18.5
6 x 8 18.5
In Line Double Connector 7.5 x 10 16.5
for Nylon Pipe 9 x 12 23
12 x 16 24
Thread (metric) Torque Nm

M12 10 - 15
M14 15 - 20
M16 15 - 20
M22 20 - 30
Thread (imperial) Torque Nm
1
/8 10 - 15
1
/4 15 - 20
3
/8 25 - 30
Cut the tube squarely using a tube cutter for
1
/2 35 - 40 polyamide tubing.
Maximum offset angle: 15°
Marked Tubing
Pre-marked tubing is pre-marked at regular intervals
corresponding to the penetration length. The tube
should be cut on the mark.
Only marked tubing designed for the fitting
guarantees proper assembly. Brake Tubing Cutter
SERVICE MANUAL
Replacing fittings Plastic/Metal Pipe Fitting

The recommended assembly torques are as follows This pipe connector is a one piece bite type fitting with
back compression. The wedging action of the nut, when
Thread (metric) Torque Nm tightened, causes the ferrule to bit into the outside
M12 10 - 15 diameter of the tube wall for a leakproof connection.
M14 15 - 20 This fitting can be assembled and disassembled at least

15 times. At each remake, hand tighten the nut, then
M16 15 - 20 wrench tighten 1/6 of a turn.
M22 20 - 30
Thread (imperial) Torque Nm
1
/8 10 - 15
1
/4 15 - 20
3
/8 25 - 30
1
/2 35 - 40
It is recommended that a sealing product, such as Teflon

tape, Loctite, etc should be used on NTP threads.
If renewing the fitting, it is important that the pipe is cut

Metal Pipe Fitting Type MA square and deburred, if metal. Insert the tube through the
nut and ferrule until it bottoms. The nut should then be
In this type of connection, the pipe end has a conical flare done up finger tight and tightened with a spanner 1 - 11/2
and is secured to the fitting with a nut, a sleeve pressing turn depending on fitting size.
the pipe into close contact with the cone on the fitting to
form a good seal. The fitting can be secured to the valve,
etc, either by a taper male NPTF thread or by a straight
JIC thread. In the latter case the joint is sealed by a
washer and an ‘O’ ring. Spare pipes are supplied
complete with sleeves and nuts.
SERVICE MANUAL
Electrical System and Instrumentation Amended:310811
Contents
Electrical System and Instrumentation

Description . . . . . . . . . . . . . . Page 5.3 IOU 1 Inputs/Outputs . . . . Page 5.23
Precautions . . . . . . . . . . . . . . Page 5.3 IOU 2 Inputs/Outputs . . . . Page 5.24
Electric arc welding . . . . . . . . Page 5.3 Degrade Mode . . . . . . . . . Page 5.25
Alternator . . . . . . . . . . . . . . . Page 5.3 IOU 3 Inputs . . . . . . . . . . . Page 5.26
Alternator drive belt . . . . . . . . Page 5.3
Batteries . . . . . . . . . . . . . . . Page 5.3 - 4 Multiplex System (continued)
Safety precautions . . . . . . Page 5.3 IOU 3 Outputs . . . . . . . . . . . . Page 5.27
Batteries in service . . . . . . Page 5.4 IOU 4 Inputs . . . . . . . . . . . . . Page 5.28
High rate discharge testing Page 5.4 IOU 4 Outputs . . . . . . . . . . . . Page 5.29
Rapid battery check . . . . . Page 5.4 IOU 5 Inputs . . . . . . . . . . . . . Page 5.30
Starter . . . . . . . . . . . . . . . . . Page 5.4 IOU 5 Outputs . . . . . . . . . . . . Page 5.31
Description . . . . . . . . . . . . Page 5.4 IOU 6 Intputs . . . . . . . . . . . . Page 5.32
Test equipment . . . . . . . . . Page 5.4 IOU 6 Outputs . . . . . . . . . . . . Page 5.33
Preliminary checks . . . . . . Page 5.4
Wire Identification
Test 1 Battery test . . . . . . Page 5.4
Colour Coding . . . . . . . . . . . Page 5.34-50
Optima Battery care . . . . . Page 5.5-5.6
Care Points
Multiplex System . . . . . . . . . Page 5.7
Can Connector . . . . . . . . . . . Page 5.52
Description . . . . . . . . . . . . Page 5.8
Input / Outputs Connectors . . Page 5.52
System components . . . . . Page 5.9
Harness Connectors . . . . . . . Page 5.53
System configuration . . . . Page 5.9
Instrument Panel . . . . . . . . . . . Page 5.54
Communication lines . . . . Page 5.9
Driver’s Information Screen . . Page 5.54 - 57
Driver’s Display Screen . . Page 5.9
Front & Rear EDC . . . . . . . . . . Page 5.59 - 61
Medium & High priority warnings Page 5.10
Alternator AC172R . . . . . . . . . . Page 5.62 - 81
Vehicle information screen Page 5.10
Chassis Schematics Euro 5 (ZF) Page 5.83 - 108
On Board diagnostics . . . . Page 5.11 - 12
Chassis Schematics Euro 5 (Voith)Page 5.109 - 134
System operating modes . Page 5.14
Chassis Schematics Euro 5 (ZF)
Software overview . . . . . . Page 5.15
4 Battery Start . . . . . . . . . . . . . Page 5.136 - 160
Diagostics using PC . . . . . Page 5.16
Multibus flowchart . . . . . . . Page 5.17
System wake up . . . . . . . . Page 5.18
Camu & IOU connections . Page 5.19
CAMU Inputs / Outputs . . . Page 5.20
Multic IC Inputs . . . . . . . . Page 5.21
Multic IC Outputs . . . . . . . Page 5.22
Section 5
SERVICE MANUAL
Electrical System and Instrumentation Amended:
CAUTION
The vehicle master switch must be in the OFF position before attempting to remove any
components from the instrument panel, this includes the removal of warning light bulbs for
replacement. If these precautions are not observed, there is a high risk of causing an electrical
short which will damage the instrument panel beyond repair.
NOTE
If the engine control module is disconnected, the throttle potentiometer may need re-calibrating.
SERVICE MANUAL
Description Alternator
The vehicle is fitted with a Multiplex electrical Keep the alternator clean and ensure that the
system. Further details are given later in this ventilation slots or air spaces are clear and
unobstructed.
section. Routine maintenance and any fault finding
and correction should only be carried out by a skilled Alternator Drive Belt
automotive electrical engineer as it is highly
probable that permanent damage may be done by Check that the drive belt is in good condition at the
tampering with the equipment. correct tension. Under no circumstances allow the
belt to slip. (See Maintenance Section).
Precautions
Batteries
The following precautions are by no means fully
comprehensive and must be observed when working During the course of normal running, the battery is
on the electrical system and when driving: recharged by the vehicle charging system and
provided the vehicle does enough running time, will
1. Never connect a battery into the system have stored energy ready for the next start
without checking for current polarity and operation.
correct voltage.
2. Never disconnect any electrical lead without NOTE
first stopping the alternator and turning all A vehicle standing unused will not maintain
switches to the OFF position. a charged battery.
3. Always identify a lead to the correct terminal
before it is removed to ensure correct As a battery fault can have adverse effects on the
reconnection. operation of the various systems, particularly the
starting and charging system, some knowledge of
4. Never flash connections to check for current
battery testing is an essential part of fault diagnosis.
flow.
5. Always isolate the battery cables when using Safety Precautions
a battery charger.
The charging, handling and use of lead-acid
6. Always disconnect the battery before batteries is not dangerous providing appropriate
connecting test instruments (except care is taken.
voltmeter) or before replacing any unit or
wiring.
WARNING
Electric Arc Welding It is vital to ensure that no source of
ignition can exist close to batteries.
In the event of a vehicle requiring any form of
1. Do not smoke.
electrical welding to be carried out the following
precautions must be taken. 2. No naked flames.
1. Turn off the vehicle battery master switch. 3. Switch off current before making/breaking
electrical connections, especially during
2. Disconnect the main positive and negative charging.
leads at the batteries.
4. Avoid short circuits.
3. Remove the B-VE lead from the alternator or
the fast fuse if fitted.
4. Remove the NG28 cable from the alternator Main Fuse - Battery Carrier
(this cable can provide a negative route from
the rear junction terminal block) which in turn Situated on the battery carrier the main fuse is under
is connected to the chassis if fitted. a cover. The fuse should be checked for corrosion.
A coating of wax over the main fuse and terminals
5. Disconnect any electronic control units should be applied if corrosion is present. If the fuse
(E.C.U.) fitted; gearbox, engine and vehicle is changed the fuse and terminals should be re
ECU’s. waxed using Aerosol wax Dennis no. 652441.
SERVICE MANUAL
Batteries in Service resistance at the main connections, between posts

and cable lugs.
1. Clean and dry - the battery, particularly the
top must be kept clean and dry. Starter
2. State of charge - the battery must never be
left in a discharged state. A battery in a poor
state of charge i.e. less than 70% should be
removed and charged from an independent
source at the normal recharge rate.
Otherwise the plates may become sulphated
(hardened) making it difficult to accept a
charge, with the consequent early failure of
the battery.
3. Installation - the battery must be securely
clamped (not overtight) to prevent damage
from vibration, which may cause shedding of
active material from the plates, resulting in a
loss of capacity or short-circuit between the
plates.
Description
By operation of a solenoid the starter pinion is
Battery Lugs engaged with the flywheel ring gear before the
starter is energised, after which the pinion can be
The effect of corrosion is far more serious than is retained in mesh for as long as is necessary to start
generally realised. For example, excessive the engine. When the engine is firing and the pinion
corrosion of the battery lugs will lead to sluggish is being driven at high speed by the flywheel, the
operation of the starter. This is due to voltage drop armature is protected against over-speeding by the
at the battery terminals, when the higher starter freewheel action of a roller or plate clutch.
current is flowing.
If corrosion occurs the lugs should be cleaned and Test Equipment
both the lug and battery post smeared with
Basic test equipment required is a moving coil
petroleum jelly as an added precaution against
voltmeter scale 0 - 35V for nominal 24V systems.
corrosion. Never use force when removing lugs, if as
a result of corrosion a lug cannot be removed, soak
a cloth in hot water and apply it to the corroded lug.
Preliminary Checks
After freeing the lug, remove all traces of corrosion. Inspect all connections in the starter system. Ensure
that battery connections are clean and tight. If
High Rate Discharge Testing necessary, disconnect and remove all traces of
corrosion. Remake connections after smearing
This test is used for checking a batteries ability to
terminal posts/lugs with petroleum jelly.
supply a high current for short period of time. The
tester should not be used on batteries which are
suspected as being in a discharged condition. There
Test 1: Battery Test
are several high rate discharge testers on the Using a high rate discharge tester, check that the
market, and the manufacturers instructions for use battery is at least 70% charged. The full battery test
should be strictly followed. procedure is outlined in Section 1.
Rapid Battery Check NOTE

A method of quickly checking the condition of a A battery in poor condition will cause
battery fitted to a vehicle is to switch on the lights difficult starting.
and ignition, the attempt to operate the starter. If the
starter operates and the lights dim slightly, the
battery can be considered as serviceable.
Sever fading of lights may indicate that the battery is
in a poor state of charge, is no longer capable of
supplying a high current, or it may be there is high
SERVICE MANUAL
Battery Care - Optima Amended: 04.10.10
Battery Maintenance
CAUTION
The OPTIMA battery is truly maintenance free.
Safety Information:
When charged properly you will not have to worry
DO NOT ADD WATER TO THE about leaking, corrosion, or gassing. Periodically
OPTIMA BATTERY inspect your battery terminal connections to ensure
Always wear proper eye, face and they are clean, snug, and protected from the
elements.
hand protection when working with
batteries Open circuit voltage (OCV) and storage:
Never lean over battery while OCV: 34 / 34R / 34/78 / 34M / 75/25 / 78 / 35 / 25
boosting, testing, or charging >12.8 volts
Exercise caution when working with (for a fully charged battery)
metallic tools or conductors to
D34 / D34/78 / D27M / D31M / D27F / D75/25 / D35
prevent short circuits and arcing
/ D31T / D31A / D51 / D51R / D34M >13.0 volts
Keep terminals protected to prevent
(for a fully charged battery)
accidental shorting
Replace any battery that has signs of
damage to the terminals, case, or Battery Storage
cover Because of the high purity lead grid in the OPTIMA
battery, it has a self-discharge rate much lower than
Install battery in a ventilated area for
conventional flat-plate batteries. This means the
operation and during charging
OPTIMA can sit for longer periods retaining enough
Always use a voltage regulated charge to start your vehicle. Depending on storage
battery charger with limits set to the temperature, the OPTIMA can usually sit for 8 to 12
above ratings. months and start most vehicles.
When possible, store your battery in a cool, dry
Overcharging can cause the safety
location. Check the battery voltage every 6 months
valves to open and battery gasses to
and charge if it falls below 12.6 volts.
escape, resulting in premature
failure. These gasses are flammable! Remember, newer vehicles with on-board
electronics such as computers, LCD screens, game
Any battery that becomes very hot or
systems, GPS units, clocks, etc., require battery
makes a hissing sound while
power to retain system memory while the vehicle is
recharging should be disconnected
parked. If the vehicle is to be stored for long periods
immediately. you should use a maintenance charger to
compensate for this drain. This charger should be
voltage regulated between 13.2 - 13.8 volts, 1 amp
maximum. On older vehicles, without electronics,
disconnect the battery cables when the vehicle is not
being used for extended periods.
Boost Starting
NOTE
Boost starting Optima batteries that show a
lower voltage than 21.5v will lead to
irreversible damage and battery failure.
SERVICE MANUAL
Battery Care - Optima Amended:260312
OPTIMA Commercial YellowTop Charging Rapid Recharge: Maximum voltage 15.6 volts
Information (regulated), no current limit as long as battery
temperature remains below 125°F (51.7°C). Charge
YellowTop Type: D31A & D31T
until current drops below 1 amp.
These batteries are dual purpose. They are
Float Charge: 13.2 to 13.8 volts, 1 amp maximum
designed for engine start and deep-cycle
current, time indefinite (at lower voltage).
applications for use in vehicles with large accessory
loads. All limits must be strictly adhered to.
Recommended charging information: Failure to fully charge a battery can result in poor
performance and a reduction in capacity.
Alternator: 13.65 to 15.0 volts, no amperage limit.
Battery Charger: 13.8 to 15.0 volts, 10 amps
Battery Securing
maximum, 6-12 hours approximate. When securing the battery into the battery carrier,
the securing bar must be horizontal and flat to the
Cyclic Applications: 14.7 volts, no current limit as
upper face of the battery.
long as battery temperature remains below 125°F
(51.7°C). When current falls below 1 amp, finish with Position the lower nut at the correct level under the
3 amp constant current for 1 hour. securing bar before securing with the upper nut and
tighten. The securing bar should apply equal
pressure across the top of the battery.
OPTIMA Battery - Start Battery Option - OL1553-1

The Optima Battery is also used in the four battery start option used on the Enviro 400. This sytem allows for
a dedicated pair of batteries to be used just for the start function, leaving the remaining two available for other
vehicle systems.
STARTER
ALTERNATOR MOTOR
MEGA
FUSE
TO FEDC
(Switched Supply)
TO CAMU TO CAMU
MEGA MASTER MASTER
FUSE SWITCH SWITCH
No 1 No 2
AUXILIARY START
VEHICLE BATTERIES BATTERIES
SYSTEM LOADS
FUSES
PERMANENT
SUPPLY VIA
FUSES FUSES
) SCHEMATIC - OPTIMA FOUR START BATTERY SYSTEM
SERVICE MANUAL
Multiplex System Combination Instrument Cluster (MultIC)

provides the gateway to the driveline systems and
Description relays information and warnings to the driver.The
The electrical system, is a fully modular multiplex unit includes an LCD Screen Control Module.
system. The advantage of this type of electrical The MultIC, in addition to presenting driver
system is that it simplifies vehicle harnesses, information, provides the interface for data exchange
integrates most electrical/electronic systems, between the vehicle control system and the driveline
reduces fuse/relay use and offers increased control modules e.g. engine, transmission and ABS.
diagnostic capability - reducing test and repair time
in service. Configurable Membrane Switch Panel for body
control variants.
System Components
The vehicle control system does not provide
The Central Management Unit (CAMU) is complex driveline system control, this is achieved
responsible for vehicle behaviour and instructs the through the dedicated control module supplied with
other units how to function. each driveline component. However, there is limited
Input/Output Units (IOUs) are remotely located in interaction required for provision of safety interlocks,
key areas to control functions. driver information and system fault diagnostics.
Central Management Unit

Input/Output Units Input/Output Units
Input/Output Units
Rear EDC
Front EDC
Instrument Panel
SERVICE MANUAL
IOU 1 CAMU
IOU1 IOU6
IOU (#6) IOU6
IOU (#5) IOU6
IOU (#4)
CAN BLACK CAN GREY CAN

CANGREY
BLACK CAN
CAN BLACK
GREY CAN
CANBLACK
GREY CAN
CAN GREY
BLACK CAN
CANBLACK
GREY CAN
CAN GREY
BLACK CAN
CANBLACK
GREY CAN
CAN GREY
BLACK
MultiBus CAN 1
(I CAN)
MultiBus CAN 2
(I CAN)
CAN GREY
GREY CAN BLACK
IOU3(#3)
IOU
DASHBOARD
ABS
Key
GEARBOX Multibus CAN – Chassis supply
Aux devices e.g.
CAN IO Module,
Multibus CAN – Body fit
ENGINE
Battery Equalizer Driveline CAN – Chassis supply
(P CAN)
Note: Function dependant body IOU's

have alphabetical notation to avoid
confusion when IOU's are omitted
CAN GREY
GREY CAN BLACK
due to vehicle build variant.
Numerical reference in brackets.
IOU2
IOU3
Multiplex Closed Loop System Configuration - Double Deck - High Spec
Body IOU's C & D and optional

Body IOUE contained with Body EDC
Central Management Unit (CAMU) located on upper deck inside cabinet Chassis IOU2 and optional
Chassis IOU1 located on lower at top of staircase Body IOUF contained within
deck inside cabinet behind drivers rear EDC located inside rear
area 5 way seat box
MultIC and Body switch panel

located within dashboard
System Component Locations
SERVICE MANUAL
Electrical System and Instrumentation Amended:03.08.09
Communication Lines Bulb Test

The complete vehicle system utilises 3 lines of During Phase ignition - Bulb Test required, Engine
communication to transfer information and issue drive screen is shown as Default Display.
control commands :
MultiBus CAN1 (I-CAN) – interconnects the CAMU

master controller, the chassis/body IOU modules
and the body membrane switch panel.
MultiBus CAN2 (I-CAN) – interconnects the CAMU

master controller and the MultIC instrument cluster.
Powertrain CAN (P-CAN) – interconnects the MultIC

instrument cluster and the driveline control modules.
Driving Screen
Integral Chassis and Body System The diagram below shows the layout for the
The full vehicle integrated chassis and body system information to be displayed on the MultIC TFT
can be configured in a open or closed loop screen. This shows the normal driving screen and
communication topology. the locations of the fuel and Adblue Meters.
It begins always by the side of the CN2 until the end
of the branch and then, if it’s an opened network,
continues on branch1 on CN3. If it’s a looped
network the last one is the IOU connected to the
CN3 of the CMU.
IOU Connections
The Input connector for an IOU is always CN4 and
CN5 is the Output connector.
Drivers Display Screen

The driver's display screen relays information from Low Priority Warning
the vehicle systems to alert the driver / operator of Low priority symbols are to be shown along the top
faults or warnings with the vehicle. These may be of the screen with a transparent background to limit
displayed as warning LED's above the screen unit the look of severity and show that it is a normal
and coloured bitmaps arranged within the screen. function of the vehicle.
Welcome Screen
The drivers display screen powers up on application
of the Battery Master switch. The screen then
displays the "Alexander Dennis Enviro 400" as a
welcome screen.
SERVICE MANUAL
Medium and High Priority Warnings Vehicle Information Screen

Medium and High Priority warning are shown in the This screen is accessed by pressing the Screen
centre area of the screen and have a coloured Function Button (see fig below). It displays
background to highlight the driver’s attention to the information of Transmission Temperature, Retarder
problem; medium priority faults have a yellow/amber Temperature and Engine Oil Pressure. The vehicle
background and allow the driver to continue at their information system can only be entered if the system
discretion. is normal with no faults. AdBlue remains visible on
this screen as well but fuel (if displayed) is replaced
by oil temperature.
Press Button to Access

Medium Warning (Amber/Yellow)
Vehicle Information Screen
1 2 3
High Priority Warning (Red)
Chassis Functions
1. Transmission Oil Temperature (oC)
2. Oil Temperature
3. Retarder Oil Temperature (oC)
This screen remains for 20 seconds then the normal

driving screen returns.
Body Functions
SERVICE MANUAL
On Board Diagnostics Main Menu

The system incorporates on board diagnostics, this allows If the passcode typed in is correct the Main Menu
engineers to diagnose the majority of faults without need screen is displayed. In this screen Time & Date,
of PC (laptop) based diagnostics. The system condition Software, Running Data, Diagnostics or Battery
can be viewed through the screen display. Guard can be selected. The scroll bar can scroll
Once Vehicle Information is active, selections are made down to Battery Guard and scroll up to Exit using the
using the buttons on the panel below the corresponding Scroll Switch.
screen displayed, with the following functions:
Scroll Up, Scroll Down Select, Exit
The Battery Guard option is dependant on a

parameter, if this parameter is inactive the text string
“Battery Guard” will not be shown in this menu, and
Passcode it will be impossible to scroll further down than the
A pass code can be entered using the Select Switch “Diagnostics”.
and Scroll Switch while in ignition phase for 4
seconds. Use the Scroll up/down Switch to change
Time and Date
the highlighted digits and use the Select Switch to
confirm and go to the next digit. In the Time & Date screen the Time can be changed
between BST & GMT.
By pressing the Select Switch on Time, the hours will
be highlighted and arrows will appear to indicate the
values can be changed. By pressing the Select
Switch again the minutes will be highlighted and
arrows will appear to indicate the values can be
changed. By pressing the Select Switch again the
Time will be validated.
Once a digit is confirmed, going back and changing

the confirmed digit is not possible. If the wrong
password is entered, exit must be selected to return
to the password screen.
SERVICE MANUAL
Time and Date (continued) Powertrain Information

By pressing the Select Switch again the months will This menu allows the user to select one of five
be highlighted and arrows will appear to indicate the diagnostic screens.
values can be changed. By pressing the MMI Select
Switch again the days will be highlighted and arrows
will appear to indicate the values can be changed. Engine
By pressing the Select Switch again the Date will be
validated. Engine speed
By pressing the Select Switch on Time Format the Vehicle speed
current Time Format will be highlighted and an arrow Oil Pressure
will appear either under or above the current Time
Format to indicate either to scroll up or down to Coolant temperature
change the current Time Format. By pressing the Throttle position
Select Switch again the Time Format will be
validated. Red warning
Amber warning
Software Version Shutdown
Shows the currently installed software versions, the
Gearbox
scroll bar can scroll up to Exit using the Scroll
Switches. Sump temperature
Current gear
Driveline engaged
Check transmission
Retarder
Hydraulic temperature
Retarder active
Percentage torque %
ABS
ABS active
Running Data Wheel speed

LHF
RHF
LHR
RHR
SERVICE MANUAL
Module Status
1 - Module identification. It can be shown in three
different colors,
1. White in full operation mode
2. Amber for communication problems
3. Red when no communication is taking

place with the module in question.
2 - Connector and terminal number with the name of the

input/output in plain text.
Battery Guard
3 - The Status of the input/output. Module Status This display number of Activations available
1. A white empty circle when the input/output is from the CAMU and the ability to reset the cumulative total
off. of battery guard activations.
2. A green dot when on when fault can be

detected by the system.
3. Red exclamation point is displayed when the

input/output is faulty together with a 2 digits fault
counter.
Note:
The fault counters can be reset with the reset button. The
user can navigate from screen to screen using the +/-
uttons and the diagnostic menu can be returned to by
pressing the menu button.
Smart Coolant Activations
Module Status This display number of Activations available
from the CAMU and the ability to reset the cumulative total
of Smart Coolant activations.
SERVICE MANUAL
System Operating Modes System Operating Modes – Leaving Sleep Mode

Sleep mode
To reduce current consumption the Multiplex system There are 3 ways to leave Sleep Mode
goes to ‘sleep’ when system operation is not
required. In this mode all ECU’s in the system do not
operate. 1. Low level on a Wake-up input.
Wake-up mode
In each ECU, some features, when activated, can 2. Low level on the communication address
wake that ECU. When all the system is active, the lines (address lines normally held HIGH in
CAMU starts the addressing mode. In case of false Sleep Mode and Normal Mode).
wake-up, the system goes back to sleep mode.
Addressing mode 3. Activation of the battery switched supply.
All Multiplex units have a certain number of options
in terms of hardware and the hardware configuration
is stored permanently in the eeprom of each IOU. System Operating Modes – ‘Wake-Up’ Sequence
Also, the software inside each IOU is generic and not
specific to a particular vehicle application. The IOU
configuration is performed by the CAMU during the 1. CAMU wake-up via Battery Switch or
addressing phase, that compares the configuration Hazard Switch
of each IOU with the configuration dictated by the Battery or Hazard Switch pressed – CAMU
vehicle specific software loaded into the CAMU. If wakes up, vehicle specific software activated
there is a mismatch, it programs the IOU in – Address lines ‘grounded’ to wake rest of
accordance with the vehicle specific software. When system - CAMU initiates Addressing Mode –
the CMU has been triggered to wake up, the IOU’s System enters Normal Mode – Vehicle
must then be ‘addressed’. This process is a check to specific software assumes control of system.
ensure that each unit is responding and is in the
correct location in the system. 2. System wake-up external to CAMU e.g.
For an SLU, the CAMU sends specific messages to Drivers Access Switch
configure the inputs/outputs of these units. Access Switch pressed – IOU wakes up -
When all the Multiplex units are verified and/or Address lines ‘grounded’ to wake rest of
programmed, the system switches to normal mode. system - CAMU wakes up, vehicle specific
software activated - CAMU initiates
Normal mode Addressing Mode – System enters Normal
Normal mode has 2 phases – Mode – Vehicle specific software assumes
Normal Mode (battery switch OFF, system woken by control of system.
some other ‘wake-up’ feature) – the system is able to
read all inputs and also to drive certain equipment Note – For optional wake-up inputs such as Driver
e.g. hazards. Access Switch the software option must also
Normal Mode (battery switch ON) – the system is in be enabled via the correct parameter file
full operation. otherwise the system will wake up, will not
know how to function with respect to this
In this mode, the system works normally, with a signal and so will then re-enter Sleep Mode.
periodical information exchange between all the If the input is permanent, this becomes a
units and the CAMU. cyclic event.
SERVICE MANUAL
MultiBus CAN Communication Network
CAMU IOU 1 IOU 6 IOU 7

Battery switch input
Drivers access input
Hazard switch input
Software Overview
The files required by the Multiplex System are:
1. CAMU Application File - this is the operational
software implementing the relevant vehicle control
funtions according to the vehicle specifications.
2. CAMU Parameter File - This Customises the
Application for a particular build specification e.g.
add exit door.
3. MultIC Application File - Contains all the vehicle
control functions.
CAMU Application File
CAMU Parameter File
MULTIC Application File
Software Components
SERVICE MANUAL
Diagnostics Using PC
Configuration - This allows you to set what options
In addition to the on board diagnostics, a PC are fitted to the vehicle
diagnostic tool is available for rapid fault finding and
diagnosis. The diagnostic tool uses an industry Setting - This allows specific parameters in the
standard PC or laptop computer in conjunction with system to be adjusted, I.E. Battery guard voltage.
the to diagnose faults on the inputs and outputs
connected to the multiplex system. Network - This shows a graphical picture of the
system integrity, identifying if there are any
Typical diagnostic functions are as follows: communication problems on the system.
Autotest - activates all outputs connected to the
system and reports if any faults are present. Download - This function can be used to update the
control software that is stored in the CAMU. (See
IO Status - displays the current status of the inputs download procedure).
and outputs connected to each unit and will indicate
if they are ON, OFF, Open Circuit or Short Circuit. Equipment:
Master Mode - Allows individual outputs to be Vehicle Communication Interface DP037231
activated independently, bypassing any logic or Diagnostic Extension Cable DP037215
interlocks.
Multibus Diagnostic Adapter Cable DP037216
Read Faults/ Clear Faults - Allows the user to read Multibus Forced Download Adapter Cable DP037218
any intermittent faults that are stored inside the
CAMU whilst the vehicle has been running. SCU Download Adapter Cable DP037221
Fuse Battery unswitched feed

- + Battery unswitched feed
CAMU 1 -Line
CAMU
CAMU 2-Line
Battery switch input CAN2 -Line
Ground
Diagnostic Connector
MultIC Feed
Actia BasicXS
Diagnostic Interface
PC Based Diagnostics
SERVICE MANUAL
MultiBus FlowChart
Sleep Mode
(Battery Guard Reset)
If the Hazard Switch (Hardware Latch) or If Hazard switch is Open (Hardware Latch)
Master Switch (software latch) are closed the and Master Switch is open (software latch)
enter Wake up phase enter sleep mode.
NOTE: Ignition switch options the ignition switch

can be momentary push switch (wired to Elog1)
or Latching key switch (wired to efreq1).
Momentary Switch: When the master switch is

closed and the ignition software latch is Off,
Wake-Up
pressing the ignition push button will set the
software latch flag to ON. When the flag is
set to on pressing the ignition push button or
the master push button will turn the ignition
flag OFF. if either the Master Switch is open (Software
If Master Switch is Closed (Software latch)
latch) or the battery guard is active and
Latching Switch: If the system is powered enter master phase
ignition has been off for over 5 seconds enter
up with the ignition key in the ON position the wakeup phase
ignition key must be keyed OFF then ON to set
the ignition flag. When the Master switch is closed,
turning the ignition key to the ON position will set
the Ignition Flag to ON, turning the Ignition key to
the Off position will set the ignition flag to OFF.
If the ignition key is in the ON position and the Master
master push button is pressed the ignition flag
is set to OFF.
if ignition switch is closed (software latch for mometry if battery Guard is if battery master
switch (Elog1) or Hardware latch for latching Switch active enters master switch is pressed
(efreq1 on V2, multiplexed on V3)) and battery guard phase. enters master
is not active enter igntion phase
if ignition switch is open

(software latch for mometry
Ignition switch (Elog1) or Hardware
latch for latching Switch
(efreq1 on V2, multiplexed
on V3) ) the vehicle enters
master phase.
If starter switch is open and

engine is not running enter
Ignition Phase If Starter Switch is closed enter
starter phase
If the engine is no longer

If either High oil pressure has been detect for considered to be running
the vehicle enters ignition
Starter 10 sec
OR Engine Speed has been detected above phase.
300rpm for 4 sec
OR Low oil is detected and engine speed
has been detected above 300rpm for 1sec
If either High oil pressure has been detect for 10 sec
enter engine running.
OR Engine Speed has been detected above 300rpm
for 4 sec
OR Low oil is detected and engine speed has been
detected above 300rpm for 1sec enter engine
running. Engine Running
If J1939 failure is detected(see warnings), engine
running will be detected from the Alternator w-signal
input will replace the engine speed signal
Oil Pressure Falling = 49 RAW
Oil Pressure Rising = 61 RAW
If the vehicle speed is above 5kph the vehicle If the vehicle speed is below
enters vehicle moving phase moving (Note 5kph the vehicle enters
that on V2 the vehicle speed can be engine running phase
overriden when Setting confirm = NO and
Override parameter != 0)
Vehicle Moving
SERVICE MANUAL
What to do if the system fails to Wake up

Vehicle will not wake up from the master switch
Does system Wake up with YES Possible Master Switch Fault,

Hazard switch? (allow 20 sec Master Relay Fault. CN5
for wakeup) Connect Laptop, Diagnose
fault
NO
Disconnect then reconnect
CMU CN5 connector
YES Procedure Error occured during

Does system Wake up with
application download - see
Hazard switch? (allow 20 sec
application download guide
for wakeup)
NO
Remove CN2 and CN3
Connections from CAMU
Check if battery voltage is low.

Check power feeds to CMU
Does system Wake up with NO
(CN5.1 Perm feed).
Has vehicle previously been CN2 CN3
for wakeup) running with current CAMU? If
not download required.
YES
Power down system.
Reconnect CN2 to CAMU
Does system Wake up with NO

Fault on CAMU CN2 IOU Chain.
for wakeup)
YES
Fault on CMU CN3 IOU chain
Power down system.
Reconnect CN2 to CAMU
On Main Dash disconnect the CAN
cable which comes from the CAMU
Does system Wake up with NO Check all cables to SLU for short
Hazard switch? (allow 20 sec to ground or 24V.
for wakeup) Possible Panel fault.
YES
Power down system.
Reconnect the Dash CAN cable
On the Side Console disconnect the
cable which comes from the Main
Dash
Does system Wake up with NO Power down system.

Hazard switch? (allow 20 sec Remove CN3 of first IOU in Chain.
for wakeup)
YES Diconnect then reconnect
NO IOU CN5 connector
Check all cables to Side console
for short to ground or 24V
for wakeup)
Possible Panel fault
Power down system. for wakeup)
Connect CN3 of first IOU in chain NO
Remove CN2 of Next IOU in chain
Check all cables to IOU for short
to ground or 24V. Swap IOU with
another from system to determine
if faulty IOU.
SERVICE MANUAL
CN4 Inputs CN1
CN2
CN5
Outputs
CN3
CAMU & IOU Connections
Addressing Line 0
Addressing Line 0
CAN 2 L Ground
CAN 2 H
CAN 2 Ground CAN L
CAN 1 Ground CAN H
CAN 1 L
CAN 1 H
Addressing Line 1
Addressing Line 1
CAN 2 L
CAN 2 H Ground C
CAN 2 Ground CAN L
CAN 1 Ground C CAN H
CAN 1 L
CAN 1 H
CAMU CAN Connections IOU CAN Connections
SERVICE MANUAL
CMU / CAMU Inputs (Standard 1)Front

Logical Inputs
Label Connect. pin Input feature Other feature Function
Log. contact Wake-u p Option N°1 Option N°2
EREV0 CN4.8 Gnd Y Master Switch( better for master to control this -(safety issue)
EREV1 CN4.7 Gnd Hazards Switch
ELOG0 CN4.3 Gnd DDA Brake Failure Pressure Switch

ELOG1 CN4.2 Gnd RH Front PadWear Sensor
ELOG2 CN4.1 Diag K Line
ELOG3 CN4.14 Diag L Line
ELOG4 CN4.15 Gnd
ELOG5 CN4.16 ECU Ground
ELOG6 CN4.17 Gnd LH Front PadWear Sensor
ELOG7 CN4.18 Gnd RH Rear PadWear Sensor
ELOG8 CN4.19 Gnd LH Rear PadWear Sensor
ELOG9 CN4.20 Gnd
ELOG10 CN4.21 Gnd
ELOG11 CN4.22 Gnd
ELOG12 CN4.23 Gnd
ELOG13 CN4.24 Gnd
ELOG14 CN4.4 Gnd
EANA3 CN4.12 Gnd (*2)
Frequency / Logical Inputs

Frequency type Logical contact Option N°1 Option N°2
EFREQ0 CN4.6 Gnd (*3) Foot Brake Pressure - Switch 2
EFREQ1 CN4.5 Gnd (*3) ABS Fault
Analog / Logical Inputs Analog inputs must be referenced to the ECU ground : CN4.16
Bias voltage Log. contact Option N°1 Option N°2
EANA0 CN4.9 2,2K to 20V "+15V"
EANA1 CN4.10 2,2K to 20V Gnd (*3)
EANA2 CN4.11 2,2K to 20V Gnd (*3) Foot Brake Pressure - Switch 1
EANA4 CN4.13 2,2K to 20V Gnd (*3) Retarder Disable Switch
EANA5 CN4.25 2,2K to 20V Gnd (*3)
Outputs
Label Connect. pin Output feature Function
Power Power supply (*1) /
Interface options
OUT0 CN5.20 LS5A Battery Master Relay
OUT1 CN5.21 LS5A
OUT2 CN5.22 LS5A
OUT3 CN5.23 LS5A Handbrake
OUT4 CN5.24 HS7A UNSWITCHED SLU feed
OUT5 CN5.25 HS7A UNSWITCHED Horn
OUT6 CN5.13 HS1.5A (*4) SWITCHED pedal sensor 1
OUT8 CN5.11 HS1.5A (*4) SWITCHED pedal sensor 2
OUT9 CN5.10 HS1.5A SWITCHED Ignition Relay
OUT10 CN5.9 HS1.5A SWITCHED Chassis Lub Hub / Bus Stop Brake Solenoid(Hong Kong)
OUT11 CN5.8 HS1.5A SWITCHED Ferry Lift Solenoid
OUT12 CN5.7 HS1.5A SWITCHED Daylight Running LEDS
OUT13 CN5.2 HS1.5A SWITCHED Suspension Control Valve 1
OUT14 CN5.3 HS1.5A SWITCHED Suspension Control Valve 2 and 3
OUT15 CN5.16 HS1.5A SWITCHED External switch illumination /selector
OUT16 CN5.15 HS1.5A SWITCHED DDA Brake Solenoid
OUT17 CN5.4 HS1.5A SWITCHED blocking valve double deck use only
OUT18 CN5.5 HS1.5A SWITCHED Retarder Disable +ve
OUT19 CN5.6 HS1.5A SWITCHED Reverse Horn
OUT20 CN5.14 HS1.5A SWITCHED Handbrake NBS signal to transmission
OUT21 CN5.17 Galva. (*2) Speedo Output Optional Chassis
OUT22 CN5.19 Galva. (*2)
OUT23 CN5.18 Galva. (*2) Speedo Output Optional Body
Power supplies
(30) CN5.1 Supply from + Battery Direct (30)
(15) CN1.1 Supply from + Battery switched (15)
GND CN1.2 Ground
SERVICE MANUAL
MULTI IC
Wake up Inputs
Label Connect. pin Function
Wakeup 0 CN5:1 SLU Trigger Feed
Wakeup 1 CN5:2
Wakeup 2 CN5:3
Wakeup 3 CN5:4
Logical Inputs
IN9 CN3:1 Starter Switch
IN10 CN3:2 Ignition Switch
IN11 CN3:3 Horn
IN12 CN3:4 Door 1 Switch
IN13 CN3:5 Main Beam Flasher
IN14 CN3:6 Park brake switch
IN15 CN3:7 RH Indicator Switch
IN16 CN3:8 LH Indicator Switch
IN17 CN3:9 Windscreen Wiper Intermittent Switch
IN18 CN3:10 Wndscreen Wiper Slow Switch
IN19 CN3:11 Drivers Emergency Stop ECE36
IN20 CN5:12 Door 2 Switch
IN21 CN4:1 Windscreen Wiper Fast Switch
IN22 CN4:2 Washer Pump Push Switch
IN23 CN4:3 Main beam/Dipped Beam Switch
IN24 CN4:4 Kneel Switch
IN25 CN4:5 Full Kneel Switch
IN26 CN4:6 Raise Switch
IN27 CN4:7 Sidelight Switch
IN28 CN4:8 Headlight Switch
IN29 CN4:9 Spare 1
IN30 CN4:10 Rear Fog Switch/Bus Stop Brake (Hong Kong)
IN31 CN4:11 Spare Switch 2
IN32 CN4:12 Hybrid Drive Drivers Emergency Overide
IN5 CN5:5
IN6 CN5:6
IN7 CN5:7
IN8 CN5:8

EFREQ0 CN5:15
EFREQ1 CN5:16
Analog / Logical Inputs

EANA0 CN5:9
EANA2 CN5:10
EANA1 CN5:11 Spare 3
EANA2 CN5:12 Spare 4
EANA4 CN5:13
EANA5 CN5:14
SERVICE MANUAL
MULTI IC Outputs
Logical Outputs
OUT0 CN3:13 Switch Backlight Illumination
OUT1 CN3:14 Start switch illumination
OUT2 CN3:15 External Buzzer
OUT3 CN3:16 Hazard Sw illumination
Warning Lights
Label Diagram Key Function
WL1 2 Tacho Error
WL2 3 LH Indicator
WL3 4 Park Brake
WL4 5 Headlights
WL5 6 Low Air
WL6 7 Pre-Heater
WL7 8 Amber Warning
WL8 9 Main Beam
WL9 10 Red warning
WL10 11 Engine Fault
WL11 12 Front Fog
WL12 13 Rear Fog
WL13 14 ABS Warning
WL14 15 RH Indicator
WL15 16 Tacho Error
WL16 19 Low Fuel
WL17 20 High Engine Temperature
WL18 29 Low Air 1
WL19 30 Low Air 2
Buzzer
Buzzer 1 Internal Chassis Buzzer
Gauges
Gauge1 1 Speedometer
Gauge2 17 Tachometer
Gauge3 18
Gauge4 21
Gauge5 28 Air Pressure 1
Gauge6 31 Air Pressure 2
SERVICE MANUAL
IOU1 Inputs
Logical Inputs
Label Connect. Pin Input feature Function
Logical contact Wake-up
EREV0 CN4.16 Gnd Y
EREV1 CN4.17 Gnd Y
EREP CN4.18 ACTIA reserved

ELOG0 CN4.19 Gnd (*1) Wiper Park Signal
ELOG1 CN4.20 Gnd Hybrid Engine Test
ELOG2 CN4.21 Gnd
ELOG3 CN4.22 Gnd
ELOG4 CN4.23 Gnd
ELOG5 CN4.24 Gnd
ELOG6 CN4.25 Gnd
Analog / Logical Inputs Analog inputs must be referenced to the ECU ground : CN4.1, CN4.5, CN4.9, CN4.14, CN4.15
Bias Voltage Logical contact
EANA0 CN4.2 2.2K to Vref (5v) (*2) Gnd (*2) Ambient Air Temp Sensor
EANA1 CN4.3 2.2K to Vref (5v) (*2) Gnd (*2) Front Air Pressure Transducer
EANA2 CN4.4 2.2K to Vref (5v) (*3) Gnd (*3) RH Indicator Fault(Body builder)
EANA3 CN4.6 2.2K to Vref (5v ) (*3) Gnd (*3) LH Indicator Fault(body Builder)
EANA4 CN4.7 none +32V (*4) MAN Water in Fuel Sensor
EANA5 CN4.8 none +15V (*5) Brake Pedal potentiometer

Frequency type Logical contact
EFREQ0 CN4.11 Freq/PWM (*6) Gnd (*6) Front Light fault
EFREQ1 CN4.12 Freq/PWM (*7) +15V (*7) Front Kneel Sensor
EFREQ2 CN4.13 Freq/PWM (*8) Gnd Stanadyne Water In fuel Sensor
IOU1 Output
Outputs
Label Connector pin Output feature Function
Power interface Power supply (*2)
OUT0 CN5.24-25 HS9A SWITCHED Wiper Fast Speed

OUT1 CN5.7 HS3.2A SWITCHED RH Main Beam
OUT2 CN5.8 HS3.2A SWITCHED Washer Pump
OUT3 CN5.9 HS3.2A SWITCHED Webasto Relay Trigger Signal
OUT4 CN5.10 HS2A UNSWITCHED LH Side Repeater
OUT5 CN5.22-23 HS7A SWITCHED LH Main Beam
OUT6 CN5.11 HS2A UNSWITCHED RH Front Indicator
OUT7 CN5.12 HS2A UNSWITCHED RH Side Repeater
OUT8 CN5.13 HS2A UNSWITCHED LH Front Indicator
OUT9 CN5.3 HB (*9)(HS2A) SWITCHED LH Sidelight
OUT9 CN5.3 HB (*9)(LS2A)
OUT10 CN5.4 HB (*9)(HS2A) SWITCHED RH Sidelight
OUT11 CN5.14-15 HB (*1) (HS7A) SWITCHED Front Fog Lights
OUT11 CN5.14-15 HB (*1) (LS5A)
OUT12 CN5.16-17 HB (*1) (HS9A) SWITCHED Wiper Slow
OUT12 CN5.16-17 HB (*1) (LS5A)
OUT13 CN5.18-19 HB (*1) (HS7A) SWITCHED LH Dipped Beam
OUT13 CN5.18-19 HB (*1) (LS5A)
OUT14 CN5.20-21 HB (*1) (HS7A) SWITCHED RH Dipped Beam
OUT14 CN5.20-21 HB (*1) (LS5A)
OUT14A CN5.5 HB (*1) (LS5A)
Alim Capt CN4.10 HS50mA Internal 0-12V Suspension Front Sensor supply
Power supplies
(30) CN5.1-2 Supply from + Battery Direct (30)
GND CN1.2 Ground
SERVICE MANUAL
IOU2 Inputs
Logical Inputs
EREV0 CN4.16 Gnd Y Oil Master Warning
EREV1 CN4.17 Gnd N Engine Bay Fire Sensor

ELOG0 CN4.19 Gnd (*1) Emergency Stop Push Switch
ELOG1 CN4.20 Gnd Park Pressure Switch
ELOG2 CN4.21 Gnd Rear Start Push Switch
ELOG3 CN4.22 Gnd Rear Light Fault
ELOG4 CN4.23 Gnd Engine Hatch Switch
ELOG5 CN4.24 Gnd Low coolant sensor
ELOG6 CN4.25 Gnd Stanadyne WIF Euro4.5 only
Analog / Logical Inputs Analog inputs must be referenced to the ECU ground : CN4.1, CN4.5, CN4.9, CN4.14, CN4.15
EANA0 CN4.2 2.2K to Vref (5v) (*2) Gnd (*2) Rear Air Pressure Transducer
EANA1 CN4.3 2.2K to Vref (5v) (*2) Gnd (*2) Fuel Level Sender
EANA2 CN4.4 2.2K to Vref (5v) (*3) Gnd (*3) LH rear LED indicator input voltage
EANA3 CN4.6 2.2K to Vref (5v ) (*3) Gnd (*3) RH rear LED indicator input voltage
EANA4 CN4.7 none +32V (*4)
EANA5 CN4.8 none +15V (*5) Retarder Active (Telma retarder only)

EFREQ0 CN4.11 Freq/PWM (*6) Gnd (*6) Alternator Speed Signal 1
EFREQ1 CN4.12 Freq/PWM (*7) +15V (*7) Rear Kneel Level sensor
EFREQ2 CN4.13 Freq/PWM (*8) Gnd Alternator Speed Signal 2
IOU2 Outputs
Outputs
Label Connector pin Output feature Function
Power interface Power supply (*2)
OUT0 CN5.24-25 HS9A SWITCHED Alternator WL Terminal Feed 1

OUT1 CN5.7 HS3.2A SWITCHED Rear Fog Light
OUT2 CN5.8 HS3.2A SWITCHED Rear Suspension Valve 1
OUT3 CN5.9 HS3.2A SWITCHED LH Stop Lights
OUT4 CN5.10 HS2A UNSWITCHED RH Rear Indicator
OUT5 CN5.22-23 HS7A SWITCHED Reverse Light
OUT6 CN5.11 HS2A UNSWITCHED LH/ Tail Light & Number Plate Lts
OUT7 CN5.12 HS2A UNSWITCHED RH/ Tail Light & Number Plate Lts
OUT8 CN5.13 HS2A UNSWITCHED LH Rear Indicator
OUT9 CN5.3 HB (*9)(HS2A) SWITCHED RH Stop Lights
OUT10 CN5.4 HB (*9)(HS2A) SWITCHED Rear Suspension Valve 2 and 3
OUT11 CN5.14-15 HB (*1) (HS7A) SWITCHED Alternator WL Terminal Feed 2
OUT11 CN5.14-15 HB (*1) (LS5A)
OUT12 CN5.16-17 HB (*1) (HS9A) SWITCHED Rear Suspension Blocking Valve
OUT12 CN5.16-17 HB (*1) (LS5A)
OUT13 CN5.18-19 HB (*1) (HS7A) SWITCHED Accelerator interlock for MAN
OUT13 CN5.18-19 HB (*1) (LS5A)
OUT14 CN5.20-21 HB (*1) (HS7A) SWITCHED Starter Relay - (Push Pull)
OUT14 CN5.20-21 HB (*1) (LS5A)
Alim Capt CN4.10 HS50mA Internal 0-12V Rear Suspension Level sensor supply
Power supplies
GND CN1.2 Ground
SERVICE MANUAL
DEGRADED MODE DEFINITION
Status in
IOU Output Soft. Ref. Output function
degraded mode
OUT0 Wiper Fast Speed 0

OUT1 RH Main Beam 0
OUT2 Washer Pump 0
OUT3 Webasto Relay Trigger Signal 0
OUT4 LH Side Repeater 1
OUT5 LH Main Beam 0
OUT6 RH Front Indicator 1
OUT7 RH Side Repeater 1
IOU1
OUT8 LH Front Indicator 1
OUT9 LH Sidelight 1
OUT10 RH Sidelight 1
OUT11 Front Fog Lights 0
OUT12 Wiper Slow 1
OUT13 LH Dipped Beam 100%
OUT14 RH Dipped Beam 100%
Sensor Suspension Front Sensor supply 0.0V
OUT0 Alternator WL Terminal Feed 1 0

OUT1 Rear Fog Light 0
OUT2 Rear Suspension Valve 1 0
OUT3 LH Stop Lights 1
OUT4 RH Rear Indicator 1
OUT5 Reverse Light 0
OUT6 LH/ Tail Light & Number Plate Lts 1
OUT7 RH/ Tail Light & Number Plate Lts 1
IOU2
OUT8 LH Rear Indicator 1
OUT9 RH Stop Lights 1
OUT10 Rear Suspension Valve 2 and 3 0
OUT11 Alternator WL Terminal Feed 2 0
OUT12 Rear Suspension Blocking Valve 0
OUT13 Accelerator interlock for MAN 0
OUT14 Starter Relay - (Push Pull) 0
Sensor Rear Suspension Level sensor supply 0.0V
SERVICE MANUAL
IOU3 Inputs
Label Connection Input feature Function
EREV0 CN4.16 Gnd Y Drivers entrance door access/emergency open switch

EREV1 CN4.17 Gnd Y Assault alarm set switch

ELOG0 CN4.19 Gnd (*1) Security socket pin B - OK condition
ELOG1 CN4.20 Gnd Security socket pin A - alarm condition
ELOG2 CN4.21 Gnd Manual ramp fully stowed switch
ELOG3 CN4.22 Gnd RH Saloon stop request bell push
ELOG4 CN4.23 Gnd LH Saloon stop request bell push
ELOG5 CN4.24 Gnd Disabled Stop Request Switch LH & External
ELOG6 CN4.25 Gnd Emergency hammer microswitches
Analog inputs must be referenced to the ECU ground : CN4.1, CN4.5, CN4.9, CN4.14, CN4.15
EANA0 CN4.2 2.2K to Vref (5v) (*2) Gnd (*2)
EANA2 CN4.4 2.2K to Vref (5v) (*3) Gnd (*3) Maximum Resistance of Demister Valve Feedback
EANA3 CN4.6 2.2K to Vref (5v ) (*3) Gnd (*3) Positional resistance of Demister Water Valve
EANA4 CN4.7 none +32V (*4) Ramp fully retracted microswitch
EANA5 CN4.8 none +15V (*5) Ramp fully deployed microswitch

EFREQ0 CN4.11 Freq/PWM (*6) Gnd (*6) Entrance door open drivers foot switch - logical GND
EFREQ1 CN4.12 Freq/PWM (*7) +15V (*7)
EFREQ2 CN4.13 Freq/PWM (*8) Gnd Assault alarm reset switch - logical GND
Analog Reference Grounds

Label Connection Function
GND REF CN4.1 Demister Valve Feedback GND Ref

GND REF CN4.5
GND REF CN4.9
GND REF CN4.14
GND REF CN4.15
EREP CN4.18 Not Connected
SERVICE MANUAL
IOU3 Outputs
Label Connection Output feature Function Degrade
Power interface Power Supply
OUT0 CN5.24-25 HS9A SWITCHED Interior Lighting bank B (relay board) OFF
OUT1 CN5.7 HS3.2A SWITCHED Saloon bus stopping bell OFF
OUT2 CN5.8 HS3.2A SWITCHED Saloon bus stopping sign OFF
OUT3 CN5.9 HS3.2A SWITCHED Drivers stopping bell for lower saloon OFF
OUT4 CN5.10 HS2A UNSWITCHED Drivers disabled next stop request buzzer OFF
OUT5 CN5.22-23 HS7A SWITCHED Heating Circuit boost pump (Soft Start PWM) OFF
OUT6 CN5.11 HS2A UNSWITCHED Entrance door step lights ON
OUT7 CN5.12 HS2A UNSWITCHED Drivers cab/ticket machine light MAINTAIN
OUT8 CN5.13 HS2A UNSWITCHED Voice Alarm Set - HS OFF
OUT9 CN5.3 HB (*9)(HS2A) SWITCHED
Demister water valve motor OFF
Demister water valve motor OFF
OUT11 CN5.14-15 HB (*1) (HS7A) SWITCHED MAINTAIN
OUT11 CN5.14-15 HB (*1) (LS5A) Ramp motor retract
OUT12 CN5.16-17 HB (*1) (HS9A) SWITCHED
OFF
OUT12 CN5.16-17 HB (*1) (LS5A) Ramp motor extend
OUT13 CN5.18-19 HB (*1) (HS7A) SWITCHED MAINTAIN
OUT13 CN5.18-19 HB (*1) (LS5A) Demister Motor Supply 1 ( PWM Speed Cantrol + Soft Start)
MAINTAIN
OUT14 CN5.20-21 HB (*1) (LS5A) Demister Motor Supply 2 ( PWM Speed Cantrol + Soft Start)
Alim Capt CN4.10 HS50mA Internal 0-12V
Power supplies
GND CN1.2 Ground
SERVICE MANUAL
IOU4 Inputs
EREV0 CN4.16 Gnd Y

EREV1 CN4.17 Gnd Y

ELOG0 CN4.19 Gnd (*1) Entrance Door obstruction detected switch
ELOG1 CN4.20 Gnd Entrance door emergency open switch
ELOG2 CN4.21 Gnd Entrance door fully closed microswitch LS
ELOG3 CN4.22 Gnd Entrance door low air pressure switch
ELOG4 CN4.23 Gnd Entrance door fully open microswitch LS
ELOG5 CN4.24 Gnd Emergency window microswitch
ELOG6 CN4.25 Gnd Emergency door microswitch
EANA0 CN4.2 2.2K to Vref (5v) (*2) Gnd (*2) Door lock start disable - logical GND
EANA1 CN4.3 2.2K to Vref (5v) (*2) Gnd (*2) Daylight running lights switch
EANA2 CN4.4 2.2K to Vref (5v) (*3) Gnd (*3) Lower Saloon Temperature Sensor
EANA3 CN4.6 2.2K to Vref (5v ) (*3) Gnd (*3)
EANA4 CN4.7 none +32V (*4) Entrance door fully open microswitch HS
EANA5 CN4.8 none +15V (*5) Entrance door fully closed microswitch HS

EFREQ0 CN4.11 Freq/PWM (*6) Gnd (*6) Entrance door internal close switch - logical GND
EFREQ2 CN4.13 Freq/PWM (*8) Gnd DDA Brake Overide Switch (limp-home) - logical GND

GND REF CN4.1 Lower Saloon Temperature Sensor GND Ref

GND REF CN4.5
GND REF CN4.9
GND REF CN4.14
GND REF CN4.15
SERVICE MANUAL
IOU4 Outputs
OUT0 CN5.24-25 HS9A SWITCHED Heated auxiliary equipment - Seat/Screen OFF

OUT1 CN5.7 HS3.2A SWITCHED Saloon A Heater Solenoid OFF
OUT2 CN5.8 HS3.2A SWITCHED AC Compressor Clutch / Enable OFF
OUT3 CN5.9 HS3.2A SWITCHED Destination supply (relay board) OFF
OUT4 CN5.10 HS2A UNSWITCHED Destination Illumination (relay board) OFF
OUT5 CN5.22-23 HS7A SWITCHED Interior lighting bank D (door switched) ON
OUT6 CN5.11 HS2A UNSWITCHED Entrance Door Open solenoid OFF
OUT7 CN5.12 HS2A UNSWITCHED Entrance Door Close solenoid OFF
OUT8 CN5.13 HS2A UNSWITCHED Drivers cab fan OFF
MAINTAIN
OUT9 CN5.3 HB (*9)(LS2A) Interior lighting bank A (relay board)
Ramp warning OFF
Assault Alarm Set / Voice Alarm Reset - LS OFF
OUT11 CN5.14-15 HB (*1) (LS5A)
Ramp enable signal to controller - LS OFF
OUT12 CN5.16-17 HB (*1) (LS5A)
Saloon A Heater Blower Motor Output 1 (Soft Start PWM) OFF
OUT13 CN5.18-19 HB (*1) (LS5A)
Saloon A Heater Blower Motor Output 2 (Soft Start PWM) OFF
OUT14 CN5.20-21 HB (*1) (LS5A)
Power supplies
GND CN1.2 Ground
SERVICE MANUAL
IOU5 Inputs
EREV0 CN4.16 Gnd Y

EREV1 CN4.17 Gnd Y

ELOG0 CN4.19 Gnd (*1)
ELOG1 CN4.20 Gnd Upper saloon LH stop request bell push
ELOG2 CN4.21 Gnd Upper saloon RH stop request bell push
ELOG3 CN4.22 Gnd
ELOG4 CN4.23 Gnd
ELOG5 CN4.24 Gnd WC arm fully retracted microswitch
ELOG6 CN4.25 Gnd WC arm fully deployed microswitch
EANA2 CN4.4 2.2K to Vref (5v) (*3) Gnd (*3) Upper Saloon Temperature Sensor
EANA4 CN4.7 none +32V (*4) Exit door obstruction / sensitive edge (HS)
EANA5 CN4.8 none +15V (*5) Exit door slide / 98% closed sensor

EFREQ0 CN4.11 Freq/PWM (*6) Gnd (*6)
EFREQ2 CN4.13 Freq/PWM (*8) Gnd

GND REF CN4.1 Upper Saloon Temperature Sensor GND Ref

GND REF CN4.5
GND REF CN4.9
GND REF CN4.14
GND REF CN4.15
SERVICE MANUAL
IOU5 Outputs
OUT0 CN5.24-25 HS9A SWITCHED Engine bay lights OFF

OUT1 CN5.7 HS3.2A SWITCHED Saloon B Heater Solenoid OFF
OUT2 CN5.8 HS3.2A SWITCHED Heated mirrors OFF
OUT3 CN5.9 HS3.2A SWITCHED Interior Lighting Bank D heater supply MAINTAIN
OUT4 CN5.10 HS2A UNSWITCHED Emergency Door Lock OFF
OUT5 CN5.22-23 HS7A SWITCHED Screen Vent Fan (Soft Start PWM) OFF
OUT6 CN5.11 HS2A UNSWITCHED Wheelchair arm motion buzzer OFF
OUT7 CN5.12 HS2A UNSWITCHED Interior Lighting bank C (e.g. Double Deck single seat) ON
OUT8 CN5.13 HS2A UNSWITCHED Interior Lighting Cab heater supply MAINTAIN
Saloon light dim Bank B - if 24v/28v PWM OK ? OFF
OFF
OUT10 CN5.4 HB (*9)(LS2A) Drivers upper saloon stop request buzzer
OFF
OUT11 CN5.14-15 HB (*1) (LS5A) WC Arm Motor
OFF
OUT12 CN5.16-17 HB (*1) (LS5A) WC Arm Motor
Saloon B Heater Blower Motor Output 1 (Soft Start PWM) OFF
OUT13 CN5.18-19 HB (*1) (LS5A)
Saloon B Heater Blower Motor Output 2 (Soft Start PWM) OFF
OUT14 CN5.20-21 HB (*1) (LS5A)
Power supplies
GND CN1.2 Ground
SERVICE MANUAL
IOU6 Inputs
OPTION, Exit Door and A/C
EREV0 CN4.16 Gnd Y

EREV1 CN4.17 Gnd Y

ELOG0 CN4.19 Gnd (*1) Exit door obstruction / edge overide
ELOG1 CN4.20 Gnd Exit Door internal close switch
ELOG2 CN4.21 Gnd
ELOG3 CN4.22 Gnd Exit door emergency open switch
ELOG4 CN4.23 Gnd Exit door low air pressure sensor
ELOG5 CN4.24 Gnd Exit Door Open cushioning switch (NOT USED)
ELOG6 CN4.25 Gnd Exit door close cushioning microswitch (NOT USED)
EANA0 CN4.2 2.2K to Vref (5v) (*2) Gnd (*2) Exit door cushion adjust potentiometer
EANA4 CN4.7 none +32V (*4) Exit door slide open / 100% open sensor
EANA5 CN4.8 none +15V (*5) Exit door plug in / 100% closed sensor

EFREQ0 CN4.11 Freq/PWM (*6) Gnd (*6) Exit Door obstruction (LS) - logical GND
EFREQ1 CN4.12 Freq/PWM (*7) +15V (*7) Exit door plug out sensor
EFREQ2 CN4.13 Freq/PWM (*8) Gnd

GND REF CN4.1 Exit door cushion adjust potentiometer GND

GND REF CN4.5
GND REF CN4.9
GND REF CN4.14
GND REF CN4.15
SERVICE MANUAL
IOU6 Outputs
OPTION, Exit Door and A/C
OUT0 CN5.24-25 HS9A SWITCHED

OUT1 CN5.7 HS3.2A SWITCHED Exit door step lights ON
OUT2 CN5.8 HS3.2A SWITCHED AC Evaporator Blower Motors Slow Speed OFF
OUT3 CN5.9 HS3.2A SWITCHED AC Evaporator Blower Motors Fast Speed OFF
OUT4 CN5.10 HS2A UNSWITCHED 5kph output for door interlock valve (Ventura) OFF
OUT5 CN5.22-23 HS7A SWITCHED
OUT6 CN5.11 HS2A UNSWITCHED AC Condenser Fans OFF
OUT7 CN5.12 HS2A UNSWITCHED Extractor Motors 1 and 2 OFF
OUT8 CN5.13 HS2A UNSWITCHED Extractor Motors 3 and 4 OFF
OFF
OUT9 CN5.3 HB (*9)(LS2A) Exit door warning buzzer
OFF
OUT10 CN5.4 HB (*9)(LS2A) Exit Door Cushioning solenoid
OFF
OUT11 CN5.14-15 HB (*1) (LS5A) Exit door plug open sol OR open sol +ve (Push-Pull)
OFF
OUT12 CN5.16-17 HB (*1) (LS5A) Exit door plug close sol OR open sol -ve (Push-Pull)
OUT13 CN5.18-19 HB (*1) (HS7A) SWITCHED OFF
OUT13 CN5.18-19 HB (*1) (LS5A) Exit door slide open sol OR close sol +ve (Push-Pull)
OFF
OUT14 CN5.20-21 HB (*1) (LS5A) Exit door slide close sol OR close sol -ve (Push-Pull)
Power supplies
GND CN1.2 Ground
SERVICE MANUAL
Wire Identification - Colour Coding

TAN - Permanent battery supplies. Connections made either directly to the battery positive
terminal or via a fuse and/or connector to the battery positive terminal.
RED - Master battery supplies. Connections made either directly after the main contactor
switched terminal or via a fuse and/or connector to the main connector switched
terminal.
WHITE - Ignition supplies. Connections made either directly to the ignition relay or via a fuse
and/or connector to the ignition relay.
YELLOW - General loads. Connections made to lighting units, motors, actuators etc.
BLUE - Switches and sensors. Inputs from switches or sensors to either the multiplex system or
relays etc.
LIGHT GREEN - Data / communication. Connections carrying data i.e. CAN / SAE J1939.
SLATE or BLACK - Ground. Connection made directly to chassis ground or connection made via
connectors to chassis ground.
SERVICE MANUAL

WIRE No SYSTEM FUNCTION SUB-FUNCTION COLOUR GUIDE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45 lighting exterior
46 lighting exterior indicator current monitor RHS right hand BLUE
47 lighting exterior indicator current monitor LHS left hand BLUE
48 lighting exterior indicator current monitor supply front indicators RED
49 lighting exterior indicator current monitor supply rear indictors RED
50 lighting exterior side light left hand YELLOW
51 lighting exterior side light right hand YELLOW
52 lighting exterior tail light left hand YELLOW
53 lighting exterior tail light right hand YELLOW
54 lighting exterior headlight main beam left hand YELLOW
55 lighting exterior headlight main beam right hand YELLOW
56 lighting exterior headlight dip beam left hand YELLOW
57 lighting exterior headlight dip beam right hand YELLOW
58 lighting exterior indicator current monitor LHR left hand BLUE
59 lighting exterior indicator current monitor RHR right hand BLUE
60 lighting exterior indicator indicator front left hand YELLOW
61 lighting exterior indicator indicator front right hand YELLOW
62 lighting exterior indicator indicator side repeater left hand YELLOW
63 lighting exterior indicator indicator side repeater right hand YELLOW
64 lighting exterior indicator indicator rear left hand YELLOW
65 lighting exterior indicator indicator rear right hand YELLOW
66 lighting exterior indicator
67 lighting exterior indicator indicator w/l YELLOW
68 lighting exterior indicator indicator side repeater additional left hand YELLOW
69 lighting exterior indicator indicator side repeater additional right hand YELLOW
70 lighting exterior foglight front YELLOW
71 lighting exterior foglight rear YELLOW
72 lighting exterior foglight front w/l YELLOW
73 lighting exterior foglight rear w/l YELLOW
74 lighting exterior indicator rear high level left hand YELLOW
75 lighting exterior indicator rear high level right hand YELLOW
76 lighting exterior stoplight left hand YELLOW
77 lighting exterior stoplight right hand YELLOW
78 lighting exterior stoplight high level left hand YELLOW
79 lighting exterior stoplight high level right hand YELLOW
80 wipers power supply RED
81 wipers auxiliary supply RED
82 wipers input slow YELLOW
83 wipers input fast YELLOW
84 wipers output slow YELLOW
85 wipers output fast YELLOW
86 wipers park YELLOW
87 wipers intermittent YELLOW
88 wipers washer pump positive YELLOW
89 wipers washer level switch BLUE
90 Demister blower motor YELLOW
91 Demister water valve motor (4) YELLOW
92 Demister water valve motor (6) YELLOW
93 Demister water valve position sensor BLUE
94 Demister water valve input signal heater control panel BLUE
95 Demister motor speed signal heater control panel BLUE
96 Demister air direction flap motor (4) YELLOW
97 Demister air direction flap motor (6) YELLOW
98 Demister air direction flap sensor YELLOW
99 Demister air direction flap input signal heater control panel YELLOW
SERVICE MANUAL

100 Demister heater control panel heater control panel YELLOW
101 Demister heater control panel clock heater control panel YELLOW
102 Miscellaneous DDA brake (output) YELLOW
103 Miscellaneous Vehicle speed > 5 kph (input) YELLOW
104 Miscellaneous Wheelchair access door lamp (output)
105 Miscellaneous reverse horn YELLOW
106 lighting interior
107 lighting interior YELLOW
108 lighting interior Upper RH interior lights YELLOW
109 lighting interior Upper LH interior lights YELLOW
110 lighting interior saloon main left hand YELLOW
111 lighting interior saloon main right hand YELLOW
112 lighting interior engine bay YELLOW
113 lighting interior
114 lighting interior cab YELLOW
115 lighting interior entrance YELLOW
116 lighting interior destination lighting YELLOW
117 lighting interior entrance step YELLOW
118 lighting interior reading front YELLOW
119 lighting interior reading rear YELLOW
120 lighting interior continental door step YELLOW
121 lighting interior map YELLOW
122 lighting interior locker YELLOW
125 lighting interior entrance /cab heater supply YELLOW
126 lighting interior saloon night (dimmed) YELLOW
127 lighting interior coolant level illumination YELLOW
128 lighting interior servery light YELLOW
129 lighting interior gangway lights YELLOW
130 passenger stop bell YELLOW
131 passenger stop bell push toilet BLUE
132 passenger stop bell push BLUE
133 passenger stop hostess call push BLUE
134 passenger stop Upper Bell YELLOW
135 passenger stop Upper Bell push BLUE
136 passenger stop Upper Bus stop sign YELLOW
137 passenger stop Rear Bell YELLOW
138 passenger stop bus stopping sign YELLOW
139 passenger stop microswitch YELLOW
140 entrance door air power supply YELLOW
141 entrance door air pressure monitoring YELLOW
142 entrance door entrapment YELLOW
143 entrance door drivers foot sw BLUE
144 entrance door drivers door open BLUE
145 entrance door drivers door close BLUE
146 entrance door door opened BLUE
147 entrance door door closed BLUE
148 entrance door door open warning BLUE
149 entrance door door not request BLUE
150 entrance door door request or door open BLUE
151 entrance door door not request emergency BLUE
152 entrance door door open emergency BLUE
153 entrance door door emergency close BLUE
154 entrance door door open solenoid YELLOW
155 entrance door door closed solenoid YELLOW
156 entrance door door close cushion sw BLUE
157 entrance door door cushion solenoid YELLOW
158 entrance door emerg door sw warning BLUE
159 entrance door
160 audio/visual
161 audio/visual amplifier / pre-amplifier +24v YELLOW
162 audio/visual CD player +24v YELLOW
163 audio/visual Video player +24v YELLOW
164 audio/visual speaker drivers LH YELLOW
165 audio/visual speaker drivers RH YELLOW
166 audio/visual speaker saloon LH YELLOW
167 audio/visual speaker saloon RH YELLOW
168 audio/visual monitor front +ve YELLOW
169 audio/visual monitor centre rack +ve YELLOW
170 audio/visual Video play signal YELLOW
171 audio/visual monitor centre toilet +ve YELLOW
172 audio/visual monitor stowed BLUE
173 audio/visual passenger information RED
174 audio/visual power amplifier +24v YELLOW
175 audio/visual 2 Way radio supply RED
176 audio/visual 2 Way radio panic signal BLUE
177 audio/visual
178 audio/visual
Heating Ventilation and Air
179 Conditioning (HVAC) saloon water valve YELLOW
180 Conditioning (HVAC) saloon sensor 1 BLUE
183 Conditioning (HVAC) demister water valve demand BLUE
184 Conditioning (HVAC) demister air flap demand BLUE
185 Conditioning (HVAC) demister air flap feedback BLUE
186 Conditioning (HVAC) demister water valve feedback BLUE
187 Conditioning (HVAC) water valve position feedback BLUE
188 Conditioning (HVAC) Preheater Diagnostic GREEN
SERVICE MANUAL

189 Conditioning (HVAC) Preheater pump supply Heater Supply (2) TAN
190 Conditioning (HVAC) saloon temperature sensor BLUE
191 Conditioning (HVAC) saloon sensor supply RED
192 Conditioning (HVAC) fresh air flap control motor (4) left hand YELLOW
194 Conditioning (HVAC) fresh air flap control motor (4) right hand YELLOW
196 Conditioning (HVAC) fresh air flap sensor left hand BLUE
197 Conditioning (HVAC) fresh air flap sensor right hand BLUE
198 Conditioning (HVAC) saloon temperature set point heater control panel BLUE
199 Conditioning (HVAC) coolant temperature sensor BLUE
200 Conditioning (HVAC) rack blower No 1 front YELLOW
201 Conditioning (HVAC) rack blower No 2 centre YELLOW
202 Conditioning (HVAC) rack blower No 3 rear YELLOW
203 Conditioning (HVAC) saloon water valve motor (4) YELLOW
204 Conditioning (HVAC) saloon water valve motor (6) YELLOW
205 Conditioning (HVAC) saloon water valve position sensor BLUE
206 Conditioning (HVAC) rack blower on/off signal heater control panel BLUE
207 Conditioning (HVAC) air condition on signal heater control panel BLUE
208 Conditioning (HVAC) air conditioning refrigerant low pressure BLUE
209 Conditioning (HVAC) air conditioning refrigerant high pressure BLUE
210 Conditioning (HVAC) combustion heater run signal heater control panel BLUE
211 Conditioning (HVAC) combustion heater on/off w/l BLUE
212 Conditioning (HVAC) compressor clutch No 1 YELLOW
213 Conditioning (HVAC) compressor clutch No 2 YELLOW
214 Conditioning (HVAC) condenser fan No1 YELLOW
218 Conditioning (HVAC) extractor YELLOW
219 Conditioning (HVAC) external air temperature sensor BLUE
220 Conditioning (HVAC) anti-ice stat BLUE
221 Conditioning (HVAC) combustion heater supply TAN
222 Conditioning (HVAC) refrigerant valve pod air conditioning YELLOW
223 Conditioning (HVAC) water pump YELLOW
Heating Ventilation and Air saloon blower No 1
224 Conditioning (HVAC) saloon blower LH slow YELLOW
225 Conditioning (HVAC) saloon blower LH fast YELLOW
226 Conditioning (HVAC) saloon blower RH slow YELLOW
227 Conditioning (HVAC) saloon blower RH fast YELLOW
228 Conditioning (HVAC) drivers fan YELLOW
229 Conditioning (HVAC) couriers fan YELLOW
230 marker lights front left hand YELLOW
231 marker lights front right hand YELLOW
232 marker lights rear left hand YELLOW
233 marker lights rear right hand YELLOW
234 marker lights side left hand YELLOW
235 marker lights side right hand YELLOW
236 marker lights side high level left hand YELLOW
237 marker lights side high level right hand YELLOW
238 marker lights number plate number plate YELLOW
239 marker lights YELLOW
240 central locking central locking YELLOW
241 clock clock YELLOW
242 clock
243 clock
244 clock
245 clock
246 clock
SERVICE MANUAL

247 clock
248 clock
249 clock
250 mirror heated left hand YELLOW
251 mirror heated right hand YELLOW
252 mirror
253 mirror
254 mirror
255 mirror
256 mirror
257 mirror
258 mirror
259 mirror
260 mirror adjustable left hand YELLOW
264 mirror adjustable right hand YELLOW
268 mirror adjustable supply YELLOW
269 mirror adjustable s/t supply YELLOW
270 Window lower YELLOW
271 Window raise YELLOW
272 Window heated side window YELLOW
273 Window heated windscreen YELLOW
274 Window heated windscreen boost YELLOW
275 Window heated windscreen LH YELLOW
276 Window heated windscreen RH YELLOW
277 Window heated windscreen RH no 2 YELLOW
278 Window
279 Window
280 toilet toilet enable BLUE
281 toilet servery enable BLUE
282 toilet toilet door locked BLUE
283 toilet waste water level BLUE
284 toilet clean water level BLUE
285 toilet toilet engaged BLUE
286 toilet toilet permanent supply TAN
287 toilet
288 toilet
289 toilet
290 warning horn YELLOW
291 warning reverse horn YELLOW
292 warning drivers assault alarm YELLOW
293 warning drivers assault alarm return to cmu BLUE
294 warning assault reset sw BLUE
295 warning
296 warning Door interlock control 5Kph speed signal YELLOW
297 warning
298 warning Emergency Hammer BLUE
299 warning lift-up roof YELLOW
300 warning signs emergency door open BLUE
301 warning signs continental door open BLUE
302 warning signs fasten seat belts YELLOW
303 warning signs Lift access door closed (input) BLUE
304 warning signs Lift locker door closed (input) BLUE
305 warning signs Wheelchair lift warning lamp YELLOW
306 warning signs Rear window open
307 warning signs engine bay door open
308 warning signs
309 warning signs
310 12 volt supply mobile phone driver YELLOW
311 12 volt supply mobile phone courier YELLOW
312 12 volt supply mobile phone YELLOW
313 12 volt supply
314 12 volt supply
315 12 volt supply
316 12 volt supply
317 12 volt supply
318 12 volt supply
319 12 volt supply
320 emergency signal BLUE
321 emergency saloon lighting LH YELLOW
322 emergency saloon lighting RH YELLOW
323 emergency DDA brake overrode (input) BLUE
324 emergency
325 emergency
326 emergency
327 emergency
328 emergency
329 emergency
330 camera systems signal reverse BLUE
331 camera systems signal entrance door NOT fully closed BLUE
332 camera systems signal exit door NOT fully closed BLUE
333 camera systems CCTV Power Supply Ignition supply & Permanent RED & TAN
334 camera systems
335 camera systems
336 camera systems
337 camera systems
338 camera systems
339 camera systems
340 camera systems
341 camera systems
342 camera systems
343 camera systems
344 camera systems
345 camera systems
SERVICE MANUAL

346 camera systems
347 camera systems
348 camera systems
349 camera systems
350 ticket equipment ticket machine power supply RED
351 ticket equipment validator RED
352 ticket equipment coin Vault RED
353 ticket equipment
360 wheelchair ramp ramp driver extend YELLOW
361 wheelchair ramp ramp drive retract YELLOW
362 wheelchair ramp ramp extend YELLOW
363 wheelchair ramp ramp retract YELLOW
364 wheelchair ramp ramp request - disable bell -push input BLUE
365 wheelchair ramp ramp magnet hold YELLOW
366 wheelchair ramp ramp magnet release YELLOW
367 wheelchair ramp ramp request - disable buzzer output YELLOW
368 wheelchair ramp ramp supply RED/WHITE
369 wheelchair ramp ramp buzzer YELLOW
370 wheelchair ramp Wheelchair lift enable (input) BLUE
371 wheelchair ramp Lift fully stowed (input) BLUE
372 wheelchair ramp Wheelchair NOT fully stowed (input) BLUE
373 wheelchair ramp Wheelchair enable (output) YELLOW
374 wheelchair ramp Ramp overide BLUE
375 wheelchair ramp Motor (G) YELLOW
376 wheelchair ramp Motor (P) YELLOW
377 wheelchair ramp
378 wheelchair ramp
379 wheelchair ramp
380 exit door air power supply YELLOW
381 exit door air pressure monitoring BLUE
382 exit door entrapment internal BLUE
383 exit door entrapment external BLUE
384 exit door door open YELLOW
385 exit door door close YELLOW
386 exit door door opened BLUE
387 exit door door closed BLUE
388 exit door door open warning YELLOW
389 exit door door not request BLUE
390 exit door door request or door open BLUE
391 exit door door not request emergency BLUE
392 exit door door open emergency BLUE
393 exit door cushion close sw BLUE
394 exit door door step light YELLOW
395 exit door Sensitive edge supply YELLOW
396 exit door Sensitive edge signal BLUE
397 exit door cushion sol. YELLOW
398 exit door emergency switch warning BLUE
399 exit door
destination ECU power supply
400 front Ignition supply & Permanent WHITE & BROWN
401 side WHITE
402 rear WHITE
403 destination Hanover comms + GREEN
404 destination Hanover comms - GREEN
405 destination
406 destination
407 destination
408 destination
409 destination
410
411
412
413
414
415 Fuel Monitoring Supply and Ground Igniton and Negative supply White and Slate
416 Fuel Monitoring identic supply RED
417 Fuel Monitoring identic sensor signal BLUE
418
419
420 Roof Hatch Front Hatch supply Permanent,Master & Return BROWN, RED & SLATE
421 Roof Hatch Rear Hatch supply Permanent,Master & Return BROWN, RED & SLATE
422 Roof Hatch Front Hatch front lift Master sw supply YELLOW
423 Roof Hatch Front Hatch rear lift Master sw supply YELLOW
424 Roof Hatch Rear Hatch front lift Master sw supply YELLOW
425 Roof Hatch Rear Hatch rear lift Master sw supply YELLOW
426 Roof Hatch Roof hatch not closed Warning BLUE
427 Roof Hatch Roof hatch emergency release Warning BLUE
428
429
430 Wheelchair arm restraint Motor YELLOW
431 Wheelchair arm restraint Motor YELLOW
432 Wheelchair arm restraint Buzzer YELLOW
433 Wheelchair arm restraint Fully in signal BLUE
434 Wheelchair arm restraint Fully out signal BLUE
435
436
437
438
439
440
441
SERVICE MANUAL

442
443
444
445
446
447
448
449
450 Security plug Start BLUE
451 Security plug Alarm activation BLUE
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470 Spare Front edc to drivers locker Yellow
471 Spare Front edc to drivers locker Yellow
472 Spare Front edc to drivers locker White
473 Spare Front edc to drivers locker Red
474 Spare Front edc to drivers locker Blue
475 Spare
476 Spare
477 Spare
478 Spare
479 Spare
480 Spare Rear edc to exit door Yellow
481 Spare Rear edc to exit door Yellow
482 Spare Rear edc to exit door Blue
483 Spare Drivers locker to entrance door Yellow
484 Spare Drivers locker to entrance door Blue
485 Spare Drivers locker to entrance door Yellow
486 Spare
487 Spare
488 Spare
489 Spare
490 Spare
491 Spare
492 Spare Front edc(15 way )to b/builder plug 1mm sq wire Tan
493 Spare Front edc(15 way )to b/builder plug 2mm sq wire Red
494 Spare Front edc(15 way )to b/builder plug 2mm sq wire White
495 Spare Front edc to b/builder plug 1mm sq wire Yellow
496 Spare Front edc to b/builder plug 2mm sq wire Red / Tan
497 Spare Front edc to b/builder plug 2mm sq wire red
498 Spare front EDC to rear EDC 1mm sq wire white/yellow/blue
499 Spare front EDC to rear EDC 2mm sq wire white/yellow/blue
500 lighting exterior side lights input signal from switch blue
501 lighting exterior headlights input signal from switch blue
502 lighting exterior headlights dip beam input from switch blue
503 lighting exterior headlights main beam input from switch blue
504 lighting exterior headlights flash / input from switch blue
505 lighting exterior yellow
506 lighting exterior column switch common ground input slate
508 lighting exterior INDICATOR hazard input signal from switch blue
509 lighting exterior INDICATOR INDICATOR l/h input from switch blue
510 lighting exterior INDICATOR INDICATOR r/h input from switch blue
520 wipers intermittent input signal from switch blue
521 wipers park park switch signal blue
522 wipers washers input signal from switch blue
523 wipers washer low level warning output to light yellow
524 wipers
525 wipers
526 wipers
527 wipers
528 wipers
529 wipers
530 heating / cab and saloon external temperature sensor supply signal blue
531 heating / cab and saloon external temperature sensor return signal blue
532 heating / cab and saloon
537 heating / cab and saloon boost pump/combustion heater diagnostic green
SERVICE MANUAL

542 heating / cab and saloon on/off switch tan
543 heating / cab and saloon external activation circulation pump switch tan
544 heating / cab and saloon economy mode switch tan
545 heating / cab and saloon operation indicator w/lt yellow
546 heating / cab and saloon flame w/lt yellow
550 central locking
551 central locking
552 central locking
553 central locking
554 central locking
555 central locking
556 central locking
557 central locking
558 central locking
559 central locking
560 clock
561 clock
562 clock
563 clock
564 clock
565 clock
566 clock
567 clock
568 clock
569 clock
570 electric windows
590 warnings water in fuel supply white
591 warnings water in fuel output yellow
592 warnings
593 warnings
594 warnings
595 warnings horn input from switch blue
596 warnings horn horn unit yellow
597 warnings
598 warnings
599 warnings
600 warnings
601 warnings
602 warnings
603 warnings
604 warnings
605 warnings
606 warnings
607 warnings
608 warnings
609 warnings
610 12 volt supply
611 12 volt supply
612 12 volt supply
613 12 volt supply
614 12 volt supply
615 12 volt supply
616 12 volt supply
617 12 volt supply
618 12 volt supply
619 12 volt supply
620 emergency
621 emergency
622 emergency
623 emergency switch EEC 36 cab input to CMU blue
624 emergency switch EEC 36 battery carrier input to CMU blue
625 emergency
626 emergency
627 emergency
628 emergency
629 emergency
630 emergency
631 emergency
632 emergency
633 emergency
634 emergency
635 emergency
636 emergency
637 emergency
638 emergency
639 emergency
SERVICE MANUAL

640 brake interlocks dda brake solenoid valve yellow
641 brake interlocks dda brake pressure switch blue
642 brake interlocks Bus Stop brake solenoid valve yellow
643 brake interlocks Bus Stop brake drivers switch blue
644 brake interlocks
659 brake interlocks Queue Brake solenoid supply yellow
660 engine ecu / vehicle interface positive PIN1 neg = PIN3 tan/slate
661 engine ecu / vehicle interface fuel heater return signal blue
662 engine ecu / vehicle interface gridheater return signal blue/Slate
663 engine ecu / vehicle interface fan clutch driver yellow
664 engine ecu / vehicle interface positive PIN7 neg = PIN9 tan
665 engine ecu / vehicle interface w/l's & diagnstc sw pos supply yellow
666 engine ecu / vehicle interface fan clutch return signal blue/Slate
667 engine ecu / vehicle interface exhaust brake driver yellow
668 engine ecu / vehicle interface positive PIN12 neg = PIN14 tan/slate
669 engine ecu / vehicle interface positive PIN 13 neg = PIN15 tan/slate
670 engine ecu / vehicle interface gridheater no.1 driver yellow
671 engine ecu / vehicle interface gridheater no.2 driver yellow
672 engine ecu / vehicle interface fuel heater driver yellow
673 engine ecu / vehicle interface idle validation return blue
674 engine ecu / vehicle interface exhaust brake on / off blue
675 engine ecu / vehicle interface remote throttle switch blue
676 engine ecu / vehicle interface fan clutch switch blue
677 engine ecu / vehicle interface a/c pressure switch blue
678 engine ecu / vehicle interface remote pto on / off blue
679 engine ecu / vehicle interface r s g limit switch blue
680 engine ecu / vehicle interface eng override protection switch blue
681 engine ecu / vehicle interface park brake signal blue
682 engine ecu / vehicle interface diagnostic lamp supply pos yellow
683 engine ecu / vehicle interface wait to start lamp driver yellow/blue
684 engine ecu / vehicle interface j 1708 negative ( low ) green
685 engine ecu / vehicle interface j 1708 positive ( high ) green
686 engine ecu / vehicle interface w I f / temp sensor return blue
687 engine ecu / vehicle interface analog torque driver yellow
688 engine ecu / vehicle interface tachometer high side driver yellow
689 engine ecu / vehicle interface accelerator interlock switch blue
690 engine ecu / vehicle interface ignition switch positive supply white
691 engine ecu / vehicle interface torque control switch blue
692 engine ecu / vehicle interface coolant level low switch blue
693 engine ecu / vehicle interface coolant level high switch blue
694 engine ecu / vehicle interface starter lockout signal blue
695 engine ecu / vehicle interface engine stop lamp driver blue
696 engine ecu / vehicle interface tachometer low side driver blue
697 engine ecu / vehicle interface remote thrttle / coolnt sensor rtn blue/slate
698 engine ecu / vehicle interface tachograph return C3 green
699 engine ecu / vehicle interface throttle supply white
700 engine ecu / vehicle interface vss low green
701 engine ecu / vehicle interface tachograph signal C3 green
702 engine ecu / vehicle interface idle decrement switch blue
703 engine ecu / vehicle interface idle increment switch blue
704 engine ecu / vehicle interface clutch switch blue
705 engine ecu / vehicle interface w i f lamp driver yellow/blue
706 engine ecu / vehicle interface c o r s driver yellow
707 engine ecu / vehicle interface remote throttle supply yellow
708 engine ecu / vehicle interface diagnostic lamp driver yellow/blue
709 engine ecu / vehicle interface remote throttle input blue
710 engine ecu / vehicle interface idle validation on switch blue
711 engine ecu / vehicle interface idle validation off switch blue
712 engine ecu / vehicle interface vss high green
713 engine ecu / vehicle interface pto on /off switch blue
714 engine ecu / vehicle interface diagnostic switch blue
715 engine ecu / vehicle interface service brake switch input blue
716 engine ecu / vehicle interface throttle return signal (gnd) blue/slate
717 engine ecu / vehicle interface throttle input signal blue
718 engine ecu / vehicle interface remote throttle input signal blue
719 engine ecu / vehicle interface 9 way front diagnostic tan/slate
720 engine ecu / vehicle interface 9 way rear diagnostic tan/slate
721 engine ecu / vehicle interface ECU fuse supplies tan/slate
722 engine ecu / vehicle interface ECU fuse supplies tan/slate
723 engine ecu / vehicle interface ECU supplies tan/slate
726 engine Fuel heater tan/slate
727 engine Grid heater tan/slate
728 engine ecu / vehicle interface MIL lamp driver blue
729 engine ecu / vehicle interface ECU switch return blue
730 engine Urea doser pump air solenoid yellow/slate
731 engine Urea doser pump battery/ignition supplies red/white/slate
732 engine Engine SCR interface catalyst inlet temp sensor signal/return blue/slate
733 engine Engine SCR interface catalyst outlet temp sensor signal/return blue/slate
734 engine Engine SCR interface urea tank level signal/return blue/slate
735 engine Engine SCR interface urea tank temperature signal/return blue/slate
736 engine Engine SCR interface urea tank level supply/signal yellow/blue
737 engine Engine SCR interface heater relay enable/ground yellow/slate
738 engine Urea Tank heater supply to relay/ground red/slate
SERVICE MANUAL

739 engine Urea Tank heater relay to heaters red
740 engine ecu / vehicle interface manual fan switch blue
741 engine ecu / vehicle interface Accelerator Sensor Supply (5vdc) White
742 engine ecu / vehicle interface Accelerator Position Sensor 2 Blue
743 engine ecu / vehicle interface Accelerator ECM Return Slate
744 engine ecu / vehicle interface ECM Return (exhaust temperature sensors) Slate
745 engine ecu / vehicle interface Exhaust delta pressure sensor signal ECM Blue
746 engine ecu / vehicle interface Exhaust filter temperature sensor 1(inlet) Blue
747 engine ecu / vehicle interface Exhaust filter temperature sensor 2(mid) Blue
748 engine ecu / vehicle interface Exhaust filter temperature sensor 3(outlet) Blue
749 engine ecu / vehicle interface Fan Speed Sensor Blue
750 engine hi temp warning
751 engine NOx sensor ignition supply & gnd White/Slate
752 engine ecu / vehicle interface dual pot throttle sensor return Blue
753 engine
754 engine ecu / vehicle interface Blue
755 engine ecu / vehicle interface Blue
756 engine
757 engine ecu / vehicle interface ECM diesel particulate filter lamp driver Yellow
758 engine ecu / vehicle interface ECM high exhaust temperature lamp driver Yellow
759 engine
760 engine ecu / vehicle sensor ECM coolant level sensor Blue
761 engine Engine SCR interface urea tank common return Slate
762 engine ecu / vehicle sensor Trican Sensor supply white/slate
763 engine ecu / vehicle sensor Trican Sensor CAN lo green
764 engine ecu / vehicle sensor Trican Sensor CAN hi yellow
765 engine
766 engine
767 engine
768 engine
769 engine
770 transmission transmission ecu supplies white/tan/slate
771 transmission transmission ecu supplies white/tan/slate
772 transmission trans external switches fused feed tan/white
773 transmission trans external switches neutral at bus stop switch blue/yellow
774 transmission trans external switches gearguard switch blue/yellow
775 transmission trans external switches retarder switch blue
776 transmission warning lights output status monitor yellow
777 transmission warning lights temperature yellow
778 transmission controls starter interlock blue
779 transmission diagnostics "k" line green
780 transmission diagnostics "l" line green
781 transmission controls retarder / brake lights signal blue
782 transmission controls neutral signal blue
783 transmission controls foot pedal output yellow
784 transmission controls foot pedal positive supply white
785 transmission controls foot pedal return slate
786 transmission controls control relay input blue/white
787 transmission temperature yellow
788 transmission shift program ( 5th gear ) blue
789 transmission controls ecu 5 V output white
790 transmission warning light oil level blue
791 transmission controls limp home blue
792 transmission proprietry canbus can high yellow
793 transmission proprietry canbus can low green
794 transmission proprietry canbus can ground slate
795 transmission controls gear selector supply white
796 transmission controls retarder disable signal blue
797 transmission controls gear selector neutral blue
798 transmission transmission extra reverse switch blue
799 transmission controls partial brake valve yellow
800 transmission controls ZF S17 reverse gear release ignition supply white
801 transmission controls ZF S5 program selector ignition supply white
802 transmission controls ZF S6 gear release switch ignition supply white
803 transmission controls ZF S7 neutral bus stop switch ignion supply white
804 transmission controls ZF S8 neutral external switch ignition supply white
805 transmission wabco allison brake pedal foot pedal 1st position microswitch yellow
806 transmission wabco allison brake pedal foot pedal 2nd position microswitch yellow
807 transmission wabco allison brake pedal foot pedal 3rd position microswitch yellow
808 transmission Allison External switch 4th stage retarder switch yellow
809 transmission
810 transmission
811 transmission
812 transmission
813 transmission
814 transmission
815 transmission
816 transmission
817 transmission
818 transmission
819 transmission
820 transmission
821 transmission
822 transmission
823 transmission
824 transmission
825 transmission
826 transmission
827 transmission
828 transmission
829 transmission
830 retarder / intarder ecm/vehicle interface ecm supplies whiteslate
831 retarder / intarder ecm/vehicle interface hand controller supply yellow
832 retarder / intarder ecm/vehicle interface hand control stage 1 blue
836 retarder / intarder ecm/vehicle interface speed signal green
837 retarder / intarder ecm/vehicle interface abs enable white/blue
SERVICE MANUAL

838 retarder / intarder ecm/vehicle interface brake-cruise warning lt yellow
839 retarder / intarder ecm/vehicle interface retarder active warning lt yellow
840 retarder / intarder ecm/vehicle interface output to brake lts yellow
841 retarder / intarder ecm/vehicle interface retarder on/off switch blue
842 retarder / intarder
905 braking systems low pressure warning air 4 (handbrake) transducer signal blue
906 braking systems low pressure warning air 4 (handbrake) transducer return blue/slate
907 braking systems low pressure warning tag axle switch blue/slate
908 braking systems low pressure warning air 3(aux) transducer signal blue
909 braking systems low pressure warning air 3 (aux) transducer return blue/slate
910 braking systems stop lights switch input air 1 blue
911 braking systems stop lights switch input air 2 blue
912 braking systems low pressure warning handbrake tank switch blue
913 braking systems low pressure warning air 1 transducer signal blue
914 braking systems low pressure warning air 1 transducer return blue
915 braking systems low pressure warning air 2 transducer signal blue
916 braking systems low pressure warning air 2 transducer return blue
917 braking systems warnings handbrake active switch blue
918 braking systems low pressure warning air 1 low tank switch blue
919 braking systems low pressure warning air 2 low tank switch blue
920 braking systems low pressure warning air 2 regulator supply yellow
921 braking systems back pressure warning crt transducer blue
922 braking systems back pressure warning crt transducer rtn blue
923 braking systems low pressure warning bus stop pressure switch blue
924 braking systems abs ecu primary supply
925 braking systems
926 braking systems
927 braking systems abs diagnostics "k" line green
928 braking systems abs diagnostics "l" line green
929 braking systems abs abs cut-off signal blue
930 braking systems abs warning lamp output yellow
931 braking systems abs modulator valves left hand front av yellow
932 braking systems abs modulator valves left hand front ev yellow
933 braking systems abs modulator valves right hand front av yellow
934 braking systems abs modulator valves right hand front ev yellow
935 braking systems abs modulator valves left hand rear av ( drive axle ) yellow
936 braking systems abs modulator valves left hand rear ev ( drive axle ) yellow
SERVICE MANUAL

937 braking systems abs modulator valves right hand rear av ( drive axle ) yellow
938 braking systems abs modulator valves right hand rear ev ( drive axle ) yellow
939 braking systems abs modulator valves left hand av ( tag axle ) yellow
940 braking systems abs modulator valves left hand ev ( tag axle ) yellow
941 braking systems abs modulator valves right hand av ( tag axle ) yellow
942 braking systems abs modulator valves right hand ev ( tag axle ) yellow
943 braking systems abs modulator valves left hand front return slate
944 braking systems abs modulator valves right hand front return slate
945 braking systems abs modulator valves left hand rear return slate
946 braking systems abs modulator valves right hand rear return slate
947 braking systems abs modulator valves left hand tag return slate
948 braking systems abs modulator valves right hand tag return slate
949 braking systems diagnostic switch ASR blinkcode blue
950 braking systems air dryer yellow
951 braking systems pad wear l/hand front blue
952 braking systems pad wear r/hand front blue
953 braking systems pad wear l/hand rear blue
954 braking systems pad wear r/hand rear blue
955 braking systems ABS diagonal 1 tan
956 braking systems ABS diagonal 2 tan
957 braking systems ASR Valve yellow/slate
958 braking systems ABS Diagonals Batt supply red
959 braking systems
960 braking systems
961 braking systems
962 braking systems
963 braking systems
964 braking systems
965 braking systems
966 braking systems
967 braking systems
968 braking systems
969 braking systems
970 braking systems
971 braking systems
972 braking systems
973 braking systems
974 braking systems
975 braking systems
976 braking systems
977 braking systems
978 braking systems
979 braking systems
980 braking systems
981 braking systems
982 braking systems
983 braking systems
984 braking systems
985 braking systems
986 braking systems
987 braking systems
988 braking systems
989 braking systems
990 suspension systems front sensor positive supply yellow
991 suspension systems front sensor output blue
992 suspension systems kneeling valve block ( front ) valve 41(SG) yellow
993 suspension systems kneeling valve block ( front ) valve 42(SOB) yellow
994 suspension systems kneeling valve block ( front ) valve 43(SUB) yellow
995 suspension systems single valve ( front ) valve 6 yellow
996 suspension systems kneeling valve block ( rear ) valve 41 yellow
999 suspension systems single valve ( rear ) valve 6 yellow
1000 suspension systems rear sensor positive supply yellow
1001 suspension systems rear sensor output blue
1002 suspension systems ferry lift valve (front) valve 44 yellow
1003 suspension systems Kneeling switch front blue
1004 suspension systems Kneeling switch full blue
1005 suspension systems Raise switch blue
1006 suspension systems
SERVICE MANUAL

1040 ancilliaries coolant header tank output resistor 2K2 Ohms blue
1041 ancilliaries resistor upper probe blue
1042 ancilliaries output resistor 150 Ohm blue
1043 ancilliaries input resistor 2k2 Ohms blue
1044 ancilliaries fuel tank sender blue
1045 ancilliaries Warning Light Low Coolant Level yellow
1046 ancilliaries Fuel tank solenoid cut off valves tan
1047 ancilliaries switch ignition input to CMU blue
1048 ancilliaries switch master (dash) input to CMU blue
1049 ancilliaries switch master relay output from CMU blue
1050 ancilliaries supply master relay battery to m/sw coil red
1051 ancilliaries relay front ignition white
1052 ancilliaries relay rear ignition white
1053 ancilliaries
1054 ancilliaries autolube pump yellow
1055 ancilliaries coolant header tank output from IOU to module yellow
1056 ancilliaries input to IOU from module blue
1057 ancilliaries input from upper probe to module blue/slate
1058 ancilliaries module ground slate
1059 ancilliaries input from top up probe to module blue
1060 ancilliaries cooling upper header tank output resistor 2k2 ohms blue
1061 ancilliaries cooling upper header tank resistor upper probe blue
1062 ancilliaries cooling upper header tank output resitor 150 ohms blue
1063 ancilliaries input resistor 2k2 Ohms blue
1064 ancilliaries header tank water pump yellow
1065 ancilliaries (Oil Master) oil reservoir level sensor Engine mounted solenoid blue/slate
1066 ancilliaries (Oil Master) supply tan/white/slate
1067 ancilliaries (Oil Master) Optional test switch Grounded if not used slate
1068 ancilliaries (Oil Master) Warning Light input to Multibus (IOU) blue
1069 ancilliaries (Oil Master) Diagnostic K-line green
1070 ancilliaries cooling upper header tank output from IOU to module yellow
1071 ancilliaries cooling upper header tank input to IOU from module blue
1072 ancilliaries cooling upper header tank input from probe to module blue/slate
1073 ancilliaries cooling upper header tank module ground slate
1074 ancilliaries Webasto on/off backlighting yellow
1075 ancilliaries Webasto fuel cut off valve control relays blue/tan/slate
1076 ancilliaries Fozmula S45 coolant sensor header tank low level monitor white /blue/slate
1077 ancilliaries Fire Sensor engine bay gnd input blue/slate
1078 ancilliaries
1079 ancilliaries
1080 ancilliaries VDO Can link suppy/ground white/slate
1081 ancilliaries VDO Can link J1939 CAN yellow/green
1082 ancilliaries VDO Can link C3 output to datalogger yellow
1083 ancilliaries VDO Can link Vehicle speed output to data logger yellow
1084 ancilliaries VDO Can link Neutral gear output to datalogger yellow
1085 ancilliaries VDO Can link Brake light output to datalogger yellow
1086 ancilliaries VDO Can link Engine RPM output to datalogger yellow
1087 ancilliaries VDO Can link Engine overtemp yellow
1088 ancilliaries Datalogger supply/ground brown/slate
1089 ancilliaries
1090 starting systems relay start signal yellow
1091 starting systems relay output / supply red/yellow
1092 starting systems switch start input blue
1093 starting systems switch engine door blue
1094 starting systems switch start input rear blue
1095 starting systems switch stop input rear blue
1096 starting systems pressure switch charge coupling blue
1097 starting systems external switch stop input rear blue
1098 starting systems
1110 charging systems alternator 1 warning light yellow
1111 charging systems alternator 1 a/c signal green
1112 charging systems alternator 2 warning light yellow
1113 charging systems alternator 2 a/c signal green
1114 charging systems alternator 2 battery D+ red
1115 charging systems alternator 1 sensing line brown
1116 charging systems alternator 1 ignition white
1117 charging systems alternator 1 battery D+ red
1118 charging systems alternator 2 sensing line brown
1119 charging systems alternator 2 ignition white
1120 instrumentation tachograph ignition white
1121 instrumentation tachograph battery permanent batt tan
1122 instrumentation tachograph battery switched batt red
1123 instrumentation tachograph illumination output from CMU yellow
1124 instrumentation tachograph speed signal PWM output from CMU green
1125 instrumentation tachograph speed signal C3 output from tacho green
1126 instrumentation
1130 multibus diagnostics CMU K line green
1131 multibus diagnostics CMU L line green
1132 multibus diagnostics SCU K line green
1133 multibus diagnostics SCU L line green
1134 multibus diagnostics MultIC K line green
SERVICE MANUAL

1135 multibus alternator 1 diagnostics green
1136 multibus communications (CAN) Address green
1137 multibus CAN 1 ground green
1138 multibus CAN 1 low green
1139 multibus CAN 1 high green
1140 multibus CAN 2 low green
1141 multibus CAN 2 high green
1142 multibus SLU Supply from CMU tan
1143 multibus CAN 2 ground green
1144 multibus
1145 multibus
1146 multibus
1147 multibus MultIC Perm Supply tan
1148 multibus SCU Supply from CMU tan
1149 multibus SCU tan/red
1150 multibus CMU tan/red
1151 multibus IOU1 tan/red
1160 earthing point Splice front harness slate
1161 earthing point Splice EDC-Foundation slate
1162 earthing point Splice front cross member slate
1163 earthing point Starter Motor Splice slate
1164 earthing point Dash panel slate
1165 earthing point Splice chass harness R/H -R/H/R slate
1166 earthing point Splice chass harness-Rrear edc slate
1167 earthing point Splice in harness rear 440434 slate
1168 earthing point Rear EDC ground to rear harness slate
1169 earthing point
1170 diagnostics Multibus 16 way diagnostic tan/slate
1171 diagnostics OBD 2 16 way diagnostic tan/slate
1172 diagnostics OBD 2 can high Yellow
1173 diagnostics OBD 2 can low GReen
1174 diagnostics
1175 diagnostics
1176 diagnostics
1177 diagnostics
1178 diagnostics
1179 diagnostics
1180
1181
1182
1183
1184
1185
1186
1187
1188
1189
1190 Spares
1191 Spares
1192 Spares
1193 Spares
1194 Spares
1195 Spares FEDC TO BB DASH CONNECTOR Future use white/yellow/blue
1196 Spares MOKI TO BB DASH CONNECTOR SPARE SW INPUTS Yellow/ Blue
1197 Spares front EDC fused supply 1mm sq wire white
1198 Spares front EDC to rear EDC 1mm sq wire white/yellow/blue
1199 Spares front EDC to rear EDC 2mm sq wire white/yellow/blue
1200 Spares front EDC fused supply 2mm sq wire brown
1201 Spares Rear EDC fused supply 2mm sq wire red
1202 Rear EDC fused supply 2mm sq wire red
1203
1204
1205
1206
1207
1208
1209
1210
1211
1212
1213
1214
1215
1216
1217
1218 Illumination Drivers controls ECE36 switch Yellow
1219 Illumination Drivers controls Moki Illumination dimmer output Yellow
1220 Illumination Drivers controls Full/ Front Kneeling switch Yellow
1221 Illumination Drivers controls Raise switch Yellow
1222 Illumination Drivers controls Hazard switch Yellow
1223 Illumination Drivers controls Master switch Yellow
1224 Illumination Drivers controls Side Head light switch Yellow
1225 Illumination Drivers controls D Mux Select switch Yellow
1226 Illumination Drivers controls D Mux Scroll switch Yellow
1227 Illumination Drivers controls Hazard switch tell tale warning Yellow
1228 Illumination Drivers controls Bus Stop Brake switch Yellow
1229
1230 Hybrid systems ZEV Sw Cab mtd white/yellow/blue
1231 Hybrid systems Water pump Roof mtd traction batteries white/yellow/blue
1232 Hybrid systems Cooling fan Roof mtd traction batteries white/yellow/blue
1233 Hybrid systems MST Generator Controller Supplies pin1(neg) pin15(mpos) pin22(perpos) slate/red/tan
SERVICE MANUAL

1234 Hybrid systems MST Generator Controller Supplies pin 2 (neg) pin 16 (master pos) slate/red
1235 Hybrid systems MST Generator Motor Controller Inhibit blue

1236 Hybrid systems MST Generator Motor Controller Electronics cooling circ fan relay yellow
1237 Hybrid systems MST Generator Motor Controller Auxiliary controller enable blue
1238 Hybrid systems MST Generator Motor Controller enable blue
1239 Hybrid systems MST Generator Motor Controller HV DC insulation OK # 1 blue
1240 Hybrid systems MST Generator Motor Controller Continuity feed to blue
1241 Hybrid systems MST Generator Motor Controller Continuity return blue
1242 Hybrid systems MST Generator Motor Controller GCLR contactor blue
1243 Hybrid systems MST Generator Motor Controller MCLR contactor blue
1244 Hybrid systems MST Generator Motor Controller ACLR contactor blue
1245 Hybrid systems MST Generator Motor Controller GCLR HV DC Insulation OK #2 blue
1246 Hybrid systems Battery Interface Unit contactor blue
1247 Hybrid systems GPS pin 23 tan
1248 Hybrid systems GPRS pin 24 tan
1249 Hybrid systems MST Generator Motor Controller PT CAN bus CAN cable
1250 Hybrid systems MST Generator Motor Controller GCLR diag CAN bus CAN cable
1251 Hybrid systems MST Generator Motor Controller MCLR diag CAN bus CAN cable
1252 Hybrid systems GPS TXD,RXD,GND white,black, braid
1253 Hybrid systems Varta Diagnostic RxD,TxD,CTS,RTS,GND,shield black,red,green,yellow,blue,braid
1254 Hybrid systems
1255 Hybrid systems GPRS TXD,RXD,GND white,black, braid
1256 Hybrid systems
1257 Hybrid systems
1258 Hybrid systems PTMS Ignition white
1259 Hybrid systems PTMS TXD,RXD,GND white,black, braid
1260 Hybrid systems PTMS Main supply red
1261 Hybrid systems PTMS pin10(neg) pin20(mpos) pin30(perpos) tan/red/slate
1262 Hybrid systems PTMS pin9(neg) pin19(mpos) red/slate
1263 Hybrid systems PTMS pin8(neg) pin18(mpos) red/slate
1264 Hybrid systems BIU CAN_LS_L , CAN_LS_H, BMS string shield yellow,green,black
1265 Hybrid systems PTMS pin21(mpos) red
1266 Hybrid systems BIU Switched (pin34) red
1267 Hybrid systems BIU Guard In/out using A,B etc for branches blue
1268 Hybrid systems BIU CoolingfanGND(pin 46/47)switched(pin 44/45) red/slate
1269 Hybrid systems BIU Gnd (pin6 and 7)/24v Battery (pins 1 and 4) tan/slate
1270 Hybrid systems BIU fansupplyGnd (pin4)/24v switched (pin42/43) red/slate
1271 Hybrid systems BIU FAN 1 slate (neg)/ red (pos)
1279 Hybrid systems BIU Vext green
1280 Hybrid systems BIU GNDext green
1281 Hybrid systems BIU 1stMC green
1282 Hybrid systems BIU t sensor shield, t sensor +, t sensor - Braid, white, black
1283 Hybrid systems PTMS Enable 2 out yellow
1284 Hybrid systems PTMS Enable 2 in blue
1285 Hybrid systems PTMS GP out A yellow
1286 Hybrid systems PTMS GP out B yellow
1287 Hybrid systems PTMS CAN 3 HS LS Shield yellow,green,black
1288 Hybrid systems PTMS Analogue A Gnd slate
1289 Hybrid systems PTMS GP in A blue
1290 Hybrid systems PTMS TTYS3 Txd Rxd Gnd white,black, braid
1291 Hybrid systems PTMS Analogue B Gnd slate
1292 Hybrid systems PTMS Analogue A in blue
1293 Hybrid systems PTMS GP Inp B in blue
1294 Hybrid systems PTMS Analogue B 5V out yellow
1295 Hybrid systems PTMS Analogue B in blue
1296 Hybrid systems PTMS GP Inp C blue
1297 Hybrid systems PTMS Analogue A 5V out yellow
1298 Hybrid systems
1299 Hybrid systems
1300 Hybrid systems
1301 Hybrid systems
1302 Hybrid systems Hybrid electronics header tank output from IOU to module yellow
1303 Hybrid systems input to IOU from module blue
1304 Hybrid systems input from upper probe to module blue/slate
1305 Hybrid systems module ground slate
1306
1307
1308
1309
1310
SERVICE MANUAL

1311
1312
1313
1314
1315
1316
1317
1318
1319
1320 MAN Engine Exhaust Sensor Lambda Sensor supply and ground red/slate
1321 MAN Engine Exhaust Sensor Lambda Sensor Heater supply and ground red/slate
1322 MAN Engine Exhaust Sensor Lambda Sensor Trim resistor yellow
1323 MAN Engine Exhaust Sensor Lambda Sensor Nernst Voltage yellow
1324 MAN Engine Exhaust Sensor Inlet 1 blue/slate
1325 MAN Engine Exhaust Sensor Exhaust 2 blue/slate
1326 MAN Engine Exhaust Sensor Relative Pressure Supply Gnd O/put White/Slate/Yellow
1327 MAN Engine Exhaust Solenoid CRT engine back pressure flap yellow/slate
1328 MAN Engine Vehicle Computer FFR Positive supplies red/white/slate
1329 MAN Engine Vehicle Computer FFR K line green
1330 MAN Engine Vehicle Computer FFR M CAN Hi yellow
1331 MAN Engine Vehicle Computer FFR M CAN Lo green
1332 MAN Engine Vehicle Computer FFR MCAN Gnd slate
1333 MAN Engine Vehicle Computer FFR Resistor Pack common blue
1334 MAN Engine Vehicle Computer FFR
1339 Vehicle Computer FFR
1343
1344
1345
1346
1347
1348
1349
1350 Hybrid systems - BAE HPS TEST CONTROL GND BLUE
1351 Hybrid systems - BAE 4PSI BRAKE PEDAL SW N/O GND BLUE
1352 Hybrid systems - BAE EMERGENCY OVERIDE SW N/O GND BLUE
1353 Hybrid systems - BAE HEV STOP W/L OUTPUT GND YELLOW
1354 Hybrid systems - BAE HEV CHECK W/L OUTPUT GND YELLOW
1355 Hybrid systems - BAE HEV MOTOR O/SPD W/L OUTPUT GND YELLOW
1356 Hybrid systems - BAE HEV REGEN W/L OUTPUT GND YELLOW
1357 Hybrid systems - BAE HEV MAINTENANCE W/L OUTPUT GND YELLOW
1358 Hybrid systems - BAE 24V IGNITION SUPPLY INPUT IGN WHITE
1359 Hybrid systems - BAE 24V IGNITION SUPPLY OUTPUT IGN WHITE
1360 Hybrid systems - BAE SELECTOR NEUTRAL INPUT GND BLUE
1361 Hybrid systems - BAE SELECTOR DRIVE INPUT GND BLUE
1362 Hybrid systems - BAE SELECTOR REVERSE INPUT GND BLUE
1363 Hybrid systems - BAE GROUND GND SLATE
1364 Hybrid systems - BAE HIGH IDLE INPUT IGN BLUE
1365 Hybrid systems - BAE REGEN/RET SW INPUT IGN (VIA CAMU OUTPUT WIRE 775) BLUE
1366 Hybrid systems - BAE BRAKE LIGHT OUTPUT GND (INTO IOU1) YELLOW
1367 Hybrid systems - BAE REVERSE LIGHT OUTPUT GND (SPARE) YELLOW
1368 Hybrid systems - BAE DATALOGGER PERM INPUT BATT + 24V BROWN
1369 Hybrid systems - BAE ACTM COOLANT PRESSURE SW GND BLUE
1370 Hybrid systems - BAE 12V IGNITION SUPPLY INPUT IGN ORANGE
1371 Hybrid systems - BAE DIAGNOSTIC PORT IDS DISCRETE INPUT - (INV DI EE ILOCK) BLUE
1372 Hybrid systems - BAE DIAGNOSTIC PORT IDS DISCRETE INPUT - (SC DI EE ILOCK) BLUE
1373 Hybrid systems - BAE ACTM TEMP #1 SIGNAL INPUT BLUE
1374 Hybrid systems - BAE ACTM TEMP #1 SIGNAL RETURN L/GREEN
1375 Hybrid systems - BAE ACTM TEMP #2 SIGNAL INPUT BLUE
1376 Hybrid systems - BAE ACTM TEMP #2 SIGNAL RETURN L/GREEN
1377 Hybrid systems - BAE ACTG TEMP #1 SIGNAL INPUT BLUE
1378 Hybrid systems - BAE ACTG TEMP #1 SIGNAL RETURN L/GREEN
1379 Hybrid systems - BAE THERMISTOR HIGH HIGH BLUE
1380 Hybrid systems - BAE THERMISTOR LOW LOW L/GREEN
1381 Hybrid systems - BAE BATTERY COOLING CONTROL GND (OUTPUT) YELLOW
1382 Hybrid systems - BAE ESS CONTACTOR RELAY GND (OUTPUT) YELLOW
1383 Hybrid systems - BAE ESS FAN POWER +24V SWITCHED M/SW 24V + GND RED, SLATE
1384 Hybrid systems - BAE ESS CONTACTOR - GND ESS ENABLE LO SLATE
1385 Hybrid systems - BAE ESS CONTACTOR + IGN ESS ENABLE HI WHITE
1386 Hybrid systems - BAE HIGH IDLE INPUT 24V IGN / OPEN DISCRETE INPUT WHITE
1387 Hybrid systems - BAE FAN REQUEST OUTPUT (IOU4 CN5-14) GND (OUTPUT) YELLOW
1388 Hybrid systems - BAE THROTTLE INTERLOCK POSITIVE INPUT BLUE
1389 Hybrid systems - BAE M/SW SUPPLY M/SW 24V RED, SLATE
1390 Hybrid systems - BAE HIGH VOLTAGE INTERLOCK LOOP (HVIL) HEV IGN WHITE, ORANGE
1391 Hybrid systems - BAE SCU HEV M/SW SUPPLY HEV SWITCHED M/SW 24V + GND RED(RW), SLATE
1392 Hybrid systems - BAE PCS PSU HEV M/SW SUPPLY HEV SWITCHED M/SW 24V + GND RED(RW), SLATE
1393 Hybrid systems - BAE ESS HEV M/SW SUPPLY HEV SWITCHED M/SW 24V + GND RED, SLATE
1394 Hybrid systems - BAE MTS HEV M/SW SUPPLY HEV SWITCHED M/SW 24V + GND RED, SLATE
1395 Hybrid systems - BAE PSU OUTPUT PASS THROUGH TO SCU PTSCURTN YELLOW, BLUE
1396 Hybrid systems - BAE PSU OUTPUT PASS THROUGH TO SCU (+5V) PTSCU P5V YELLOW, BLUE
1397 Hybrid systems - BAE PASS THROUGH SCU KEY ON PTSCU IGNITION WHITE
1398 Hybrid systems - BAE PSU OUTPUT PASS THROUGH TO SCU (+15V) PTSCU P15V YELLOW, BLUE
1399 Hybrid systems - BAE PSU OUTPUT PASS THROUGH TO SCU (-15V) PTSCU N15V YELLOW, BLUE
1400 Hybrid systems - BAE PASS THROUGH PSU HOLD ON PTSCU PSUHOLDON YELLOW
1401 Hybrid systems - BAE TURN ON PCS YELLOW, SLATE
1402 Hybrid systems - BAE PASS THROUGH OVERFOLTAGE DETECTED PTSCU POLOV YELLOW
1403 Hybrid systems - BAE ENABLE ESS OUTPUTS YELLOW, BLUE
1404 Hybrid systems - BAE GEAR SELECTOR RETURN TWIST WITH 1360, 1361, 1362 YELLOW
1405 Hybrid systems - BAE TURN ON ESS YELLOW, SLATE
1406 Hybrid systems - BAE ECP FAN PWM ELECTRONIC COOLING PACK YELLOW, GREEN
1407 Hybrid systems - BAE ENGINE START YELLOW, GREEN
1408 Hybrid systems - BAE ESS FAULTED YELLOW, GREEN
1409 Hybrid systems - BAE PCS FAULTED YELLOW, GREEN
SERVICE MANUAL

1410 Hybrid systems - BAE MTS WEG FAN PWM SPEED YELLOW, GREEN
1411 Hybrid systems - BAE MTS WEG TEMP SENSOR YELLOW, GREEN
1412 Hybrid systems - BAE ECP WEG TEMP SENSOR YELLOW, GREEN
1413 Hybrid systems - BAE TURN ON ECP IGNITION WHITE
1414 Hybrid systems - BAE HEV OK LO GREEN
1415 Hybrid systems - BAE MTS WEG PRESSURE SWITCH YELLOW, GREEN
1416 Hybrid systems - BAE ENABLE PCS OUTPUTS YELLOW, GREEN
1417 Hybrid systems - BAE ECP WEG PRESSURE SWITCH YELLOW, GREEN
1418 Hybrid systems - BAE TEMPERATURE SENSE ACTM YELLOW, GREEN
1419 Hybrid systems - BAE TEMPERATURE SENSE ISG YELLOW, GREEN
1420 Hybrid systems - BAE HEATER TEMPERATURE SENSE YELLOW, GREEN
1421 Hybrid systems - BAE PRIMARY EXCITATION SPEED SENSOR ACTM YELLOW, GREEN
1422 Hybrid systems - BAE PRIMARY EXCITATION HALL EFFECT SENSOR ISG YELLOW, GREEN
1423 Hybrid systems - BAE EXCITATION WRAP SPEED SENSOR ACTM YELLOW, GREEN
1424 Hybrid systems - BAE SENSOR C HALL EFFECT SENSOR ISG YELLOW, GREEN
1425 Hybrid systems - BAE SENSOR A SPEED SENSOR ACTM YELLOW, GREEN
1426 Hybrid systems - BAE SENSOR A HALL EFFECT SENSOR ISG YELLOW, GREEN
1427 Hybrid systems - BAE SENSOR B SPEED SENSOR ACTM YELLOW, GREEN
1428 Hybrid systems - BAE 128 WAY TWISTED PAIR - SPARES SPARE YELLOW, L/GREEN
1429 Hybrid systems - BAE 128 WAY TWISTED PAIR - SPARES SPARE YELLOW, L/GREEN
1430 Hybrid systems - BAE AUX SYSTEMS INPUT AIR COMPRESSOR YELLOW, L/GREEN
1431
1432
1433
1434
1435
1436
1437
1438
1439
1440
1441
1442
1443
1444
1445
1446
1447
1448
1449
1450 VDO MULTIPLEX ZR 32 supply/ground tan/red/slate
1451 VDO MULTIPLEX Mux 1 A08/A07 supply/ground tan/red/slate
1453 VDO MULTIPLEX Mux 1 B08/B07 supply/ground tan/red/slate
1455 VDO MULTIPLEX Mux 1 E10/E09 supply/ground tan/red/slate
1466 VDO MULTIPLEX Dmux supply/ground tan/red/slate
1467 VDO MULTIPLEX Dmux scroll up switch blue/slate
1468 VDO MULTIPLEX Dmux scroll down switch blue/slate
1469 VDO MULTIPLEX Dmux select switch blue/slate
1470 VDO MULTIPLEX Communication bus Instrument Can Lo green
1471 VDO MULTIPLEX Communication bus Instrument Can Hi yellow
1472 VDO MULTIPLEX Dmux/Moki wake up supply/ground tan/red/slate
1473 VDO MULTIPLEX Moki dash K Line dash to ZR32 l/green
1474 VDO MULTIPLEX ZR32 C3 Speed Signal yellow
1475 VDO MULTIPLEX Moki dash I CAN Lo to DTCO l/green
1476 VDO MULTIPLEX Moki dash I CAN Hi to DTCO l/green
1477 VDO MULTIPLEX Moki dash K Line dash to diagnostic skt edc l/green
1478 VDO MULTIPLEX Moki dash Wake up input 2 tan
1479 VDO MULTIPLEX Moki dash Wake up input 4 tan
1480 VDO MULTIPLEX Communication Bus M1 Can lo (ZR32 - 1.3) l/green
1481 VDO MULTIPLEX Communication Bus M1 Can hi (ZR32 - 1.3) yellow
1482 VDO MULTIPLEX ZR32 K Line l/green
1483 VDO MULTIPLEX Communication Bus K Can lo (Body) l/green
1484 VDO MULTIPLEX Communication Bus K Can hi (Body) yellow
1485 VDO MULTIPLEX ZR32 Chassis Buzzer (Body) yellow
1486 VDO MULTIPLEX Communication Bus M2 Can lo (Body) l/green
1487 VDO MULTIPLEX Communication Bus M2 Can hi (Body) yellow
1488 VDO MULTIPLEX Communication Bus M1 Can lo (ZR32 - 1.1) l/green
1489 VDO MULTIPLEX Communication Bus M1 Can hi (ZR32 - 1.1) yellow
1490 VDO MULTIPLEX Communication Bus M1 Can lo (1.1 - 1.2) l/green
1491 VDO MULTIPLEX Communication Bus M1 Can hi (1.1 - 1.2) yellow
SERVICE MANUAL
NOTES
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SERVICE MANUAL
Care Points Input Output Connectors

For the correct operation of the system it is essential
that all plug and socket connections are correctly
fitted and secured. The male and female connectors
within the plugs and sockets must be correctly fitted
within thier respective housings.
Can Connector
WRONG
1 - Locate end Key
Connector Spring lock

only located on one side
RIGHT 2 - Align Locking clip
Connector spring lock must

be located on both sides
3 - Press down to lock
4 - Correct assy
SERVICE MANUAL
Harness Connectors
Check that pins are correctly located in holder and
not pushed back or bent.
Check that sockets are correctly located in holder

and not pushed back.
Hardware Features
The system provides protection against short circuit to ground or power supply on each cannector pin.
Outputs are also protected against over-current and over-temperature.
Output Type Max Continous Current Short Circuit / Overload

Current Limit (*)
9A High-side 9A 35A
7A High-side 7A 16A
5A Low-side 5A 28A
3.2A High-side 3.2A 8A
2A High-side 2A 8A
2A low-side 2A 28A
1.5A High-side 1.5A 4A
(*) The maximum current permitted for 1 second before output shutdown.
SERVICE MANUAL
Instrument Panel
Warning Lights
Drivers
Display Screen Rev Counter
Speedometer
Side & Headlight
Switch
Vehicle
Function Switches
Master
Ignition Switch P ! - + STOP ! ABS
40
30 50 15
60 10 20
20 80 r/min
40 MPH 60 x100
0 km/h 100
20
5 25
10 70
0
0 30 R
0 80
bar 10 10 bar
5 5
1 0 0 2
2 1
Hazard
Light Switch Display Screen
Function Select
Rear Fog Air Pressure Air Pressure Engine
Light Switch Gauge Gauge Start Switch
Engine
Stop Switch
Driver’s Information Screen

4
1
2
6 7 8 5 9
Symbol Function
1. Fuel Gauge (Option) 6. Time Display
2. AdBlue® Gauge 7. Ambient Temperature
3. Warning Symbols - High/Medium Priority 8. Total Vehicle Mileage
4. Warning Symbols - Low Priority 9. Vehicle Mileage - Trip Indicator
5. Door Open/Close Status
SERVICE MANUAL
Instrument Panel
Emergency Hammer removed.
Warning & Fault Symbols (yellow)
These symbols are displayed along the top of the Driver’s
Screen.
Windscreen Wash Fluid
Low. (yellow)
Engine Door Open. (red)
Traction Control Active.
(yellow)
Rear Fog Lights On. (yellow)
These symbols are displayed in the central area of the
Driver’s Screen.
Kneeling/Ferry Lift. (yellow)
Symbols with a red background indicate a high priority
fault which requires immediate attention.
DDA Brake applied. (yellow)

Charge Warning 1 (red)
Low External Temperature,

Possible Ice. (yellow)
Charge Warning 2 (red)
Air Conditioning, Low Pressure Warning.

(yellow)
Engine Oil Pressure
too Low (red)
Wait To Start. (yellow)

Coolant Temperature too High
(red)
Passenger, Next Stop Request Pressed.
(yellow)
Flashes for 3 seconds Transmission Oil Temperature too High
(red)
Passenger, Next Stop Requested. Battery Guard Active

(green) Stage 2 (red)
Disabled, Next Stop Engine Bay Fire (red)

Request Pressed. (yellow)
Flashes for 3 seconds
Driveline Communication
Disabled, Next Stop Requested. Fault (red)
(green)
Multiplex Communication
Fault (red)
Wheelchair Restraint
Arm fully extended. (yellow)
Suspension Fault (red)
Exterior Light Fault. (yellow)

Note: On screen these symbols will appear Black on a
Red Background
DDA Brake Override
active. (yellow) Continued
SERVICE MANUAL
Continued
Check Transmission
Note: On screen these symbols will appear Black on a (yellow)
Red Background
Transmission Range
Engine Coolant Level Inhibit Active (yellow)
too Low (red)
Service Transmission
DDA Brake Fault (red) Warning (yellow)
Low Fuel Warning (yellow)

Emergency Door Open (red)
Battery Guard Active

Emergency Window Open Stage 1 (yellow)
(red)
Engine Stop Button

Low Air Pressure Warning Pressed (yellow)
(red)
Transmission Temperature
Retarder Oil Temperature High (yellow)
too High (red)
Oil Pressure Low

Symbols with a yellow background are a warning and the (yellow)
vehicle may continue to be driven at the driver’s discretion.
Coolant Temperature
High (yellow)
Engine Warning (yellow)
Retarder Oil
Temperature High (yellow)
Low Level of UREA (yellow)
Transmission Warning
Detected (yellow)
Low Oil Level Warning
(yellow)
Transmission Temperature
Low Coolant Level High (yellow)
Warning (yellow)
Oil Pressure Low

Water In Fuel (yellow) (yellow)
Coolant Temperature
High Exhaust System Temperature (yellow) High (yellow)
Retarder Oil
Brake Pad Wear - Front Temperature High (yellow)
(yellow)
Transmission Warning
Brake Pad Wear - Rear Detected (yellow)
(yellow)
SERVICE MANUAL
When the vehicle is brought to a stop, the Display Screen

will show the side view of the bus with areas highlighted to
indicate the status of the door(s) and ramp(s).
Entrance Door Open (red)
Entrance Door Emergency

Controls Active or
Obstruction (red)
Ramp Out (red)
Entrance Door Fault
2-Door vehicles:
Exit Door Open (red)
Exit Door Emergency

Controls Active or
Obstruction (red)
Exit Door Fault
SERVICE MANUAL
Buzzer Warnings
Intermittent Tone
Driveline Communication Fault
Multiplex Communication Fault
Battery Guard Active
Hazard Warning Lights - In phase with lights
The chassis buzzer sounds with the following:

Continuous Tone
Entrance and/or Exit Door Open above 2kph
Entrance and/or Exit Door Low Air Pressure
DDA Brake Override Active
Emergency Door Open
Engine Coolant Temperature High
Engine Coolant Level Low
Engine Oil Pressure Low
Engine Warning Red
Transmission Temperature High
Low Air Pressure
DDA Brake Fault
Suspension Fault
Emergency Hammer Removed (Optional)
Front EDC
Single Period Tone

Entrance and/or Exit Door Emergency Controls
Active
Intermittent Tone
Retarder Disabled (Optional)
Direction Indicator Audible Warning (Optional)
SERVICE MANUAL
Front Electrical Distribution Centre (E.D.C.)
Diagnostic Socket ABS Diagnostic Switch

(Multibus) Retarder Switch
(ABS) Diagnostic Socket
(Engine)
CAMU
BLINK
CODE
IOU
ABS ECU
Current Monitor
ALEXANDER-DENNIS
SW
PCB - FRONT - EDC
BATT+
PT. NO 439617
30A
torque
3,9Nm F18
F12
14
Ignition
20 F19
F20
F13
F29 F21
30 F30 F22
F31 F23
F14
F32 F24
35
F33 F25
F15
F34 F26
R1 R2
25 F27
F6 F28
F16
F7 F1
30
F8 F2
F17 F9 F3
40 F10 F4
F11 torque F5
torque
17 Nm 3,9Nm
GND BATT+
31 30
445894
10
20A
15A
10A
7.5A
5A
3A
445288-FRT
1
8
2
5
SERVICE MANUAL
Front EDC Fuses Rear EDC Fuses

F1 Dash Perm 5A F1 IOU2 Mast 20A
F2 IOU3 Perm 3A F2 Body Mast 30A
F3 IOU4 Perm 3A F3 Spare Mast 30A
F4 IOU5 Perm 3A F4 Spare Mast 30A
F5 DIAG Perm 5A F5 H20 LVL Sensor Perm 3A
F6 IOU1 Perm 5A F6 Spare / G/Box Perm 10A
F7 CAMU Perm 5A F7 Doser Pump Perm 20A
F8 Dest Perm 5A F8 IOU2 Perm 5A
F9 CCTV Perm 5A F9 Body Perm 5A
F10 Chassis Perm 10A F10 Spare Perm 5A
F11 BODY Perm 10A F11 Diagnostic Perm 3A
F12 CAMU Mast 20A F12 Engine ECU Perm 15A
F13 IOU1 Mast 30A F13 Engine ECU Perm 15A
F14 IOU3 Mast 35A F14 Engine ECU Ign 5A
F15 IOU5 Mast 25A F15 G/Box ECU Ign 7.5A
F16 IOU4 Mast 30A F16 Water in Fuel Ign 3A
F17 BODY Mast 40A Ind Current
F18 ABS Mast 15A H20 level sensor
F19 Trans Mast 10A Fuel Cut Off Sol
F20 Ticket Machine 7.5A F17 Gearbox Mast 10A
F21 Radio Mast 10A F18 Chassis Spare Mast 20A
F22 CCTV Mast 15A F19 Air Dryer Ign 5A
F23 Assault Alarm 5A F20 Doser Pump Ign 5A
F24 Coin Vault Mast 5A F21 Body Ign 5A
F25 Exit Door Mast 1A F22 NOx sensor Mast 20A
F26 Fire Supression Mast 5A F23 Starter Sol Mast 30A
F27 Ent Door Mast 1A F24 Chassis Spare Mast 30A
F28 W/Chair Ramp 15A
F29 Tachograph/Trans Control Ign 3A
F30 Body Ign 10A
F31 Body / Spare Ign 10A
F32 Ticket Validator Ign 5A
F33 CCTV Ign 10A
F34 ABS Ign 7.5A
SERVICE MANUAL
Rear Electrical Distribution Centre (R.E.D.C.)
Dual Channel
Starter Relay Current Monitor
NOX
SENSOR
GEARBOX ECU
IOU
445346/445248
ALEXANDER-DENNIS
SW
PCB - REAR- EDC
IGNITION
BATT+
PT. NO 439609
30A
12
F1 torque
9Nm
20 F14
20
F15
F2
F16
3A 2
30
30 F17
F19
F3 F20 F18 5A 3
30
30 F21 F22
Fuel Heater
Coolant 7.5 4
F4 Module - Lower
11
30
30
10
10A 5
F23 Coolant
Module - Upper
30
30 F5
F10
15A 6
F24 F6
SPARE F11
30 F7
30 20A 7
F12
F8
F13
10
torque torque F9
17 Nm 3,9Nm
GND BATT+
31 30
445884
SERVICE MANUAL
Alternator AC172R - 140 amp Amended:
Specification
Nominal voltage 24V
Maximum output 3990W
Maximum permissible alternator speed 8,000 rpm
Maximum ambient operating temperature 80°C
Rotation Reversible
Mounting Swing
Drive V-belt
Weight (approx. excluding pulley) 13.5 kg
Surge voltage protection nominal trip @ 55V
Surge voltage protection 70v maximum for 2us.
Surge voltage protection Over vol. trip @ 31.1V nom.for >3s
Maximum torque 22.5 Nm at 2000 rpm
Maximum power absorbed 10.7 kW
Stator winding connections Delta
Minimum slip-ring diameter 22.2mm
Service life 250,000 miles or 10,000 hrs
Workshop Tests
Performance
Cutting in speed 1100 rpm
Output at max. load (28V) 140A at 6000 rpm
Regulated voltage 28.5V
Stator Volt Drop Test (with winding at 20° and carrying 40A DC) 1.75 to 1.85V
Rotor Resistance (with rotor at 20°) 5.4 ± 0.3 ohm
Torque Settings
Nm lb.ft. lbf in
Rear cover securing screws 1.7 - 2.3 15 - 20
Top cover securing screws 2.8 - 3.4 25-30
Regulator securing screws 1.4 - 1.7 13 - 15
Drive shaft nut 90 -100 800 - 885
Main negative terminal nut 2.0 - 2.3 18 - 20
Main positive terminal nuts 2.8 - 3.4 25 - 36
Auxiliary lead tag nuts 1.7 - 2.3 15 - 20
Alternator pulley 100 73
Alternator positive terminal 1.3 - 2.45 11.5 - 21.6
Alternator negative terminal 4.52 - 5.65 40 - 50
SERVICE MANUAL
Alternator AC172RA Amended:
Description Operation
The AC172RA alternator represents a range of alternators All alternators have a revolving field coil assembly (the
for use in the public service vehicle market. Normally rotor) and a stationary armature (the stator). Field coil
supplied for 24 volt systems only, it is available in various current flows through two carbon brushes which bear on
outputs. two slip-rings mounted on the rotor shaft. The slip- rings
and brushes operate in an enclosed compartment, thus
The AC172RA is a ventilated machine, similar in basic
preventing dust or water contaminating the slip-rings.
construction to the familiar AC5R. A narrow stator
containing the winding laminations is housed between two As the rotor revolves, alternating current (AC) is
end shields. There is a fan mounted externally at the drive generated. This is converted (rectified) to direct current
end and a cover protecting the regulator, brush box and (DC) by six diodes mounted in heat sinks fitted to the slip-
diodes at the rear (slip-ring) end. A rotor revolves inside, ring end shield; these diodes can be press-fit or stud type.
supported at either end by a ball bearing.
A second rectifier bridge is formed by three additional
This derivative has smaller slip rings to give longer brush press-fit diodes mounted in the same heat sinks as the
life and an extra terminal marked L, which is used for main diodes. These, together with the main negative
diagnostic testing only. diodes, provide the current for the field coil.
The electrical DC output is delivered through two main
terminals, with the voltage being controlled by the
regulator. The alternator is self limiting in respect of
maximum output current.
AC172RA - Fig 1 - 100 - 24 Alternator
SERVICE MANUAL
Alternator AC172RA - Dismantling Amended:
NOTE
When a machine is being checked to isolate a
fault, it is advisable to test the regulator as
described in "Testing & Lubrication", Page 5.22
- 5.23 before dismantling the complete machine.
Thoroughly clean the alternator before dismantling. Refer

to "Cleaning Fluids", for details on cleaning fluids and
their use.
Special tools required for dismantling are also detailed in
"Special Tools".
Removing The Pulley And Fan

Grip the alternator pulley in a vice, ensuring that the pulley
is protected from damage (use a pair of rubber drive belts),
and that the body of the alternator is supported. Unscrew
and remove the drive shaft nut and spring washer (3) and
remove the pulley (2). Line up the notch in the fan (1) with
the Woodruff Key and slide the fan off the drive shaft.
Lever out the Woodruff Key (4).
Removing The Rear Cover

Unscrew and remove the four screws, spring washers and
plain washers (2) then remove the rear cover (1).
NOTE
In the case of a radio-suppressed machine it will
be necessary to disconnect the two capacitor
leads to release the cover.
SERVICE MANUAL
Removing The Capacitors

If it is deemed necessary to remove a capacitor, proceed
as follows: Unscrew the four screws securing the capacitor
(2) to the clamp plate (1) and, holding the clamp plate,
withdraw the capacitor.
Removing The Terminal Box

Prise off the rubber terminal cover (9) and disconnect the
three leads (6), (7) and (8). Unscrew and remove the two
screws, washers and spring washers (1) and (3) and
remove the brush holder and gasket (2). Remove the
plastic insulator then disconnect the Lucar connector from
lead (6). Remove the terminal box (5) and discard the
gasket (4).
Removing The Regulator

Remove the screw and spring washer (1) securing the
black regulator lead to the main negative terminal pillar.
Similarly, remove the red lead (if fitted) from the main
positive terminal pillar (8).
Unscrew and remove the three regulator securing screws,
washers and spring washers (5), and remove the regulator
(4).
Unscrew and remove the four rear cover mounting pillars
(2), (3), (6) and (7), if fitted.
SERVICE MANUAL
Removing The Heat Sink Assembly

Unscrew and remove the three screws and spring washers
(6), (8) and (10), securing the stator leads. Remove the
two nuts and spring washers (2) and (4) and lift off the
terminal link (3), if fitted. Remove the regulator pillars and
washers (7) and (9). Unscrew and remove the three
screws and washers (5), (11) and (12), and the terminal
pillar (1). Pull the stator leads clear. The heat sink
assembly can now be removed.
Separating The Stator From The End

Shields
Straighten the three stator leads (1) as shown. Scribe a
line (5) across the two end shields and stator. Unscrew
and remove the four through bolts and spring washers (3).
Using two screwdrivers, carefully prise the slip-ring end
shield (2) from the stator (4). Similarly, separate the stator
from the drive end shield (6).
Separating The Rotor From The Drive

End Shield
Using a standard workshop press, separate the rotor from
the drive end shield as shown.
SERVICE MANUAL
Removing The Clamp Plate

Position the drive end shield (1) as shown, holding a hand
underneath to catch the spacer (4) as it falls out. Unscrew
and remove the three clamp plate securing screws and
spring washers (2), and remove the clamp plate (3).
Removing The Drive End Bearing

Using a standard workshop press, remove the bearing
from the drive end shield.
Removing The Slip-Ring End Bearing

Remove the spacer (3) from the rotor shaft. Fit a 'Sykes'
race extractor to the slip-ring end of the rotor (taking care
not to damage the slip-ring moulding) and remove the slip-
ring end bearing (1). Slide the plastic spacer (2) off the
rotor shaft.
SERVICE MANUAL
Removing The Drive End Bearing Seal
NOTE
The following instruction does not apply to
machines with sealed bearings.
Using a large screwdriver, lever out the rubber seal (1)

from the drive end shield (2): use a piece of wood or
similar material to avoid damage by the screwdriver to the
edge of the end shield. Discard the rubber seal.
SERVICE MANUAL
Alternator AC172RA - Component Inspection & Renewal Amended:
General Stator
Wipe all components clean with a dry cloth then use Visual Check
compressed air to remove loose dust from inaccessible Check the stator visually for signs of damage or
areas. DO NOT 'spin' the bearings with compressed air as deterioration of the insulation of windings and leads.
this can cause damage to the bearing. Ensure that the windings are held securely in place and
All components must be thoroughly cleaned with an that all bindings are tight and in good condition.
approved cleaning fluid before examination (refer to
Insulation Test
"Cleaning Fluids", Page 5.24). The stator frame and rotor
shaft should be wiped clean using a non-fluffy rag Check the insulation between the frame and one of the
moistened with white spirit. Take care to avoid the spirit three stator leads using the 100 V 'Megohm' test meter or
having prolonged contact with the winding insulation and 100 V 'Flash' tester. A minimum resistance of 10 megohms
stator leads. should be indicated if the 'Megohm' test meter is being
used. If the resistance is below this figure, clean and
All seals and gaskets must be renewed. thoroughly dry the stator then check the insulation again.
Examine all components visually for signs of cracking, Renew the complete stator if the specified resistance
corrosion, local discolouration and any other signs of cannot be obtained.
damage or excessive wear. Check all internal and external Stator Volt Drop Test
threads.
Check for continuity and correct resistance by wiring the
It is essential to remove all remaining traces of carbon dust 24 V battery in series with the adjustable load and the 0-
with compressed air before carrying out any insulation 50 A ammeter; complete the circuit across one pair of
tests. stator leads. Adjust the resistor until a current of 40 A flows,
then measure the voltage across these two same stator
In addition to the usual workshop facilities, the following
leads with the 'Avo'. Repeat this complete test on the
electrical equipment will be required:-
remaining two pairs of leads. The indicated voltage should
1. First-grade moving coil DC ammeter with a range be the same each time and within the limits given in
of a to 50 A. "Specification", Page 5.6. If the results are not similar in
each test, renew the stator.
2. 'Avo' or similar 'multimeter'.
3. 100 V 'Megohm' test meter or similar 100 V 'Flash'
tester.
4. 4 V battery of 50 ampere-hour minimum capacity.
5. Adjustable load capable of carrying a current of 40
A at 24 V.
6. 24 V 44/48 W lamp and single pole ON/OFF
switch.
Brushgear
Examine the moulded brush box for cracks and any other
signs of damage or 'tracking'.
Check that the brushes are in good condition and that they
protrude from the brush box for a minimum of 11.0mm
(0.429 in).
Should the brushes or brush box be faulty, the complete
brush box must be renewed. It is recommended that the
brush box is renewed when a complete overhaul is being
carried out.
SERVICE MANUAL
Rotor Carefully examine the field coil leads for any signs of
mechanical stress or damage to the insulation. Pay
Check the rotor for any signs of damage or rubbing. particular attention to the ends where they were attached
Examine the field windings for damage or deterioration of to the slip-rings. Ensure that the coil leads are long enough
the insulation and ensure that they are held securely in to connect to the new slip-rings.
place.
Ensure that the slip-rings are clean and free from grease,
then check for continuity by measuring the resistance
between them with the 'Avometer'. Take care not to
damage the brush tracks with the meter prods. The
resistance should be as specified in "Specification", Page
5.6. Renew the complete rotor if this resistance cannot be
obtained.
Check the insulation between each slip-ring and the drive
shaft with the 100 V 'Megohm' test meter or 100 V 'Flash'
tester. The resistance should be 10 megohms minimum if
the 'Megohm' test meter is being used.
If the resistance is below this figure, clean and thoroughly
dry the rotor then check the insulation again. Renew the
complete rotor if the specified resistance cannot be
obtained. AC172R - Fig 2 Renewing the field coil leads
Check the slip-ring surfaces for any pitting or scoring. If

skimming is necessary, mount the rotor in a lathe using the Should the lead ends be defective in any way, they should
bearing journals for location. Remove the minimum be renewed in the following manner:-
amount of metal necessary using a diamond or tungsten Cut the two leads as indicated in Fig. 2.
carbide tipped tool to obtain a fine even finish. The
minimum permissible slip-ring diameter is 22.2 mm (0.875 Taking each lead in turn, trim back a short length of the
in). glass fibre sleeving and clean off the covering of the wire
to expose the copper surface. Lightly twist a new length of
Should it prove impossible to remove all pitting or scoring 21 swg enamelled copper wire (Fig. 2) to the existing wire
without reducing the diameter below the minimum stated and solder the joint together. Snip off any excess wire.
figure, new slip-rings must be fitted.
Apply a coating of Z6/V A445 varnish to the joint. Slide a
The slip-rings must be concentric with the rotor shaft to short length of 2 mm glass fibre sleeving (Fig. 2) over the
within 0.05 mm (0.002 in). joint so that it slides inside the existing sleeve. Apply a
Great care must be taken when handling the rotor to avoid further coating of varnish to the sleeve and slide on a new
damaging the slip-ring surfaces. length of 3 mm glass fibre sleeving to abut the original
sleeve. Apply a final coating of Z6/VA445 varnish to the
outside.
Degrease the shaft with white spirit and allow to dry. Coat
Bearings the relevant part of the shaft with 'Araldite' using the two-
It is recommended that new bearings are fitted as normal tube method in accordance with the manufacturer's
routine when the alternator is being completely instructions. Do NOT allow 'Araldite' to come into contact
overhauled. with any other part of the shaft.
Slide the slip-rings on to the shaft and over the field coil
lead, ensuring that the lead passes through the groove in
the slip-ring. Allow to set for one hour at 70ºC or 20 hours
Renewing The Slip-Rings (See Fig. 2) at 20ºC (ambient).
Should it prove impossible to remove pitting or scoring Cut the extended field coil leads to length, bare the ends
without reducing the diameter below the minimum stated for the minimum length necessary, then solder one lead to
figure, new slip-rings must be fitted. Proceed as follows:- each slip-ring.
Carefully unsolder and remove the two leads from the slip- Mount the drive shaft of the rotor in a lathe and support the
rings. outer race of the slip-ring bearing in a 'steady'. Use a
Using a 'Sykes' puller " remove the defective slip-rings. diamond or tungsten carbide tipped tool to obtain the fine
Clean and polish the rotor shaft until the new slip-rings are finish required. Remove just enough metal from the slip-
a sliding fit on the shaft. rings to ensure that they are concentric with the rotor shaft
to within 0.05 mm (0.002 in).
SERVICE MANUAL
Test Probe Position Diode Correct

Test Being Test Lamp
Positive Probe Negative Probe
Tested Indication
1 Each Heat Sink in Turn Main Output Terminal D + Pos. ON

2 Main Output Terminal D + Each Heat Sink in Turn Pos. OFF
3 Main Output Terminal D - Each Heat Sink in Turn Neg. ON
4 Each Heat Sink in Turn Main Output Terminal D- Neg. OFF
5 Each Heat Sink in Turn Terminal 'A' (on Main D+) Aux. ON
6 Terminal 'A' (On Main D+) Each Heat Sink in Turn Aux. OFF
Testing The Diodes

All the diodes can be tested while the three heat sinks are
Renewing the stud type diodes
still assembled in the slip-ring end shield. Using the 24 V Unscrew and remove the securing nut and spring washer
44/48 W lamp connected in series between a probe and (3) from the diode using an 11mm thin-walled tubular
the positive terminal of the 24 V battery plus a second spanner. Push the diode (4) clear of the heat sink.
probe connected to the negative side of the battery, carry Thoroughly clean the contact face and hole in the heat sink
out the tests detailed in the diode testing chart above. then smear both surfaces with 'Biccon X' jointing
Should a lamp indication be obtained that does not agree compound (see "Cleaning Fluids", Page 5.24).
with the table, the diode being tested is faulty and the heat Ensure that the new diode is clean and free from grease;
sink containing it must be renewed or repaired. insert it into the heat sink. Secure with the spring washer
and nut.
NOTE
Tighten the diode securing nut to a torque of 2.7 to 3.1 Nm
A broken lead between diode and terminal or a
using an 11 mm thin-walled tubular spanner.
high resistance solder joint could also indicate
a faulty diode. Check for either of these faults Replacing the heat sinks
before removing a heat sink. Renew the heat sink(s) ensuring that the insulating bushes
and washers are fitted in the correct sequence to insulate
the heat sinks from the end shield and from each other
(see Fig. 3 inset).
Diode And Heat Sink Renewal Ensure that the connecting surfaces of the main leads and
(See Fig. 3 on the next page) diodes are clean and free from grease. Reposition the
leads and solder them to the diodes.
Individual stud diodes can be renewed but a faulty press-
fit diode will necessitate renewal of the complete assembly To connect the auxiliary diode lead, slide a small glass
comprising heat sink and diode(s). The following fibre sleeve of suitable diameter over the lead to be joined.
procedure should be adopted in either case: If necessary, splice in a small length of suitable cable to
lengthen the lead. Twist the bared ends together and
NOTE solder the joints. Apply Z6/ V A445 varnish to the joint.
65 A machines have press-fit type main diodes; When partly dry (tacky), slide the glass fibre sleeve over
the main diodes in 100 A and 120 A machines the joint and varnish with more Z6/VA445.
are stud type. All machines have press-fit When complete, paint the entire assembly - heat sink,
auxiliary diodes. diodes and leads - with Pacific Blue 014 synthetic enamel.
'Crimping' together the auxiliary diode leads is permitted
provided the correct crimping tool and a connector of the
Removing the heat sinks correct size and electrical value are used; typical field
Unsolder the connecting lead (5) from each of the main current is 3.5 A.
diodes in the faulty heat sink.
Cut the leads (1) from the auxiliary diode (2) at a point
approximately 25 mm (1.0 in) from the diode.
Remove the insulating washers and brush (7) and detach
the heat sink (6).
SERVICE MANUAL
AC172RA - Fig 3 View of heat sink and diode assembly
Key
1. Auxiliary diode lead.
2. Auxiliary diode.
3. Nut and spring washer.
4. Main diode (stud type).
5. Main diode lead.
6. Heat sink.
7. Insulating bush and washers.
SERVICE MANUAL
Alternator AC172RA - Reassembly Amended:
Fitting The Drive End Bearing Seal

Fit a new rubber seal (1) to the drive end shield (2). The
solid side of the seal must face away from the drive end
shield.
Fitting The Drive End Bearing

Press the drive end bearing into the drive end shield as
shown, using a standard workshop press and pressing
against the outer race only.
Fitting The Clamp Plate

Fit the triangular clamp plate (3) to the drive end shield (2)
and secure it using the three screws and spring washers
(1), tightened to a torque value of 2.3 to 2.8 Nm. Fit the
metal spacer (4) so that it sits snugly inside the clamp
plate.
SERVICE MANUAL
Fitting The Slip-Ring End Bearing

Fit the plastic spacer (2) onto the rotor shaft as shown.
Mount the rotor (1) in a press, drive end uppermost, with
the slip-ring end of the rotor shaft sitting loosely in the slip
ring end bearing (3); the rubber seal of the bearing should
face downwards. Support the inner race of the bearing
with a suitable cylindrical spacer then press the rotor shaft
into the bearing.
Fitting The Rotor Into The Drive End

Shield
Fit the rotor into the drive end shield (2), pressing firmly on
the shoulders of the rotor claws (1) to make sure that the
rotor is pushed fully home.
Fitting The Stator To The Drive End

Shield
Fit the stator (1) to the drive end shield (2) ensuring that
the marks scribed during dismantling are in line with each
other.
SERVICE MANUAL
Fitting The Slip-Ring End Shield

Fit the slip-ring end shield (2) to the stator (4), making sure
that the three stator leads (1) are correctly positioned and
do not foul the slip-ring end shield; if necessary use a
press. Make sure that the scribe marks (5) made during
dismantling are all in line, then secure the whole assembly
using the four through bolts and spring washers (3),
tightened to a torque value of 6.2 to 7.4 Nm.
Fitting The Heat Sink & Diode Assembly

Fit the heat sink and diode assembly to the slip-ring end
shield. Secure it using the following procedure: The two
regulator pillars (7) and (9), together with their washers
and spring washers; torque value 2.8 to 3.4 Nm.
The three (or four) securing screws, washers and spring
washers (5), (11) and (12); torque values - 2.8 to 3.4 Nm
(large) and 1.7 to 2.3 Nm (small).
The terminal pillar (1) together with its washer and spring
washer. If fitted, this item replaces one of the smaller
securing screws. The torque value is 1.7 to 2.3 Nm.
Fit the terminal link (3) (if fitted) as shown. Secure it with
the two nuts (2) (torque value 1.7 to 2.3 Nm) and (4)
(torque value 2.8 to 3.4 Nm). Secure the stator leads to the
heat sinks using the three screws and spring washers (6),
(8) and (10) tightened to a torque value of 2.0 to 2.3 Nm.
Fitting The Terminal Box

Place the plastic terminal box (3), with a new gasket (4), in
position over the brush box. Pass the yellow lead (5)
through the hole and fit a new Lucar connector and
insulator (2). Insert the brush holder (7) into the terminal
box and secure using the two screws, washers and spring
washers (1) and (6); tighten to a torque value of 1.4 to 1.7
Nm. Connect the Lucar connector (2) as shown.
SERVICE MANUAL
Fitting The Regulator

Fit the regulator (4) and secure it using the three screws,
washers and spring washers (5), (8) and (9), tightened to
a torque value of 1.4 to 1.7 Nm. Connect the black
regulator lead to the main negative terminal and secure it
using the small screw and spring washer (2), tightened to
a torque value of 1.4 to 1.7 Nm. Similarly, connect the red
regulator lead (if fitted) to the main positive terminal (12).
Connect the two remaining regulator leads (13) to the two
remaining brush box terminals (green lead to the 'F'
terminal) then re-fit the rubber terminal box cover (1).
In the case of radio-suppressed machines, fit the four rear
cover mounting pillars (3), (6), (7) and (10), and tighten to
a torque value of 1.7 to 2.3 Nm. Fit new capacitors (15)
and (18) (if previously removed) to the rear cover and
secure each using the four screws and spring washers
(not shown) screwed into the clamp plates (14) and (19).
Connect the two capacitor leads (16) and (17) in the rear
cover to the main positive terminal (12) and the auxiliary
(warning light) terminal (11); tighten the terminal nuts to
torque values of 2.8 to 3.4 Nm and 1.7 to 2.3 Nm
respectively.
Fitting The Rear Cover

Fit the rear cover (1) and secure using the four screws and
spring washers (2), tightened to a torque value of 1.7 to
2.3 Nm.
SERVICE MANUAL
Fitting The Pulley And Fan

Slide the remaining spacer (1) onto the rotor shaft and
engage it with the recess in the drive end shield as shown.
Fit a new Woodruff Key (5) into the slot in the rotor shaft.
Slide the fan (2) onto the rotor shaft (there is a notch to
enable it to slide over the key) and seat it firmly against the
spacer. Re-fit the pulley (3) and secure it using the nut and
spring washer (4) tightened to a torque value of 90 to 100
Nm (secure the pulley in a vice as described at the
beginning of "Dismantling", Page 5.8 - 5.12).
SERVICE MANUAL
Alternator AC172RA - Testing & Lubrication Amended:
Test Equipment The batteries (24V and 6 V) must be fully charged; no

significant volt drop should occur when the variable
Equipment required to test the alternator resistor is set at its lowest value.
• Test machine with variable speed drive capable of Set the variable resistance until 24 V is indicated on the
driving the alternator at speeds of up to 8000 rpm meter; the lamp should be ON.
on full load.
• 24 V 100 ampere-hour lead acid battery.
• Carbon pile or similar variable electrical load
capable of carrying a current of 120 A at 30 V.
• 100 V 'Megohm' test meter or a 100 V 'Flash'
tester.
• First grade DC moving coil ammeter with a range
of 0 to 150 A.
• First grade moving coil DC voltmeter with a range
of 0 to 50 V.
• 'Avo' or similar multimeter with a resistance range.
• 24 V, 2.8 W warning lamp. AC172R - Fig 4
Test Circuit for 546 & 547 regulators
Additional equipment required to test the Decrease the resistance until the lamp goes out; this must
regulator occur at between 28 V and 29 V. The lamp must switch off
cleanly - no flickering is permissible.
• 6 V battery (low capacity acceptable).
If the regulator fails this test it is faulty and must be
• Field coil from AC172R alternator.
renewed.
NOTE
If a suitable field coil is not available a 10
ohm 100 W wire wound resistor can be
Static Tests - Alternator
used as a substitute load. If a 10 ohm 100
W resistor is not available, a similar Before mounting the alternator on the test machine or
resistance can be made up using two 22 making any connections, check the insulation resistance of
ohm 50 W resistors in parallel. Resistors the alternator windings.
of this value can be obtained from RS
Components Ltd. under stock No. 158- NOTE
345. They should be used with heat sinks
stock No. 401-4 03. These heat sinks The regulator must be disconnected from the
must be placed so that the fins are alternator when carrying out the following
vertical in free air. insulation tests; UNDER NO CIRCUMSTANCES
MUST THE INSULATION TESTER BE
CONNECTED TO ANY OF THE REGULATOR
• 250 ohm 3 W variable resistor. LEADS.
Connect one side of a 100 V 'Megger'-type tester to the

alternator frame and keep it there until the test has been
Static Tests - Regulator completed. Connect the other side of the tester to one of
the heat sinks, then the main positive, main negative and
The alternator and regulator form an integral unit, 'A' terminals in turn. The resistance between any of these
therefore before undertaking repair work on the alternator terminals and earth should be not less than 10 megohms.
it is essential to carry out a test to determine which is at
fault.
Remove the regulator leads from the terminals on the
alternator and connect the leads to the test circuit as
shown in Fig. 4.
SERVICE MANUAL
Alternator AC172RA - Testing & Lubrication Amended:
Performance Testing Lubrication

1. Mount the alternator on the test machine and Although some machines are fitted with sealed bearings,
connect the drive. many are 'Stauffer' lubricated. The following instructions
apply to 'Stauffer' lubricated machines only:
2. Make the connections as shown in Fig. 5
Before re-assembly, pack the following with Shell 'Dolium
NOTE R' grease:-
DO NOT REMOVE ANY CONNECTIONS • The grease passageways in both end shields.
WHILE THE ALTERNATOR IS RUNNING.
• Both bearings.
3. Start the drive and increase speed to 1500 rpm • The cavity between the slip-ring end bearing and
(approx.). Check that the alternator is charging. the plastic spacer, two thirds full.
4. Reduce speed until the ammeter reads zero and NOTE
the lamp is extinguished. This speed should
correspond to the cutting-in-speed. See It is important that the slip-ring end
"Specification", Page 5.6. bearing is fitted the correct way round
with the sealed end towards the slip-ring.
5. Adjust alternator speed and load to correspond to
the figures in the performance table, in Smear a thin film of Volium R' grease on the lips of the
"Specification", Page 5.6. Check for each drive end seal and also on the rotor drive shaft.
condition specified.
Every 100,000 km, or every year (whichever is the
Some variation from the stated outputs is permissible but shorter), remove the lubricator caps and add TWO caps
failure to reach within 10% of the required figures indicates full of 'Dolium R' grease to the drive end lubricator and one
a faulty machine. If the static tests were satisfactory then cap full to the slip-ring end lubricator. No other lubrication
the regulator must be considered suspect and should is required.
therefore be replaced.
The adjustable load must be set so that the machine NOTE
provides the maximum rated output at 28 V. If the battery Do Not Over-Lubricate The Machine.
is fully discharged it may not be possible to obtain the
rated voltage.
Identification
If the load will not absorb the full rated output it may be
necessary to discharge the battery before commencing • The alternator model type is marked on the
the performance tests. identification label. It can also be identified from
the terminal configuration as shown below:
WL
S L
AC172RA
AC172RA - Fig. 5
Test Circuit for AC172RA alternator
SERVICE MANUAL
Alternator AC172RA Amended:
Special Tools Cleaning Fluids

Kerosene may be used on parts which do not contain
electrically insulated components.
Components containing electrical insulation should be
cleaned with a chlorinated solvent. Usually wiping with a
moistened cloth is quite sufficient.
WARNING
Chlorinated solvents can be dangerous.
Avoid breathing the vapour.
These solvents are safe when properly used but
in common with other halocarbons inhalation of
high concentration of vapour will cause
AC172RA - Fig. 6 'Sykes' type race extractor drowsiness, headaches and giddiness. Severe
exposure may lead to unconsciousness or
prove suddenly fatal.
These vapours are considerably heavier than
A 'Sykes' race extractor of the type shown in Fig. 6 will be air and may collect at low levels, particularly in
necessary to remove the slip-rings and the slip-ring end undisturbed areas.
bearing. No other special tools are required.
Do not smoke when using these solvents.
Do not use the solvent in a place which is not
well ventilated, but avoid draughts.
Do not lean into any vessel containing the
solvent - liquid or vapour.
Avoid contact with the skin and eyes.
These solvents will remove the natural grease
from the skin. Contact with the hands should be
avoided as far as possible, and if contact is
likely PVC gloves should be worn.
Solvent in the eyes will be irritating and if there
is any danger of splashing, eye protection
should be worn.
Do not take internally.
Avoid contact of the liquid or vapour with naked
flames or red hot surfaces (e.g. welding arcs) as
acidic and toxic decomposition products will be
formed.
SERVICE MANUAL
Battery Carrier Area & Rear Frame
Add A Fuse
MEGA
40
150A
Master Switch MEGA

150A
MEGA
175
REAR FRAME
Torque settings
Master switch bolt . . . . . . . . . . . . . . . . . . .9 Nm (M6)
Master switch coil terminal . . . . . . .2.0 - 2.2 Nm (M4)
Master switch main terminal . . . . . .18 - 22 Nm (M12)
Mega-fuse terminations . . . . . . . . . . . .13 Nm (9.5 lbf ft)
SERVICE MANUAL
Wiring Diagrams - Chassis
Chassis Diagrams - ZF Gearbox

Batteries, Starting, Charging & Power Distribution . . . . . . . . . . . . . . . . . . . . .Page 5.84
Front EDC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.85
Rear EDC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.86
CMU Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.87
IOU 1 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.88
IOU 2 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.89
Dash Panel (Multic Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.90
Multiplex CAN Com Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.92
Cummins ISBe5 Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.93
Chassis CAN Network & Engine Emission Control . . . . . . . . . . . . . . . . . . . . . Page 5.94
ZF Transmission Option Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.95
Wabco “E” Series ABS Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.96
Spares & Body Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.97
IOU Supplies, Bodybuilder Multic Interface . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.98
Earth Points, Soldered Joints & Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.99
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.100
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.101
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.102
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.103
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.104
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.105
Basic Harness Layouts & Earth Points (viewed from above) . . . . . . . . . . . . . .Page 5.106
Basic Harness Layouts & Earth Points (viewed from rear) . . . . . . . . . . . . . . .Page 5.107
Basic Harness Layouts & Earth Points (viewed from front) . . . . . . . . . . . . . . .Page 5.108
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Wiring Diagrams Amended:
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Chassis Diagrams - Voith Gearbox

Rear EDC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.112
CMU Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.113
IOU 1 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.114
IOU 2 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.115
Voith Transmission Option Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.121
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.126
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.127
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.128
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.129
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.130
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.131
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Electrical System and Instrumentation Amended:310811
Chassis Diagrams - ZF Ecolife Gearbox - 4 Start Batteries

Rear EDC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.138
Actia CMU Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.139
Actia Input/output Unit 1 (IOU1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.140
Actia Input/output Unit 2 (IOU2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.141
ZF Transmission Option Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.147
Connectors C to AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.152
Connectors AC to BU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.153
Connectors BV to EL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.154
Connectors FC to GJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.155
Connectors GU TO RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.156
Connectors Actia 1 to 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 5.157
SERVICE MANUAL
Wiring Diagrams Amended:310811
SHEET 1 of 25
DRG No : SK11705
WIRING DIAGRAM - E400 EURO 5 - GEN 2 - ZF ECOLIFE - 4 START BATTERIES
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1
1 4 7 10 13 16 19 1 4 7 10 13
2 5 8 11 14 17 20 2 5 8 11 14
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3 6 9 12 15 18 21 3 6 9 12 15
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19 16 13 10 7 4 1
20 17 14 11 8 5 2
21 18 15 12 9 6 3
1 4 7 10 13 16
2 5 8 11 14 17
3 6 9 12 15 18
WIRING DIAGRAM - E400 EURO 5 - GEN 2 - ZF ECOLIFE - 4 START BATTERIES DRG No : SK11705 SHEET 20 of 25
Amended:310811
Page 5.155
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Suspension, Wheels Amended:17.05.11
Contents
Air Suspension
Air circuit diagram . . . . . . . Page 6.2
Description . . . . . . . . . . . . Page 6.3 - 5
Main component diagram . Page 6.6
Main components . . . . . . . Page 6.7
Charging valve adjustment Page 6.8
Levelling Valve . . . . . . . . . Page 6.9
Checking the ride height . . Page 6.10
Proximity switch adjustment Page 6.11
Front Suspension
Assembly diagram . . . . . . Page 6.12
Torque settings . . . . . . . . . Page 6.13
Removal &
dismantling procedure . . . Page 6.14 -15
Rear Suspension
Rear air suspension assembly
diagram . . . . . . Page 6.16
Torque settings . . . . . . . . . Page 6.17
Shock Absorbers
Removal . . . . . . . . . . . . . . Page 6.18
Fitting . . . . . . . . . . . . . . . . Page 6.18
Checking shock absorbers Page 6.18
Wheels and Tyres

Wheel inspection . . . . . . . Page 6.19
Tyre inspection . . . . . . . . . Page 6.19
Fitting wheels ......... Page 6.19
Thread protection . . . . . . . Page 6.20
Wheel and stud removal . . Page 6.20
Replacement tyres . . . . . . Page 6.20
Tyre pressure . . . . . . . . . . Page 6.20
Tyre pressure
recommendations . . . . . . . Page 6.20
Chassis Jacking Points . . . Page 6.21
Section 6
SERVICE MANUAL
Air Suspension System Amended:
SUSPENSION
AUXILIARY &
RESERVOIR
FRONT
LOCATION
2 1 3
CHARGING
KEY TO PIPE SIZES
VALVE
12 GREEN
3
12 BLACK
SOLENOID LINE
6 GREEN
3
VALVE FILTER
11/25
6 BLACK
23
6 BLUE 2
24/13
1
22
2
12
1
3
23
6
21/14
STEERING COLUMN
SOLENOID
4
TEST
PILOT VALVE
VALVE
POINT
LEVELLING
VALVE
LH-FRONT
1
21
21
FRONT
21
21
LEVELLING
VALVE
RH-FRONT
REAR
1
1
21
21
21
21
LEVELLING
VALVE LEVELLING
LH-REAR VALVE
RH-REAR
FRONT KNEEL AR8535
SERVICE MANUAL
Description
The vehicle is fitted with air suspension, a function of exhausting, the correct ride height is obtained.
this is the facility to kneel the vehicle at the front, or For the kneeling system this function is controlled by
when fitted, an option to lower the suspension all a solenoid valve block and electrical relays via
round. "Raise" and "Kneel" buttons in the drivers cab.
The air suspension is supplied from an auxiliary A proximity switch is fitted on the vehicle. The switch
tank, sited on the right hand side of the chassis and senses movement past a fixed indicator on the front
forward of the battery carrier. Output supply passes axle. The indicator is sited at approximately half
through the system line filter, which filters the air distance of its full travel. When the switch senses
before it enters the solenoid valve block and the this indicator, the level warning light (yellow) will
levelling valves. Foreign matter in these items may come on and the vehicle can be stopped at any point
cause them to malfunction. while the light is on. If the button is released before
Levelling valves are fitted to the front and rear axles the light comes on the vehicle will return to a normal
of the vehicle. The levelling valves have a neutral or ride height.
zero setting and at this position the vehicle ride
height is set. Should the vehicle experience an
increase in load, the chassis will move nearer to the Kneeling
ground resulting in the connection linkage pushing When the kneel button is pressed valves 42 and 43
up and the valve spindle turning clockwise. This are energised. Valve 42 will be put in the open
results in the valve allowing more air to be pumped position and simultaneously valve 43 will close. The
into the air bags until the original ride height is closing of valve 43 isolates the front levelling system
achieved, although at a greater pressure. For a and stops the levelling valve exhausting or inflating
decrease in load the reverse happens, with the the air bags. Opening valve 42 allows the front air
supply pressure shut off and the air bag pressure bags to exhaust, allowing the vehicle to kneel.
(24) (12)
41 42 43
6
FUNCTION 41 42 43 6
NORMAL 0 0 0 0
3
1 2 FNT KNEEL 0 1 1 1
3
(21) RAISE 1 1 1 1
11 22 23
Kneel
SERVICE MANUAL
AUXILIARY &
FRONT SUSPENSION
LOCATION RESERVOIR TO STEERING
COLUMN
PILOT VALVE
CHARGING
VALVE
11/25
2
3
41
6
24
1
42
22 SOLENOID
12 VALVE
43
23
1 LEVELLING 21 SOLENOID
21 21 VALVE
LH-FRONT TEST
VALVE
POINT
FROM
PORT 24
MCPV
24
1 FRONT
LEVELLING
21 21 VALVE
RH-FRONT
FRONT KNEEL
KEY TO PIPE SIZES

AUXILIARY & LINE
SUSPENSION FILTER 12 GREEN
RESERVOIR
12 BLACK
6 GREEN
REAR
6 BLACK
LOCATION
2
6 BLUE
ZF GEARBOX
SUPPLY
LEVELLING
3
LEVELLING
VALVE
VALVE
LH-REAR SOLENOID RH-REAR
VALVE
21 21
1 1
21 21
REAR
11/25 22 23
21
CHARGING
VALVE
3
12
24 SOLENOID
VALVE
FULL KNEEL AR7794

41 42 43
SERVICE MANUAL
Raise Normal Running

When the “raise” button is pressed, valves 41, 42 For normal vehicle running valve 43 is at rest thus
and 43 are energised. Valve 41 changes over to completing the levelling circuit. The levelling valve
allow the auxiliary air supply to reinflate the front air will detect whether to inflate or exhaust the air bags
bags. Valve 42 will open to allow the air through to depending on the load.
re-inflate the front air bags. Valve 43 closes to
isolate the levelling system to allow re-inflation from
the auxiliary reservoir.
(24) (12)
41 42 43 FRONT LOCATION SOLENOID VALVES REAR LOCATION SOLENOID VALVES
6 FUNCTION 41 42 43 6 FUNCTION 41 42 43 6
NORMAL 0 0 0 0 NORMAL 0 0 0 0
3
FNT KNEEL 0 1 1 1 FNT KNEEL 0 0 0 0
1 2
3 FULL KNEEL 0 1 1 1 FULL KNEEL 0 1 1 1
(21)
RAISE 1 1 1 1 RAISE 1 1 1 1
11 22 23
Raise
Normal Running
SERVICE MANUAL
Single Solenoid Valve

(front)
Triple Solenoid Valve Auxiliary Reservoir

& Charge Valve & Line Filter
(front)
Levelling Valve
Levelling Valve
Proximity Sensor
Levelling Valve
Levelling Valve
Triple Solenoid Valve

(rear - full kneel only)
Auxiliary Reservoir
SERVICE MANUAL
Levelling Valve Location

The valve is mounted beneath the drivers seat area
Description
on the chassis side member next to the solenoid
The levelling valve controls the inflation or valve block.
exhausting of air bags. By the use of an eccentric
cam within the valve, air pressure is adjusted
depending on the load on the vehicle.
Location Solenoid Valve
The vehicle is fitted with four levelling valves, two at Description
the front and two at the rear. They are bolted to the
side of the chassis ahead of the wheels. The solenoid valve block has three valves which
control the "kneel" and "raise" functions. For the
kneel function the solenoid block isolates the
levelling system and exhausts through charge valve
Air Spring to reduce the pressure in the air bags. For the raise
function the levelling system is again isolated and air
Description
from the auxiliary reservoir re inflates the air bags.
The air bags are of the "rolling diaphragm type" this For vehicles fitted with a full kneeling system a triple
term refers to the manner in which the inturned solenoid valve block is mounted at the rear of the
portion of the spring rolls up and down the piston chassis frame, behind the rear axle, adjacent the air
piece during suspension movement. dryer.
Location Location
The air bags are fitted one per wheel, the front air Beneath the drivers seat area mounted on the
bags are fitted centrally behind the wheel and the chassis side member.
rear air bags are mounted on the axle suspension
arms.
Solenoid Valve - Single
Proximity Switch Location
Description The single solenoid valve for the front kneel system
The proximity switch detects the lowering of the is situated behind the battery carrier mounted on the
chassis and will indicate, via a warning light, when chassis frame. If the vehicle is fitted with a full kneel
the vehicle can be knelt. system the second solenoid is mounted at the rear
right hand side of the vehicle on the outer frame near
Location
the engine dipstick.
The proximity switch is situated on the right hand
side member directly above the axle beam. The Function
proximity switch is mounted in a slotted plate
attached to the chassis frame and the indicator or The closing of this solenoid valve isolates the
“flag” is attached to the axle beam. For full kneel levelling system when the vehicle is in kneel mode
vehicles the rear proximity switch is mounted on the and stops the system being charged or exhausted.
right hand side member forward of the rear axle.
Charge Valve Line Filter

Description Description
The charge valve is effectively a pressure regulator The line filter is fitted to the output side of the
valve which is preset at 1 bar. When the solenoid auxiliary reservoir, sited at the front, right hand side
valve exhausts on the kneel cycle to the charge forwards of the battery carrier.
valve the minimum pressure in the air bags will be 1
bar. This will protect the air bags from damage as Function
the system pressure will not let the air bags "bottom This filters the air before it enters the solenoid valve
out". and has a replaceable element.
SERVICE MANUAL
Charging Valve Adjustment - Kneeling

System
1. Release adjusting screw locknut and turn

adjusting screw full in.
2. Press and hold in the BLACK kneel button until the
vehicle stops lowering.
NOTE
The vehicle may not lower at all at this
stage.
3. With the BLACK button held in, slowly turn out the
charge valve adjusting screw until the frame just
contacts the bump stops.
4. Turn the adjuster screw OUT a further HALF turn
and tighten the lock nut.
5. Check system operation:
Press the raise button to bring the vehicle back to
the normal ride height. Press and hold in the kneel
button, the vehicle should lower and stop on the
bump stops. The front air bags should be firm, as
a nominal pressure is retained in the bags to
reduce air consumption and prevent air bag
detachment - Readjust the valve if necessary.
Charge Valve
(front)
SERVICE MANUAL
Levelling Valve
Description
The levelling valve controls the pressure in the air
suspension bellows in proportion to the vehicle load.
Operation
The vehicle body with its levelling valve will move
down as the load on the body is increased.
The linkage between the vehicle axle and the
levelling valve raises both lever (f) and guide (d) via
eccentric cam (e). As guide (d) moves up, it also lifts
its pin, thus opening inlet valve (b), allowing air from
the reservoir to flow through the valve via port 1 and
check valve (a) into the air bellows which are
connected to ports 21 and 22.
6. Move the lever on the levelling valve up and
In order to minimise air consumption, the outside of down to ensure that the valve is charging and
the pin is machined in such a way that the passage
exhausting correctly.
of air through the valve is regulated at two levels
depending on the deflection of lever (f). 7. Shorten the connecting rods until the chassis
As the pressure in the air bellows increases, the height sits 15 - 20 mm below the required
chassis height is adjusted, and lever (f) causes inlet height.
valve (b) to close. In this position, ports 21 and 22 8. Slowly charge the suspension by increasing
are connected to each other via a transverse throttle. the length of the connecting rod until the
When the vehicle load is decreased, the reverse correct ride height is achieved. Tighten the
process takes place. jubilee clips.
The vehicle chassis is now raised by the excess 9. When all adjustments have been made,
pressure in the air suspension bellows and lever (f) recheck all dimensions and re-adjust if
with eccentric cam (e) and guide (d) are pulled necessary.
down. This causes the pin to be moved downwards
from its seat on inlet valve (b), permitting excess 10. Tighten all jubilee clips on the connecting
pressure from the air bellows, to escape to rods.
atmosphere via drilling (c) and vent holes 3.
With this drop in pressure in the air bellows the WARNING
chassis height is lowered and lever (f) is returned to As air is exhausted from the suspension system, the
its normal horizontal position. As drilling (c) is vehicle chassis will be lowered, personnel must
blocked by the pin resting on inlet valve (b), the
ensure that they do not position themselves such,
levelling valve is again in a balanced position.
that they may become trapped or crushed.
If possible ride height adjustment should be carried
Levelling Valve Adjustment out over a pit.
1. Position the vehicle on level ground. Always completely drain the air system before
2. Fully charge the system with air. removing any pipe, connector or component from the
air system.
3. Check the system for leaks. Rectify as
necessary.
NOTE
4. Check ride height as per diagram, if incorrect,
The ride height must always be set as the air bellows
continue with adjustment.
is being charged.
5. Slacken the jubilee clips at the ends of the
connecting rods.
SERVICE MANUAL
Checking The Ride Height

If it is suspected that the ride height is incorrect, the All dimensions are with the vehicle in the laden
measurements shown on the illustrations below condition.
should be checked.
240
Front Suspension Levelling
Side View on Drive Axle
SERVICE MANUAL
Proximity Switch Adjustment If adjustment is required, the chassis must be sitting

on the bump stops. The proximity switch should then
The proximity switch is mounted on a slotted plate be adjusted so that the upper edge of the proximity
attached to the chassis frame. The switch senses switch is 2 to 3 mm below the top of the “flag”. By
the location, travelling up and down, of a bracket or slackening off the locking nuts the switch can be slid
“flag” mounted on the panhard rod mounting. up or down in the slot to the correct position and the
nuts retightened. The clearance gap between the
When the air suspension is in kneel mode, the air end face of the switch and the flag should be 6.0 to
springs will exhaust and the chassis will start to 6.4 mm.
lower; coming to rest on the bump stops.
The vehicle should then be Raised and Knelt to
As the proximity switch passes in front of the “flag” check correct positioning of the proximity switch.
the kneeling lamp on the instrument panel will be
illuminated and the suspension will be held in the
knelt position.
In the Raise mode the suspension lifts quickly off the
bump stops until the proximity switch clears the
“flag”. The Raise solenoid valve is then switched off
allowing the chassis to come to the correct ride
height under the control of the levelling valves.
SERVICE MANUAL
Front Air Suspension Assembly Amended:210213
24
23
RH 13
16 15
21
ZF AXLE
19
IN K 13
RL
14
P E
UP
13
14 24
15
DANA Axle
Anti Roll Bar
Platess shown
See Insets for ZF Axle
18 arrangement
20
16
K
2
LIN
16
ER
T
ON LH
LOW
FR
ZF AXLE
13
2
00332
Front Air Suspension Assembly
1. Torque arm -lower 11. Bush - anti roll bar 20. Shim - link - top
2. Bolt - link to frame 12. Bolt - bush to frame 21. -
3. Torque arm - upper 13. Link plate - 22. Damper - c/w mounting kit
4. Bolt - arm to tower A.R.B. mounting 23. Air spring assembly
5. Bolt - arm to frame 14. Mounting rubber 24. Damper mounting nuts
6. Nut special 15. Bush 25. Proximity switch
7. Tower - LH 16. Bolt 26. Switch bracket
8. Tower - RH 17. Nut 27. Switch “flag”
9. Bolt - tower to axle 18. Block - arm mounting
10. Anti roll bar 19. Bolt - block to axle
SERVICE MANUAL
Front Air Suspension - Maintenance Amended:050112
Description Precautions
The front axle is located on the frame by two pairs of • Stop the engine before working under a
torque arms. The upper torque arms (3) are attached vehicle.
to the suspension towers (7) and anchored to the
• Always chock the wheels because depleting
chassis frame. The lower torque arms (1) are
vehicle air system pressure may cause the
attached to the angled mounting block (18) secured
vehicle to roll.
to the centre of the axle beam, and anchored to the
chassis frame. Where the torque arms (1 & 3) are • Keep hands away from actuator push rods
attached to the chassis, shims are fitted. and slack adjusters; they may apply as
system pressure drops.
These shims control the suspension angles and
must not be left out on assembly. • Never connect or disconnect a hose or line
containing air pressure, it may whip as air
The front suspension has an anti-roll bar, (10) which
escapes.
is rubber mounted (11, 14) to the frame and to the
suspension towers via link plates. Suspension is • Never remove suspension components
provided by spring units (28), mounted on the without first releasing stored pressure held in
suspension towers, and two hydraulic dampers (22). the air springs
 WARNING
• Never remove a component or pipe plug
unless you are sure that all system pressure
Before working on or around air systems and has been depleted.
components, the following precautions
should be observed. • Never exceed recommended air pressure
and always wear safety glasses when
working with air pressure.
• Never look into air jets or direct them at
anyone.
Torque Settings • Never attempt to dismantle a component until

you have read and understood
 Bolt - lower torque arm (2) . . . . . . . . . . . . . . . . . . . recommended procedures. Some units
353 - 438 Nm (260 - 323 lb ft) contain powerful springs and injury can result
Bolt - upper link/tower mounting (4,5) . . . . . . . . . . . if not properly dismantled. Use only correct
 tools and observe all precautions relative to
250 - 316 Nm (184 - 233 lb ft)
the use of these tools.
Bolt - Axle beam/air spring tower (9) . . . . . . . . . . . .
491 - 613 Nm (362 - 452 lb ft) Surface damage
Bolt - Anti-roll bar mounting (12) . . . . . . . . . . . . . . . Any surface damage in the form of scores, dents etc
101 - 111 Nm (74 - 82 lb ft) or weld splatter can cause premature failure of the
Bolt - link plates (16) . . . . . . . . . . . . . . . . . . . . . . . spring due to stress concentration.

250 - 316 Nm (184 - 233 lb ft) Surface damage can also destroy the corrosion
 Bolt - Mounting block/axle beam (19) . .. . . . . . . . . protection layer.
491 - 613 Nm (362 - 4562 lb ft) Check the air bags for signs of damage or wear.
 Nut - damper mounting (24) . .. . . . . . . . . . . . . . . .
63 Nm + -7Nm (46.5 lb ft + -5b ft)
Nut - air spring top plate . .. . . . . . . . . . . . . . . . . . .
(19-22Nm (14-16 lb ft )
SERVICE MANUAL
Front Air Suspension Assembly Amended:210213
24
23
RH 13
16 15
21
ZF AXLE
19
IN K 13
RL
14
E
UPP
13
14 24
15
DANA Axle
Anti Roll Bar
Platess shown
See Insets for ZF Axle
18 arrangement
20
16
K
2
LIN
16
ER
T
ON LH
LOW
F R
ZF AXLE
13
2
00332
Front Air Suspension Assembly
1. Torque arm -lower 11. Bush - anti roll bar 20. Shim - link - top
2. Bolt - link to frame 12. Bolt - bush to frame 21. -
3. Torque arm - upper 13. Link plate - 22. Damper - c/w mounting kit
4. Bolt - arm to tower A.R.B. mounting 23. Air spring assembly
5. Bolt - arm to frame 14. Mounting rubber 24. Damper mounting nuts
6. Nut special 15. Bush 25. Proximity switch
7. Tower - LH 16. Bolt 26. Switch bracket
8. Tower - RH 17. Nut 27. Switch “flag”
9. Bolt - tower to axle 18. Block - arm mounting
10. Anti roll bar 19. Bolt - block to axle
SERVICE MANUAL
Front Air Suspension - Maintenance Amended:
Removal / Dismantling Procedure • Lower the roll bar (10) on to the lower torque
arms (1).
 WARNING • Before replacing the clamp bushes make
sure that the roll bar is clean and free from
No work is to be undertaken beneath grease, dirt and grit.
the vehicle using jacks as a sole
means of support. Additional • With the clamps refitted, tighten all bolts and
support, capable of accepting the torque up with the weight of the vehicle on
vehicle weight when the jacks are the suspension.
removed, are to be positioned under
Axle Removal
the framework junction slightly
forward of the gearbox side 1. Remove the Bolts (4 & 5) and shims (20)
mountings. securing the upper torque arm to the tower (7
& 8) and the frame, with draw the unit.
1. Jack up the vehicle and situate vehicle 2. Remove the bolts )(19) securing the lower
supports as necessary. torque arms (1) to the axle block (18).
2. Remove the road wheels. These arms need not be removed.
3. With the weight of the axle and suspension
3. Disconnect and remove the shock absorbers (22).
assembly supported on jacks carefully lower
4. Completely depressurise the vehicle air the assembly away from the vehicle. During
systems. this process the air bags (28) will start to
5. Slacken back at the delivery connections on break away from either the upper or lower
the levelling valves and release any air seats. If this does not occur the break away
pressureentrained in the air bags (28). should be assisted, either with firm use of the
6. Disconnect the levelling rod and the levelling hands or with the use of tyre levers or similar
valve wiring harness from the lower torque tools. If tools are used care must be taken not
arm. to cause damage to the seal area.
7. Mark and disconnect the autolube pipes and 4. Completely remove air bags.
connectors from the axle.
Anti-Roll bar Removal and Bush Replacement Axle Replacement
1. Loosen the bolts (16) securing the anti roll Axle replacement is the reversal of the removal
bar (10) to the bottom of the link plates (13), procedure but with attention to the following details:
but do not remove.
1. Use new anti roll bar bushes if the existing
2. Loosen the bolts (16) securing the link plates ones show any sign of wear or damage.
(13) to the tower (7 & 8), but do not remove
as these will support the weight of the roll bar 2. Reconnect all harnesses, air pipes and
when the front clamp bushes (11) are autolube connections.
removed. Re secure their pipe runs on the axle or
• Remove bolts (16) and link plates (13) chassis frame.
• Remove the bushes (14) and replace. 3. Re-attach the levelling valve rod.
• The bushes sit in a taper seat and do not 4. When refitting the air bag diaphragms apply
require pressing in or out. liquid soap to bead of the air bag.
• The front anti roll bar bushes (11) may need
5. Apply air pressure to the air bags and inflate
to be slackened off to help with alignment on
ensuring that the seal is satisfactory.
assembly.
• The bolts should be torqued up with the 6. Only retorque the anti roll bar fixing with the
suspension at operating height. vehicle at operating height.
3. Undo and remove the bolts (12) securing the 7. Do not leave out the torque arm shims as
roller clamp bushes (11) to the frame, start to they control the suspension angle. If not
lower the bar and then remove the link plate replaced correctly the tyre wear or handling
bolts (16). The roll bar will rest on the lower may be affected.
torque arms (1) and should then be slid out
sideways.
SERVICE MANUAL
Rear Air Suspension Assembly Amended:050112
Upper Link Lower Link
25 26
Rear Suspension - drive axle
1. Anti roll bar 9. Pin 18. Washer - top

2. Link - Anti roll bar 10. Mounting rubber - roll 19. Mounting rubber - link
3. Bearing - Anti roll bar bar eye 20. Nut - self locking
4. Spacer - bearing to link 11. Washer-inner 21. Control arm - Upper link
5. Bolt 12. Washer - outer 22. Control arm - Lower link
6. Nut 13. Nut - self locking 23. Bolt to axle
7. Mounting bracket - Anti 14. Screw - countersunk 24. Damper - c/w mounting
roll bar - RH 15. Bolt kit
8. Mounting bracket - Anti 16. Bolt 25. Bolt to frame - upper link
roll bar - LH 17. Washer - bottom 26. Bolt to frame - lower link
SERVICE MANUAL
Rear Air Suspension Amended:050112
Description
The twin wheeled drive axle has integral spring
carriers as part of the axle design. The spring
carriers the air springs and shock absorbers are
mounted to the chassis frame. Torque arms are
attached at the front of the axle to the chassis. The
drive axle has an anti roll bar which is attached at the
rear suspension plate with the roll bar link to the
frame.
Torque Settings
Bolt - link / bearing (5) . . . . . . . . . . . . . . . . . . . . . .
101 - 111 Nm(74-82 lb ft)
Nut - Anti roll bar pin (13) . . . . . . . . . . . . . . . . . . . .
230 - 260 Nm (170-192lb ft)
Countersunk screw - ARB bracket to frame (14) . . .
295 Nm (218 lb ft)
Setscrew - ARB bracket to frame (15,16) . . . . . . . .
210 Nm (155 lb ft)
) Nut - damper mounting(22) . .. . . . . . . . . . . . . . . . .
63 Nm + -7Nm (46.5 lb ft + - 5 lb ft)
) Bolt - torque arm to axle casing (23) . . . . . . . . . . .
390 Nm (288 lb ft)
Bolt - torque arm to chassis (25) . . . . . . . . . . . . . .
353 - 438 Nm (260 - 323 lb ft)
Bolt - torque arm to chassis (26) . . . . . . . . . . . . . .
415 - 507 Nm (306 - 374 lb ft)
NOTE
Apply Loctite HO-242 (606152) to the threads
of items 14, 15 &16.
SERVICE MANUAL
Shock Absorbers Amended:
Description • Note that the two flat washers are positioned

at each side of the mounting bushes, are of
Four hydraulic double acting shock absorbers are different internal diameters. The washer with
used on the suspension system, one at each front the large internal diameter is positioned
wheel, one adjacent to each rear air bag and adjacent to the shock absorber body; the
another at either side of the rear axle. other washer being positioned adjacent to the
The shock absorbers are sealed units and require attachment nut.
no servicing, all mountings are rubber bushed. • Torque mounting nuts to 81 Nm (60 lb.ft.).
Armalok nut
Outer washer
Rubber bush Checking Shock Absorbers
Inner washer The shock absorbers are fully sealed, and cannot be
overhauled. If in any of the following checks the
shock absorber proves to be faulty, a new unit must
be fitted.
• Check visually for signs of fluid leakage.
• Check for dented or cracked body.
Part number • Check for scored or bent piston rod.
• Slowly expand and contract the shock
absorber several times and note the
resistance. The resistance should be even
throughout full travel in both directions.
• There should be no zone of reduced or zero
resistance as the direction of travel is
reversed.
A useful indication of the efficiency of the shock
absorber can be gained by comparison with a new
Removal unit. Allowance must, however, be made for slightly
more resistance in the new unit due to tightness of
• Remove the nut from the shock absorber seals.
lower attachment stud. Remove the lower
bush and contract the shock absorber to
enable the lower stud to clear the mounting
bracket.
• Remove the nut from the shock absorber
upper attachment stud. Remove the upper
bush and withdraw the shock absorber.
Fitting
Refitment is a reversal of the removal procedure.
The following points, should, however, be noted.
• Renew the mounting bushes if these show
signs of deterioration.
SERVICE MANUAL
Wheels and Tyres Amended: 17.05.11
Wheel Inspection
Carefully examine the wheels for corrosion, damage NOTE
or cracks, particularly in the region of studholes. Early relaxation of tension in the wheel fixing
after initial tightening is a recognised
Examine the studholes for signs of ovality or fretting
condition. It is recommended that the
caused by slack wheel nuts.
wheelnuts are checked and re-torqued to
Examine the stud threads for damage or severe 660Nm, 30 minutes after initial fitment if the
burring, when they must be replaced. If only slight vehicle is stationary or within 25 to 50 miles
burring exists clean up the threads using a ‘chaser’. if the vehicle is used. Operators may choose
Inspect the wheel nuts for thread damage, renewing to work their own practices. The above is a
where suspect. D.O.E.T.R. recommendation.
If in doubt renew. Do not simply re-tighten very
loose wheel fixings or wheels which are continually
NOTE
becoming loose. Find out why they are loose and
whether any damage has been caused. When fitting twin rear wheels, ensure that
the tyre valves are positioned 180° apart.
Use trained personnel and keep records of all
attention to wheels and fixings, including which parts
were renewed and when. CAUTION
Whenever a wheel is removed and
) Wheel Removal & Fitting reinstalled, always remove any corrosion
between the mounting surface of the
• Using the jacking points raise the wheel to be wheel and hub or drum that contacts the
changed. Check exposed wheel stud thread for wheel.
damage. Remove the wheel nuts. Installing the wheel without good metal to
• Remove the wheel. metal contact at the mounting surface can
• Clean the mating edges of the hub and the cause the wheel nuts to loosen and could
wheel. Apply a thin coat of water repellent grease allow the wheel to come off while the
to the wheel knave spigot(s). vehicle is in motion, causing loss of
control.
• Check that the threads of the wheel studs are
undamaged, clean, and free from lubricant.
• Mount the wheel(s) onto the hub spigot, aligning
the wheel knave mounting holes with the wheel
studs by rotating the hub to avoid damage to the Wheel spigot
studs. Final Torque 660Nm
2nd Torque 500Nm
• Fit the wheelnuts by hand to all wheel studs. Initial Torque 300Nm
Ensure the wheel is flush against the hub.
• Tighten the wheelnuts in the sequence shown. If 1
an air wrench is used the initial torque should not 5 7
exceed 300Nm.
10 3
• One nut must never be screwedfully while others
are still loose.
4 9
• Tighten in sequence at increasing torque values
starting at 300Nm, then 500Nm and then to final 8 6
torque to 660Nm as applicable shown below: 2
The maximum torque figure should not exceed

660Nm. Therefore torque wrench tolerance
should be set to achieve a value of between 600
& 660Nm.
SERVICE MANUAL
Wheels and Tyres Amended: 17.05.11
Thread Protection Tyre Pressure

Under condition of abnormal corrosion, a modest Tyre pressure for any vehicle will depend on its
amount of lubricant may be applied to the protruding laden axle loadings. The pressures can therefore
threads only of the wheel studs. Do not use only be finally determined by the bodybuilder, to take
penetrating oil. account of varying body types, passenger weights
etc.
Wheel Stud Removal The attached table gives the nominal pressures for
If a wheel stud breaks due to loose wheel nuts, a range of axle loadings for the vehicle and can be
install a new stud and also renew both adjacent used as a basis for determining tyre pressures after
studs which could have become cracked or fatigued laden axle weights have been established.
due to the original failure. The pressures quoted have been determined to
ensure an acceptable compromise between ride
Tyre Inspection comfort, handling, and tyre life. Reduction of
Examine the tyre sidewalls for any signs of cuts, pressures below those identified for any given axle
bulges, splitting or chafing. Inspect the tyre tread load is not permitted unless agreed by the tyre
for damage such as splitting, bulges, sections of manufacturer. An increase of up to 10% in front tyre
tread lifting and remove any foreign objects from the pressures may provide improved front tyre life,
tyre. particularly in urban conditions where sharp corners
or roundabouts are frequently encountered.
Remove any oil or grease from tyres using a petrol However, this improved wear life may be
soaked cloth. Kerosene must not be used. accompanied by a reduction in ride quality.
If uneven tread is evident the cause should be Increasing the rear tyre pressures in isolation is not
investigated and the fault rectified. permitted on rear engined bus applications, as
Radial and cross ply tyres must not be mixed on the handling could be adversely affected.
same axle. In case of doubt, reference should be made to
Alexander Dennis Dennis Engineering Department
Replacement Tyres or the Technical Department of the tyre
manufacturer
Replacement tyres should be of a similar
specification. Fitting tyres of a different rating will
affect accuracy of speedometer readings and of
plated weight ratings. Under no circumstances may
crossply and radial ply tyres be mixed.
TYRE PRESSURE RECOMMENDATIONS - TYPICAL AXLE LOADS

TYRE SIZE:- BUS: XZU+ 275/70 R22.5 max plated weights
LADEN FRONT AXLE LOAD LADEN DRIVE AXLE LOAD
Load (kg) Pressure Load (kg) Pressure
psi bar psi bar
6300 131 8.9 11500 123 8.4
WHEELNUT TORQUE FIGURES lb.ft. Nm

Front Axle Dana / ZF 487 660
Rear Axle ZF 487 660
SERVICE MANUAL
Chassis Jacking Points Amended:
Description
The Enviro 400 bus chassis is equipped with jacking
points for both axles. The jacking points should
always be used when carrying out vehicle
maintenance. The diagram below shows their
location.
Front axle location: Position the jack under the Rear axle location: Position the jack under the
jacking location point, ensure that the top of the jacking location point, ensure that the top of the
bottle jack is correctly located in the jacking point. bottle jack is correctly located in the jacking point.
Jacking Points
SERVICE MANUAL
Steering, Front Axle Amended:15.05.13
Contents
Steering Font Axle - ZF-RL-75A

Steering system diagram . Page 7.2 Description . . . . . . . . . . . . Page 7.53
Description . . . . . . . . . . . . Page 7.3 Routine Maintenance . . . . Page 7.53
Maintenance . . . . . . . . . . . Page 7.3 Greasing instructions . . . . Page 7.53- 54
Specification . . . . . . . . . . . Page 7.3 Checking Swilvel Play . . . Page 7.55
Ball joint Inspection . . . . . Page 7.4 - 5 Disassembly . . . . . . . . . . Page 7.56
Checking steering alignment Page 7.7 Pressing out Swivel (King) Pin Page 7.56
Adjustment of hydraulic steering Disassembly of wheel head Page 7.57-59
automatic limiter . . . . . . . . Page 7.8 - 9 Checking Compact bearing Page 7.60
Fault finding . . . . . . . . . . . Page 7.9 Removing Compact bearing Page 7.60
Steering trackrod clamp Disassembly of Steering
positioning . . . . . . . . . . . . Page 7.10 knuckle . . . . . . . . . . . . . . . Page 7.61-62
Steering gear and drop arm Reassembly of wheel head Page 7.63-67
alignment . . . . . . . . . . . . . Page 7.11-12 reassembly of bearing unit Page 7.67-68
Fitting seal . . . . . . . . . . . . Page 7.69
Refitting hub . . . . . . . . . . . Page 7.70-72
Font Axle - Dana Fitting brakes . . . . . . . . . . Page 7.73
Description . . . . . . . . . . . . Page 7.13 Special Tool list . . . . . . . . . Page 7.74-77
Routine Maintenance . . . . Page 7.13
Greasing instructions . . . . Page 7.13
Hub bearing checks . . . . . Page 7.13
Front wheel "Toe in" check Page 7.14
Swivel (King) pin check . . Page 7.15
Ball joint movement and corrosion
checks . . . . . . . . . . . . . . . Page 7.16-17
Care of wheels . . . . . . . . . Page 7.17
Brake Disc surface evaluation Page 7.18-19
Swivel / axle bed tightening
torques . . . . . . . . . . . . . . . Page 7.20
Swivel / hub end tightening
torques . . . . . . . . . . . . . . . Page 7.21
Overhaul procedures . . . . Page 7.22
Swivel / axle bed disassembly Page 7.22-25
Removal and refitting of steering
levers . . . . . . . . . . . . . . . . Page 7.26
Swivel / axle bed reassembly Page 7.27-36
Hub end disassembly . . . . Page 7.37-42
Hub end reassembly . . . . . Page 7.43-50
Stud fitting procedures . . . Page 7.51
Tool list . . . . . . . . . . . . . . . Page 7.52
Section 7
SERVICE MANUAL
Steering Gear Amended:
1. Steering wheel 5. Drop arm

2. Steering column 6. Steering box
3. Steering shaft 7. Drag link
4. Universal joint
SERVICE MANUAL
Steering Amended:01.10.13
Description
The air adjustable steering column is mounted on the drivers floor structure. The base of the column
incorporates a bevel box which is connected to the ZF power steering box by a torque shaft with a universal
joint at each end. The drop arm on the steering box is connected to the steering lever on the offside front hub
by a drag link with an adjustable ball joint at each end. The track levers on the two front hubs are
interconnected by an adjustable track rod. Hydraulic power is supplied by an engine-driven pump as
described under Hydraulic System.
Maintenance (See Hydraulics system also)

Check overall play at steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First, weekly A, B & C
Check front security - drop arm securing nut,steering box,
mounting bolts, track rod clamp bolts and steering lock stops . . . . . .First, B & C Service Intervals
Check the steering box for leakage . . . . . . . . . . . . . . . . . . . . . . . . .First, B & C Service Intervals
Check wheels do not foul other parts when on full lock . . . . . . . . . .First, B & C Service Intervals
Check front axle and wheel alignment adjust if necessary . . . . . . . .First, B & C Service Intervals
Check all ball joints and linkages for play . . . . . . . . . . . . . . . . . . . . . . .A, B & C Service Intervals
Check bevel box oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First, B & C Service Intervals
Check bevel box for leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A, B & C Service Intervals
Lubricate steering relay shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C Service Interval
Service Intervals
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,000miles (1,600km)*
A service interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6,000miles (10,000km) / 3months *
B service interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12,000miles(20,000km) / 6months *
C service interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24,000miles(40,000km) / 12months *
* whichever is sooner
Specification
Front Axle
Steering lock - back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 deg.
Steering lock - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 deg.
Castor angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 deg.
Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 deg.
King pin inclination .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6deg.
Tracking
Toe in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 deg.
Toe out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 deg.
Torque Loadings
Drag link ball joint nut (castellated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 230 Nm
Drag link clamp bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 - 80 Nm
 Steering box drop arm to steering box nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .850 Nm +10%
Steering wheel to column nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 - 50 Nm
Steering box to frame bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543 - 577 Nm
Yoke - relay shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Nm
SERVICE MANUAL
Steering Amended:230910
BALL JOINT INSPECTION

The drag link ball joints should be inspected at the interval indicated in the service schedule.The signs of
failure that may indicate ball joint failure are:
Front end shimmy,shake or vibration; abnormal front end noise; hard steering; Steering wheel doesn’t return
or centre properly; cupped tyres; steering feels unstable. If any of the previous signs are detected the
following process for checking the ball joint should be carried ou.
CHECKING THE BALL JOINTS
Firstly with the steered wheels in the straight-ahead position, supporting the weight of the vehicle, the steering
wheel should be rocked firmly in each direction against the resistance of the tyres. The force should be
sufficient to load the steering mechanism and joints. The ball joint should be visually examined for signs of
excessive play.
NOTE: Those engaged in the checking of steering joints must appreciate that; end lift movement in this design
of joint is normal. This feature is demonstrated by a kick action as the joint is articulated. This kick may lead
some inspectors to reject the part as worn. The kick is due to the construction of the socket, which
incorporates a true sphere ball pin running in a toroidal socket seat. This kick will increase with the life of the
joint. Therefore this feature alone should not render the joint unfit for further use and until the “worn out”
measurement is exceeded the joint may be considered acceptable to remain in service.
An end lift measurement should be carried out to determine if the joint is excessively worn. This is done by
applying a load through the axis of the pin and measuring its movement relative to the socket body. A socket
on a vehicle, which is said to exhibit excessive wear, should be measured for end lift. If the figure recorded is
below the stated wear out limit the socket is acceptable to remain in service.
The following data gives designed end lift, and worn out end lift figures, when the load is applied at ‘B’: and
the recommended checking load at ‘B’.
Note: The load applied at ‘B’ must never exceed the maximum figure stated otherwise internal components
may be damaged making the joint unfit for further service.
JOINT SIZE DESIGNED CHECKING WEAROUT MAX ALLOWABLE
END LIFT LOAD ‘B’ END LIFT ‘A’ CHECKING LOAD
25 0.85 MAX 1000 N 2MM MAX* 2200N
30 0.85 MAX 1000 N 2MM MAX* 2200N
35 0.85 MAX 1000 N 2MM MAX* 2200N
40 0.85 MAX 1000 N 2MM MAX* 2200N
* Or if free play exists under hand pressure.
SERVICE MANUAL
Steering Amended:230910
END LIFT MEASUREMENT

Fix dial test indicator (1) to measure the lift in the ball joint - see illustration.
NOTE: some lift, under spring pressure, is normal in joints. Use a lever (2) under the joint to check lift as
shown.
IF LIFT EXCEEDS THE “WORN OUT” LIFT FIGURE, THE JOINT MUST BE REPLACED.
ADDITIONAL CHECKS
If examination shows the boot to be split, cut, or damaged so as to allow the ingress of foreign matter or
moisture, the steering joint must be replaced irrespective of end lift movement.
SERVICE MANUAL
Air Adjustable Steering Column

The vehicle may be fitted with an air adjustable steering column. The column is adjustable for height and rake.
The foot operated column adjustment switch is mounted in the floorplate adjacent the column.
To adjust the column position, the handbrake must be applied.
NOTE
The steering column is only adjustable when the handbrake is in the on position, the column cannot be
adjusted when the vehicle is on the move.
FROM RELAY FROM RELAY

6 mm 6 mm
VALVE SIGNAL VALVE SIGNAL
SUPPLY FROM ORANGE ORANGE HANDBRAKE
LINE - Port 4 LINE - Port 1
AUXILIARY & 1 VALVE
2
SUSPENSION
RESERVOIR
6 mm
ORANGE 21
1
ORANGE
6 mm
EXHAUST
4 mm
BLACK
3 SOLENOID
4mm VALVE
2
BLUE
1
2
4 mm PILOT
BLACK VALVE
3
1
ORANGE
6 mm
2
12 STEERING
COLUMN
1 3
PILOT VALVE OPERATION
EXHAUST
AR7828 AR7573
SERVICE MANUAL
Check the Steering Alignment

1. If the power steering box has been removed the securing bolts should be fitted with new spring washers and
torque tightened to 543 - 577Nm.
Check that the drop arm is fitted to the splined shaft so that the index marks on the two components are in
alignment.
2. With the front wheels in the straight ahead position check that the front wheel rims are parallel (i.e. no toe in or
out). To allow for inaccuracies in the wheel rims, repeat the check with the vehicle moved to give the wheels one
half turn. Adjust the length of the track rod as necessary.
 Front Dimension “B” should be 0.0” to 0.04” (0.0 - 1mm) Less than rear measurement “A”.
4. Remove the cap from the centre of the steering wheel and check that the mark on the column shaft is at 12
o’clock. If necessary disconnect the torque shaft at the base of the column and reset the steering wheel.
5. Check that the two universal joint forks on the torque shaft are horizontal as shown. If necessary the shaft must
be disconnected and reset.
6. Set the wheels in the straight ahead position and check that the mark on the steering box input shaft is in line with
the mark on the box casing. If necessary reset the length of the drag link to obtain this condition. If adjustment is
made, check that at least 50mm of thread is engaged in each ball joint.
7 Remove both hydraulic limiters from the steering gear and plug the open ports to avoid contamination. Check the
back lock at each wheel. The angle should be 55° +0°/-1°. If it is not, fit or remove shims behind the wheel stops
at the hubs.
HUB AT 40˚ FRONTLOCK HUB AT 55˚ BACKLOCK

BA
CK
55 CK
° -1
LO
0
K
LOC
40˚
NT
FRO
SERVICE MANUAL
Steering Amended:
Adjustment of Hydraulic Steering Automatic Limiter
CAUTION
Steering systems with automatically adjustable

steering limiters must not be mechanically
turned to the limit positions if the steering
linkage has been removed or the system
dismantled. The sliding sleeves would then be
pushed into maximum possible cut-off position
and automatic setting in the vehicle would only
be possible with new sliding sleeve assemblies
(left and right hand adjusting screws). If
necessary, fit new sliding sleeve assemblies. Starting position of sliding sleeves not yet set
The steering gear should only be rotated with
power off using a steering torque of 2.5Nm in
either direction to avoid changing the limiters.
Sliding sleeve assemblies and normal setting
screws are not interchangeable.
Once the limiters have been set the steering
lock angles can be increased without replacing
the limiters, but if the steering angles are to be
decreased the limiters MUST be replaced.
Replacement hydraulic limiter - Pt No 656602.
Functioning of Automatically Adjustable Hydraulic Steering Limiter
With the automatically adjustable hydraulic steering

limiter, left and right hand adjusting screws with
pressed-on sliding sleeves are located in place of
setting screws.
These function in the same way as with the manually
adjustable hydraulic steering limiter. In the limit
positions, the valve piston tappets meet the sliding
sleeves and open the steering limiter valves. The
opening point is determined by the position of the
sliding sleeves on the screws.
Setting process
Positioning the sliding sleeves
SERVICE MANUAL
Steering Amended:
Setting
NOTE
Setting is only possible after the steering system has been installed in the vehicle.
The steering linkage and the axle stops must be mounted and set.
This process must be carried out in both directions of

rotation until a fixed stop has been reached.
The sliding sleeves are automatically returned to the
correct cut-out position shown
Fault Finding
Noises in the steering can occur for the
following reasons:
1. Dirty filter element. Fit new element.
2. Unions at intake side not properly tightened, i.e. Left steering limiter valve open,
air is sucked in. Retighten unions.
oil pressure greatly reduced
3. Insufficient oil in system. Top up.
Play in power steering when pump is stopped or running.

During normal driving, i.e. when the oil pump is delivering pressure oil, the torsion bar is twisted and the valve piston
displaced when the steering wheel is turned or the vehicle travels over a bump. This causes the power assistance to come
on. Only a very slight movement of the steering wheel or rocker shaft is necessary to trigger this process and the driver
immediately notices the power assistance come into effect.
The situation is different if the steering has to be operated with the pump at a standstill, e.g. when the vehicle is towed.
The steering effort is much higher and it is then necessary to overcome the whole stroke of the control valve, as far as
the stop, before the steering wheels movement is transmitted to the rocker shaft. For this reason there is noticeable play
at the steering wheel when there is no power assistance.
SERVICE MANUAL
Steering Trackrod Clamp Positioning Amended:
The position of the trackrod assembly above indicates the minimum distances required between the bolt
head/shank and the axle track control arms after front axle track adjustment.
Operators must ensure that there is sufficient clearance between bolt and control arm by twisting the trackrod
assembly to maximum ball joint articulation. FAILURE to observe this requirement can result in a bolt and
arm foul condition at full lock angles.
SERVICE MANUAL
Steering Gear & Drop Arm Arrangement Amended:
SERVICE MANUAL
Steering Gear & Drop Arm Arrangement Amended:01.10.13
The procedure assumes torquing of sector shaft nut with pneumatic torque gun with appropriately set air
pressure for torque value and drop arm held at neutral position to avoid over-setting hydraulic steering
limiters. If torque wrench is used the automatic adjustable hydraulic steering limiters must be removed before
torque is applied unless drop arm can be held in neutral position.
 1. Torque the drop arm nut to a torque of 850Nm + 10%.
2. ”Bed” the drop arm to the sector shaft by shocking with a copper mallet.
3. After “bedding down“ the drop arm, re-torque the nut.
4. Repeat the process twice more.
5. Stake the drop arm nut to the dimensions shown.
SERVICE MANUAL
Front Axle - DANA Amended:
Description
The axle is a ‘Reverse Elliot’ type comprising a girder section axle bed or beam with stub axles. Each stub
axle is carried on a parallel king pin, with a steep angle taper roller bearing at the top and a plain phosphor
bronze bush at the bottom.
The hub taper roller bearings are Timken Unipac-plus assemblies pre set at the manufacturers.
Routine Maintenance
Grease top and bottom lubricators
until grease can be seen escaping
Greasing Instructions from swivel / axle bed interfaces
Pressure lubricate every 6 months 0r
30000 miles (48000km)
1. Grease points as shown in Fig. 1.
Recommended lubrication
Lithium base roller bearing grease NLGI No. 2
All other components are greased for

life and require no further lubrication
during the life of the component. Grease top and bottom lubricators
Fig 1
HUB BEARINGS
Hub bearing check - every 30000 miles (48000km)

1. Before commencing checks, apply parking brake, raise wheels off the ground and support on axle
stands. Remove the road wheels.
Never work under a vehicle support only by jacks. Always use suitable axle stands.
2. Place magnetic base of a dial indicator on brake shoe / caliper and position dial indicator stem against
a convenient marked spot on face of Hub flange.
3. With dial indicator in position pull hard but steadily on Hub flange and oscillate at same time until a
steady reading is achieved.
4. Without releasing the pressure, turn bearing so that dial indicator stem contacts marked spot and note
reading on indicator.
5. Push bearing flange hard and oscillate as before until a steady reading is achieved.
6. Without releasing the pressure, turn bearing so that indicator stem again contacts the marked spot and
note new reading on indicator.
7. The difference between readings is amount of mounted end play in bearing unit.
8. The mounted end play figure should not exceed 0.050mm for a new bearing.
If original bearing unit is re-fitted, and end float is measured at 1 mm with hub nut fully tightened
to correct torque, then the retaining clip within the bearing unit is damaged / displaced and a new
unit must be fitted.
SERVICE MANUAL
Front Axle - DANA Amended: 15.05.13
TO CHECK FRONT WHEEL 'TOE IN'

1. To preserve correct steering and avoid excessive tyre wear, tracking (or alignment) of front wheels
should be checked periodically, as follows :-
Set front wheels in straight ahead position and at points level with wheel centre, measure distance over
hubs / wheel rims, both in front and behind axle centre.
For correct 'Toe In' front measurement 'B' should be 0" to 0.04" (0 to 1mm) smaller than rear
measurement 'A' . See Fig.2.
Fig 2
2. To allow for inaccuracies in wheels, same check should be made with vehicle moved an equivalent to
half of a wheel revolution (180°). Any adjustment required can be effected by backing off clamp bolts
in ball sockets and rotating tie (track) rod tube.
 After adjustment, tighten clamp bolts to 51-66 lbs ft (70-89 Nm).
It is important that when the power assisted steering is fitted, the steering gear is adjusted so that the
hydraulic assistance cuts out just before the lockstops come into contact with the axle beam, to avoid
excessive loads being transmitted through the steering linkages.
Incorrectly adjusted steering could lead to premature failure or shortened life of all steering
components.
Check condition of brake pads as described in the Braking section.
SERVICE MANUAL
CHECK PERMISSIBLE SLACKNESS IN SWIVEL (KING) PINS EVERY 48,000 KM (30,000MILES):

Aspects to be considered are:
• Lateral slackness
• Vertical slackness
1. Checking lateral slackness

Whilst this is being carried out the brake must be applied.
Place a set-square with its stock on ground and its blade against the tyre wall.
Place a mark on the ground to indicate position of stock end.
Insert a lever through bottom cut-out of wheel and lever it upwards thus moving set-square outboard
Mark changed position of stock end.
Maximum allowable stock displacement for 17.5” wheels = 6mm.
19.5” wheels = 7mm
If displacement exceeds 8mm then the need for bush/bearing attention and possible renewal, is in
evidence.
2. Checking vertical slackness
This measured by a dial indicator anchored to the axle beam and having its pointer placed against the
swivel top.
Place a jack against the underside of the swivel and, whilst applying a lifting force, observe any
movement on indicator dial.
If vertical movement is evident and it exceeds 1.02mm (0.040”) then re-adjustment of swivel is
required.
CHECK MOVEMENT IN BALL JOINTS AS FOLLOWS:-
This test to be carried out with vehicle in loaded condition.
DO NOT JACK UP VEHICLE.
1. Axial end float (axial travel)

End float in direction of axis of ball pin, as shown in Fig. 3 should be within
limits of 0.4mm to 2.0mm max. using a test force of 850N.
Fig 3
SERVICE MANUAL
2. Radial end float (radial travel)

Radial end float at right angles to axis of
ball pin as shown in Fig. 4 should be within
limits of 0.4 mm to 0.8 mm max. using a
test force of 6000N.
Replace ball joints if outside limits given in
a. and / or b.
Fig 4
EVERY 6 MONTHS INSPECT BALL JOINTS FOR CORROSION AS FOLLOWS:-
Inspection of balljoints is important, especially those in older vehicles, because DAMAGED

SEALING BOOTS, salt on roads in winter climatic conditions can cause loss of the corrosion
protection coating applied during manufacture.
Inspection instructions
Ensure that ball joint is in an easy access-position.
Carefully clean the sealing boot contact area, to ensure that pollutants cannot get under the sealing boot
during the following inspection procedure.
Use an appropriate inspection sheet-metal-tool, eg. spatula with cut out (Fig. 5) to push up the sealing boot
(without damaging it) until ball pin surface is visible. Degrease the ball pin surface.
Fig 5
If there is corrosion of the ball pin or the sealing boot has deteriorated through ageing or is damaged, replace
the ball joint in question, or the complete tie rod or drag link as appropriate.
If there is corrosion of the steering lever area which is in contact with the sealing boot, clean and eliminate
all surface irregularities.
SERVICE MANUAL
If there is no corrosion or damage to the sealing boot, smear the steering lever surface with Lithium grease
and push the sealing boot back into its properly seated position.
When dismantling tie rods, drag links or drop arms ensure that no damage is caused to the sealing boots or
ball joint housings.
WARNING
VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS
Please refer to Page 1.3.4 of this manual for detailed safety procedures
CARE OF WHEELS AND FIXING FACES (ALL AXLES WITH SPIGOT FIXING)
At approximately 100 miles after fitting wheels, wheel nut torque should be checked with wheel ends in "cold"
condition (i.e. not after prolonged braking).
If any relaxation of original torque 660 Nm (487 lbs ft) has occurred, re-tighten.
Relaxation of initial torque may occur because of " Bedding Down" of hub and wheel surfaces.
Tightening should not be done immediately after prolonged braking i.e. When wheel ends are
hot. A relaxation of wheel nut torque does occur when wheel end is hot but should revert back
to the original setting as the wheel end cools down. Re-tightening when hot will produce a
higher torque reading when cold.
1
Although this single re-tightening after first 100 miles should be sufficient 5 7
to ensure wheels stay tight, extra checks are recommended within at least
the first 1000 miles to check that wheel assembly is stable and that no
10 3
further relaxation is occurring.
4 9
See graphic for correct tightening sequence of wheel nuts.
8 6
2
Fig 6
CARE OF WHEELS
Check for cracks in wheels, especially around the fixing holes, and in studs, nuts and washers.
If in doubt renew. Do not simply re-tighten very loose wheel fixings or wheels which are continually becoming
loose. Find out why they are loose and whether any damage has been caused.
Use trained personnel and keep records of all attention to wheels and fixings, including which parts were
renewed and when.
Further details are given in British Standard Code of Practice for the selection and care of tyres
and wheels for commercial vehicles BSAU50: Part 2 Section 7A: 1995
PROTECTION OF SPIGOT WHEEL FIXING DIAMETERS AND PRESSURE SURFACES.

Although an initial surface coating to wheel rim mating faces on spigot is applied to stop rusting and facilitate
easy removal of wheels. The application of P.B.C. grease such as 'Rocol Tufgear' or equivalent to wheel
register is recommended.
SERVICE MANUAL
Brake Disc Surface Evaluation

1. Upon removal of brake disc Fig. 7, its
surface should be checked for defects.
Inspection should cover both sides of the
braking surface as well as the outer diameter
of the disc. Brake disc thickness should be
7 checked in accordance with manufacturers
dimensional recommendations.
You should inspect for the following:
• Heat checking
• Cracks
• Grooves - scoring
• Blue marks - Banding
• Polished discs
Heat checking can be light or heavy,
8 If light heat checking type cracks (fine and light)

are found as shown in Fig. 8 the disc can continue
to be used.
If heavy heat checking type cracks (deep and
wide) are found the disc must be replaced.
Cracks can be of two types Radial or Through.

If any radial cracks are found in the brake disc
surface as shown in Fig. 9 then the disc must be
replaced..
If any Through cracks are found in the brake disc

as shown in Fig. 10 then the disc must be
replaced.
10
SERVICE MANUAL
Brake Disc Surface Evaluation

(continued)
Grooving - Scoring can be light or heavy, If light

grooving is found as shown in Fig. 11 then the disc
can continue to be used.
11
If Heavy grooving is found as shown in Fig. 12

then the disc must be replaced.
12
Blue marks - banding indicates that the disc has

been exposed to very high temperatures.
If Blue marks - banding are found, the reason for

the high temperatures must be investigated and
13 corrected. Refer to the Brake manufacturer for
details. if left uncorrected the formation of heavy
heat checking / cracks will occur.
Polished discs indicate the use of improper lining

material or that the disc has been re- machined to
too fine a surface finish.
14
The Gloss / polish should be removed using (80)
grit Emery cloth and the brake manufacturer should
be contacted for an alternate liner material.
SERVICE MANUAL
Front Axle - DANA Amended:15.05.13
14
15
16
9 13
12
8 11
10
7
6
5
4
3 17
2
1
18
19
20
21
22
23
24
25
26
27
38 28
37
39 36
40
35
34
33
32
29
30
31
Fig 15
SWIVEL / AXLE BED TIGHTENING TORQUES
Item Description Tightening Torque

1. Brake backplate nut 1/2" UNF 85 - 103 lbs.ft 115 - 140 Nm
2. Brake backplate stud 1/2" UNF See TD 183/1 (All axles)
 8. Swivel top cap 65 - 80 lbs.ft 88 - 108 Nm
9. Swivel top cap lubricator 10 - 15 lbs.ft 14 - 20 Nm
11. Top lever bolts M20 x 2.5 grade 12.9 520 - 575 lbs.ft 705 - 780Nm
14. Single Cotter pin nut 51 - 61 lbs.ft 69 - 82 Nm
 Double Cotter pin nut 24 - 36 lbs.ft 33 - 49 Nm
23. Lockstop nut 90 - 120 lbs.ft 122 - 162 Nm
24&25. Bottom lever bolts M20 x 2.5 grade 12.9 520 - 575 lbs.ft 705 - 780Nm
27. Ball pin nut 155 - 170 lbs.ft 210 - 230 Nm
 30. Socket pinch bolt 51 - 66 lbs.ft 70 - 89 Nm
33. Swivel bottom cap lubricator 10 - 15 lbs.ft 14 - 20 Nm
 34. Swivel bottom cap 65 - 80 lbs.ft 88 - 108 Nm
40. Hub nut 575 - 626 lbs.ft 778 - 849 Nm
SERVICE MANUAL
4 6a 5a 5b
SB
SN
3
2
1
7
8
9
658470,659387,661335
10
Fig 16
SWIVEL / HUB END TIGHTENING TORQUES
Item Description Tightening Torque

1. Wheel nut M22 x 1.5 475 - 525 lbs.ft 644 - 712 Nm
6. SN Brake Caliper Mounting Bolt M20 x 1.5 350 - 393 lbs.ft 475 - 533 Nm
4. Brake air cylinder retaining nuts M16 x 1.5 133 - 155 lbs.ft 180 - 210 Nm
10. Hub flange retaining bolt M14 x 1.5 174 - 192 lbs.ft 236 - 260 Nm
SERVICE MANUAL
SWIVEL / AXLE BED DISASSEMBLY

(continued)
3. Remove split pin (if fitted) and loosen but do

not remove ball socket nuts on tie rod.
17
For ease of disassembly when loosening
self locking ball pin nuts.
Insertion of a hexagonal key (allen key)
into the ball pin itself will aid in removal.
If for service reasons the tie rod is only to

3 mm be removed in isolation without removing
gap any other parts it may be necessary to use
a long reach thin walled socket in certain
applications.
4. Back off nuts approximately 3 - 4 mm.

18
5. Using a suitable extraction tool, disconnect
ball sockets from bottom steering lever.
6. Disconnect steering linkages from top
steering lever, using a suitable extraction
tool as in steps 3, 4, & 5.
When separating ball socket from steering

lever, an extractor tool MUST be used. DO
NOT strike areas around ball pin tapers with
hammer blows under any circumstances due
to possible ball pin taper deformation.
19 Also take care not to trap the rubber boot

during removal of the socket assembly, as
this would require replacement of the entire
socket assembly.
7. Inspect rubber boots of socket assemblies

as described in routine maintenance section.
if damaged replace entire socket assembly.
20
SERVICE MANUAL
Overhaul Procedures
PREPARATION
Prepare for axle overhaul as follows:
1. Set parking brake and block drivewheels to prevent vehicle movement.
2. Raise vehicle until tyres are off the ground. Support raised vehicle with safety stands.
WARNING
NEVER WORK UNDER A VEHICLE SUPPORTED ONLY BY A JACK
ALWAYS USE SAFETY STANDS

1. Disconnect brakes and A.B.S sensor from vehicle. Fit plugs to connectors to prevent dirt ingress.
2. Remove roadwheels, brake drums (if fitted), hub flanges,hub bearings and brakes from swivel.
The Hub bearing assembly should only be removed if it is to be replaced or for removal of brake
assembly / backplate. Unnecessary removal can cause damage to the unit.
CAUTION
Take care to avoid breathing in brake dust during removal swivel / axle bed disassembly.
SERVICE MANUAL

(continued)
8. Remove lubrication nipples from top and
bottom caps.
9. Remove top and bottom caps. Discard ‘O’
21 ring seals and foam inserts.
10. Remove Cotter pin nut and washer, then
drive out cotter pin using a soft metal drift.
11. Drive kingpin out of swivel / axle bed with a
hide faced / brass hammer and a suitable
drift.
12. Carefully remove swivel from axle beam.
WARNING
Component is heavy, care should be
taken when removing. Also take care not
22 to drop bearing and shims when sliding
swivel from axle bed.
CLEANING
Once swivel has been removed clean all parts as

below:
1. Castings / forgings and rough parts
• Clean with wire brush or steam clean.
2. Steel parts
23
• Clean with suitable cleaning agent.
• Rinse thoroughly.
• Dry off, using clean rags.

3. Inspect rubber boots of socket assemblies
as described in routine maintenance section
if damaged replace entire socket
WARNING
Never use petrol (gasoline) to clean parts
due to extreme combustability.
24
Do not clean hub bearing assembly due
to possibility of seal damage.
Take care not to use wire brush to clean
bearing journals on swivel.
SERVICE MANUAL
SWIVEL DISASSEMBLY (continued)
1. Measure and record for later use the length

of swivel stops.
2. Remove swivel stops and put in a safe

place.
25
3. Remove king pin bush dirt seals from swivel
using a suitable tool.
4. Discard seals.
5. Remove swivel / king pin bushes using

correct service tool (see tool list on
Page 7.50).
6. Discard bushes.
7. Remove swivel lock stops and check for

wear / damage. Replace if found to be
26 faulty.
8. Thoroughly clean seal / bush area using a

wire brush and suitable cleaning agent.
27
28 Draw bush
out of swivel
SERVICE MANUAL
REMOVAL AND REFITTING OF STEERING

LEVERS
CAUTION
The following instructions should be strictly
adhered to.
29
Fitment of the steering levers is one of the
most safety critical factors on the vehicle.
Removal
1. Using a suitable socket, loosen but do not
remove the steering lever bolts.
2. Using a hide faced mallet, tap the steering
lever to loosen it from the swivel face if
required. Do not strike the steering lever with
a steel hammer.
30 3. Carefully remove steering lever bolts and

steering lever.
4. Discard steering lever bolts.
5. Clean and check the screw thread in the
swivel, the thread should be un damaged.
6. Clean and degrease the mating surfaces of
steering lever and swivel.
Refitting
1. Apply a small amount of Loctite 275 to new
steering lever bolt threads.
31 2. Refit steering lever and tighten new bolts to
specified torque.
32
SERVICE MANUAL
SWIVEL REASSEMBLY
1. Lightly lubricate outside of replacement

bushes with clean grease.
2. Hand start replacement bush in swivel bore.
Note
33 position of
split line Ensure split line in replacement bush is
positioned as shown in Fig. 33
3. Draw bush into swivel using correct service

tool (see Tool list on Page 7.50).
4. Check bushes are to correct depth by
tapping into position using top section of
correct service tool (see Tool list on
Page 7.50).
5. Use same procedure for both upper and
Draw lower bushes.
bush into 6. Once bushes are correctly positioned in
34
swivel swivel bore they require reaming.
7. Ream bushes using correct Kentmoore tool
for the bush fitted (see tools table).
35
SERVICE MANUAL
SWIVEL REASSEMBLY (continued)

8. Install new upper and lower swivel seals
using correct service tool (see chart at front
of this section). as follows:-
Use of correct tool ensures that the seal

36 is seated at the correct depth.
Incorrect fitting of seal can cause
problems when fitting the swivel
assembly to axle bed.
A. Place seal onto tool, open side fist see

Fig 41 on Page 7.27 to check correct
orientation.
B. Position tool, into seal / bush bore in
swivel as shown.
C. Insert remainder of tool, through
swivel as shown.
37 D. Gently tap seal into swivel bore to
depth.
Ensure lip of seal is positioned as shown

below. The seal sits 0.25mm below
swivel face. This helps to prevent
damage during assembly of swivel onto
axle beam.
38
39
SERVICE MANUAL
DIAGRAM SHOWING CORRECT BUSH SEAL INSTALLATION
Slot in bush must be

positioned within
these limits
Fig 40
Install top seal face down
5.50mm
5.25mm
Bush depth
Ensure seal is
below surface
when fitted
5.50mm
5.25mm
Bush depth
Install bottom seal face up
Fig 41
Kingpin Bushing Specification

Axle Model Finished Dimension Kentmoore Tool Part No
NDS 80 1.8745" PT4370 - 95
SERVICE MANUAL
Front Axle - DANA Amended
SWIVEL / AXLE BED REASSEMBLY

(continued)
Always replace kingpin and thrust

bearing if found to be faulty.
42
1. Lightly lubricate the following components
with clean grease before assembly:
• Thrust bearing areas of swivel
• Axle beam ends
• Kingpin bore of axle bed
2. Prepack dimples in bushing bores with
grease.
Also pack thrust bearing with grease, by
manually kneading grease into rollers.
Do not disassemble when packing
43
On no account simply wipe grease
around inside of bearing. Rollers must
be fully packed with grease to avoid
failure in service.
Top of thrust bearing. Note dirt seal
3. Select a nominal shim pack of 0.13mm
thickness.
Setting tool (see chart)
4. Place shim pack onto bottom of swivel.
5. Place thrust bearing onto top of shim pack,
ensuring that the bearing is the correct way
up (see photograph.) See note below.
44 6. Insert setting tool (see chart at front of this
section) into bottom bore of swivel, through
bush, shims and thrust bearing (this serves
to assist in placing swivel onto axle bed).
Top of thrust bearing

Note dirt seal
NOTE
On new axle build from April 2004 (axle serial
number P3307-04 onwards) instead of the shims
being placed below the kingpin thrust bearing, the
adjusting shims are now placed between the upper
face of the axle bed and the lower side of the upper
fork of the swivel. (Fig 45).
45
When replacing king pins or performing king pin
adjustments on axles built prior to the change date
it is recommended that the new procedure is
followed.
SERVICE MANUAL

(continued)
Use setting tool (see Tool list on Page

7.50). not king pin to align bearing and
shims. This prevents bearing dirt seal
45a from being pushed upwards and causing
dirt seal to become trapped upon
assembly of swivel to axle beam.
7. Offer swivel, shims, thrust bearing and

setting tool, up to axle beam.
Drive King Pin down WARNING

through the swivel,
Component is heavy, care should be
displacing setting tool
taken when lifting.
8. Position kingpin in top of swivel.

46
Align slot in kingpin with cotter pin hole in
bed.
Setting tool For ease of fitting!

Suggest that slightly turning swivel pin
will aid when cotter pin is to be fitted
later.
9. Drive kingpin down through the swivel and

axle bed using a hide faced / brass hammer
and a suitable drift until bottom of kingpin is
flush with bottom of lower swivel bush. (see
Fig 41 on Page 7.27).
47
At this point it is necessary to check the
vertical play in the swivel and adjust if
necessary.
END PLAY CHECKING / ADJUSTMENT

A. Position swivel in straight ahead position.
B. Mount a D.T.I on axle bed with stylus
positioned on top face of swivel.
C. Position a suitable pry bar between axle bed
and swivel and check for lift.
48
Correct reading should be between 0.05mm
to 0.13mm.
D. Add or remove shims until correct D.T.I
reading is obtained.
SERVICE MANUAL

(continued)
10. Once vertical play adjustment is correct,
check alignment of kingpin flat and cotter
pin hole.
49
11. Install a new cotter pin.
Cotter pin is fitted from rear of axle.
12. Drive cotter pin home using a hammer and

a drift if necessary.
13. Fit new cotter pin washer and new nut.
Tighten nut to correct torque.
14. Check cotter pin is correctly seated by
tapping further with hammer and punch.
15. Re-check torque on cotter pin nut.
50
Note flat on
cotter pin
51
52
SERVICE MANUAL
16. Lightly grease ‘O’ ring bores in top and

bottom of swivel. (This helps to hold the ‘O’
ring in place)
17. Place a new ‘O’ ring into top and bottom
bores in swivel, and new foam insert lightly
lubricated using clean oil on each top and
53 bottom cap. (this helps to prevent foam
insert from deforming upon fitment of top /
bottom caps)
18. Install new king pin top and bottom caps.
Should existing top and bottom caps be

in good condition, it is possible to re-use
them, provided the following procedure
is followed:
1. Remove all existing sealant using a
wire brush.
2. Apply a bead of Loctite 577 to
second thread for 180° and refit
54 Spicer speciality axle division does
not recommend re-use of top/bottom
caps with original sealant.
For ease of assembly:
Suggest using a socket and ratcheting
spanner to press down top / BTM cap and
tighten at the same time,
On no account use an air powered gun to
tighten topcaps due to possibility of
stripping threads.
19. Tighten top and bottom caps to correct

torque.
55
20. Refit top and bottom cap lubricators, tighten
to correct torque and orient in correct
direction.
Note orientation
of foam insert Top and bottom cap lubricators are self
tapping.
Take care when fitting to avoid stripping
threads.
21. Charge top and bottom bushes with grease

until grease seepage is evident at both the
swivel / axle bed interface and thrust
bearing axle bed interface.
56
If grease is seen to seep from top and
bottom cap threads, the 'O' ring seal has
become damaged and must be replaced.
SERVICE MANUAL

(continued)
22. If Top and bottom steering levers have been
removed for replacement / Checking, Refit
to swivel using bolts and tighten to specified
torque.
57
23. Offer tie rod assembly up to bottom steering
lever.
24. Fit Ball socket nuts and tighten to specified
torque.
Suggest initial tightening of ball pin nut

to lower torque figure. Then tighten just
enough to align split pin hole.
Do not exceed maximum torque figure.
58
59
60
SERVICE MANUAL

(continued)
25. Check alignment of split pin holes in nut and
ball pin. If necessary tighten ball pin nut to
align holes.
26. Insert a new split pin into ball pin.
61
27. Using suitable pliers, bend new split pin to
secure ball pin nut.
62
63
64
SERVICE MANUAL
The following instructions are general.

Refer to hub end maintenance manual
and vehicle manufacturers assembly
instructions for more detailed
descriptions.
65 2. Re fit brake assemblies / brake drums.

3. Re connect brake connections.
4. Check that interfaces between hub flange
and wheel rim are free of the following:-
Dirt - including liner materials
Rust
Paint
Failure to keep the interfaces, can and

will cause the wheel rim to distort upon
tightening of wheel nuts.
For further details see BS AU 50: Part 2:
66 Section 7A; 1995
5. Refit road wheels.

6. Refit wheel nuts and tighten in correct
sequence (as shown in Fig 66) to specified
torque
7. Check wheel alignment.
8. Refit swivel stop screws to original recorded
length and check lock angles. (see relevant
installation arrangement and / or vehicle
manufacturer’s instructions.)
Due to manufacturing tolerances on

beam forgings, it is impossible to state a
required length for longstops. Actual
lock angle should be checked on the
vehicle.
9. Lower vehicle to ground.
All steer axles supplied by Spicer Speciality Axle Division have their lockstops set to
customer requirements.
It is important that when the power assisted steering gear is fitted, the steering gear is
adjusted so that the hydraulic assistance cuts out before the lockstops come into contact
with the axle beam, to avoid excessive loads being transmitted through the steering
linkages. Incorrectly adjusted steering could lead to premature failure or shortened life of
all steering components.
SERVICE MANUAL
PREPARATION
Prepare for axle overhaul as follows:
1. Set parking brake and block drive wheels to
prevent vehicle movement.
2. Raise vehicle until tyres are off the ground.
67 support raised vehicle with safety stands.
WARNING
Never work under a vehicle supported
only be a jack.
Always use safety stands.
HUB END DISASSEMBLY

1. Disconnect brake connections and ABS
sensor from vehicle.
68 Fit plugs to connections to prevent dirt
ingress.
2. Loosen but do not remove, brake caliper
retaining bolts
3. Using suitable lifting equipment, support the
brake caliper.
4. Remove brake caliper retaining bolts and
remove brake caliper from axle.
CAUTION
Brake caliper is heavy. Ensure weight is
fully supported before removing retaining
bolts. Take care to avoid caliper
swinging and trapping fingers.
Brake calipers are handed!

Spicer Speciality Axle Division
recommends marking calipers with paint
or marker pen to facilitate correct
refitting.
Brake air cylinders should only be
removed if replacement or repair is
required.
Refer to the brake manufacturer's manual
for details of caliper or air cylinder
service.
SERVICE MANUAL
14
15
16
9 13
12
8 11
10
7
6
5
4
3 17
2
1
18
19
41 20
21
22
23
24
25
26
27
38 28
37
39 36
40
35
34
33
32
29
30
31
SERVICE MANUAL
Item No Description
1 Brake backplate nut

2 Brake backplate stud
3 Swivel assembly
4 King pin oil seal (top)
5 King pin bush (top)
6 Top cap ‘O’ ring
7 Top cap foam insert
8 Top cap
9 Top cap lubricator
10 Top steering lever L/H
11 Top lever bolts
12 Setting shims
13 King pin thrust bearing
14 Cotter pin nut 1/2” UNF
15 Cotter pin washer
16 Axle bed
17 Cotter pin
18 Cable protector A.B.S sensor
19 Tie wrap
20 A.B.S sensor
21 A.B.S sensor brush
22 Lockstop screw
23 Lockstop nut
24 Bottom lever bolt - M20
25 Bottom lever bolt - M24
26 Bottom lever
27 Ball pin nut
28 Split pin (Ball pin nut)
29 Tie rod
30 Socket pinch bolt
31 Socket assembly
32 Bottom cap lubricator
33 Bottom cap
34 Bottom cap foam insert
35 Bottom cap ‘O’ ring
36 King pin
37 King pin bush (bottom)
38 King pin oil seal (bottom)
39 Thrust washer (hub bearing)
40 Hub nut
41 Hub nut grubscrew
SERVICE MANUAL
HUB END DISASSEMBLY (continued)

5. Loosen but do not remove hub flange bolts.
6. Remove 2 diametrically opposed hub flange
bolts.
7. Replace 2 diametrically opposed hub flange
69 bolts with 2 studs (loosely fitted).
Replacement studs should protrude

beyond front face of hub flange to aid
removal.
8. Gently tap hub flange outwards using a hide

faced hammer.
9. Support weight of hub flange and remove
hub flange retaining bolts.
10. Remove hub flange and place on a suitable
workbench.
70
CAUTION
Component is heavy.
Ensure weight is fully supported before
removing retaining bolts.
11. Inspect wheel studs and remove for

replacement, any that are found to be
defective.
71
SERVICE MANUAL

12. Once hub flange has been removed, insert
two bolts into brake disc extraction holes
13. Tighten to free brake disc from hub bearing.
14. Support weight of brake disc and carefully
72 slide along dummy studs to remove.
CAUTION
Component is heavy.
Ensure weight is fully supported before
removing retaining bolts.
15. Place brake disc on a suitable work bench

and inspect for cracks and defects, Replace
if necessary.
(See Pages 7.16 & 7.17 for details of typical
defects and acceptability)
73 Check brake disc thickness is within
manufacturer's specifications.
Refer to table below for Acceptable dimensions:
WARNING
Do not allow brake disc to wear below
minimum thickness!
74
Brake Disc Type Original Thickness Minimum Thickness

SN7000 45MM 37MM
SERVICE MANUAL

16. Undo and remove hub nut locking
grubscrew, inspect for replacement if
required.
17. Remove hub nut.
76 18. Remove bearing thrust washer.
19. Fit bearing guide sleeve onto swivel thread.
(See Tool list on Page 7.50 )
20. Carefully pull unitised hub bearing assembly
towards end of swivel stub and remove.
21. Place on a suitable workbench and inspect
for wear / damage, taking care not to
damage the ABS exciter ring in the process.
The unitised bearings used on the NDS

range of axles are non serviceable items.
77 Bearings are pre-adjusted, lubricated and

have seals fitted as part of the
manufacturing process.
The bearings are greased for life and
there is no need or facility for re-
lubrication.
22. Remove ABS sensor and sensor bush

inspect for wear / damage and replace if
necessary.
Strip down remainder of axle as described in swivel
assembly removal and refitting instructions.
78
Place bearing this way up on bench to

avoid damaging pole wheel.
SERVICE MANUAL
HUB END REASSEMBLY

1. Follow instructions contained in swivel / axle
bed reassembly section, before attempting
to reassemble hub end.
2. Fit Unitised hub bearing guide sleeve onto
swivel stub (see Tool list on Page 7.50)
79
3. Smear swivel stub axle with a thin layer of
anti-fretting assembly paste white i.e.
Optimol Paste White T (Castrol) or
equivalent.
4. Offer new unitised bearing onto swivel stub.
80
81
82
SERVICE MANUAL
HUB END REASSEMBLY (continued)

5. Place unitised hub bearing thrust washer
onto axle stub.
6. Fit hub nut.
7. Tighten to specified torque.
83
Rotate unitised hub bearing whilst
tightening.
84
85
86
SERVICE MANUAL

8. Lock the hub nut in position. Use a
grubscrew in the most suitable of the six
tapped holes in the hub nut.
9. Using a modified hub flange bolt as a guide,
carefully position brake disc onto unitised
88
hub bearing.
10. Tap securely home (using a hide faced
hammer to avoid damaging the brake disc
itself.)
11. Remove the modified hub flange bolt at this
point.
12. Carefully offer hub flange up to brake disc /
unitised hub bearing assembly and hold in
position by inserting 1 - off hub flange bolt
and tightening hand tight.
13. Insert remainder of hub flange bolts.
89 14. Tighten to correct torque using selection
procedure as shown in Fig 90.
90
SERVICE MANUAL

15. Refit ABS sensor bush and sensor into
swivel.
A new sensor bush should be fitted

whenever a new sensor is fitted.
91 If fitting a new sensor and bush into an
ABS ready axle. Sensor and bush
should be supplied from the same
manufacturer.
Refit ABS sensor bush and sensor into
swivel.
16. Push sensor through bush until it comes
into contact with polewheel on hub
assembly.
17. Rotate hub bearing assembly through at
least one revolution.
This serves to set the correct gap

between sensor and polewheel.
Refit ABS sensor bush and sensor into swivel.
SERVICE MANUAL
18. Check A.B.S. sensor performance as follows

a. Insert probes from a volt-meter into two plugs in sensor connector.
b. Set voltmeter to read mili-volts AC.
c. Rotate hub in any direction at a constant speed of 60Hz (7Kph).
To determine this speed use the following calculation ;
60Hz
RPM = x 60 secs
z
where z = number of teeth on pole wheel
Reading may not be steady due to possibility of pole wheel run out and
inconsistent speed of wheel.
d. Maximum reading (Vmax) must not be more than 80% greater than minimum reading (Vmin).
i.e.
Vmax
= or < 1.8
Vmin
If following is true then it is likely that there is excessive pole wheel runout. Pole wheel
installation will therefore need to be inspected and remounted or replaced.
Vmax
> 1.8
Vmin
e. Minimum reading must be greater than voltage threshold (Vt) i.e.
Vmin > Vt Vt = 60mV
If this is not the case, then sensor gap is too large or there may be excessive pole wheel
runout. The pole wheel will therefore need to be inspected and remounted or replaced.
f. If sections d. and e. are satisfied, then the installation can be considered as satisfactory.
The above test procedure is as recommended by the ABS manufacturers.
SERVICE MANUAL

19. Using suitable lifting equipment, support the
brake caliper.
CAUTION
92 Brake caliper is heavy.
20. Offer brake caliper up to brake bracket.

(Ensure correct hand of brake caliper is
selected)
21. Insert brake caliper retaining bolts and
tighten hand tight.
22. Tighten brake caliper bolts to secure
assembly.
23. Remove caliper lifting equipment
CAUTION
93
Brake caliper is heavy.
Ensure weight is fully supported by
retaining bolts before removing lifting
equipment.
24. Tighten brake caliper bolts to correct torque.

25. If the brake caliper air chamber has been
removed; Refit to caliper and tighten nuts to
correct torque.
Take care not to damage pad wear sensor

cable during reassembly of chamber to
caliper.
SERVICE MANUAL

26. Refit lockstop screws and adjusting nuts
27. Reset lockstop screws to achieve correct
lock angles as shown on installation
drawing or vehicle manufacturer's
specifications.
94
Do not allow lockstop threads to protrude
through front face of swivel.
28. Check wheel alignment as follows

a. Set axle in straight ahead position.
Clamp bolt b. At a point level with wheel centre, measure

distance over hubs / wheel rims, both in
type A front and behind axle centre.
Socket assembly
c. Front measurement ‘B’ should be 0.0" to
0.04" (0.0 to 1mm) LESS than rear
95 measurement ‘A’.
d. Any adjustment on type A socket and tie rod
assemblies can be effected by slackening
End of threads must clamp bolts in ball sockets and rotating track
rod tube.
not be visible here
For type B socket and tie rod assemblies,
slacken the clamped end of the assembly
and use the adjuster ring.
Adjuster ring
e. After adjustment, tighten clamp bolts to
type B Socket specified torque.
assembly
When adjusting Type A tie rods, ensure
socket threads are equally positioned in
96
each end of the tie rod and that the end of
the socket thread is not visible through
Crimped end the sawcut.
type B socket
assembly
SERVICE MANUAL
97
29. Re-connect brake hose to vehicle air

system.
30. Clean interfaces of wheelnuts, wheel rim &

98 hub then re-fit road wheels securing with
wheel nuts and tighten in correct sequence
(as shown) to specified torque.
Interfaces must be free from dirt,

including brake liner material debris, rust
and paint.
Failure to keep interfaces clean can and
will cause wheel rim to distort upon
tightening of wheel nuts.
For further details see BS AU50: Part 2:
Section 7A: 1995.
31. Remove axle supports and lower vehicle to

ground.
SERVICE MANUAL
STUD FITTING PROCEDURES

Standard studs - fitted into machined chamfered holes.
Studs to be inserted until thread run-out locks into parent metal.
Fig 99
IMPORTANT
This stud fitting procedure is to to be used in lieu of stated torque values on existing
arrangements. New arrangements will specify TD183/1 from the date of issue.
Special studs - filled into machined parallel counterbore
Studs to be inserted
until correct torque
value is obtained - as
shown on relevant
arrangement drawing.
Fig 100
This specification is for stud fitting only; nuts & setscrews must be torqued to value specified.
SERVICE MANUAL
TOOLING REQUIRED
Number Description
E660 ALIGNMENT SLEEVE FOR Ø70 HUB BEARING
E659 PULLER FOR TOP & BOTTOM SWIVEL BUSHES
E661 KINGPIN OIL SEAL BUSH BUMPER
E657 ALIGNMENT TOOL FOR FITTING SWIVEL TO BED
SERVICE MANUAL
Front Axle - ZF-RL-75A Amended:
Description
The axle is a ‘Reverse Elliot’ type comprising a girder section axle bed or beam with stub axles.
Grease Lubrication Hub Bearing
Grease Change Interval

Recommended lubrication Lithium base roller bearing grease NLGI No. 2
Every 2 years or 312,500 miles (500,000km)

1. Steering knuckle assy.
2. Bearing unit assy. 7
6
2a Bearing outer/inner ring 2
2b. ‘O’ Ring
2c. Cassette-type seal
2d. Retaining Ring. 1
2d
2e. Shaft seal.
3. Hub with brake disc.
4. Slotted nut. 5
4
5. ‘O’ ring. 2e
2a
6. Locking plate. 3
2a
7. Cover.
2b 2c
Fig 1
Hub Bearings
Removal
1. Remove the hub with the disc brake (3).
2. Remove the grease from the hub (3), clean hub and bearing inner rings/bearing outer rings (2a).
Remove only the inner rings of the tapered roller bearing from the hub.
3. Check condition and wear of tapered roller bearings (2a) (inner and outer ring). Replace worn or
damaged tapered roller bearings by a new bearing unit.
4. Thoroughly grease the tapered roller bearings (2a) and fill them with the specified grease quantity..
5. Fill quantity 96g per hub.
6. Install hub. install new shaft seal (2e), cassette- tpye seal (2e) and ‘O’ Ring (2b).
7. Refit the wheel head. Fit new ‘O’ ring (5) and new locking plate (6).
SERVICE MANUAL
Front Axle - ZF-RL-75A Amended: 04.03.15
Grease Lubrication - Steering Knuckle
Grease Interval
Recommended lubrication Lithium -saponified multipurpose grease NLGI No. 2 which is mixable with mineral
oil (grease code LP2K-30 acc, to DIN 51825 or ISO-L-XCCHB2 acc. to ISO/DIS 6743-9) is to be used at the
greasing points.
Every year or 50000- 56250 miles (80,000 - 90,000km).
Fig 2.
Position of Lubricating Nipples.
1 = Steering Knuckle bearing Top.
2 = Steering Knuckle bearing Bottom.
Lubrication
Lubricate the greasing points with a grease gun until grease comes out at the seal rings (steering knuckle
bearing).
Front Wheel 'TOE IN'

1. To preserve correct steering and avoid excessive tyre wear, tracking (or alignment) of front wheels
should be checked periodically, as follows :-
Set front wheels in straight ahead position and at points level with wheel centre, measure distance over
hubs / wheel rims, both in front and behind axle centre.
The correct 'Toe In measurement should be (0mm to max + 2mm).
Torques: Ball Joint Nut 210 - 230Nm
 Track Rod Ball Joint Clamp Nut 160 - 180Nm
SERVICE MANUAL
Front Axle - ZF-RL-75A Amended: 15.05.13
 Check Permissible Play in Swivel
IMPORTANT
The play on point 1 must only be measured in the area of the marked (green) surface shown in Detail
‘X’ and ‘Y’. The recess of 0.2 to - 0.1 shown in Detail Y is necessary for the grease to escape after
lubrication of the king pin bearing.
00463
Fig 2a
Axial Play Point 1

Measuring Point 1. The vehicle must be standing on its wheels (not jacked up). Measure with feeler gauge
in the marked (green area). Wear limit max 1.3 mm.
Axial Play Point 2

Measuring Point 2. The vehicle must be jacked up. Attach a dial gauge to the axle beam / frame. Check
the axial play by loading and unloading the knuckle. Wear limit max 1.3 mm.
SERVICE MANUAL
Front Axle - ZF-RL-75A Amended:15.05.13
Disassembly
Pressing-out of King Pin (axle removed):
Remove grease nipple and snap out retaining ring.
Use striker to force closing cover out of the steering
knuckle
3 hole.
(S) Striker 5870 650 001
Remove lower seal holder.
Attach Press device to the steering knuckle. Use a

hydraulic cylinder to press out the King Pin.
Pay attention that the axle bolt does not drop.

4
(S) Pull rods 5870 285 028
(S) Pressure plates 5870 285 027
(S) Hydraulic spindle 5873 003 007
(S) Hydraulic pump 5870 287 010
Pressing-out of King Pin (axle installed

into the vehicle):
5 For removal of brake see later details.
Remove seal holder according to Figure 3.
Attach press device to the steering knuckle. Use a

hydraulic cylinder to press out the King Pin.
Pay attention that the King Pin does not drop!
6 (S) Pull rods 5870 285 028
(S) Bracket 5870 281 043
SERVICE MANUAL
The installation situation and available space can

vary.
The axle bolt may also be pressed out from the
bottom. In this case, attach the press device to the
axle housing in a 180° turned position as shown in
Figure 6.
7 Support hub with tool as shown.
Disassembly of RL-75 A wheel head

Separation of brake from steering knuckle
8 Loosen hexagon screws (1) and tight-fit screw (2)

and separate brake caliper from steering knuckle.
1
2
Remove stop screw with hexagon nut (1) and

9 tachometer with clamping bush (2).
1 2
Disassembly of wheel head
Loosen hexagon screws (1).

10
SERVICE MANUAL
Separate cover from hub.
11
Remove O-ring (1).
12
Unlock outer slotted nut (see arrow).
13
Loosen outer slotted nut, remove locking plate and

loosen inner slotted nut.
14 (S) Slotted nut wrench 5870 401 136

(S) Centering bracket 5870 912 012
SERVICE MANUAL
Separate hub/brake disk from steering knuckle.

15
In case the bearing inner rings are stuck due to

fretting corrosion as a consequence of water entry,
use a two-armed puller to facilitate the separation.
16
Using a puller, pull the hub/brake disk off the
steering knuckle.
1 Loosen bolted connection (1) and separate brake

disk/hub.
2
17
It is not necessary to press out the wheel studs (2).
Remove the shaft seal.
18
SERVICE MANUAL
Remove O-ring (1).

1
Remove cassette-type seal on side of brake disk
from the hub hole.
2
Impulse disk (2) only needs to be removed in case
of damage.
19
Check compact bearing and remove it.

Inspection of the compact bearing inside followed
6 1 2 3 7
by a grease change is also required.
• within the maintenance interval, see List of
Lubricants TE-ML 12.
• in case of grease leakage on the shaft seal (1)
20
and cassette-type seal (3).
• in case of overheated brake parts (e.g. burnt
bellows on pressure pieces).
4 5
Legend to Figure 20:
1 = Shaft seal (on side of wheel stud) *(Bearing
Unit)
2 = Bearing inner and outer ring - (Bearing Unit)
3 = Cassette-type seal (on side of brake
disk)*(Bearing Unit)
4 = Retaining ring - (Bearing unit)
5 = O-ring* - (Bearing unit)
6 = Hub
7 = Impulse disk
These spare parts are available separately.
Remove retaining ring (see arrow – Fig 20, item 4).
21
SERVICE MANUAL
Remove both bearing inner rings (1).

1 If required, remove both bearing outer rings (2).
2
22
1 Disassembly of steering knuckle / steering

knuckle carrier:
Remove grease nipple (1).
2
Snap out retaining ring (2).
23
Use a striker to force closing cover out of the

steering knuckle hole.
24 (S) Striker 5870 650 001
Remove lower seal holder.
Attach press device to the steering knuckle. Use

hydraulic cylinder to press out the axle bolt.
Pay attention that the axle bolt does not drop.
25
(S) Pull rods 5870 285 028
SERVICE MANUAL
Remove axial roller bearing (1) and shim (2).

26
2
Remove lower and upper seal ring from the

steering knuckle hole.
27
Force lower and upper needle sleeve out of the

28 steering knuckle.
SERVICE MANUAL
Reassembly of RL-75 A wheel head

Reassembly of steering knuckle/steering knuckle
4
carrier:
3 5 The figure shows the assembled axle bolt.
2 6 1 = Steering knuckle carrier
29 2 = Steering knuckle
8 1 3 = Axle bolt
7 4 = Seal holder with grease nipple and retaining
6 ring
5 5 = Needle sleeve. Note: Bush may be fitted in the
4
lower position.
6 = Seal ring
7 = Axial roller bearing
8 = Shim (adjusting shim for axial play)
3
2
1 The fig30 shows the required special tool for
assembling the needle sleeve / bush and the seal
rings (see Figures 4 to 5).
30 Use the specified special tool to obtain the
exact installation position.
Handle
(S) Driver tool set (part 1 to 3) 5870 055 107
(S) Handle 5870 260 003
Fit lower and upper needle sleeve to the steering

knuckle (see Figures 32 to 33). Note: On some
axle models a bush may be fitted in the lower
position.
31 When pressing in the needle sleeve, always

place the press-fit mandrel onto the marked
(hardened) side (arrow) to avoid damage to the
needle sleeve.
As an initial step, press in the first needle sleeve or

Bush (1) with special tool (part 1) until contact is
obtained.
Then use special tool (part 1 and part 2) to bring

32
1 the needle sleeve or bush into the final position.
Now press in the second needle sleeve with

special tool (part 1) until contact is obtained.
Note: This stage is not required when bush is fitted.
SERVICE MANUAL
Press in seal ring (1) with special tool (part 1 and

part 3) until contact is obtained.
Install the seal ring with the open side (see

arrow) to face the special tool.
33 Install upper needle sleeve and seal ring.
Place seal holder (1) with assembly disk (2) into

the lower steering knuckle hole, preliminarily
without O-ring, and fix them with retaining ring 58x2
(3).
The installation of the assembly disk is necessary

34 to ensure the exact axial position of the axle bolt.
2 Remove the assembly disk after having fitted the

1 axle bolt.
3
Adjusting disc 0630 000 197
Setting of steering knuckle axial play 0.05 –

0.15 mm
Place axial roller bearing (1) and determine
dimension „A“.
35 The contact surface for the digital depth gauge

(see arrow) must be machined and clean to
avoid inaccuracies in measurement.
A It is also possible to determine the dim. „A“
1
with an inside micrometer.
Ensure correct measurement:
The dim. ‘A’ must be determined from the

contact surface of the steering knuckle (marked
36 surface) to the axial roller bearing.
Countersink 0.2-0.1 (see arrow) is required for

A grease overflow after lubrication of the steering
knuckle bearing.
SERVICE MANUAL
Determine dim. „B“.
Example of calculation:
Dim. „A“……...…………………………… 90.4 mm
Dim. „B“ ………………………………... - 87.5 mm
_________
37 Difference = 2.9 mm
B Required axial play 0.05-0.15 e.g. - 0.1 mm
__________
Shim (adjusting shim) thickness = 2.8 mm
__________
When fitting the swivel pin it is highly important

to do the work steps (Figures 38 to 40)
immediately one after the other.
Prior to fitting the axle bolt, heat up the hole of

the steering knuckle carrier to approx. 100 to
120° C and cool the axle bolt to approx. -10° to
38 -20° C.
(S) Thermometer 5870 220 011
Use a hot-air blower to ensure that the hole is
heated up evenly. Check with a thermometer.
Unqualified heating (e.g. flame) is not allowed.
 CAUTION
Caution must be observed when handling
cooled pin. Always wear protective gloves. Do
not allow cooled pin to contact exposed skin.
S
Position the steering knuckle carrier (1) with the
lifting device, fit axial bearing and shim (2) and
39 align them with the swivel pin (S).
1
See also sketch in Figure 29.
2
Make sure that the crimping of the axial roller
bearing faces the steering knuckle (see arrow).
(S) Centering pin 5870 912 018
1 Wear protective gloves.
Insert the cooled swivel pin (1) until contact is

obtained.
40
Ensure that swivel pin is free of grease.
SERVICE MANUAL
2 1
Place O-ring 55x3 into the groove of the seal
holder (1) and grease it.
Place seal holder (1) into the steering knuckle hole

41 and fix it with a retaining ring (2).
Installation position of tab see Figure 44.

Tab serves as a guide for the ABS sensor cable.
Place O-ring 55x3 into the groove of the seal

holder (1) and grease it.
Place seal holder into the steering knuckle hole

42 and fix it with retaining ring 58x2 (2).
Remove lower preassembled seal holder.

1 Remove assembly disk (see Figure 34).
2
43 Fit upper and lower grease nipple M10x1 (1).
Installation position of seal holder’s tab see arrow.

1
Use a grease gun to lubricate the steering knuckle
bearing at the lower and upper grease nipple (1)
until grease comes out at the seal ring.
44 Grease overflow at the seal ring after

lubrication (see arrows Figure 15).
See Lubrication and Maintenance Instructions

5871 197 901 and ZF List of Lubricants TE-ML
012.
e.g. grease Renolit 283 EP (Fuchs)
SERVICE MANUAL
Reassembly of wheel head
1 If wheel studs (1) need to be replaced, use the

proper special tool for fitting.
(S) Wheel stud puller - basic tool 5870 610 010

45 (S) Insert M22x1.5 5870 610 002
Reassembly of bearing unit (Figures 46 …53)

2 1
When replacing the compact bearing or when
5 3 changing grease within the maintenance interval,
make sure that hub and compact bearing are
cleaned thoroughly.
46
Figures 46 and 47 show the single parts of the
compact bearing and their installation position.
1 = Shaft seal (on side of wheel studs) *

6 1 2 3 2 = Bearing inner and outer ring
3 = Cassette-type seal (on side of brake disk)*
bearing unit
4 = Retaining ring
47 5 = O-ring*
6 = Hub
These spare parts are available separately, and

are supplied as loose parts for the bearing unit.
4 5
Press in both bearing outer rings until contact is

obtained.
(S) Driver tool 5870 050 003

48 (S) Handle 5870 260 004
SERVICE MANUAL
Grease compact bearing in the marked area - -
Grease quantity: 96 g
Richly grease the bearing rollers inside and

outside and on the front sides.
49 Do not use grease types other than those

approved by ZF (e.g. Renolit LX-NHU 2, ZF
Order No.: 0671 190 177).
Refer to ZF List of Lubricants is TE-ML 12.
The latest update of the List of Lubricants is
available at internet site www.zf.com
Service/Techn. Information
Place hub onto the support and fit bearing inner

ring on brake disk side.
To ensure the exact contact position of the

bearing rollers in the bearing outer ring, press
bearing inner ring firmly and rotate it several
50 times (rolling in).
The brake-disk-sided bearing inner ring can be

identified by the annular groove for the O-ring
(arrow) and has an inner diameter of Ø100 mm.
(S) Support 5870 345 121
Turn hub upside down, place it onto the support

and fit outer bearing inner ring.
To ensure the exact contact position of the

bearing rollers in the bearing outer ring, press
bearing inner ring firmly and rotate it several
51 times (rolling in).
Clearance-free contact of both bearing inner

rings must be ensured.
The bearing inner ring has a diameter of Ø 99.8
mm.
(S) Support 5870 345 121
Fix both bearing inner rings with a retaining ring.
Pay attention to the exact installation position

of the
retaining ring. When it is correctly fixed, the
52 reference dimension is: 135 ± 0.4 mm
Lifting of the outer bearing inner ring is no

1 longer possible.
SERVICE MANUAL
Detail „X“
53
X
135 ± 0,4
Fitting of shaft seal on side of wheel studs.
Install the shaft seal with the open side facing

the special tool (see Figure 47; item 1).
Use the specified special tool (S) to obtain the

correct installation depth.
54
(S) Driver tool 5870 053 026
(S) Handle 5870 260 011
(S) Support 5870 345 121
Fit cassette-type seal on side of brake disk.
The crimped side on the outer diameter must

face the special tool (see Figure 47, item 3).
55 Use the specified special tool (S) to obtain the

correct installation depth.
(S) Driver tool 5870 048 317

(S) Support 5870 345 121
Fit the brake disk (1) into position on the hub (2)
3 and tighten it with Torx screws M16x1.5x60 (3).
Tightening torque (M16/10.9x1.5x60)…... MA =

2 240 Nm
56
(S) Support 5870 345 121
1
SERVICE MANUAL
Press impulse disk (1) onto the hub evenly.

Pay attention to avoid any damage to the impulse
1 disk.
(S) Support 5870 345 121

57
Place O-ring 109x5 (1) into the annular groove of

1 the bearing inner ring and grease it.
(S) Support 5870 345 121

58
Grease bearing seat (see arrows) with lubricant

„MOLYKOTE DX“.
Protection against fretting corrosion.
59 Mount inner installer onto the steering knuckle.
(S) Inner installer 5870 651 099
Use the lifting device to carefully bring the

preassembled hub into contact position.
Now remove inner installer.
60
SERVICE MANUAL
Fit internal slotted nut M95x1.5.

slotted nut - chamfer to show outwards.
First step: Tighten slotted nut with 100 Nm.

Rotate hub 15 times.
61 Second step: Tighten slotted nut to torque.
Rotate the hub 15 times.
Tightening torque (inner slotted nut ) ….. MA = 850

Nm.
(S) Slotted nut wrench 5870 401 136
(S) Centering bracket 5870 912 012
If during the tightening process of the slotted

nut (Figure 61) no increase of the bearing
rolling torque is noticeable, or if an axial play of
the wheel bearing is detected (Figure 62), this
1 may be caused by the unsnapping of the
retaining ring (Figures 52 and 53).
62 Correct assembly fault, if required.
Mount locking plate (1) and fit outer slotted nut.

locking plate. Securing clip (see arrow) to show
inwards.

slotted nut – chamfer to show inwards.
Rotate hub 15 times.
63 Tightening torque (outer slotted nut ) …….. MA =

1200 Nm.
Secure slotted nut by deforming the locking plate,

i.e. by indenting the locking plate into a groove of
the outer slotted nut.
64 Now mark the indentation of the locking plate at

the groove with safety marking paint - see
arrow.
SERVICE MANUAL
Insert O-ring 155x3 (1) into the annular groove of

1 the cover and grease it.
65
Mount cover and fix it with hexagon screws

2 M12x25 (1).
Tightening torque (M12/10.9x25…………MA = 100
Nm).
Tighten the Torx screws M16x1.5x60 (2) of the
bolted
66 connection -brake disk/hub- to torque.
Tightening torque (M16/10.9x1.5x60)…... MA =
240 Nm.
Lubricate the outer diameter of the sensor with

silicone grease (corrosion protection), front surface
(sensing area) to be free of grease.
Insert bushing (1) and press tachometer (2) into the

67 2 bushing until contact is obtained, without using
1
striking tools.
The distance between tachometer and measuring

ring is automatically adjusted by the wheel play.
3
Install new bushing
Tightening torque without lock nut

(M16/10.9x1.5x30) MA = 300 Nm.
Tightening torque with lock nut (M16/10.9x1.5x30)

MA = 130 Nm.
Adjust steering angle by stop screw M16x1.5x30

(3).
SERVICE MANUAL
Fitting Brake Caliper (Figures 68 to 69):
The brake manufacturer’s instructions and

specifications are mandatory for any operations
done on the braking system.
68
Fix brake to the steering knuckle using hexagon

screws M16x1.5x60 (1) and tight-fit screw Ø19 mm
(2).
Tightening torque (M16/10.9x1.5x60) ...... MA =

270 Nm
69
1
Tightening torque (M16/10.9x1.5x60) ...... MA =
270 Nm
(tight-fit screw)
2
SERVICE MANUAL
Special Tools for Disassembly and

Reassembly
Assembly truck assy

1
with tilting device 5870 350 000
2 Bracket 5870 281 043
3 Fixing plate 5870 350 119
Clamping angle 5870 350 093

4
5 Striker 5870 650 001
SERVICE MANUAL

Reassembly
6
Pull rods 5870 285 028
7 Pressure plates 5870 285 027
8 Hydraulic spindle 5873 003 007
9 Hydraulic pump 5870 287 010
10 Slotted nut wrench 5870 401 136
SERVICE MANUAL

Reassembly
11
Centering bracket 5870 912 012
12 Driver tool 5870 055 107
13 Handle 5870 260 003
14 Adjusting disc 0630 000 197
15 Thermometer 5870 220 011
SERVICE MANUAL

Reassembly
16
Centering pin 5870 912 018
17 Wheel stud puller 5870 610 010
18 Insert M22x1,5 5870 610 002
19 Driver tool 5870 050 003
20 Handle 5870 260 004
SERVICE MANUAL
Alphabetical Index Amended:
A H
A.B.S. Braking system 4.17 Hand Brake Valve 4.10
ABS Warning Light 4.27 Hazardous Materials 1.3
Fault Code List 4.27 Health and Safety 1.2
Air Cleaner 2.2 Hydraulic Pump, Tandem 2.26
Air Cleaner Maintenance - Main Points 2.5 Hydraulic System 2.20
Air Suspension System 6.2
I
Air Suspension, Front 6.12, 6.14
Instrument Panel 5.54
Alternator AC172R 5.62
Intake Hoses & Air Leaks 2.4
B
L
BALL JOINT INSPECTION 7.4
Levelling Valve 6.7
Batteries 5.3
LUBRICATION CHART 1.16
Battery Carrier Area 5.81
Braking System 4.1, 4.2 M
Braking System - SB Caliper 4.32 Multiplex System 5.7
Braking System - SN Caliper 4.62 N

C Non Standard Torque Figures 1.28
CAMU &IOUConnections 5.19 P
Chassis Jacking Points 6.21 Pipe Connectors, Braking System 4.102
Cooling System 2.6 Propshaft 3.12, 3.13
Corrosion Protection 1.14 Proximity Switch 6.7
D R
Diagnostics Using PC 5.16 Rear Axle 3.16
Driver’s Information Screen 5.54
Rear EDCFuses 5.60
E
Rear Electrical Distribution Centre (R.E.D.C.) 5.61
Electrical System 5.1
Rear Suspension 6.16
Engine and Mountings 2.30
S
Exhaust Gas Processor System 2.12
SB Caliper 4.33
Exhaust System 2.12
Service Schedule 1.5
F
Shock Absorbers 6.18
Fan Motor 2.24
Fault Code Readout, Engine 2.36 SN Caliper 4.62
Foot Brake Valve 4.11 Special Tools 1.26
Front Axle - DANA 7.13 Standard Torque Figures 1.27

Front Axle - ZF-RL-75A 7.53 Starter 5.4
Front EDCFuses 5.60 Steering 7.1
Front Electrical Distribution Centre (E.D.C.) 5.59 Steering Gear 7.2
Front Suspension 6.12, 6.14 Supporting Vehicle for Maintenance Purposes 1.25
Fuel System 2.16 Suspension 6.1
SERVICE MANUAL
Alphabetical Index Amended:
T
Tandem Hydraulic Pump 2.26
Towing 1.24
Transmission - ZF EcoLife Gearbox 3.2
V
VIN Plate 1.4
Voith Gearbox 3.8
W
Warning and Caution Categories 1.2
Wheels 6.1
Wheels and Tyres 6.19
Wire Identification - Colour Coding 5.36
Wiring Diagrams 5.83

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SERVICE MANUAL

Publication Number: 2377 Date: Feb 2009 (10/12)

Alexander Dennis Ltd

PARTS, SERVICE & TECHNICAL CENTRES

AFTER MARKET SUPPORT LINE Amended:22.05.13

AFTER MARKET SUPPORT LINE

0845 358 9988

including : Part Number Identification

On-Line Parts Ordering at www.adl247parts.com

FAX numbers : Parts Ordering . . . . . . . . . . . .0845 358 9992

BRIAN EVANS E-MAIL : brian.evans@alexander-dennis.com

TECHNICAL SUPPORT MANAGER

REGIONAL SERVICE MANAGER STEVE HARDY

REGIONAL PARTS MANAGERS Amended:

CUSTOMER MANAGEMENT ROB WILLIAMS

REGIONAL PARTS MANAGER MARK BOWLEY

REGIONAL PARTS MANAGER TBC

REGIONAL PARTS MANAGER GARY GLOVER

REGIONAL PARTS MANAGER LES RIVETT

REGIONAL PARTS MANAGER JIM WEBB

REGIONAL SERVICE MANAGERS Amended:300610

LONDON, KENT AND EAST & WEST SUSSEX

REGIONAL SERVICE MANAGER STEVE EDMONDS

REGIONAL SERVICE MANAGER JOHN CHAVES

REGIONAL SERVICE MANAGER GLEN WILKIE

REGIONAL SERVICE MANAGER DAVID ALLEN

REGIONAL SERVICE MANAGER JOHN BRADLEY

REGIONAL SERVICE MANAGER BEN WAITE

HARLOW SERVICE CENTRE: Unit B, Barrows Road, Pinnacles Industrial

TRAINING MANAGER PAUL HOPWOOD

Health and Safety Corrosion Protection . . . . . Page 1.16 - 17

Body Servicing Schedule . . Page 1.13 - 15

Warning and Caution Symbols

Moving the Vehicle

The following potential hazards should be considered:

Use Common Sense - If in Doubt Ask

Health and Safety - PLEASE READ Amended:090311

Use Common Sense - If in Doubt Ask

Health and Safety - PLEASE READ Amended:090311

Hazardous Materials (continued)

VITON ‘O’ RINGS AND SEALS (fluoro-elastomers)

IF IN DOUBT THE FASTENER SHOULD BE REPLACED

Use Common Sense - If in Doubt Ask

Environmental Warnings - PLEASE READ Amended:090311

Those which may cause noxious fumes if allowed to burn:

Coatings (chassis protection)

Mineral oil (engine and transmission)

Rubber and synthetic alternatives (tyres, hoses, bushes, seals, insulation)

Vehicle Identification Numbers - Chassis or Body Amended:090311

Sample VIN and Body Plates

LATER ECWVTA ADL CHASSIS ADL BODY

ALEXANDER DENNIS V.I.N

KEY TO CHASSIS VIN PLATE

SFD World Manufacturers Identity A Type Approval Number

The VIN and body plates are sited

Service Intervals Recommended Servicing sequence

Air Cleaner NOTE DAILY FIRST A B C

Check the restriction indicator    

Check the restriction indicator