Terex TR60 Maintenance Manual
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Terex TR60 Maintenance Manual

Off-highway truck
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Table of Contents

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TR60
Off-Highway Truck

Maintenance Manual

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MAIN LIBRARY INDEX
TECHNICAL PUBLICATIONS DEPARTMENT
TEREX EQUIPMENT LIMITED,
MOTHERWELL, SCOTLAND, ML1 5RY
REF. NO. SM750/782
SM 1564 Rev 3 02-02

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Summary of Contents for Terex TR60

  • Page 1: Maintenance Manual

    CLICK HERE FOR TABLE OF CONTENTS TR60 Off-Highway Truck Maintenance Manual CLICK HERE TO RETURN TO MAIN LIBRARY INDEX TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED, MOTHERWELL, SCOTLAND, ML1 5RY REF. NO. SM750/782 SM 1564 Rev 3 02-02...
  • Page 3 Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process where the gaseous products are treated by alkaline scrubbing. TEREX SERVICE DEPARTMENT TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046 TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752...
  • Page 4 THIS PAGE IS INTENTIONALLY LEFT BLANK...
  • Page 5 IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service procedures recommended and described in this publication, are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. The special tools should be used when, and as recommended.
  • Page 6 THIS PAGE IS INTENTIONALLY LEFT BLANK...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Section No. Description SM No. GENERAL INFORMATION 0000 TR60 Off-Highway Truck 1566 0010 Welding Procedure 2172 CHASSIS 0010 Chassis, Hood and Fenders 1570 ENGINE 0030 Engine and Mounting 1571 0050 Air Cleaner 1572 0130 Power Takeoff 1573...
  • Page 8 TABLE OF CONTENTS Section No. Description SM No. STEERING SYSTEM 0000 Steering System Schematic 1591 0040 Steering and Brake Control Tank 1592 0050 Steering Pump 1204 0080 Accumulator 1205 0090 Steering Valve 1206 Rev 1 0110 Double Relief Valve 1208 0120 Steering Cylinder and Linkage - Pre October 1999 Production 1207 Rev 1...

  • Page 9: Tr60 Off-Highway Truck

    GENERAL INFORMATION - TR60 Off-Highway Truck Section 000-0000 SM - 1957 4 470 (14-8) 1 425 Body (4-8) Depth 4 270 (14-0) 3 950 (12-11) (3-1) (2-0) 1 380 Vehicle Clearance Diameter (SAE) 21 m (68-10) (4-6) 8 050 2 900 (9-6)

  • Page 10: Steering System

    General Information - TR60 Off Highway Truck Section 000-0000 DRIVE AXLE Parking Heavy duty axle with single reduction spiral bevel gear Application of rear brakes by springs in brake disc pack. differential, full floating axle shafts, and planetary reduction Hydraulically released.
  • Page 11 General Information - TR60 Off-Highway Truck Section 000-0000 BODY Typical Noise Levels Longitudinal 'V' type floor with integral transverse box- Operator Ear (ISO 6394) ..........79 dbA section stiffeners. The body is exhaust heated and rests on resilient impact absorption pads.
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  • Page 13 CHASSIS - Chassis, Hood and Fenders Section 100-0010 SM - 1785 8 - Washer 12 - Hardened Washer 4 - Channel 13 - Locknut 1 - Frame Assembly 5 - Bolt 9 - Bolt 2 - Bushing 10 - Transmission Guard 14 - Spring Disc 6 - Nut 3 - Engine Guard...
  • Page 14 Chassis - Chassis, Hood and Fenders Section 100-0010 MAINTENANCE SM - 1958 Inspection Inspect the frame and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending/twisting of the frame. Any defects found should be repaired before they progress into major failures.
  • Page 15 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 1959 49 50 SEC. 18 19 260-0010 DETAIL A 18 19 17 1 - LH Fender Assembly 13 - Engine Access Cover 26 - Bolt 39 - Plate Bent 14 - Bolt 27 - Bolt 2 - LH Platform Assembly 40 - Plate bent...
  • Page 16 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 1960 14 13 14 13 7 - Washer 11 - Bolt 8 - Bolt 1 - LH Step Assembly 4 - 'U' Bolt 12 - Hardened Washer 2 - RH Step Assembly 5 - Step 9 - Locknut 13 - Nut...
  • Page 17 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 1961 12 9 10 - Bracket 1 - Radiator Guard 4 - Bolt 7 - Bolt 11 - Bolt 2 - Cover Plate 5 - Bolt 8 - Grille 12 - Hardened Washer 3 - Washer 6 - Nut 9 - Bolt...
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  • Page 19: Welding Procedure

    GENERAL INFORMATION - Welding Procedure Section 000-0010 Welding WARNING Welding and flame cutting cadmium plated WARNINGS metals produce odourless fumes which are Before any welding is done on a machine toxic. Recommended industrial hygiene equipped with any electronic systems, practice for protection of the welding operator disconnect the following (if applicable) in this from the cadmium fumes and metallic oxides order: Battery earth cable, battery supply...
  • Page 20 General Information - Welding Procedure Section 000-0010 3. Pre-heat area to 100° C (212° F), measured 3 - 4" 3 - 4" either side of repair prior to gouging. On either side of repair. Avoid local overheating. completion of gouging grind to remove thin carbon layer.
  • Page 21 CHASSIS - Chassis, Hood and Fenders Section 100-0010 SM - 2395 13 - Locknut 14 - Spring Disc 1 - Frame Assembly 9 - Bolt 5 - Bolt 2 - Bushing 10 - Transmission Guard 15 - Washer 6 - Nut 3 - Engine Guard 11 - Bolt 16 - Spacer...
  • Page 22 Chassis - Chassis, Hood and Fenders Section 100-0010 MAINTENANCE SM - 2396 Inspection Inspect the frame and attached parts at intervals not exceeding 250 hours for cracked or broken welds and bending/twisting of the frame. Any defects found should be repaired before they progress into major failures.
  • Page 23 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 2397 18 19 18 19 17 DETAIL A 43,46,57 43 - Nut 44 - Plate 1 - LH Fender Assembly 15 - Locknut 29 - Mudguard 45 - Mirror Arm Assembly 2 - LH Platform Assembly 16 - Hardened Washer 30 - Mudguard...
  • Page 24 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 1960 14 13 14 13 7 - Washer 11 - Bolt 1 - LH Step Assembly 4 - 'U' Bolt & Nut 8 - Bolt 12 - Hardened Washer 2 - RH Step Assembly 5 - Step 9 - Locknut 13 - Nut...
  • Page 25 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 2398 10 - Bracket 1 - Radiator Guard 4 - Bolt 7 - Bolt 11 - Hardened Washer 2 - Cover Plate 5 - Bolt 8 - Grille 12 - Nut 3 - Washer 6 - Nut 9 - Bolt...
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  • Page 27 ENGINE - Engine and Mounting Section 110-0030 SM - 1962 55 56 57 51 52 53 54 16 17 22,23 POSITION A S.W.E. POSITION B SECURITY KIT SECURITY KIT ENGINE OIL FILL ENGINE DIPSTICK 34 27 65 64 17 - Lockwasher 34 - Latch Assembly 18 - Bolt 1 - Engine...
  • Page 28 Engine - Engine and Mounting Section 110-0030 elements and out through another passage in the filter 1. Electronic Control Module (ECM) - Receives adaptor. electronic inputs from the driver as well as from mounted sensors that provide information electronically, such as oil pressure and temperature Engine coolant filter (38) and conditioner is a compact and intake manifold pressure.
  • Page 29 Engine - Engine and Mounting Section 110-0030 SM - 1791 STOP 6 - Engine 'Stop' Light 7 - Engine 'Warning' Light 1 - Electronic Control Module (ECM) 2 - Programmable Read Only Memory (PROM) 8 - Engine 'Fluid' Light 3 - Electronic Fuel System Injectors 9 - Diagnostic Test Point 4 - Batteries 10 - Diagnostic Request Switch...
  • Page 30 Engine - Engine and Mounting Section 110-0030 fault code, pressing the bottom of the will go back to A special diagnostic data reader (INSITE) is available the previous code. that can be plugged into the engine computer memory via the onboard diagnostic test point (9). The reader is used to extract information related to the cause of On machines which have a Low Idle Adjustment the problem.
  • Page 31 Engine - Engine and Mounting Section 110-0030 ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES Error Code Description Fault Lamp ECM Hardware Internal Failure - Mission disabling Timing Actuator - Mechanically stuck Timing Actuator - Component shorted high Yellow Timing Actuator - Component shorted low Yellow Engine Speed Sensor - Both signals lost Fuel Timing Pressure Sensor - Component shorted high...

  • Page 32: Air Cleaner

    Engine - Engine and Mounting Section 110-0030 REMOVAL 7. If the truck is equipped with an air conditioning system, evacuate refrigerant from the system and Numbers in parentheses refer to Fig. 1. disconnect lines at the compressor. Refer to Section 260-0130, AIR CONDITIONING.

  • Page 33: Power Takeoff

    Engine - Engine and Mounting Section 110-0030 18. Attach suitable lifting equipment to the lifting Note: Adjuster screw and link assembly (53 thru 57) brackets on engine (1) assembly and raise lifting will have been released when removing radiator equipment to take up the slack. assembly from the vehicle.
  • Page 34 Engine - Engine and Mounting Section 110-0030 ASSEMBLY 10. Position fan to fan pulley on engine (1) and secure Numbers in parentheses refer to Fig. 1. with bolts (22) and lockwashers (23). Tighten bolts (22) in a star shaped pattern to a torque of 34 Nm (25 lbf ft). Note: Tighten all fasteners without special torques specified to standard torques listed in Section 11.
  • Page 35 Engine - Engine and Mounting Section 110-0030 7. Tighten bolt (62) securing alternator (50) to engine 19. Fill the engine with lube oil specified in Section mounting bracket and bolt (51) securing link (53) 300-0020, LUBRICATION SYSTEM. Check oil level assembly to alternator (50) to a torque of 81 - 95 Nm as described under 'Maintenance'.
  • Page 36 Engine - Engine and Mounting Section 110-0030 3. Lightly coat new oil filter (36) seal with clean Coolant Filter (38): Check condition of coolant engine oil as specified in Section 300-0020, inhibitor as described in Section 210-0000, COOLING LUBRICATION SYSTEM. SYSTEM.
  • Page 37 Engine - Engine and Mounting Section 110-0030 Using belt tension gauge, adjust the belt tension to Belts should be neither too tight nor too loose. Belts the following values: that are too tight impose excess loads on the crankshaft, fan and alternator bearings, shortening both belt and bearing life.
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  • Page 39 ENGINE - Air Cleaner Section 110-0050 SM - 1532 1 - Air Cleaner Body 2 - Primary Element 3 - Safety Element 4 - Cover Assembly 5 - Latch 6 - Vacuator Valve Fig. 1 - Exploded View of Air Cleaner DESCRIPTION SM - 1964 Numbers in parentheses refer to Fig.
  • Page 40 Engine - Air Cleaner Section 110-0050 SM - 1701 1 - Bolt 17 - Adaptor 2 - Hardened Washer 7 - Cap Assembly 12 - Tube Assembly 18 - Nylon Tube 3 - Hardened Washer 13 - Bracket Assembly 8 - Hump Hose 19 - Nipple 4 - Bolt 9 - Clamp...
  • Page 41 Engine - Air Cleaner Section 110-0050 cleaned twice a year. Do not apply heat in any form to 2. Remove primary element (2) from air cleaner body (1). air cleaner body (1). 3. Using a damp cloth and a suitable solvent, wipe out 1.
  • Page 42 Engine - Air Cleaner Section 110-0050 10. Install cover assembly (4) on air cleaner body (1) (air cleaner outlet) increases. This vacuum is generally and secure with latches (5). measured as 'restriction in mm (inches) of water'. The recommended maximum allowable intake Secondary Element restrictions at rated speed and load are as follows: Numbers in parentheses refer to Fig.
  • Page 43 ENGINE - Power Takeoff Section 110-0130 DESCRIPTION AND OPERATION SM - 1361 Numbers in parentheses refer to Fig. 1. The function of the power takeoff (PTO), as the name implies, is to provide the means of mounting and driving an auxiliary component. The tandem pump for the body hoist system and disc brake cooling system is mounted to PTO cover (26) and its input shaft is meshed with the internal splines in the hub of driven...
  • Page 44 Engine - Power Takeoff Section 110-0130 SM - 2399 10 17 29 20 25,23 15 - Driveshaft 23 - Bolt 1 - Flywheel Cover Case 16 - Locknut 24 - Lockwasher 8 - Lockwasher 2 - Dowel Pin 17 - Snap Ring 25 - Bolt 9 - Oil Seal 3 - Bolt...
  • Page 45 Engine - Power Takeoff Section 110-0130 PTO cover (26) are damaged, both parts must be 6. Install driven gear (12) and driveshaft (15) into replaced as an assembly. flywheel cover case (1). Slide drive gear (14) over driveshaft (15) to its proper location. 5.
  • Page 46 Engine - Power Takeoff Section 110-0130 MAINTENANCE case (1) and drain oil into a suitable container. Numbers in parentheses refer to Fig. 1. Reinstall drain plug (6) securely when draining is complete. Note: Refer to Section 300-0020, LUBRICATION SYSTEM for recommended check and drain intervals To refill: Remove oil level plug (6) from the front of and lubricant specifications.

  • Page 47: Commercial Electronic Control (Cec) Shift System

    TRANSMISSION - Transmission and Mounting Section 120-0010 SM - 1965 20 21 35,36 9 11 10 40 - Drain Cock 27 - Padlock 41 - Adaptor 28 - Bolt 42 - Adaptor 1 - Transmission 14 - Gasket 29 - Cover Plate 43 - Snubbing Washer 2 - Trunnion 15 - Clamp...

  • Page 48: Transmission Oil Filter

    Transmission - Transmission and Mounting Section 120-0010 When the pump turns faster than the turbine, the torque Transmission Oil Cooler converter is multiplying torque. When the turbine The transmission oil is cooled by a separate oil cooler approaches the speed of the pump the stator starts to mounted between the radiator and transmission to rotate with the pump and turbine.
  • Page 49 Transmission - Transmission and Mounting Section 120-0010 Note: It is important that the electrical connections are transmission (1) and move bracket and valve clear of removed in the order listed in step 4 to prevent the transmission (1). damage to the electrical components. 17.
  • Page 50 Transmission - Transmission and Mounting Section 120-0010 3. Remove nut/locknut (38) securing output yoke/ grease. Install output yoke/flange (39) on output shaft flange (39) on transmission (1). Pull output yoke/flange by tapping lightly until the yoke is seated. If output (39) from transmission (1).
  • Page 51 Transmission - Transmission and Mounting Section 120-0010 7. Secure accumulator valve mounting bracket to the Note: It is important that the electrical connections are front left hand side of transmission (1) assembly with made in the order listed in step 21 to prevent damage mounting hardware removed during removal.
  • Page 52 Transmission - Transmission and Mounting Section 120-0010 high, the oil will aerate and the transmission will SM - 1250 overheat. It is absolutely necessary that the oil put into the transmission be clean. Oil must be handled in clean containers to prevent foreign material from entering the system.
  • Page 53 Transmission - Transmission and Mounting Section 120-0010 Welding on Vehicles Equipped With CEC WARNING When conducting a stall test, the vehicle must WARNINGS be positively prevented from moving. The The ECU can be damaged by improper welding parking brake must be applied and the vehicle procedures.
  • Page 54 Transmission - Transmission and Mounting Section 120-0010 6. During the stall check the transmission oil for mechanical troubleshooting, as outlined in the temperature should rise while the engine is under 'Mechanical Trouble Shooting' charts, before carrying load and drop when the transmission is returned to out electrical troubleshooting procedures.
  • Page 55 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY C - Heavy metal debris found Transmission internal failure Completely disassemble, clean and repair in oil transmission. Replace filters and clean lines and oil cooler. D - Coolant found in oil Transmission oil cooler leaking Completely disassemble and thoroughly clean transmission.
  • Page 56 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY M - Vehicle operates in fifth Fifth and sixth gear clutch Overhaul transmission and sixth gears and moves failed (won't release) forward in neutral when engine is accelerated, but stalls in all other gears when engine is accelerated - Electronic Troubleshooting OK...
  • Page 57 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY T - Low engine speed at Low engine output torque Tune engine and check output converter stall Converter element Check for noise at stall; overhaul converter if interference necessary Transmission oil not up to...
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  • Page 59 TRANSMISSION - Transmission and Mounting Section 120-0010 SM - 2400 20 21 35,36 9 11 10 40 - Drain Cock 41 - Adaptor 1 - Transmission 14 - Gasket 27 - Padlock 42 - Adaptor 2 - Trunnion 15 - Clamp 28 - Bolt 43 - Snubbing Washer 3 - Bolt...
  • Page 60 Transmission - Transmission and Mounting Section 120-0010 When the pump turns faster than the turbine, the Transmission Oil Cooler torque converter is multiplying torque. When the The transmission oil is cooled by a separate oil cooler turbine approaches the speed of the pump the stator mounted between the radiator and transmission to starts to rotate with the pump and turbine.
  • Page 61 Transmission - Transmission and Mounting Section 120-0010 Note: It is important that the electrical connections are transmission (1) and move bracket and valve clear of removed in the order listed in step 4 to prevent the transmission (1). damage to the electrical components. 17.
  • Page 62 Transmission - Transmission and Mounting Section 120-0010 trunnion (2). 6. Coat output shaft splines and threads, and lip of oil seal with a thin layer of EP, NLGI molybdenum 3. Remove nut (38) securing output yoke (39) on grease. Install output yoke (39) on output shaft by transmission (1).
  • Page 63 Transmission - Transmission and Mounting Section 120-0010 6. Install filler hose (16) to filler tube (17) and adaptor level as described in Section 220-0040, STEERING (25) and secure with clamps (15). AND BRAKE CONTROL TANK. 7. Secure accumulator valve mounting bracket to the Note: It is important that the electrical connections are front left hand side of transmission (1) assembly with made in the order listed in step 21 to prevent damage...
  • Page 64 Transmission - Transmission and Mounting Section 120-0010 level is too low, the converter and clutches will not SM - 1250 receive an adequate supply of oil. If the oil level is too high, the oil will aerate and the transmission will overheat.
  • Page 65 Transmission - Transmission and Mounting Section 120-0010 Welding on Vehicles Equipped With CEC WARNING When conducting a stall test, the vehicle must WARNINGS be positively prevented from moving. The The ECU can be damaged by improper welding parking brake must be applied and the vehicle procedures.
  • Page 66 Transmission - Transmission and Mounting Section 120-0010 6. During the stall check the transmission oil for mechanical troubleshooting, as outlined in the temperature should rise while the engine is under load 'Mechanical Trouble Shooting' charts, before carrying and drop when the transmission is returned to neutral. out electrical troubleshooting procedures.
  • Page 67 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY C - Heavy metal debris found Transmission internal failure Completely disassemble, clean and repair in oil transmission. Replace filters and clean lines and oil cooler. D - Coolant found in oil Transmission oil cooler leaking Completely disassemble and thoroughly clean transmission.
  • Page 68 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY M - Vehicle operates in fifth Fifth and sixth gear clutch Overhaul transmission and sixth gears and moves failed (won't release) forward in neutral when engine is accelerated, but stalls in all other gears when engine is accelerated - Electronic Troubleshooting OK...
  • Page 69 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY T - Low engine speed at Low engine output torque Tune engine and check output converter stall Converter element Check for noise at stall; overhaul converter if interference necessary Transmission oil not up to...
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  • Page 71 TRANSMISSION - CEC Plus II Shift System Section 120-0070 DESCRIPTION seconds and then, if the condition fails to correct itself, The CEC (Commercial Electronic Control) shift system locks in gear and prevents any further shifting. The continually monitors the transmission and shift system Check Trans and Do Not Shift lights will both come on.
  • Page 72 Transmission - CEC Plus II Shift System Section 120-0070 SM - 1966 TEST MANUAL AUTO POWER ECONOMY BODY HYD CONTROL VALVE 7 - Manual Mode Warning Light 1 - Electronic Control Unit (ECU) 13 - Circuit Breakers 8 - Check Trans Warning Light 2 - Battery Equalizer 14 - Lockup Valve &...
  • Page 73 Transmission - CEC Plus II Shift System Section 120-0070 the range selector in direct response to throttle position and transmission output speed. WARNING Always select Neutral and apply the parking When Reverse is selected the reverse alarm sounds and brake before leaving the operator’s seat. the reverse light illuminates at the rear of the vehicle.
  • Page 74 Transmission - CEC Plus II Shift System Section 120-0070 and hoist interlock pressure switch mechanisms are 9. Check Trans Switch - Is used in conjunction with disengaged! This allows unauthorised selection of the check trans warning light to obtain trouble codes reverse or any forward gear with the body raised, which will indicate shift system malfunctions.
  • Page 75 CLICK HERE FOR HORIZONTAL DRAWING Transmission - CEC Plus II Shift System Section 120-0070 SM - 1967 E.C.U. TRANSMISSION SM 1575 Rev 2 11-00...
  • Page 76 Transmission - CEC Plus II Shift System Section 120-0070 SM - 1968 WARNINGS The ECU can be damaged by improper welding B(306) procedures. W/P(203) Any time the battery equalizer is disconnected from the batteries, remove W/P(203) ground cable first, and reconnect last, to FUSE 3 prevent damaging the component.
  • Page 77 Transmission - CEC Plus II Shift System Section 120-0070 SM - 1969 BATTERIES FUSE 1 B(306) FUSE 2 (235) R(308) CHECK TRANS SHIFT LIGHT SELECTOR B(306) B(306) (87A) Fig. 4 - Circuit Breakers SM - 1970 FROM IGN. SW. W/B(330A) U/G(223) W/U(202A) RELAY 1...
  • Page 78 Transmission - CEC Plus II Shift System Section 120-0070 ECU Operating Power Circuit is completed to ground through line 306. Solenoid in Relay 2 closes Switch allowing current Refer to Fig. 6. When the engine is started, current (24 volts) flows through Line 330 and Fuse 7 to Relay (12 volts) to flow through Fuse 6, Line 87, Switch and 2, energizing solenoid.
  • Page 79 Transmission - CEC Plus II Shift System Section 120-0070 Check Trans Light When the engine is started, a switch in the ECU The Check Trans light has two functions: to warn the closes, allowing current (24 volts) to flow through the operator of a system failure and to flash trouble codes circuit made by Fuse 7, Lines 330, 215, 208 or 209 when the test switch is activated.
  • Page 80 Transmission - CEC Plus II Shift System Section 120-0070 Reverse Alarm ECU and back to ground through Lines 208 or 209 and Refer to Fig. 10. When the shift selector is placed in Line 306. Solenoid closes Switch, allowing current to Reverse, ECU closes circuit allowing current (24 volts) flow through Line 308, Switch and Line 75 to reverse to flow through Line 308 and Fuse 1 to Relay 5,...
  • Page 81 Transmission - CEC Plus II Shift System Section 120-0070 SM - 1977 VANNER B(306) R(222) N.C. B(309) N.O. EMERGENCY PARK BRAKE SW. N.C. - RUN POSITION N.O. - PARK POSITION BATTERIES Fig. 12 - Parking Brake Interlock Body Up Interlock proximity switch closes.
  • Page 82 Transmission - CEC Plus II Shift System Section 120-0070 ECU Electromagnetic Shield - Ground SM - 426 Refer to Fig. 15. Must be grounded to protect ECU. GROUND TO PASSENGER SEAT BOX Fig. 15 - ECU Electromagnetic Shield - Ground Mode Selection Switch 2.
  • Page 83 Transmission - CEC Plus II Shift System Section 120-0070 SM - 1980 ENGINE 1 - Throttle Pedal Assembly 2 - Sensor and Harness - Engine 3 - Sensor and Harness - Transmission TRANSMISSION Fig. 18 - Throttle Sensor VALVE BODY SOLENOIDS grades.
  • Page 84 M5600A 188600 vehicle from backing up while the body is being raised. TR45 M5600A 188600 If the pressure switch is opened by the body control TR60 M6600AR 208580 joystick being moved to the 'Raise' position, current is TR70 M6600AR 208580...
  • Page 85 Transmission - CEC Plus II Shift System Section 120-0070 is started. The 'Do Not Shift' lights will go 'Off' when turned to position '0', then back to position '1 and shift the ignition is switched on, unless the ECU has into Reverse and back to Neutral.
  • Page 86 Transmission - CEC Plus II Shift System Section 120-0070 Probable Cause: WARNINGS a. Throttle sensor failure. To prevent any unexpected shift during b. Shorts or open circuits in harness wiring. removal of wiring harnesses, shut down engine and switch 'OFF' both circuit breakers. Remedy: 1.
  • Page 87 Transmission - CEC Plus II Shift System Section 120-0070 SM - 432 MAIN VALVE J1B HARNESS J1A HARNESS BODY HARNESS CONNECTORS TO ECU CONNECTORS AT CONNECTOR TO MAIN VALVE SHIFT SELECTOR BODY COVER CONTROL INTERFACE MAIN CONTROL VALVE SOLENOID CONNECTORS DIGITAL DATA LINE CONNECTOR LOCKUP VALVE...
  • Page 88 Transmission - CEC Plus II Shift System Section 120-0070 SM - 433 A - J1A HARNESS CONNECTOR TO ECU B - J1B HARNESS CONNECTOR TO ECU D - J1A HARNESS C - J3 HARNESS CONNECTOR TO ECU CONNECTOR TO SHIFT SELECTOR E - J1B HARNESS F - J1B HARNESS D - J1A HARNESS CONNECTOR TO...
  • Page 89 Transmission - CEC Plus II Shift System Section 120-0070 4. Check J1B harness wiring for shorts or open circuits. 2. Check engine coolant temperature. 5. If fault cannot be located, replace ECU. 3. Check oil cooler and lines for blockage. 4.
  • Page 90 Transmission - CEC Plus II Shift System Section 120-0070 Remedy: When a CODE 52 is present, the trim boost solenoid Install new ECU, send old ECU to authorized service will either not function at all or only intermittently, centre for repair or replacement of PROM. resulting in a loss of power in Reverse or lower forward gear range.
  • Page 91 Transmission - CEC Plus II Shift System Section 120-0070 2. Remove J1B harness from main valve body 2. Above 500 rev/min, the Check Trans and Do Not harness connector. Connect VOM probes to pins Shift lights will come on and all shifts will be prevented. corresponding to Solenoids A thru E in turn.
  • Page 92 Transmission - CEC Plus II Shift System Section 120-0070 ELECTRICAL TROUBLESHOOTING - No Codes CONDITION REASON REMEDY No Check Trans light when Faulty light bulb Replace light bulb ignition keyswitch is turned to Faulty Relay 4 Replace Relay 4 position '1' Incorrect power to Relay 4 Check circuit from batteries to Relay 4 Faulty wiring to ECU...
  • Page 93 Transmission - CEC Plus II Shift System Section 120-0070 ELECTRICAL TROUBLESHOOTING - No Codes CONDITION REASON REMEDY Transmission stays in Neutral Disconnected or dirty Check and clean harness connectors (will not shift), or will not make connectors a selected shift Faulty wiring harness Check and repair harness Transmission output shaft...
  • Page 94 Transmission - CEC Plus II Shift System Section 120-0070 ELECTRICAL TROUBLESHOOTING - No Codes CONDITION REASON REMEDY Transmission will not make a Extremely low oil level Check oil level and add if low specific shift Extreme oil temperature Refer to Codes 24 and 33 troubleshooting procedures Faulty solenoid circuitry Refer to Codes 41 - 45, 54, 61, 62 or 63...
  • Page 95 Transmission - CEC Plus II Shift System Section 120-0070 SPECIAL TOOLS The following tools are contained in CEC Off-Highway Diagnostic Service Kit - 15269231 TOOL NUMBER TOOL NAME 15269232 Wire Cutter, Stripper and Terminal Crimper 15269233 Jumper Wire Set 15269234 Terminal Crimper 15269235 Terminal Remover - Metri Pack (J1A, J1B, J3 and Shift Selector Connector Terminals)
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  • Page 97 TRANSMISSION - C.E.C. 2 Section 120-0070 DESCRIPTION 2 3 4 5 6 7 The CEC–2 (Commercial Electronic Control, Version 2) continually monitors the transmission and shift system electrical components and warns the operator when a problem develops. It also takes action to prevent damage to the transmission, and provides the serviceman with diagnostic capabilities so that problems can be corrected quickly and easily.
  • Page 98 Transmission - C.E.C. 2 Section 120-0070 SM2657 CONNECTOR TO TERMINATION RESISTOR EARTH SHIFT E.C.U. SELECTOR TRANS. HARNESS INTERFACE MODULE DIAGNOSTIC REF. CONSOLE HARNESS CONNECTOR 1. Gear Shift Selector 5. Shift Control Harness 9. Bolt 2. E.C.U. 6. Mounting Plate 10. Lock Washer 3.
  • Page 99 Transmission - C.E.C. 2 Section 120-0070 SPEED SENSOR ENGINE SPEED SENSOR MODE LIGHT MODE BUTTON MODE TURBINE SPEED SENSOR DISPLAY DIAGNOSTIC BUTTON OUTPUT SPEED SENSOR Fig. 4 - Gear Shift Selector Fig. 5 - Speed Sensors Locations Shift the transmission to the next lowest range if the converter pump and turbine together as a single transmission 'Hunting' or 'Shift Cycling' occurs.
  • Page 100 Transmission - C.E.C. 2 Section 120-0070 by Service Personnel, and permit movement of the vehicle, if necessary, to a repair area. With the manual mode switch in the 'On' position, the body up interlock and hoist interlock pressure switch mechanisms are disengaged! This allows unauthorised selection of reverse or any forward gear with the body raised, constituting a safety hazard.
  • Page 101 Transmission - C.E.C. 2 Section 120-0070 MAIN VALVE BODY MAIN CONNECTOR - ALL MODELS (Solenoids A - G) PLATE & COVER CONNECTOR LOCKUP VALVE BODY (Solenoids H, I, & J) 8610, 9610, 9810 LOCKUP CONNECTOR ALL MODELS TRIM BOOST CONNECTOR (K Solenoid and sump (Solenoid J) temperature sensor)
  • Page 102 Transmission - C.E.C. 2 Section 120-0070 5. Delta P Hold - The ECU prevents any up-shifts Gear Shift Selector Procedure should the transmission filter switch sense a pressure 1. Transmission check light will illuminate when the differential of 2.5 bar (35 psi). This function is only ECU detects a fault.
  • Page 103 Transmission - C.E.C. 2 Section 120-0070 TROUBLE-SHOOTING DIAGNOSTIC CODES Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated. SOL OFF - All Solenoids Off. GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode. SM2128 02-02...
  • Page 104 Transmission - C.E.C. 2 Section 120-0070 TROUBLE-SHOOTING DIAGNOSTIC CODES (CONT.) Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated. SOL OFF - All Solenoids Off. GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode. SM2128 02-02...
  • Page 105 Transmission - C.E.C. 2 Section 120-0070 TROUBLE-SHOOTING DIAGNOSTIC CODES (CONT.) Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated. SOL OFF - All Solenoids Off. GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode. SM2128 02-02...
  • Page 106 Is the voltage to the ECU correct? TR40 M5610A 188600 • TR45 M5610A 188600 Is engine properly tuned? • TR60 M6610A 208580 Is fuel flow to the engine correct? TR70 M6610A 208580 • Is air flow to the cooler and radiator unrestricted? •...
  • Page 107 Transmission - C.E.C. 2 Section 120-0070 SPECIAL TOOLS The Special Tools listed in the following tables are required for servicing the CEC 2 Shift System and are available from your dealer. SPECIAL TOOLS TOOL NUMBER TOOL NAME 15275098 Diagnostic Data Reader (DDR) Multikit (Includes Reader, Cartridge, Cables) 15275180 CEC 2 Diagnostic Card 15269038...
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  • Page 109 TRANSMISSION - Power Takeoff Section 120-0090 SM - 1386 1 - Snap Ring 7 - 'O' Ring 13 - Pipe Plug 8 - Pinion Shaft 14 - Bearing 19 - Lockwasher 2 - Bearing 9 - Bearing 15 - Shim 0.07 mm (0.003 in) 20 - Pipe Plug 3 - Snap Ring 10 - Pinion Gear...
  • Page 110 Transmission - Power Takeoff Section 120-0090 parking brake and switch off the engine. suitable puller tool into the internally splined output shaft (4) and pull output shaft, together with bearing 2. Turn steering wheel in both directions several (14) from driven gear (5). times to relieve pressure in the steering circuit.
  • Page 111 Transmission - Power Takeoff Section 120-0090 8. Install and stake set screw (11) in housing (12). SM - 272 9. Install pipe plug (13) in the end of pinion shaft (8). INSTALLATION Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.
  • Page 112 Transmission - Power Takeoff Section 120-0090 assembly in position with bolts (18) and tighten lines and fittings as required. lockwashers (19). 11. Ensure parking brake is applied and remove 8. Remove blanking caps from adaptor (21) and hose wheel chocks from all road wheels. assembly (22) and install hose assembly (22).
  • Page 113 TRANSMISSION - Transmission Oil Filter Section 120-0100 SM - 1385 1 - Filter Assembly 4 - Adaptor 7 - Lockwasher 2 - Filter Inlet Line 5 - Clip 8 - Bolt 3 - Filter Outlet Line 6 - Bolt 9 - Nut Fig.
  • Page 114 Transmission - Transmission Oil Filter Section 120-0100 REMOVAL INSTALLATION Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless otherwise specified. otherwise specified. Note: Tighten all fasteners to standard torques listed WARNING in Section 300-0080, STANDARD BOLT AND NUT To prevent personal injury and property TORQUE SPECIFICATIONS.
  • Page 115 Transmission - Transmission Oil Filter Section 120-0100 1. Position the vehicle in a level work area, raise the SM - 1251 body and install the body prop pins. Refer to Section 270-0010, BODY AND MOUNTING. 2. Apply the parking brake and switch off the engine. 3.
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  • Page 117 TRANSMISSION - Transmission Oil Filter Section 120-0100 SM - 2401 TRANSMISSION 1 - Filter Assembly 4 - Adaptor 6 - Bolt 2 - Filter Inlet Line 5 - Elbow - 90° 7 - Washer 3 - Filter Outlet Line Fig. 1 - Transmission Oil Filter and Lines DESCRIPTION sends a signal to a filter restriction indicator warning light (mounted on the dash panel) to warn the operator...
  • Page 118 Transmission - Transmission Oil Filter Section 120-0100 REMOVAL INSTALLATION Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless otherwise specified. otherwise specified. Note: Tighten all fasteners to standard torques listed WARNING in Section 300-0080, STANDARD BOLT AND NUT To prevent personal injury and property TORQUE SPECIFICATIONS.
  • Page 119 Transmission - Transmission Oil Filter Section 120-0100 1. Position the vehicle in a level work area, raise the SM - 1251 body and install the body prop pins. Refer to Section 270-0010, BODY AND MOUNTING. 2. Apply the parking brake and switch off the engine. 3.
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  • Page 121 DRIVELINE - Front Driveline Section 130-0010 SM - 084 TRANSMISSION ENGINE 1 - Bolt 2 - Locking Strap 3 - Bearing Assembly 4 - Driveline Fig. 1 - Exploded View of Driveline Installation REMOVAL DESCRIPTION The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig.
  • Page 122 Driveline - Front Driveline Section 130-0010 SM - 085 1 - Bolt 2 - Bearing Assembly 7 - Washer 8 - Cork Washer 3 - Cross Assembly 4 - Grease Fitting 9 - Yoke 5 - Shaft 10 - Grease Fitting 6 - Retainer 11 - Locking Strap Fig.
  • Page 123 Driveline - Front Driveline Section 130-0010 Slip Joint 3. Remove cross assembly (3) from yoke by tilting 1. Install retainer (6), washer (7) and new cork slightly and lift out of yoke. washer (8) over splines of shaft (5). 4. Repeat Steps 1 through 3 at opposite end of driveline. 2.
  • Page 124 Driveline - Front Driveline Section 130-0010 MAINTENANCE Using a small pry bar, check the crosses for play. If loose, replace the cross and bearings. Check splines Lubrication at slip joint and replace yoke, if excessively worn. Lubricate driveline with either a hand-operated or a pressure grease gun.
  • Page 125 DRIVELINE - Front Driveline Section 130-0010 SM - 1982 ENGINE TRANSMISSION 1 - Driveline Assembly 2 - Universal joint 3 - Capscrew 4 - Capscrew Fig. 1 - Exploded View of Front Driveline Installation DESCRIPTION REMOVAL The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig.
  • Page 126 Driveline - Front Driveline Section 130-0010 2. Turn steering wheel in both directions several SM - 088 times to relieve pressure in the steering circuit. Block all road wheels. APPLY PRESSURE MAXIMUM PERMISSABLE HERE BY HAND GAP IS 0.2 mm (0.008 in) 3.
  • Page 127 Driveline - Front Driveline Section 130-0010 MAINTENANCE other deformity of universal joints will prevent accurate mating with the crosses and bearings. This Lubrication will cause misalignment, which is accompanied by vibration and excessive wear. Lubricate driveline with either a hand-operated or a pressure grease gun.
  • Page 128 Driveline - Front Driveline Section 130-0010 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Capscrew 128 - 142 95 - 105 Capscrew SM 1577 12-98...
  • Page 129 DRIVELINE - Rear Driveline Section 130-0020 SM - 1534 4 - Bolt and Nut Set 1 - Driveline 2 - Flange Yoke 3 - Unit Package Fig. 1 - Rear Driveline DESCRIPTION REMOVAL The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig.
  • Page 130 Driveline - Rear Driveline Section 130-0020 2. Turn steering wheel in both directions several WARNING times to relieve any pressure in the steering circuit. Rotating shafts can be dangerous. You Block all road wheels. can snag clothes, skin, hair, hands, etc. This can cause serious injury or death.
  • Page 131 Driveline - Rear Driveline Section 130-0020 DRIVELINE DIAGNOSIS CHART CONDITION REASON REMEDY Vibration or Noise Driveline bent or out of balance Clean driveline in a suitable solvent. Inspect for contact with adjacent parts. If driveline is distorted or sprung, replace. If driveline does not run smoothly, and vibration is felt, remove driveline and dynamically balance the assembly.
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  • Page 133 DRIVELINE - Rear Driveline Section 130-0020 SM - 1983 TRANSMISSION DIFFERENTIAL 1 - Driveline Assembly 2 - Universal joint 3 - Capscrew 4 - Capscrew Fig. 1 - Exploded View of Rear Driveline Installation DESCRIPTION REMOVAL The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig.
  • Page 134 Driveline - Rear Driveline Section 130-0020 2. Turn steering wheel in both directions several SM - 088 times to relieve pressure in the steering circuit. Block all road wheels. APPLY PRESSURE MAXIMUM PERMISSABLE HERE BY HAND GAP IS 0.2 mm (0.008 in) 3.
  • Page 135 Driveline - Rear Driveline Section 130-0020 MAINTENANCE other deformity of universal joints will prevent accurate mating with the crosses and bearings. This Lubrication will cause misalignment, which is accompanied by vibration and excessive wear. Lubricate driveline with either a hand-operated or a pressure grease gun.
  • Page 136 Driveline - Rear Driveline Section 130-0020 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Capscrew 312 - 325 230 - 240 Capscrew SM 1578 12-98...
  • Page 137 FRONT AXLE - Wheel, Rim and Tyre Section 140-0040 SM - 228 1 - Clamp 4 - Rim 7 - 'O' Ring 2 - Wheel Nut 5 - Lock Ring 8 - Bead Seat Band 3 - Wheel Stud 9 - Wheel 6 - Flange Fig.
  • Page 138 Front Axle - Wheel, Rim and Tyre Section 140-0040 necessary to remove the tyre from the rim on the SM - 204 machine. The tyre and rim may be removed from the machine as an assembly, and transported to a more desirable location for removing the tyre from the rim.
  • Page 139 Front Axle - Wheel, Rim and Tyre Section 140-0040 INSPECTION open to avoid any possibility of trapping air inside the tyre. Tyre 2. Break outer tyre bead loose by placing the flat Check interior surface of the tyre to determine its hooked end of a pry bar, see Fig.
  • Page 140 Front Axle - Wheel, Rim and Tyre Section 140-0040 MOUNTING TYRE ON RIM SM - 207 Numbers in parentheses refer to Fig. 2, unless otherwise specified. WARNING When lifting tyre onto rim, be sure the equipment is of sufficient capacity and properly secured to do the job safely.
  • Page 141 Front Axle - Wheel, Rim and Tyre Section 140-0040 SM - 229 BRAKE CALLIPER SEC 165-0020 1 - Lockwire 2 - Bolt 3 - Plate 4 - Shim Pack 5 - Outer Bearing Cone 6 - Outer Bearing Cup 7 - Wheel 8 - Spindle 9 - Inner Bearing Cone 10 - Inner Bearing Cup...
  • Page 142 Front Axle - Wheel, Rim and Tyre Section 140-0040 Inspection 4. Remove brake calliper. Refer to Section 165-0020, BRAKE PARTS. 1. Thoroughly clean all metal components, except bearing cones, in a suitable solvent. Dry with 5. Remove bolts (18) and lockwashers (19) which compressed air and coat all threaded components secure cover (20) to wheel (7).
  • Page 143 Front Axle - Wheel, Rim and Tyre Section 140-0040 hot enough. Slide heated bushing (14) on spindle (8) only two bolts (2) located 180 apart, adjacent to the and tap lightly with a hammer to seat it. gauging holes in plate (3). Tighten bolts (2) evenly in equal increments to 'Gauging Bolt Torque', as Note: Do not apply flame directly to bushing.
  • Page 144 Front Axle - Wheel, Rim and Tyre Section 140-0040 SM - 208 WARNING To avoid personal injury and property damage, never stand or sit in front of a mounted tyre during tyre inflation. Use a clip-on air chuck with a long hose and stand to one side while the tyre is being inflated.
  • Page 145 Front Axle - Wheel, Rim and Tyre Section 140-0040 NITROGEN TYRE INFLATION SM - 1040 Note: All Warnings and procedures under 'Tyre Inflation' will apply, except for differences covered by this passage. In certain environments it is recommended that tyres be inflated with dry nitrogen gas, and that the resulting oxygen content of the inflation does not exceed 5%.
  • Page 146 Front Axle - Wheel, Rim and Tyre Section 140-0040 TYRE EXPLOSION HAZARD observing the gauge at the pressure regulator. STAY AWAY FROM THE TYRE. e. When desired inflation pressure has been WARNINGS achieved, back off the regulator or close the valve on Whenever a machines tyre(s) is (are) exposed the compressed gas cylinder.
  • Page 147 Front Axle - Wheel, Rim and Tyre Section 140-0040 SM - 218 AT LEAST 460 m AT LEAST 15 m (50 ft) (1 500 ft) Fig. 9 - APPROACH AREA. Do Not Approach Tyre in Shaded Area Ordinary tubeless tyre punctures can be repaired WARNING without removing the tyre from the rim.
  • Page 148 Front Axle - Wheel, Rim and Tyre Section 140-0040 Prevent Tyre Contact With Oil body is free of cuts, bruises and separation, and is thoroughly sound, including previous repairs. PREVENT TYRE CONTACT WITH PETROLEUM PRODUCTS. Rubber that is exposed to oil, petrol, or grease becomes soft and spongy and deteriorates TYRE CARE rapidly.
  • Page 149 Front Axle - Wheel, Rim and Tyre Section 140-0040 SPECIAL TOOLS Babbit or lead hammers, not sledge hammers, should be used in assembling rims. Refer to Section 300-0070, SERVICE TOOLS, for part numbers of special tools outlined in this section 'O' rings are seals and should be carefully stored in a and general service tools required.
  • Page 150 Front Axle - Wheel, Rim and Tyre Section 140-0040 TYRE INFLATION PRESSURES road maintenance and length, maximum and workday average speed, job t-km/h (ton-mile/h) required and E3 tyres may be so roaded up to 48 km/h (30 mile/h), tyre t-km/h (ton-mile/h) capacity, etc., may require an maximum, with a 30 minute cooling stop after each increase in inflation pressure.
  • Page 151 REAR AXLE - Differential Section 160-0020 SM - 1984 1 - Lockwire 11 - Shim* 21 - Bolt 31 - Bolt 2 - Bolt 12 - Oil Seal 22 - Bearing Cap 32 - Thrust Washer 3 - Plate 13 - Cup 23 - Bolt 33 - Dowel Pin 4 - Set Screw...

  • Page 152: Axle Group

    Rear Axle - Differential Section 160-0020 REMOVAL 10. Remove the self locking nuts which secure the differential housing to the axle banjo housing. Each Numbers in parentheses refer to Fig. 1. time a nut is removed, deeply scribe one of the flats on the nut.
  • Page 153 Rear Axle - Differential Section 160-0020 bearing cups (26) and cones (27). If the differential is SM - 094 disassembled and parts replaced, do not rely on this line for determining the preload on the side bearings. 4. Cut and remove lockwires (1), then remove bolts (23) and locks (24).
  • Page 154 Rear Axle - Differential Section 160-0020 20. Remove dowel pins (33) from plain case (38) and SM - 096 flanged case (28) only if they are damaged and have to be replaced. Pinion Cage Group Note: Before disassembling, punch identifying marks on retainer (9) and carrier housing (19) for assembly purposes.
  • Page 155 Rear Axle - Differential Section 160-0020 2. Immediately after cleaning, dry all parts, except 10. Inspect carrier housing (19), ring gear (29), plain bearings, with compressed air, or lint-free cloth. case (38) and retainer (9) for bore damage, cracks Bearings are better left to air dry, then inspected and and wear.
  • Page 156 Rear Axle - Differential Section 160-0020 special tool as an aid in determining the required SM - 098 thickness of shims (18). GAUGING DISTANCE a. Install a shim pack (18) of approximately 1.5 mm MEASURE GAUGING DISTANCE WITH ESTIMATED, OR ORIGINAL (0.060 in), measure and record the actual thickness SHIM PACK INSTALLED.
  • Page 157 Rear Axle - Differential Section 160-0020 Spider and Component Parts Assembly SM - 100 1. Press thrust washer dowel pins (33) into holes in plain case (38) and flanged case (28), if removed. 2. Lubricate inner walls of flanged case (28) and plain case (38) and all component parts with gear lubricant.
  • Page 158 Rear Axle - Differential Section 160-0020 toward the pinion gear. Bearing adjuster (25), located SM - 102 on the opposite side of pinion gear (15) than the ring gear, pushes the ring gear away from the pinion gear. The ring gear assembly must be installed onto carrier housing (19) so that cups (26) and cones (27) are RING GEAR RUNOUT properly pre-loaded;...
  • Page 159 Rear Axle - Differential Section 160-0020 pattern within specifications is strictly a 'try, check, and 3. Gear tooth patterns can be interpreted by referring try again' method. to Figs. 12 through 17. a. If a contact pattern similar to that shown in 12.
  • Page 160 Rear Axle - Differential Section 160-0020 SM - 107 SM - 109 Fig. 14 - Excessive Backlash Fig. 16 - Pinion Out Too Far - Remove Shims SM - 110 SM - 108 MOVE GEAR IN THIS DIRECTION FOR CORRECTION IN FIG. 13 MOVE GEAR IN THIS DIRECTION FOR CORRECTION IN FIG.
  • Page 161 Rear Axle - Differential Section 160-0020 Replace any mounting studs which have become SM - 2420 EXTRACTION HOLE stripped or broken. LOCTITE BANJO SEALANT Jack up the drive axle to 'test run' the differential and listen for noises which may indicate the need for adjustment or replacement of worn parts.
  • Page 162 Rear Axle - Differential Section 160-0020 SM - 112 ONE-4340 STL. OR EQUIV.-HDN.-GRIND 7/16 11.1 12.7 15.9 19.1 29/32 23.0 25.4 1 1/8 28.6 1 1/4 31.8 1 3/8 34.9 1 1/2 38.1 ONE-4340 APPROX 1 7/8 47.6 STL.-HDN.-GRIND 50.8 2 1/32 51.6 2 1/8...
  • Page 163 Rear Axle - Differential Section 160-0020 DIAGNOSIS CHART CONDITION REASON REMEDY Vibration. Broken gear teeth. Replace damaged gear. Excessive runout of pinion or flanged case. Disassemble, correct or replace faulty part. Continual noise. Bearing worn. Replace worn parts. Gears damaged or worn. Replace gears.
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  • Page 165 REAR AXLE - Axle Group Section 160-0030 SM - 235 1 - Ring Gear Carrier 2 - Ring 3 - Retainer Plate 4 - Bolt 5 - 'O' Ring 6 - Washer 7 - Spacer 8 - Planet Pinion 9 - Sun Gear 10 - Pinion Bearing 11 - Snap Ring 12 - Planet Pin...
  • Page 166 Rear Axle - Axle Group Section 160-0030 SM - 236 1 - Ring Gear Carrier 8 - Planet Pinion 15 - Gasket 2 - Ring 9 - Sun Gear 16 - Cover 22 - Ring Gear 23 - Bolt 3 - Retainer Plate 10 - Pinion Bearing 17 - Bolt 24 - Nut...

  • Page 167: Wheel, Rim And Tyre

    Rear Axle - Axle Group Section 160-0030 4. Inspect bearings for damage or excessive wear. In SM - 237 addition, check for free fit in planet pinions and on the planet pins. Replace any parts which are in questionable condition. 5.
  • Page 168 Rear Axle - Axle Group Section 160-0030 and banjo housing, pushing the axle shaft part way SM - 238 into the differential side gear. Mesh sun gear (9) with planet pinions (8). 6. Push axle shaft (26) and sun gear (9) inward as far as they will go.
  • Page 169 Rear Axle - Axle Group Section 160-0030 SM - 1380 30 - Hardened Washer 31 - Bolt 32 - Pin 17 - Spacer 33 - Bolt 18 - Snap Ring 34 - Hardened Washer 19 - Bearing 35 - Hardened Washer 20 - Lube Fitting 36 - Locknut 21 - Lube Fitting...
  • Page 170 Rear Axle - Axle Group Section 160-0030 7. Position a hydraulic jack under the axle at the 6. Remove lube line (14), elbow (23) and lube fitting differential housing, being sure jack is of suitable (21) from link (16). capacity and proportions to lift and balance the axle assembly.
  • Page 171 Rear Axle - Axle Group Section 160-0030 WARNING WARNING To prevent personal injury and property To prevent personal injury and property damage, be sure lifting equipment is of damage, be sure lifting equipment is of adequate capacity and properly secured to do adequate capacity and properly secured to do the job safely.
  • Page 172 Rear Axle - Axle Group Section 160-0030 Noises originating in the tyres, transmission or 10. Fill banjo, planetaries and disc brake assemblies driveline might be attributed by mistake to the axle. with lubricant specified in Section 300-0020, Therefore, all possible sources of noise should be LUBRICATION SYSTEM.
  • Page 173 REAR AXLE - Wheel, Rim and Tyre Section 160-0050 SM - 203 1 - Flange 7 - Bead Seat Band 4 - Clamp 10 - Spacer Band 2 - Wheel Stud 5 - Wedge Band 8 - Lock Ring 11 - Wheel 3 - Nut 6 - 'O' Ring 9 - Rim...
  • Page 174 Rear Axle - Wheel, Rim and Tyre Section 160-0050 SM - 204 WARNING To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly secured and of sufficient capacity to do the job safely. 1.
  • Page 175 Rear Axle - Wheel, Rim and Tyre Section 160-0050 Note: If tyre and rim is on the truck, and no tyre lifting WARNING equipment is available, 'walk' tyre off rim as follows: When lifting tyre from rim, be sure the force bottom of tyre outward as far as possible;...
  • Page 176 Rear Axle - Wheel, Rim and Tyre Section 160-0050 distorted, battered, and rusted parts which may have SM - 207 resulted from abusive practices outlined above. Replace any damaged parts with new parts. 4. Discard 'O' rings and replace with new ones. Note: Handle 'O' rings carefully, as damage will prevent an airtight seal for tyre inflation.
  • Page 177 Rear Axle - Wheel, Rim and Tyre Section 160-0050 SM - 202 5 - Ring Gear 1 - Lockwire 2 - Bolt 6 - Wheel 9 - Inner Bearing Cup 12 - Spacer 3 - Plate 7 - Outer Bearing Cone 13 - Wheel Driver 10 - Inner Bearing Cone 4 - Shim Pack...
  • Page 178 Rear Axle - Wheel, Rim and Tyre Section 160-0050 2. Turn the steering wheel in both directions several with light oil to facilitate assembly. times to relieve pressure in the steering system. Block all road wheels, except the ones to be raised. 2.
  • Page 179 Rear Axle - Wheel, Rim and Tyre Section 160-0050 BEARING ADJUSTMENT TABLE GAUGING BOLT TORQUE FINAL BOLT TORQUE No. of Bolts lbf ft No. of Bolts lbf ft 7. Lubricate outer bearing cone (7) with lubricant 15. Install planetary gear assembly and fill planetary specified in Section 300-0020, LUBRICATION and differential assemblies with lubricant specified in SYSTEM.
  • Page 180 Rear Axle - Wheel, Rim and Tyre Section 160-0050 SM - 208 Make sure that paints, lacquers, paint thinners, or similar materials that produce volatile, flammable vapours are not used or stored near the air intake of the compressor that supplies the air for inflating tyres. The compressor should be isolated from all such sources of flammable vapours.
  • Page 181 Rear Axle - Wheel, Rim and Tyre Section 160-0050 NITROGEN TYRE INFLATION b. Safety relief valve, 8.6 bar (125 lbf/in²), that will Note: All Warnings and procedures under 'Tyre assure an upper limit to the pressure available for Inflation' will apply, except for differences covered by tyre inflation.
  • Page 182 Rear Axle - Wheel, Rim and Tyre Section 160-0050 and adjust the pressure with the tyre gauge in the SM - 214 usual manner. b. If the required service inflation pressure is greater than 4.1 bar (60 lbf/in²), further inflate, with dry nitrogen gas only, to the pressure level required.
  • Page 183 Rear Axle - Wheel, Rim and Tyre Section 160-0050 SM - 218 AT LEAST 460 m AT LEAST 15 m (50 ft) (1 500 ft) Fig. 10 - APPROACH AREA. Do Not Approach Tyre in Shaded Area TYRE EXPLOSION HAZARD WARNINGS There is always a possibility of a tyre Whenever a machines tyre(s) is (are) exposed...
  • Page 184 Rear Axle - Wheel, Rim and Tyre Section 160-0050 TYRE MAINTENANCE A retreaded tyre has the old tread removed entirely and a new tread cured directly onto the body of the Tyre Repairs tyre. A tyre can be recapped or retreaded if the cord body is free of cuts, bruises and separation, and is Prompt repair of tyre injuries will prevent small thoroughly sound, including previous repairs.
  • Page 185 Rear Axle - Wheel, Rim and Tyre Section 160-0050 Prevent Overloading hooks, cables, or chains in contact with the tyre Off-the-highway trucks are designed to carry a beads when lifting these tyres. If forklift trucks are maximum allowable payload. Excessive loading will used for handling they should be equipped with broad, overstress both the truck and tyres and shorten the well rounded arms to distribute the load and prevent...
  • Page 186 Rear Axle - Wheel, Rim and Tyre Section 160-0050 TUBELESS TYRE LEAK DIAGNOSIS Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of leakage, the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be checked using a soap solution.
  • Page 187 BRAKE PARTS - Front Axle Section 165-0020 DESCRIPTION AND OPERATION SM - 244 WARNINGS Use only hydraulic oils meeting specifications outlined in Section 300-0020, LUBRICATION SYSTEM. DO NOT use BRAKE FLUID (J1703). Use of improper fluids is destructive to rubber components of brakes resulting in loss of braking and possible catastrophic failure.
  • Page 188 Brake Parts - Front Axle Section 165-0020 SM - 043 9 - Plug 1 - Bleeder 5 - Brake Pad 13 - Packing 2 - Bolt 6 - Torque Pin 10 - Seal 14 - Backup Ring 7 - Bolt 11 - Piston 3 - Torque Pin 15 - Torque Plate...
  • Page 189 Brake Parts - Front Axle Section 165-0020 BRAKE REMOVAL AND DISASSEMBLY 8. Push the two unlocked pins (3) toward the brake disc. Numbers in parentheses refer to Fig. 2, unless 9. Thread the two loosened bolts (2) in until bolts seat otherwise specified.
  • Page 190 Brake Parts - Front Axle Section 165-0020 8. Inspect brake pads (4 & 5) per Step 1 in the to press pistons the remainder of the way into piston 'General Inspection Procedure'. bores. Snap open end of boot (12) into groove of piston.
  • Page 191 Brake Parts - Front Axle Section 165-0020 the brake disc. If they do, loosen bolts (2) and adjust brake treadle. Remove bleeder line. pins to clear disc by 1.5 - 3.0 mm (0.060 - 0.120 in). Check to make sure that bolts (2, Fig. 2) fully engage Note: This system is equipped with accumulators in pins and tighten bolts to a torque of 30 - 38 Nm which maintain pressure in the system even after...
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  • Page 193: Brake Parts - Rear Axle

    BRAKE PARTS - Rear Axle Section 165-0030 DESCRIPTION AND OPERATION plates (30). The rotating discs are compressed Numbers in parentheses refer to Figs. 1 and 2. between the splined plates and are held stationary, thus keeping the wheels from rotating. As long as Service Brakes there is no hydraulic pressure at port 'F', Fig.
  • Page 194 Brake Parts - Rear Axle Section 165-0030 SM - 1295 SPINDLE BEARING SECTION E-E 1 - Inner Seal Housing 16 - Hardened Washer 31 - Service Piston 17 - 'O' Ring 2 - 'O' Ring 32 - Pin 46 - Stud 3 - Face Seal *18 - Dowel 33 - Bolt...
  • Page 195 Brake Parts - Rear Axle Section 165-0030 SM - 114 PORT B PORT D PORT F PORT D SECTION C-C PORT F PORT C SECTION B-B SECTION D-D NOTE: SECTION A-A Shown on Fig. 1. 14 - Spring Housing 28 - Damper Assemblies 38 - 'D' Section Seal 17 - 'O' Ring 29 - Friction Disc...
  • Page 196 Brake Parts - Rear Axle Section 165-0030 SM - 1297 Fig. 3 - Exploded View of Typical Disc Brake Assembly SM 1583 12-98...
  • Page 197 Brake Parts - Rear Axle Section 165-0030 16 - Hardened Washers 31 - Service Piston 1 - Inner Seal Housing 2 - 'O' Ring 17 - 'O' Ring 32 - Pins 46 - Studs 47 - Pipe Plugs 3 - Face Seal 18 - Dowels 33 - Bolts 4 - 'O' Rings...
  • Page 198 Brake Parts - Rear Axle Section 165-0030 from piston housing assembly (41). Discard 'O' ring. SM - 116 9. If necessary, remove studs (46) and pipe plug (47) from piston housing assembly (41). 10. Remove bolts (43) and hardened washers (42) from piston housing assembly (41).
  • Page 199 Brake Parts - Rear Axle Section 165-0030 SM - 120 WARNING Return springs (36) are under compression. To prevent personal injury and property damage, use care when removing bolts (33) and retaining plates (34). 19. Very carefully, remove bolts (33) and retainer plates (34) securing return springs (36) in piston housing assembly (41).
  • Page 200 Brake Parts - Rear Axle Section 165-0030 at a time. Using a suitable lifting device, lift spring SM - 125 housing (14) from disc housing (25). Refer to Fig. 12. 26. Remove and discard 'O' ring (17) from spring housing (14). 27.
  • Page 201 Brake Parts - Rear Axle Section 165-0030 SM - 130 CORRECT INSTALLATION OF 'D' RING 1 - Pipe Plug 4 - Friction Disc 22 - Seal 25 - Disc Housing 5 - Splined Plate 23 - Parking Piston 2 - Retainer Pin 58 - Spacer Ring 6 - Piston Housing 24 - Seal...
  • Page 202 Brake Parts - Rear Axle Section 165-0030 DISC BRAKE WEAR LIMITS TABLE761 THICKNESS Worn NUMBER OFF Friction Discs 35.56 mm (1.40 in) 32.00 mm (1.26 in) Splined Plates 14.48 mm (0.57 in) 13.72 mm (0.54 in) Damper Plates 13.72 mm (0.54 in) 11.68 mm (0.46 in) Stack Thickness 63.75 mm (2.51 in)
  • Page 203 Brake Parts - Rear Axle Section 165-0030 install in parking piston (23) as shown in Fig. 17. SM - 131 8. Lubricate disc housing seal (24) and area around the seal generously with 'Wynns S.T.P.'. Install parking piston (23) into disc housing (25). 9.
  • Page 204 Brake Parts - Rear Axle Section 165-0030 coating of oil, of the type used in the system, to the SM - 133 discs. 19. Install friction disc (29) over disc driver (27), aligning teeth of friction disc with splines on disc driver. 20.
  • Page 205 Brake Parts - Rear Axle Section 165-0030 SM - 137 SM - 138 Fig. 24 - Installing Piston Housing on Disc Housing Fig. 25 - Tightening Piston Housing to Disc Housing SM - 140 DISC BRAKE ASSY PORT F 3/8 NPT PORTABLE ADAPTOR HAND POWERED...
  • Page 206 Brake Parts - Rear Axle Section 165-0030 brake piston cavity to 52 bar (750 lbf/in ). See Fig. 27. SM - 139 Open bleeder valve (54, Fig. 2) slightly while pressurizing Port 'D' to release any trapped air. When hydraulic oil only, flows from bleeder valve (54), close the valve and pressurize piston cavity to 52 bar (750 lbf/in Apply and release the pressure ten times to seat the...
  • Page 207 Brake Parts - Rear Axle Section 165-0030 SM - 450 SM - 451 Fig. 30 - Seal Driver Fig. 29 - Seal Sleeve SM - 452 DISC DRIVER SEAL METALLIC ELEMENT TORIC RING SEAL SPRING DRIVER SEAL PARKING SLEEVE PISTON SPRING HOUSING Fig.
  • Page 208 Brake Parts - Rear Axle Section 165-0030 slowly remove seal sleeve. When seal driver and seal SM - 148 sleeve are removed, withdraw the spring from face seal (11). Apply a thin film of oil to metal contacting surface of face seal (11). 10.
  • Page 209 Brake Parts - Rear Axle Section 165-0030 SM - 1486 8,9,10 TO MAIN AIRLINE 14,15 18,19 16,17 11 - Pressure Gauge 1 - Blanking Plate (Port 'B') 6 - Hose Assembly 2 - Blanking Plate (Port 'C') 12 - Shutoff Valve 16 - Hose Assembly 7 - Female Swivel Connector 3 - 'O' Ring...
  • Page 210 Brake Parts - Rear Axle Section 165-0030 Note: If brake discs, service and/or parking pistons, piston housing, or the complete brake assembly have WARNING been replaced, a new brake-disc-stack-height Loosen bleeder valves carefully. The braking measurement should be taken as described under system operates at high pressure.
  • Page 211 Brake Parts - Rear Axle CLICK HERE FOR HORIZONTAL Section 165-0030 DRAWING SM - 134 INCHES INCHES 0.03 0.76 0.72 18.2 0.06 1.52 0.75 19.0 0.12 0.81 20.5 0.130 1.00 25.4 0.139 1.12 28.4 0.177 1.68 42.7 0.18 2.00 50.8 0.19 2.50 63.5...
  • Page 212 Brake Parts - Rear Axle Section 165-0030 SM - 126 0.56 - 3 HOLES EQUALLY SPACED 0.12 0.50 12.7 0.56 14.22 0.62 15.7 1.00 25.4 1.62 41.1 2.00 50.8 2.50 63.5 3.25 82.5 MATERIAL: PLAIN CARBON STEEL 3.31 84.0 9.38 15.88 26.25 Fig.
  • Page 213 SUSPENSION SYSTEM - Front Ride Cylinder Section 180-0030 SM - 1985 1 - End Cap * 2 - Valve Assembly * 3 - Check Valve * 4 - Plug 5 - 'O' Ring 6 - Backup Ring 7 - Inner Tube 8 - Bolt 9 - Piston 10 - Wear Ring...
  • Page 214 Suspension System - Front Ride Cylinder Section 180-0030 pressure unseats ball (23), allowing oil to fill the SM - 190 cavity between piston rod and tube (18). When the force of piston rod (22) is expended, the compressed nitrogen pushes the piston rod outward to its original FRAME position.
  • Page 215 Suspension System - Front Ride Cylinder Section 180-0030 SM - 2004 9 - Piston 25 - Locknut 17 - Lube Fitting 1 - End Cap 10 - Wear Ring 26 - Shear Key 18 - Tube 2 - Valve Assembly 11 - 'O' Ring 19 - Wear Ring 27 - Hardened Washer...
  • Page 216 Suspension System - Front Ride Cylinder Section 180-0030 Note: Piston rod (22) must be separated from the 11. Remove and discard seal (20) and wiper (21) spindle for proper disassembly and assembly. It is from tube (18). best to disassemble and assemble piston rod from top of cylinder so holes in rod do not have to pass 12.
  • Page 217 Suspension System - Front Ride Cylinder Section 180-0030 SM - 1374 13 - Seal Retainer 19 - Wear Ring 7 - Inner Tube 14 - Seal 20 - Seal 11 - 'O' Ring 18 - Outer Tube 21 - Wiper 12 - Backup Ring Fig.
  • Page 218 Suspension System - Front Ride Cylinder Section 180-0030 INSTALLATION CHARGING RIDE CYLINDER Numbers in parentheses refer to Fig. 2. WARNING WARNING To prevent personal injury and property To prevent personal injury and property damage, be sure blocking or lifting equipment damage, be sure blocking or lifting equipment is of sufficient capacity and properly secured to is of sufficient capacity and properly secured to...
  • Page 219 Suspension System - Front Ride Cylinder Section 180-0030 SM - 2005 1 - Lube Relief Valve 2 - Pipe Plug 3 - Check Valve (Oil Fill Port) 4 - Nitrogen Charging Valve 5 - Lube Fitting DIMENSION 'A' RIDE POSITION TRUCK EMPTY 165 - 171 6.5 - 6.75...
  • Page 220 Suspension System - Front Ride Cylinder Section 180-0030 b) Make a fill-fitting by drilling through a 5/8 - 18 x SM - 1273 1.50 in bolt and tapping the head end of the hole 1/4 NPT. Use either of these methods for filling the ride cylinder and reinstall the standard fitting for machine operation.
  • Page 221 Suspension System - Front Ride Cylinder Section 180-0030 to the correct height and the truck is not being CYLINDER CHARGING PRESSURE overloaded, the oil level may be incorrect. The ride cylinders should be discharged, refilled with oil, and lbf/in² recharged as described above. 13.8 MAINTENANCE Note: As the frame rises during the charging...
  • Page 222 Suspension System - Front Ride Cylinder Section 180-0030 WARNING This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in Special permits may be required when transporting the vehicle or cylinders by any method while cylinders are charged.
  • Page 223 SUSPENSION SYSTEM - Rear Ride Cylinder Section 180-0050 SM - 1369 PASSAGE 'A' 1 - Piston Rod 7 - Plug 2 - Spherical Bushing 8 - Ball 13 - Bolt 18 - Bolt 9 - Wiper 19 - Tube 3 - Snap Ring 14 - Backup Ring 10 - Lube Fitting 20 - Spherical Bearing...
  • Page 224 Suspension System - Rear Ride Cylinder Section 180-0050 SM - 1370 1 - Ride Cylinder 2 - Bolt 5 - Pin Assembly 8 - Lube Fitting 3 - Lockwasher 6 - Spacer 9 - Bolt 4 - Washer 7 - Pin Assembly 10 - Boot Assembly Fig.
  • Page 225 Suspension System - Rear Ride Cylinder Section 180-0050 SM - 1378 1 - Piston Rod 9 - Wiper 2 - Spherical Bushing 10 - Lube Fitting 17 - Piston 24 - Small Ring 3 - Snap Ring 11 - Seal 18 - Bolt 25 - Valve Core 12 - Seal Retainer...
  • Page 226 Suspension System - Rear Ride Cylinder Section 180-0050 ASSEMBLY 9. Remove and discard seal (11) and wiper (9) from seal retainer (12) inner grooves. Numbers in parentheses refer to Fig. 3. 10. Remove check valve (6) and plug (7) assembly Note: Apply a light coating of clean hydraulic oil to all from piston rod (1).
  • Page 227 Suspension System - Rear Ride Cylinder Section 180-0050 Note: Because of close tolerances, care will have to 5. Remove lifting device or 'come-along' from ride be taken when assembling piston rod (1) and piston cylinder (1). (17) assembly into tube (19). 6.
  • Page 228 Suspension System - Rear Ride Cylinder Section 180-0050 SM - 160 FRAME 1 - Lube Fitting 2 - Nitrogen Charging Valve SPACER 3 - Plug 35 mm (1.38 in) 4 - Check Valve 5 - Check Valve TOP OF SEAL RETAINER DIMENSION 'A' RIDE POSITION...
  • Page 229 Suspension System - Rear Ride Cylinder Section 180-0050 SM - 1372 1 - Lube Fitting 2 - Nitrogen Charging Valve 3 - Pipe Plug 4 - Check Valve (upper) 5 - Check Valve (lower) 6 - Ride Cylinder 7 - Hose 8 - Tee Piece 9 - Pressure Gauge 10 - Charging Assembly...
  • Page 230 Suspension System - Rear Ride Cylinder Section 180-0050 b. Screw the swivel nuts down on nitrogen charging SM - 1273 valves (2) until they seat. c. Turn small hex on nitrogen charging valves (2) two to three turns anticlockwise to unseat the valves internally.
  • Page 231 Suspension System - Rear Ride Cylinder Section 180-0050 with the truck on a level surface. If there is less than charging of both ride cylinders and general service 30 mm (1.25 in) between stops, check for machine tools required. These parts and tools are available overload.
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  • Page 233 ELECTRICAL SYSTEM - Circuit Diagrams Section 190-0000 COMPONENT DESIGNATIONS K4 - Dir Inds Flasher Unit S7 - Emergency Brake Switch* A4 - Radio/Cassette Player K5 - Air Cond Comp Clutch S8 - Blower Switch A5 - Speaker S10 - Wiper Switch K15 - Headlamp Relay S13 - Horn Button K17 - Reverse Relay...
  • Page 234 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING SM 1585 12-98...
  • Page 235 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING SM 1585 12-98...
  • Page 236 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING SM 1585 12-98...
  • Page 237 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING SM 1585 12-98...
  • Page 238 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING SM 1585 12-98...
  • Page 239 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING SM 1585 12-98...
  • Page 240 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING INTERFACE BOX CIRCUIT DIAGRAM SM 1585 12-98...
  • Page 241 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING CEC TRANSMISSION CIRCUIT DIAGRAM SM 1585 12-98...
  • Page 242 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING SM 1585 12-98...
  • Page 243 Electrical System - Circuit Diagrams CLICK HERE FOR HORIZONTAL Section 190-0000 DRAWING SM 1585 12-98...
  • Page 244 Electrical System - Circuit Diagrams Section 190-0000 Fuses, Relays and Warning Lights CEC Fuses and Relays - Located in Interface Box Fuses, relays and warning lights which were not Fuses - Current Ratings Relay Functions described under 'Component Designations' on the 1 - 8A 1 - ECU Initial Start previous page, are identified in the following tables.

  • Page 245: Switches And Sensors

    ELECTRICAL SYSTEM - Switches and Sensors Section 190-0270 SM - 1782 BRAKE MANIFOLD VALVE HEADER TANK RETARDER VALVE TREADLE STEERING VALVE VALVE BODY ENGINE TRANSMISSION FUEL TANK HYD CONTROL VALVE HYDRAULIC TANKS 8 - Steering Oil Temperature Switch 15 - Rear Brake Accumulator Press Sw. 1 - Engine Water Temperature Sender/Sw.
  • Page 246 (2, Fig. 3) TR40 Cummins N14 16.80 when engine water temperature rises above the safe TR45 Cummins QSK 12.00 operating temperature. TR60 Cummins QSK 12.00 TR70 DD Series 2000 12.00 The temperature sender sends a signal to the Engine TR100 Cummins KTA 15.72...
  • Page 247 Electrical System - Switches and Sensors Section 190-0270 SM - 1784 STOP 1 - Alternator Charging 9 - Front Brake Accumulator Pressure 17 - Transmission Oil Temperature 2 - Engine Water Temperature 10 - Rear Brake accumulator Pressure 18 - Disc Brake Hydraulic Temperature 3 - Engine Water Level 11 - Low Steering Pressure 19 - Retarder Indicator...
  • Page 248 Electrical System - Switches and Sensors Section 190-0270 fitted, shows oil temperature consistently rising above directed to the ECU. The ECU recognises this signal the green zone (43 - 135° C; 100 - 275° F) under as output speed. Refer to Section 120-0070, CEC normal operating conditions;...
  • Page 249 Electrical System - Switches and Sensors Section 190-0270 send a signal to illuminate retarder indicator light when a temperature of 121° C (250° F) is reached. If (19, Fig. 3), and the retarder light at the rear of the the light illuminates, reduce speed and shift vehicle.
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  • Page 251 FUEL SYSTEM - Fuel Tank and Mounting Section 200-0010 SM - 1702 CHASSIS 17,21 22 - Lockwasher 1 - Fuel Tank 8 - Latch 15 - 'O' Ring 2 - Plug 16 - Nut 23 - Strainer 9 - Gauge Fuel Level 3 - Plug 24 - Lock 17 - Mounting Bracket...

  • Page 252: Fuel Lines

    Fuel System - Fuel Tank and Mounting Section 200-0010 REMOVAL DISASSEMBLY Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. 1. Remove fuel strainer (23) from fuel tank (1). WARNING To prevent personal injury and property 2.
  • Page 253 Fuel System - Fuel Tank and Mounting Section 200-0010 INSTALLATION FAST FUELLING - Optional Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 2, unless otherwise specified. Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT A fast fuel system can be installed in the fuel tank as an TORQUE SPECIFICATIONS.
  • Page 254 Fuel System - Fuel Tank and Mounting Section 200-0010 MAINTENANCE clean fuel strainer (23) and filler cap (5) as required. Numbers in parentheses refer to Fig. 1. From time to time make a visual check on the electrical connections at fuel level sender (27). Prior to starting the vehicle check the fuel level.
  • Page 255 FUEL SYSTEM - Fuel Lines Section 200-0040 SM - 1797 11 - Fuel Line 1 - Fuel Tank 6 - Fuel Pump 12 - Fuel Line 2 - Fuel Supply Line 7 - Fuel Supply Check Valve 13 - Electronic Fuel Injector 3 - Primary Filter 8 - Fuel Control Valve Supply 14 - Fuel Cooler...
  • Page 256 Fuel System - Fuel Lines Section 200-0040 OPERATION The electronic fuel injector (13) is a lightweight, compact unit that injects diesel fuel directly into the Numbers in parentheses refer to Fig. 1. combustion chamber. The amount of fuel injected and the beginning of injection timing is determined by the Fuel is drawn from fuel tank (1) through primary and ECM.
  • Page 257 Fuel System - Fuel Lines Section 200-0040 Checking Fuel Flow Note: Mechanical tightening of fuel filters is not 1. Disconnect the fuel return line from the fitting at the recommended, and may result in seal and/or cartridge fuel tank and hold the open end in a suitable container. damage.
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  • Page 259: Electronic Foot Pedal

    FUEL SYSTEM - Electronic Foot Pedal Section 200-0051 SM - 1698 26,27 13 12 29,30 ENGINE TRANSMISSION 9 - Lockwasher 17 - Bolt 1 - Pedal Assembly 18 - Lockwasher 25 - Thrust Washer 2 - Screw 10 - Plate Assembly 19 - Bushing 26 - Cover 3 - Bushing...
  • Page 260 Fuel System - Electronic Foot Pedal Section 200-0051 2. Turn steering wheel in both directions several times 1. Position pedal assembly (1) on plate assembly (10) to relieve any pressure in the steering circuit. Block all and secure with bolts (17) and lockwashers (18). road wheels.
  • Page 261 COOLING SYSTEM - Cooling System Section 210-0000 SM - 1760 1 - Header Tank 11 - Coolant Pipe 6 - DCA4 Coolant Filter 16 - Coolant Pipe 2 - Radiator 12 - Coolant Pipe 7 - Engine Oil Cooler 17 - Overflow Tubing 3 - Disc Brake Oil Cooler 13 - Bypass Line 8 - Thermostat Housing...
  • Page 262 Cooling System - Cooling System Section 210-0000 from header tank (1) through make-up line (14). The WARNING coolant passes through DCA4 coolant filter (6) mounted at engine water pump (5). Engine water Do not remove the pressure control cap from pump (5) then pumps coolant through coolant pipe the radiator header tank or attempt to drain (10) into disc brake oil cooler (3).
  • Page 263 Cooling System - Cooling System Section 210-0000 Every 250 hours: DRAINING AND FLUSHING Check and replenish the DCA4 concentration as Note: If the DCA4 coolant filter is properly described under 'Coolant Recommendations' in this maintained, the need for flushing the cooling system section.
  • Page 264 Cooling System - Cooling System Section 210-0000 COOLANT RECOMMENDATIONS In general, any flushing compound put out by a reputable manufacturer will do an acceptable job. Heavy duty diesel engines installed in these vehicles Oxalic acid and sodium bisulphate type cleaners are require a heavy duty coolant for optimum the most generally used.
  • Page 265 Cooling System - Cooling System Section 210-0000 Note: Following the correct order for mixing the a. Compare Freeze Point (end pad) to colour chart heavy duty coolant will prevent additive dropout and record the result. during the mixing process. b. Next, compare Sodium Molybdate (middle pad) to Note: The cooling system must be clean before colour chart and record the result.
  • Page 266 Cooling System - Cooling System Section 210-0000 SPECIAL TOOL AND TEST KIT Refer to Section 300-0070, SERVICE TOOLS, for part numbers of the refractometer and coolant test kit referenced in this section. These items are available from your Dealer. Precharge Chart Service Chart Cooling System Amount of DCA4 Liquid Required...

  • Page 267: Radiator, Header Tank And Mounting

    COOLING SYSTEM - Radiator, Header Tank and Mounting Section 210-0040 SM - 2402 29 30 10 - Lockwasher 19 - Baffle Plate - Upper 28 - Screen 1 - Shroud 11 - Nut 20 - Bolt 29 - Stem 2 - Ring 12 - Bolt 21 - Washer 30 - Ring...
  • Page 268 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 1986 DETAIL A-A DETAIL A-A TO ENGINE THERMOSTAT HOUSING RADIATOR ASSEMBLY USED WITH FULL TIME EXHAUST 10 - Band Clamp 20 - Bolt 1 - Header Tank 11 - Window Nut 30 - Nut 21 - Filler Cap 2 - Bolt...
  • Page 269 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 1706 POSITION A ENGINE THERMOSTAT HOUSING 1 - Band Clamp 5 - Silicone Hose 9 - Plug 2 - Coolant Tube 6 - Silicone Hose 13 - Coupling 10 - Elbow 3 - Elbow 7 - Silicone Hose...
  • Page 270 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 1707 DETAIL A - A 11,12,13,14 18,12,13,14 11,12,13,14 18,12,13,14 15,16,17 1 - Top Tank 7 - Tube Stay Strip 13 - Washer 2 - Bottom Tank 8 - Spacer 19 - Nut 14 - Lockwasher 3 - Crossbrace Rod...
  • Page 271 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 Note: Joule tube (10) type radiators are designed in bottom tank (2). Install cover plates to bottom tank such a way that individual tubes can be replaced (2), secure with screws (15), washers (16) and without the need to replace the entire radiator core.
  • Page 272 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 Header Tank 2. Using suitable lifting equipment, position radiator assembly (36) on flexible mountings (8) and secure Numbers in parentheses refer to Fig. 2, unless with bolts (13), washers (24) and nuts (14). otherwise specified.
  • Page 273 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 MAINTENANCE 1. Direct a steam jet at 100 - 300 kN/m², or Refer to Section 210-0000, COOLING SYSTEM for compressed air at 500 - 700 kN/m² on to the faces of recommended preventive maintenance procedures, the radiator core assembly.
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  • Page 275: Disc Brake Oil Cooler

    COOLING SYSTEM - Disc Brake Oil Cooler Section 210-0050 SM - 1987 FROM FROM DISC WATER BRAKE PUMP OIL FILTER TO DISC BRAKE ASSEMBLIES TO TRANSMISSION OIL COOLER 1 - Disc Brake Oil Cooler 6 - Bolt 2 - Heat Exchanger 7 - Lockwasher 15 - Bolt 11 - Split Flanges...

  • Page 276: Transmission Oil Cooler

    Cooling System - Disc Brake Oil Cooler Section 210-0050 REMOVAL securing disc brake oil cooler to mounting bracket on Numbers in parentheses refer to Fig. 1. engine front crossmember. Lower disc brake oil cooler and remove to a clean work area for disassembly.
  • Page 277 Cooling System - Disc Brake Oil Cooler Section 210-0050 3. Make up a solution composed of 1/3 muriatic acid WARNING and 2/3 water. To each 9.5 litres (2.5 gal) of solution, add 227 g (0.5 lb) of oxalic acid. To prevent personal injury and property damage, be sure wheel blocks and lifting 4.
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  • Page 279 COOLING SYSTEM - Transmission Oil Cooler Section 210-0060 SM - 1794 TO ENGINE WATER MANIFOLD 22,23 FROM DISC BRAKE OIL COOLER 1 - Transmission Oil Cooler 7 - Bolt 13 - Oil Outlet Line 19 - Sleeve 2 - Heat Exchanger 8 - Hardened Washer 14 - Clamp 20 - Clamp...
  • Page 280 Cooling System - Transmission Oil Cooler Section 210-0060 REMOVAL 11. Remove elbow (12) from port 'C'. Plug port 'C' to Numbers in parentheses refer to Fig. 1. prevent entry of dirt. 12. Support transmission oil cooler (1) with a suitable WARNING lifting device and remove bolts (7) and hardened To prevent personal injury and property...
  • Page 281 Cooling System - Transmission Oil Cooler Section 210-0060 Cleaning Water Side WARNING 1. Match mark cooler flanges (3 & 5) and heat exchanger (2) to aid in assembly. To prevent personal injury and property damage, be sure wheel blocks and lifting 2.
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  • Page 283: Steering System Schematic

    STEERING SYSTEM - Steering System Schematic Section 220-0000 DESCRIPTION Mounted off the frame at the rear of the steering and brake control tank, the accumulator assembly consists Numbers in parentheses refer to Figs. 2 through 6. of a charging valve, end cap, cylinder and piston. The steering system is of the accumulator type which The charging valve is equipped with a locking feature provides uniform steering, regardless of engine speed,...

  • Page 284: Double Relief Valve

    Steering System - Steering System Schematic Section 220-0000 Double Relief Valve (6) Steering Filter (12) Refer to Section 220-0110, DOUBLE RELIEF VALVE. Refer to Section 220-0150, STEERING FILTER. The double relief valve is installed in the lines between The steering filter is mounted off the rear left hand side the steering cylinders and the steering valve.
  • Page 285 Steering System - Steering System Schematic CLICK HERE FOR HORIZONTAL Section 220-0000 DRAWING SM 1591 12-98...
  • Page 286 Steering System - Steering System Schematic CLICK HERE FOR HORIZONTAL Section 220-0000 DRAWING SM 1591 12-98...
  • Page 287 Steering System - Steering System Schematic CLICK HERE FOR HORIZONTAL Section 220-0000 DRAWING SM 1591 12-98...
  • Page 288 Steering System - Steering System Schematic CLICK HERE FOR HORIZONTAL Section 220-0000 DRAWING SM 1591 12-98...
  • Page 289 Steering System - Steering System Schematic CLICK HERE FOR HORIZONTAL Section 220-0000 DRAWING SM 1591 12-98...
  • Page 290 Steering System - Steering System Schematic Section 220-0000 during maintenance procedures. These tools, along RELIEVING SYSTEM PRESSURE with other general service tools, are available from your dealer. Refer to Section 300-0070, SERVICE TOOLS, for part numbers of these tools. WARNING The steering system is equipped with an accumulator which maintains pressure in the Multi-gauge...
  • Page 291 Steering System - Steering System Schematic Section 220-0000 STEERING SYSTEM DIAGNOSIS (Continued) CONDITION REASON REMEDY No steering response. Completely failed steering Repair or replace steering pump and set at pump. recommended pressure. Refer to Section 220-0050, STEERING PUMP. Burst hydraulic line in steering Isolate defective line and replace with new one. system.
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  • Page 293: Accumulator

    STEERING SYSTEM - Steering and Brake Control Tank Section 220-0040 SM - 1989 23-24 1 - Tank 8 - Lockwasher 15 - Gasket 22 - Nut 2 - Filler Cap 9 - Plug 16 - Bracket 23 - Oil Level Switch 3 - Gasket 10 - Filter Assembly 17 - Bolt...
  • Page 294 Steering System - Steering and Brake Control Tank Section 220-0040 SM - 1567 SM - 1990 A B D 1 - Tank 2 - Steering Pump 10 - Oil Pressure Switch 9 - Oil Level Switch 11 - Oil Temperature Switch Fig.
  • Page 295 Steering System - Steering and Brake Control Tank Section 220-0040 Operate treadle valve continuously to discharge SM - 1991 braking accumulators. Oil should be showing in middle window nut (12). If oil is required, remove filler cap (2) and fill tank (1) with hydraulic oil specified in Section 300-0020, LUBRICATION SYSTEM, until oil shows in bottom window nut (12).
  • Page 296 Steering System - Steering and Brake Control Tank Section 220-0040 Removing Suction Screen 9. Fill tank (1) to correct level with hydraulic oil Remove and clean suction screen (11) at interval specified in Section 300-0020, LUBRICATION specified in Section 300-0020, LUBRICATION SYSTEM.
  • Page 297 Steering System - Steering and Brake Control Tank Section 220-0040 Installation 6. Using suitable lifting equipment, support tank (1) assembly. Remove bolts (20), hardened washers Numbers in parentheses refer to Fig. 1, unless (21) and nuts (22) securing tank (1) assembly to otherwise specified.
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  • Page 299 STEERING SYSTEM - Steering Pump Section 220-0050 SM - 375 1 thru 14 - Shown on Fig. 5 21 - Tapered Bearing 36 thru 41 - Shown on Fig. 5 15 - Valve Block 22 - Shown on Fig. 5 42 - Yoke 16 - Pump Housing 23 - Cylinder Block...
  • Page 300 Steering System - Steering Pump Section 220-0050 SM - 376 PISTON SUB ASSEMBLY OUTLET VALVE PLATE SLOT YOKE FACE OUTLET PORT INLET PORT DRIVESHAFT SHOE PLATE INTAKE VALVE PLATE SLOT CYLINDER BLOCK BORE Fig. 2 - Pump Rotation and Oil Flow OPERATION SM - 553 Refer to Fig.
  • Page 301 Steering System - Steering Pump Section 220-0050 SM - 377 MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE (MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT) Fig. 4 - Variable Displacement Action SM - 378 1 - Pump 4 - Snap Ring 7 - Gasket 2 - Pump Adaptor...
  • Page 302 Steering System - Steering Pump Section 220-0050 SM - 379 1 - Screw 46 - Yoke Spring 2 - Gasket 24 - Retaining Ring 35 - Driveshaft 47 - Tapered Bearing 13 - Plug 3 - 'O' Ring 48 - Valve Seat 14 - Screw 25 - Washer 36 - Screw...
  • Page 303 Steering System - Steering Pump Section 220-0050 5. Pull pump (1) and gasket (7) straight out from the clean during inspection and assembly. The close mounting flange of pump adaptor (2). Discard gasket tolerance of the parts makes this requirement very (7).
  • Page 304 Steering System - Steering Pump Section 220-0050 freeze up in the cylinder bore. SM - 380 5. Inspect each piston and shoe (32) assembly for a maximum end play of 0.127 mm (0.005 in) between the piston and shoe. 6. The face thickness dimension of each shoe must be within 0.025 mm (0.001 in) of each other.
  • Page 305 Steering System - Steering Pump Section 220-0050 scoring. If defective, remove yoke (42), yoke spring SM - 382 (46) and seat (45) as follows: a) Remove four screws (36) that hold pintle covers (37) on each side of pump housing (16). Remove pintle covers (37).
  • Page 306 Steering System - Steering Pump Section 220-0050 2. Inspect (51 & 53) for worn corners on the hex extend out beyond the end of pump housing (16). head, stripped threads and burrs in 'O' ring (52) Place the complete unit with tubing into an arbor groove.
  • Page 307 Steering System - Steering Pump Section 220-0050 shaft seal (34) end down. Lay inner race of tapered SM - 385 ARBOR PRESS bearing (47) into the outer race. Install yoke spring HERE (46) and seat (45) into pump housing (16). 3.
  • Page 308 Steering System - Steering Pump Section 220-0050 e) Set pump housing (16) on its side and hold necessary shims (38) to provide this pre-load as driveshaft (35) horizontal. Slide rotating group into follows: pump housing (16). Rotate driveshaft (35) to match shaft splines to cylinder block (23) and spherical Assume the depth readings were 0.736 mm (0.029 in) washer (30).
  • Page 309 Steering System - Steering Pump Section 220-0050 1. Install thickest bearing spacer (22) over driveshaft SM - 388 (35) with the chamfer facing pump housing (16) (toward the shoulder on driveshaft (35)). 2. Slide new inner race of tapered bearing (21) on driveshaft (35) and up against bearing spacer (22).
  • Page 310 Steering System - Steering Pump Section 220-0050 SYSTEM. Connect the case drain line to pump. Fill SM - 389 steering and brake control tank with oil specified in Section 300-0020, LUBRICATION SYSTEM. Note: It is very important that the pump cavity is completely filled with hydraulic oil.
  • Page 311 Steering System - Steering Pump Section 220-0050 SPECIAL TOOLS Special tools are shown in Figs. 17, 18, 19 & 20. SM - 391 HEAVY WALL TUBING ALUMINIUM RING PRESS RING ON END OF TUBING Fig. 17 - Shaft Seal Driver SM - 390 SM - 392 USE FOR...
  • Page 312 Steering System - Steering Pump Section 220-0050 SPECIAL TORQUE SPECIFICATIONS TABLE046 TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Screw 7 - 8 5 - 6 Bolt Bolt Screw 31 - 35 23 - 26 Screw 20 - 22 15 - 16 SM 1204 2-98...
  • Page 313 STEERING SYSTEM - Accumulator Section 220-0080 SM - 171 1 - Charging Valve 1E - Body 1A - Cap 1F - ‘O’ Ring 5 - Backup Ring 9 - Hardened Washer 1B - Core 2 - Shield 6 - 'O’ Ring 10 - Piston 3 - ‘O’...
  • Page 314 Steering System - Accumulator Section 220-0080 and releasing it quickly once or twice. Recheck for the body is completely lowered, apply the parking leakage, if leakage continues then discharge the brake and switch off the engine. accumulator as described under 'Discharging Nitrogen' in this section, then replace the valve core.
  • Page 315 Steering System - Accumulator Section 220-0080 DISCHARGING NITROGEN WARNINGS Numbers in parentheses refer to Fig. 1. Do not use Oxygen or any gas other than Nitrogen to charge an accumulator. Oxygen Make sure charging valve (1) is closed internally by under pressure coming into contact with oil or turning locknut (1D) clockwise.
  • Page 316 Steering System - Accumulator Section 220-0080 5. Insert a suitable wooden dowel through the port SM - 172 end of cylinder (12) to push out piston (10). Remove and discard seal rings (7) and wear rings (11) from FRAME piston (10). INSPECTION Numbers in parentheses refer to Fig.
  • Page 317 Steering System - Accumulator Section 220-0080 clockwise to 11 Nm (100 lbf in) to close charging 4. Install hydraulic line securely to the oil inlet port at valve. Insert valve core (1B), replace valve cap (1A) bottom of accumulator. and tighten finger tight. 5.
  • Page 318 Steering System - Accumulator Section 220-0080 AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE °C °F lbf/in² 47.7 48.8 49.8 50.9 54.1 56.2 57.3 58.3 59.4 60.5 61.5 WARNING This truck is equipped with pre-charged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in Special permits may be required when transporting the truck or cylinders by any method while cylinders are charged.
  • Page 319 STEERING SYSTEM - Steering Valve Section 220-0090 SM - 1489 14 15 13 16 19 17 11 - Centring Pin 19 - Retaining Ring 12 - Centring Springs 20 - Check Ball Retainer 13 - 'O' Ring 21 - Check Ball 1 - Cap Screws 6 - Spacer Plate 14 - Bearing Races...
  • Page 320 Steering System - Steering Valve Section 220-0090 Spool (10) contains porting matched to sleeve (9) and truck stops turning further, but will hold the present rotates within sleeve (9) to provide directional control turning radius until spool (10) is rotated past the 2.5 of the oil.

  • Page 321: Accumulator Valve

    Steering System - Steering Valve Section 220-0090 SM - 283 SM - 556 RIGHT LEFT TURN TURN SYSTEM RETURN FROM SUPPLY TO FEED FEED PRESSURE CYLINDERS CYLINDERS METER TANK PORTS Fig. 3 - Porting of Spool (10) and Sleeve (9) Fig.
  • Page 322 Steering System - Steering Valve Section 220-0090 REMOVAL SM - 462 Numbers in parentheses refer to Fig. 9. WARNINGS To prevent personal injury and property damage, turn steering wheel several times in each direction to relieve pressure in the steering accumulator. To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly...
  • Page 323 Steering System - Steering Valve Section 220-0090 SM - 288 SM - 1492 6 - Spacer Plate 7 - Driveshaft 8 - Valve Housing 26 - 'O' Rings Fig. 13 - Removing Driveshaft Fig. 10 - Valve Clamped in Vice SM - 1490 SM - 292 Fig.
  • Page 324 Steering System - Steering Valve Section 220-0090 SM - 295 SM - 297 8 - Valve Housing 14 - Bearing Race 15 - Needle Bearing Fig. 17 - Removing Needle Bearing Fig. 19 - Separating Spool and Sleeve SM - 296 SM - 298 8 - Valve Housing 8 - Valve Housing...
  • Page 325 Steering System - Steering Valve Section 220-0090 INSPECTION SM - 299 Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in a clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage.
  • Page 326 Steering System - Steering Valve Section 220-0090 8. Compress extended end of centring springs (12) SM - 616 and push into spool (10) and sleeve (9) assembly, withdrawing installation tool at the same time. 9. Centre centring springs (12) in the parts so that they push down evenly and are flush with upper surface of spool (10) and sleeve (9).
  • Page 327 Steering System - Steering Valve Section 220-0090 SM - 309 SM - 306 DRIVESHAFT PORT FACE CENTRING PIN PARALLEL WITH PORT FACE CENTRING PIN Fig. 31 - Aligning Spool and Sleeve 13 - 'O' Ring 16 - Quad Ring Seal 18 - Oil Seal 17 - Seal Gland Bushing 19 - Retaining Ring...
  • Page 328 Steering System - Steering Valve Section 220-0090 driveshaft (7), as shown in Fig. 33. Note the parallel SM - 311 relationship of reference lines A, B, C & D in Fig. 33. GEROTOR Align cap screw (1) holes without disengaging gerotor GEAR VALLEY gear (5) from driveshaft (7).
  • Page 329 Steering System - Steering Valve Section 220-0090 FILLING AND BLEEDING THE STEERING b. When the oil in the tank is clear (not cloudy or SYSTEM creamy), the system is free of air. 1. Fill steering and brake control tank to Maximum level.
  • Page 330 Steering System - Steering Valve Section 220-0090 STEERING CONTROL DIAGNOSIS CONDITION REASON REMEDY Steering wheel does not centre Binding in steering linkage to valve Align as required Worn gerotor Replace parts Broken springs Replace springs, drain and flush system Burrs on sleeve or spool Disassemble and repair or replace parts Apparent inability to steer when...
  • Page 331 STEERING SYSTEM - Double Relief Valve Section 220-0110 SM - 1326 1 - Valve Body 11 - Backup Ring 16 - Valve 6 - Spring End 2 - Valve 12 - Plug 17 - Valve Seat 7 - Adjustment Screw 3 - Valve Seat 13 - Relief Body 18 - Spring...
  • Page 332 Steering System - Double Relief Valve Section 220-0110 When oil flowing through valve body (1) at port 'B', and SM - 560 out of the opposite side exceeds valve (2) setting, valve (2) is moved off valve seat (3) against the STEERING STEERING pressure of spring (5).
  • Page 333 Steering System - Double Relief Valve Section 220-0110 body (1). Remove and discard 'O' ring (8) and backup 6. Repeat steps 1 through 5 to assemble remaining rings (9) from valve seat (3). valve (16) assembly. 7. Follow steps 1 through 6 to disassemble the 7.
  • Page 334 Steering System - Double Relief Valve Section 220-0110 If oil is discharged through port 'A' only when relief secure in place with mounting hardware. pressure is exceeded, turn adjustment screw (7) out and open needle valve slightly. Continue opening 2. Remove blanking caps from hydraulic lines and needle valve and turning adjustment screw (7) out install lines to double relief valve as identified during until discharge through port 'A' occurs at relief pressure.
  • Page 335 STEERING SYSTEM - Steering Cylinder and Linkage Section 220-0120 SM - 1526 36- LH 37- RH 46,47 44,45 46,47 7- LH 15,16 8- RH 1-3 LH 4-6 RH 20,21,22 24,23 25 - Seal 37 - Rod End 1 - Spindle Assembly - LH 13 - Expansion Plug 26 - Plug 38 - Bolt...
  • Page 336 Steering System - Steering Cylinder and Linkage Section 220-0120 REMOVAL Steering Linkage Numbers in parentheses refer to Fig. 1. 1. Remove cotter pins (45) from studs (39) and remove castle nuts (44). WARNINGS 2. With suitable lifting equipment, remove tie rod (35) To prevent personal injury and property assembly from steering arm (7) and bellcrank (10).
  • Page 337 Steering System - Steering Cylinder and Linkage Section 220-0120 SM - 168 1 - Tube 5 - Piston Rod 9 - Backup Ring 2 - Lube Fitting 6 - Wiper 10 - 'O' Ring 13 - Nut 3 - Bushing 7 - Seal 11 - Piston 14 - Bolt...
  • Page 338 Steering System - Steering Cylinder and Linkage Section 220-0120 Steering Cylinder Steering Cylinder Numbers in parentheses refer to Fig. 2. Numbers in parentheses refer to Fig. 2. 1. Clean outer surfaces of steering cylinder assembly Note: To facilitate assembly procedure, apply a light with a suitable cleaning solvent to remove dirt and coating of hydraulic oil to all components as they are grease.
  • Page 339 Steering System - Steering Cylinder and Linkage Section 220-0120 Tie Rod Assembly is in line with lube fittings (17 & 18) in bellcrank housing. Numbers in parentheses refer to Fig. 1. 2. Using suitable lifting equipment, install bellcrank (10) 1. Place tie rod (35) in a vice, or similar holding device, and screw rod ends (36 &...
  • Page 340 Steering System - Steering Cylinder and Linkage Section 220-0120 Steering Cylinder SM - 154 FRONT 1. Position seal (25) on steering arm (7) ball joint bore. OF VEHICLE 2. Insert base end of steering cylinder (32) into clevis on bellcrank housing and ball pin (31) in steering arm (7) bore.
  • Page 341 Steering System - Steering Cylinder and Linkage Section 220-0120 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft 245 - 300 180 - 220 Castle Nut 1 560 - 1 630 1 150 - 1 200 Castle Nut 1 150 - 1 290 850 - 950 75 - 81...
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  • Page 343 STEERING SYSTEM - Steering Cylinder and Linkage Section 220-0120 SM - 2407 36- LH 37- RH 44,45 46,47 46,47 7- LH 15,16 8- RH 1-3 LH 4-6 RH 20,21,22 24,23 25 - Seal 37 - Rod End 1 - Spindle Assembly - LH 13 - Expansion Plug 26 - Plug 38 - Bolt...
  • Page 344 Steering System - Steering Cylinder and Linkage Section 220-0120 REMOVAL Steering Linkage Numbers in parentheses refer to Fig. 1. 1. Remove cotter pins (45) from studs (39) and remove castle nuts (44). WARNINGS 2. With suitable lifting equipment, remove tie rod (35) To prevent personal injury and property assembly from steering arm (7) and bellcrank (10).
  • Page 345 Steering System - Steering Cylinder and Linkage Section 220-0120 SM - 2408 1 - Tube 9 - Piston 5 - Piston Rod 2 - Lube Fitting 10 - Piston Ring 6 - Wiper 3 - Bushing 11 - Nut 7 - End Cap 4 - Elbow - 90°...
  • Page 346 Steering System - Steering Cylinder and Linkage Section 220-0120 Steering Cylinder Steering Cylinder Numbers in parentheses refer to Fig. 2. Numbers in parentheses refer to Fig. 2. 1. Clean outer surfaces of steering cylinder assembly Note: To facilitate assembly procedure, apply a light with a suitable cleaning solvent to remove dirt and coating of hydraulic oil to all components as they are grease.
  • Page 347 Steering System - Steering Cylinder and Linkage Section 220-0120 Tie Rod Assembly is in line with lube fittings (17 & 18) in bellcrank housing. Numbers in parentheses refer to Fig. 1. 2. Using suitable lifting equipment, install bellcrank (10) 1. Place tie rod (35) in a vice, or similar holding device, and screw rod ends (36 &...
  • Page 348 Steering System - Steering Cylinder and Linkage Section 220-0120 Steering Cylinder SM - 154 FRONT 1. Position seal (25) on steering arm (7) ball joint bore. OF VEHICLE 2. Insert base end of steering cylinder (32) into clevis on bellcrank housing and ball pin (31) in steering arm (7) bore.
  • Page 349 Steering System - Steering Cylinder and Linkage Section 220-0120 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft 245 - 300 180 - 220 Castle Nut 1 560 - 1 630 1 150 - 1 200 Castle Nut 1 150 - 1 290 850 - 950 End Cap...
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  • Page 351 STEERING SYSTEM - Accumulator Valve Section 220-0130 SM - 169 11 - 'O' Ring 1 - Poppet 6 - Plug 16 - Pin 12 - Plug 2 - Spring 7 - Quad Ring 17 - Piston 13 - Piston 3 - 'O' Ring 8 - Relief Valve Cartridge 18 - Spring 14 - 'O' Ring...
  • Page 352 Steering System - Accumulator Valve Section 220-0130 An accumulator two-way valve (13 thru 17) is located and oil flows to the steering valve through port 'B' and in the centre portion of the assembly. In the operating to the accumulator through port 'E'. Pressure is position, engine running and two-way valve energized supplied to pressure switch (8, Figs.
  • Page 353 Steering System - Accumulator Valve Section 220-0130 SM - 1324 PRESSURE TEST POINT RETURN FROM ACCUMULATOR RETURN TO TANK Fig. 3 - Two-way Valve De-energized SM - 1325 SUPPLY TO RETURN FROM STEERING PRESSURE STEERING VALVE VALVE TEST POINT SUPPLY TO ACCUMULATOR BRAKE CIRCUIT...
  • Page 354 Steering System - Accumulator Valve Section 220-0130 SM - 170 9 - Filter 10 - Breather 11 - 'O' Ring 12 - Spring 13 - Pin 1 - Relief Valve Cartridge 14 - Quad Ring 2 - 'O' Ring 15 - Piston 3 - 'O' Ring 16 - 'O' Ring 4 - Backup Rings...
  • Page 355 Steering System - Accumulator Valve Section 220-0130 (19) from plug (18). Discard spring (20). (13) assembly in valve body (5). Install new quad ring (14) on piston (15) and install piston (15) assembly in 4. Clamp valve body (5) in a soft-jawed vice and valve body (5).
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  • Page 357: Steering Filter

    STEERING SYSTEM - Steering Filter Section 220-0150 SM - 627 1 - Housing 4 - 'O' Ring 7 - Indicator Link 2 - Bowl 5 - Magnets 8 - Visual Indicator 'B' - Outlet Port 3 - Element 6 - Bypass Valve 'A' - Inlet Port 'C' - Bypass Port Fig.
  • Page 358 Steering System - Steering Filter Section 220-0150 Element (3) should be changed immediately visual 2. Turn steering wheel in both directions several indicator registers in the yellow 'Needs Cleaning' area. times to relieve any pressure in accumulator and steering system. Block all road wheels. Note: Bypass valve (6) is still not open at this point.

  • Page 359: Body System

    BODY SYSTEM - Body System Schematic Section 230-0000 DESCRIPTION Body Control Valve (3) Numbers in parentheses refer to Figs. 2 through 5. Refer to Section 230-0060, BODY CONTROL VALVE. Also referenced in this section is Manifold Block (4). The body system schematic primarily covers operation of the body hoist system.
  • Page 360 Body System - Body System Schematic Section 230-0000 Disc Brake Oil Filter (7) Note: The body control joystick should be kept in the ‘Float’ position at all times, except when raising or There is one full flow oil filter installed in the hydraulic line between manifold block (4) and disc brake oil lowering the body.
  • Page 361 Body System - Body System Schematic Section 230-0000 Pilot Supply Valve (14) 'O' RING FACE SEALS (ORFS) Refer to Section 230-0121, PILOT SUPPLY VALVE. Where hydraulic lines are fitted with ORFS connections, the following procedure should be carried The pilot supply valve, mounted off the accumulator out during 'Installation'.
  • Page 362 CLICK HERE FOR HORIZONTAL DRAWING Body System - Body System Schematic Section 230-0000 SM 1594 Rev 2 11-00...
  • Page 363 CLICK HERE FOR HORIZONTAL DRAWING Body System - Body System Schematic Section 230-0000 SM 1594 Rev 2 11-00...
  • Page 364 CLICK HERE FOR HORIZONTAL DRAWING Body System - Body System Schematic Section 230-0000 SM 1594 Rev 2 11-00...
  • Page 365 CLICK HERE FOR HORIZONTAL DRAWING Body System - Body System Schematic Section 230-0000 SM 1594 Rev 2 11-00...
  • Page 366 Body System - Body System Schematic Section 230-0000 SERVICE TOOLS gauges through a pressure range of 762 mm (30 in) of It is recommended that the following tools are used vacuum to 345 bar (5 000 lbf/in when carrying out pressure or temperature checks during maintenance procedures.
  • Page 367 Body System - Body and Disc Brake Cooling Tank Section 230-0040 SM - 1330 SM - 1685 1 - Hydraulic Tank 12 - Breather 2 - Tandem Pump 13 - Oil Temperature Switch 10 - Relief Valve Fig. 2 - Hydraulic Schematic Fig.
  • Page 368 Body System - Body and Disc Brake Cooling Tank Section 230-0040 SM - 1683 1 - Breather 4 - Bushing 2 - Nipple 5 - Elbow 3 - Tee 6 - Breather Line Fig. 4 - Breather Line Installation MAINTENANCE running, oil at normal operating temperature and body fully lowered, the oil level should show in top window Numbers in parentheses refer to Fig.
  • Page 369 Body System - Body and Disc Brake Cooling Tank Section 230-0040 Changing Filter Elements SM - 1991 Change filter elements (13) at interval specified in Section 300-0020, LUBRICATION SYSTEM. WARNING To prevent personal injury and property damage, be sure wheel blocks are properly secured and of adequate capacity to do the job safely.
  • Page 370 Body System - Body and Disc Brake Cooling Tank Section 230-0040 and brake control tank and drain the oil. Refer to connecting hose assembly (3, Fig. 5) to access Section 220-0040, STEERING AND BRAKE cover (3). CONTROL TANK. Reinstall drain plug in hydraulic tank and tighten securely.
  • Page 371 Body System - Body and Disc Brake Cooling Tank Section 230-0040 6. Disconnect inter-connecting hose assembly 5. Check bypass valve (9) for damage or wear and (3, Fig. 5) from access cover (3). Fit blanking caps to replace if required. line.
  • Page 372 Body System - Body and Disc Brake Cooling Tank Section 230-0040 4. Remove blanking caps and plugs and install all 7. Check all lines and fittings for leaks and tighten as lines to hydraulic tank (1) , as tagged at removal. required.
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  • Page 374 BODY SYSTEM - Tandem Pump Section 230-0050 SM - 373 8 - Ring Seals 16 - Seals 24 - Name Plate * 1 - Snap Ring 9 - Bearings 17 - Connecting Shaft 25 - Drive Screws * 2 - Spacer 10 - Pocket Seals 18 - Bearing Carrier 26 - Washers *...
  • Page 375 Body System - Tandem Pump Section 230-0050 SM - 575 SM - 338 TO BODY DRIVE GEAR CONTROL VALVE TO BRAKE COOLING CIRCUIT INLET OUTLET FROM FROM DRIVEN GEAR TANK TANK Fig. 2 - Typical Pump Operation Fig. 3 - Hydraulic Schematic of Tandem Pump Operation DISASSEMBLY oil to the body control valve where, depending on Numbers in parentheses refer to Figs.
  • Page 376 Body System - Tandem Pump Section 230-0050 SM - 374 21 - Driven Gear 22 - Gear Housing 23 - End Cover 13 - Driven Gear 24 - Name Plate 14 - Seals 25 - Drive Screws 7 - Plug 15 - Gear Housing 1 - Snap Ring 26 - Washers...
  • Page 377 Body System - Tandem Pump Section 230-0050 3. Tap end cover (23) with a soft hammer and SM - 344 separate from gear housing (22). If end cover (23) must be pried off, use care to avoid damaging machined surfaces of the cover and housing. See Fig.
  • Page 378 Body System - Tandem Pump Section 230-0050 8. Separate and lift off gear housing (15) with care. SM - 348 See Fig. 12. Remove thrust plate (11) as in Step 4. 9. Mark three meshed gear teeth with a dab of Prussian blue or similar dye and remove the matched driveshaft and gear (12) and driven gear (13) set.
  • Page 379 Body System - Tandem Pump Section 230-0050 Hydraulic pressure forces the gears against the low SM - 354 pressure side of the housing. As the bearings and gear hubs wear, the housing gear bores wear. Excessive bore cutout, particularly in a short period, indicates excessive pump loading or dirty oil.
  • Page 380 Body System - Tandem Pump Section 230-0050 10. Smooth all machined surfaces with a medium-grit SM - 357 stone. See Fig. 21. Deburr all bearing bores if required. 11. Clean parts in a suitable solvent and dry with compressed air after smoothing surfaces. ASSEMBLY Numbers in parentheses refer to Figs.
  • Page 381 Body System - Tandem Pump Section 230-0050 7. With shaft end cover (6) clamped in a soft-jawed SM - 362 vice, insert driveshaft and gear (12) into the shaft end cover bore and push down until the gear is snug against thrust plate (11).
  • Page 382 Body System - Tandem Pump Section 230-0050 gear housing (22) with a soft hammer until it rests SM - 366 snugly against bearing carrier (18). Refer to Fig. 28. If a new housing is used, make sure the large oil port will be toward the inlet, and the small port toward the outlet side of the pump assembly.
  • Page 383 Body System - Tandem Pump Section 230-0050 4. Fill body and disc brake cooling tank to the proper SM - 371 level. Refer to Section 230-0040, BODY AND DISC BRAKE COOLING TANK. Refer to Section 300-0020, LUBRICATION SYSTEM, for correct oil specifications.

  • Page 384: 230-0000, Body System Schematic

    BODY SYSTEM - Body Control Valve Section 230-0060 SM - 1805 TO PRESSURE CHECK POINT PILOT PRESSURE FROM BODY FROM CONTROL JOYSTICK PUMP (LOWER) PRESSURE SWITCH TO BODY RAISE PORTS TO KICK-OVER VALVE PILOT PRESSURE FROM BODY CONTROL JOYSTICK (RAISE) 23 24 TO TANK 1 - Valve Body...

  • Page 385: Kick-Over Valve

    Body System - Body Control Valve Section 230-0060 Relief valve (18) assembly, installed in port 'F', opens SM - 2271 and allows oil to flow back to the body and disc brake cooling tank when pressure in the hydraulic system LOWER CIRCUIT RAISE CIRCUIT exceeds 190 bar (2 750 lbf/in...

  • Page 386: Relief Valve

    Body System - Body Control Valve Section 230-0060 Moving the hydraulic control joystick to the 'Float' SM - 2274 position, moves the spool to a position within valve body (1) which allows the body to lower by its own LOWER CIRCUIT RAISE CIRCUIT weight.
  • Page 387 Body System - Body Control Valve Section 230-0060 SM - 1821 7,10 8,10 3,4,5 8,10 8,10 13 12 3,4,5 1 - Body Control Valve 5 - Nut 9 - Bolt 13 - Block 2 - Mounting Plate 6 - Block 10 - Nut 14 - 'O' Ring 3 - Bolt...
  • Page 388 Body System - Body Control Valve Section 230-0060 DISASSEMBLY Valve Body Numbers and letters in parentheses refer to Fig. 1. 1. If required, remove adaptor (28) and 'O' ring (27) from port 'J' in valve body (1). Discard 'O' ring (27). WARNING 2.
  • Page 389 Body System - Body Control Valve Section 230-0060 INSTALLATION 2. If removed, install new 'O' ring on elbow (34) and secure in reducer (35). Install new 'O' ring (36) on Numbers in parentheses refer to Fig. 6, unless reducer (35) and secure adaptor assembly in port 'H' otherwise specified.
  • Page 390 Body System - Body Control Valve Section 230-0060 MAINTENANCE 7. Reconnect hoses, as identified at removal, to elbows (33 & 41, Fig. 1). Numbers in parentheses refer to Fig. 1. 8. Remove all blanking caps from hydraulic lines and Note: Limited repair of the body control valve is by install all hydraulic lines to body control valve (1, Fig.
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  • Page 392 BODY SYSTEM - Body Control Joystick Section 230-0081 SM - 1795 7 - Mounting Bracket 4 - Connector 1 - Body Control Joystick 8 - Screw 2 - Bolt 5 - Elbow 9 - Lockwasher 3 - Lockwasher 6 - Elbow 10 - Cover Plate Fig 1.
  • Page 393 Body System - Body Control Joystick Section 230-0081 operating positions of the joystick from front to rear are 2. Operate the body control joystick (1) continuously to as follows: discharge the pilot valve accumulator. Block all road wheels. 'LOWER' - This position provides hydraulic force to power-down the body.
  • Page 394 BODY SYSTEM - Kick-over Valve Section 230-0090 SM - 585 13 - Spring 20 - Screw 1 - Plug 7 - Backup Rings 21 - Guide 14 - Spring 2 - 'O' Ring 8 - 'O' Ring 22 - 'O' Ring 15 - Spring End 3 - 'O' Ring 9 - Spool Seat...
  • Page 395 Body System - Kick-over Valve Section 230-0090 SM - 583 SM - 584 RETURN FROM SUPPLY TO SUPPLY TO RETURN FROM LOWER PORT ON RAISE PORT ON LOWER PORT ON RAISE PORT ON BODY CYLINDERS BODY CYLINDERS BODY CYLINDERS BODY CYLINDERS RETURN TO SUPPLY SUPPLY...
  • Page 396 Body System - Kick-over Valve Section 230-0090 ADJUSTMENT 5. Remove plug (18) from valve body (5). Numbers in parentheses refer to Fig. 1. 6. Remove gasket (17), spring end (15), 'O' ring (16), springs (13 & 14), relief spool (12), backup ring (11) 1.
  • Page 397 Body System - Kick-over Valve Section 230-0090 cylinder extending through second stage and pilot line oils meeting specifications outlined in Section removed. 300-0020, LUBRICATION SYSTEM. 5. Remove pressure gauge from port 'G' and install MAINTENANCE cap (26) on connector (25). Inspect the kick-over valve regularly for any signs of 6.
  • Page 398 BODY SYSTEM - Relief Valve Section 230-0120 SM - 1803 TO TANK KICK-OVER VALVE 1 - Relief Valve 2 - Cartridge Assy 10 - Plug 6 - Backup Ring 3 - Cap 11 - 'O' ring 7 - 'O' ring 4 - 'O' ring 12 - Adaptor 8 - Tee Piece...
  • Page 399 Body System - Relief Valve Section 230-0120 REMOVAL INSPECTION Numbers in parentheses refer to Fig. 1. WARNING 1. Clean all metal parts thoroughly in suitable solvent To prevent personal injury and property and dry with compressed air. Inspect valve body (1) damage, be sure wheel blocks are properly bores, plug (10), adaptor (12) and cartridge assembly secured and of adequate capacity to do the job...
  • Page 400 Body System - Relief Valve Section 230-0120 MAINTENANCE 3. Remove cap (3) and install a pressure gauge in port. Check kick-over pressure is 172 bar (2 500 lbf/in²), at Inspect the relief valve regularly for any signs of leaks maximum rev/min, and with body cylinder extending or damage.
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  • Page 402 BODY SYSTEM - Pilot Supply Valve Section 230-0121 SM - 1799 6,7,8 TO MANIFOLD BRACKET IN CAB FLOOR TO STEERING TO MANIFOLD TANK BRAKE VALVE 9 - Elbow - 90° 10 - Tee Piece 1 - Valve Body 5 - Seal 2 - Accumulator 6 - Bolt 11 - Diagnostic Fitting...

  • Page 403: Pilot Supply Valve

    Body System - Pilot Supply Valve Section 230-0121 MAINTENANCE disconnect hydraulic lines. Fit blanking caps to all Numbers in parentheses refer to Fig. 1. open lines. The pilot supply valve is a non-serviceable item and 4. Remove bolts (6), lockwashers (7), washers (8) and should be replaced completely, if damaged, as follows: pilot supply valve (1) from mounting bracket (3).
  • Page 404 BODY SYSTEM - Body Cylinder Section 230-0130 SM - 178 BODY MAIN FRAME TORQUE TUBE 1 - Pins 2 - Washer 3 - Lockwasher 4 - Bolt 5 - Cylinder 6 - Lube Fitting Fig. 1 - Exploded View of Body Cylinder Mounting DESCRIPTION 1.
  • Page 405 Body System - Body Cylinder Section 230-0130 SM - 180 8 - Seal 1 - Bolt 9 - Wear Ring 2 - Bushing 15 - Seal 21 - Wear Ring 10 - Wiper 3 - Base 16 - Tube 22 - Wiper 4 - Backup Ring 11 - Wear Ring 17 - Bushing...
  • Page 406 Body System - Body Cylinder Section 230-0130 ASSEMBLY remove. Remove wear ring (6) from tube (7). Numbers in parentheses refer to Fig. 2. 7. Remove and discard wiper (10), wear ring (9) and seal (8) from tube (7). WARNING 8. Push tube (13) from outer tube (19) and remove. To prevent personal injury and property Remove wear ring (11) and piston rings (12) from damage, be sure lifting equipment is properly...
  • Page 407 Body System - Body Cylinder Section 230-0130 INSTALLATION lockwasher (3) and bolt (4). Numbers in parentheses refer to Fig. 1. 3. Install hydraulic lines to proper cylinder ports. Note: Tighten all fasteners to torques listed in Section 300-0080, STANDARD BOLT AND NUT 4.

  • Page 408: Braking System

    BRAKING SYSTEM - Braking System Schematic Section 250-0000 DESCRIPTION The accumulator is of the piston type and is Numbers in parentheses refer to Figs. 2 through 7. precharged with nitrogen to 55 bar (800 lbf/in ). It consists of a charging valve assembly, cylinder The hydraulic braking system is of closed centre assembly and a piston.

  • Page 409: Shuttle Valve

    Braking System - Braking System Schematic Section 250-0000 The differing maximum operating pressures required for service brakes, or, the retarder control valve, to utilise the front and rear brakes are achieved within the treadle the rear service brakes as a retarder. valve.

  • Page 410: Accumulator

    Braking System - Braking System Schematic Section 250-0000 Monoblock Brake Valve (8) separate retarder selection switch on the dash panel. Pressing the switch at the top will select the OCDB Refer to Section 250-0100, MONOBLOCK BRAKE retarder and pressing the bottom will select the VALVE.
  • Page 411 Braking System - Braking System Schematic Section 250-0000 Test Point B a. Ensure 'O' ring/seal is in place and that joining Transmission Pilot Pressure - Taken from a tee in the surfaces are clean. If necessary, retain 'O' ring/seal in transmission pilot pressure line to the directional place with a light coating of grease or vaseline.
  • Page 412 Braking System - Braking System Schematic Section 250-0000 Multi-gauge In the interests of safety, it is important that the exact procedure for bleeding the brakes is carried out as The multi-gauge is basically four pressure gauges in outlined in Section 165-0030, BRAKE PARTS (rear one.
  • Page 413 BODY SYSTEM - Body and Disc Brake Cooling Tank Section 230-0040 SM - 1995 1 - Hydraulic Tank 28 - Hardened Washer 10 - Plate 19 - Relief Valve 2 - Access Cover 11 - Rod 20 - Poppet 29 - Bolt 3 - Access Cover 12 - Wing Nut 21 - Cap...
  • Page 414 CLICK HERE FOR HORIZONTAL DRAWING Braking System - Braking System Schematic Section 250-0000 SM 1222 Rev 1 9-99...
  • Page 415 CLICK HERE FOR HORIZONTAL DRAWING Braking System - Braking System Schematic Section 250-0000 SM 1222 Rev 1 9-99...
  • Page 416 CLICK HERE FOR HORIZONTAL DRAWING Braking System - Braking System Schematic Section 250-0000 SM 1222 Rev 1 9-99...
  • Page 417 CLICK HERE FOR HORIZONTAL DRAWING Braking System - Braking System Schematic Section 250-0000 SM 1222 Rev 1 9-99...
  • Page 418 CLICK HERE FOR HORIZONTAL DRAWING Braking System - Braking System Schematic Section 250-0000 SM 1222 Rev 1 9-99...
  • Page 419 CLICK HERE FOR HORIZONTAL DRAWING Braking System - Braking System Schematic Section 250-0000 SM 1222 Rev 1 9-99...
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  • Page 421 BRAKING SYSTEM - Brake Manifold Valve Section 250-0050 SM - 1505 ACC1 ACC2 5,18 1 - Valve Body 6 - Retainer 11 - 'O' Ring 16 - 'O' Ring 2 - Solenoid Cartridge 7 - 'O' Ring 12 - 'O' Ring 17 - Backup Rings 3 - Solenoid Coil 8 - Spring...
  • Page 422 Braking System - Brake Manifold Valve Section 250-0050 SM - 1660 TO DIRECTIONAL TO PORT 'P2' CONTROL VALVE TREADLE VALVE FROM MONOBLOCK BRAKE VALVE FROM STEERING PUMP TO PORT 'P1' TREADLE VALVE ACC1 TO FRONT ACCUMULATOR TO REAR ACCUMULATOR ACC2 15 - Front Brake Accumulator Pressure Switch 3 - Brake Manifold Valve 16 - Parking Brake Pressure Switch...

  • Page 423: Body

    Braking System - Brake Manifold Valve Section 250-0050 SM - 1661 FROM DIRECTIONAL TO PORT 'P2' CONTROL VALVE TREADLE VALVE TO MONOBLOCK BRAKE VALVE FROM STEERING PUMP TO PORT 'P1' TREADLE VALVE ACC1 TO FRONT ACCUMULATOR TO REAR ACCUMULATOR ACC2 15 - Front Brake Accumulator Pressure Switch 3 - Brake Manifold Valve 16 - Parking Brake Pressure Switch...
  • Page 424 Braking System - Brake Manifold Valve Section 250-0050 8. If required, note orientation and remove hydraulic SM - 1508 line connectors from ports in valve body (1). ASSEMBLY Numbers in parentheses refer to Fig. 1. 1. Install new 'O' rings (11, 12, 14 & 16) and backup rings (13, 15 &...
  • Page 425 Braking System - Brake Manifold Valve Section 250-0050 MAINTENANCE SPECIAL TOOLS Inspect the brake manifold valve regularly for any There are no special tools required for procedures signs of leakage or damage and repair/replace as outlined in this section. Refer to Section 300-0070, required.
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  • Page 427 BRAKING SYSTEM - Accumulator Section 250-0060 SM - 277 1 - Charging Valve 8 - Wear Rings 1A - Cap 4 - Protector 1E - Body 9 - 'O' Ring 1B - Core 1F - 'O' Ring 5 - Piston 10 - End Cap 1C - 'O' Ring 2 - Screw...
  • Page 428 Braking System - Accumulator Section 250-0060 core (1B). Attempt to reseat the valve core by SM - 1273 depressing and releasing it quickly once or twice. Recheck for leakage, if leakage continues then discharge the accumulator as described under 'Discharging Nitrogen' in this section, then replace the valve core.
  • Page 429 Braking System - Accumulator Section 250-0060 DISCHARGING NITROGEN WARNINGS Numbers in parentheses refer to Fig. 1, unless Do not use Oxygen or any gas other than otherwise specified. Nitrogen to charge an accumulator. Oxygen under pressure coming into contact with oil or Make sure charging valve (1) is closed internally by grease will cause a violent explosion.
  • Page 430 Braking System - Accumulator Section 250-0060 DISASSEMBLY SM - 278 Numbers in parentheses refer to Fig. 1. WARNING Accumulators are charged with Nitrogen. The service pressure is 55 bar (800 lbf/in ) at C (70 F). Do not attempt to remove any valves or fittings until all nitrogen pressure is completely relieved to prevent personal injury and property damage.
  • Page 431 Braking System - Accumulator Section 250-0060 6. Test accumulator hydraulically for leakage or 5. Charge the accumulator with Nitrogen gas as failure at 255 - 276 bar (3 700 - 4 000 lbf/in described under the heading 'Charging the Discharge after testing. Accumulator' in this section.
  • Page 432 Braking System - Accumulator Section 250-0060 AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE °C °F lbf/in² 47.7 48.8 49.8 50.9 54.1 56.2 57.3 58.3 59.4 60.5 61.5 WARNING This truck is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in Special permits may be required when transporting the truck or cylinders by any method while cylinders are charged.
  • Page 433 BRAKING SYSTEM - Treadle Valve Section 250-0070 SM - 1267 1 - Adjustment Collar 2 - Actuator Plunger 16 - Reaction Plunger 3 - Glyde Ring Assembly 30 - Nut 43 - Screw 17 - Wiper Seal 4 - Plunger Return Spring 31 - Washer 44 - Retainer Plate 18 - Backup Ring...
  • Page 434 Braking System - Treadle Valve Section 250-0070 SM - 1656 SM - 1657 FROM TO FRONT FRONT BRAKES BRAKES FROM TO REAR REAR BRAKES BRAKES SUPPLY SUPPLY FROM FROM BRAKE BRAKE MANIFOLD MANIFOLD SUPPLY SUPPLY FROM FROM BRAKE BRAKE MANIFOLD MANIFOLD Fig.
  • Page 435 Braking System - Treadle Valve Section 250-0070 SM - 1658 SM - 1659 FROM TO FRONT FRONT BRAKES BRAKES FROM SUPPLY TO TANK REAR TO REAR FROM BRAKES BRAKES BRAKE BRAKE MANIFOLD MANIFOLD SOLENOID SOLENOID SUPPLY SUPPLY FROM FROM BRAKE BRAKE MANIFOLD MANIFOLD...
  • Page 436 Braking System - Treadle Valve Section 250-0070 REMOVAL (32) securing actuator pivot pin (38). Numbers in parentheses refer to Fig. 1. 5. Remove pivot pin (38) from actuator base (46) with a punch and hammer. Remove actuator cam (36) WARNINGS assembly and inspect for any abnormal wear or To prevent personal injury and property cracks.
  • Page 437 Braking System - Treadle Valve Section 250-0070 SUB-ASSEMBLY 18. Turn valve body (20) on its side on the work bench and remove regulator sleeves (14) from valve body (20). Numbers in parentheses refer to Fig. 1. 19. Remove regulator spools (8), reaction plungers Note: All metal parts should be thoroughly cleaned (16) and spool return springs (15) from regulator with a suitable solvent, dried, and lubricated with a...
  • Page 438 Braking System - Treadle Valve Section 250-0070 centre. Install threaded inserts (52) by tapping lightly SM - 1235 with a small hammer until their flanges become flush with pedal (50) surface. Be sure pedal (50) is supported to prevent breaking. 4.
  • Page 439 Braking System - Treadle Valve Section 250-0070 ASSEMBLY SM - 1237 Numbers in parentheses refer to Fig. 1. 1. Lightly lubricate glyde ring assembly (3) and install the 'B1' actuator plunger (2) into the 'B1' circuit. Be GLYDE RING ASSEMBLY careful not to damage or cut the glyde ring during installation.
  • Page 440 Braking System - Treadle Valve Section 250-0070 SM - 499 PILOT 159 bar (2 300 lbf/in²) RETURN SUPPLY SUPPLY FRONT REAR BRAKE BRAKE PRESSURE PRESSURE SIMULATED BRAKE VOLUME Fig. 9 - Typical Test Fixture 17. Install stop light pressure switch (55) and lockup SM - 1238 SCREWDRIVER drop out pressure switch (54) in plate (21) and tighten...
  • Page 441 Braking System - Treadle Valve Section 250-0070 FINAL ASSEMBLY 4. Attach tank return line to 'T' port of valve body (20). Numbers in parentheses refer to Fig. 1. 5. Attach output ports 'B1' and 'B2' to test lines. Check that all ports are used. Note: Tighten all fasteners without special torques specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE...
  • Page 442 Braking System - Treadle Valve Section 250-0070 2. Remove blanking caps and connect hydraulic lines SM - 1239 to the treadle valve assembly as noted at removal. 3. Connect electrical connections to stop light pressure switch (55) and lockup drop out pressure switch (54) as noted at removal.
  • Page 443 Braking System - Treadle Valve Section 250-0070 5. Remove pedal (50) from actuator cam (36) by 18. Insert pivot pin (38) through the hole in actuator loosening two capscrews (51) at the pedal heel. Note base (46), through the holes in 'U' bolts (32), and that capscrews (51) need not be removed.
  • Page 444 Braking System - Treadle Valve Section 250-0070 SPECIAL TOOLS There are no special tools required for procedures tools, sealants and adhesives required. These tools, outlined in this section. Refer to Section 300-0070, sealants and adhesives are available from your dealer. SERVICE TOOLS, for part numbers of general service SPECIAL TORQUE SPECIFICATIONS TORQUE...
  • Page 445 BRAKING SYSTEM - Directional Control Valve Section 250-0090 SM - 1509 1 - Valve Body 5 - Spring End Cap 9 - Allen Bolt 2 - End Cover 6 - Slide Washer 10 - Allen Bolt 13 - Sub Plate 3 - Spool 14 - Connector 7 - Spring...
  • Page 446 Braking System - Directional Control Valve Section 250-0090 SM - 1511 SM - 1510 TO 'PX' PORT FROM 'PX' PORT TREADLE VALVE TREADLE VALVE BRAKE BRAKE MANIFOLD MANIFOLD VALVE VALVE Fig. 3 - Directional Control Valve - De-energized Fig. 2 - Directional Control Valve - Energized OPERATION A controlled bleed down of the applied service brakes to the steering and brake control tank occurs through...
  • Page 447 Braking System - Directional Control Valve Section 250-0090 3. Clean directional control valve assembly and a. Install hydraulic supply capable of 0 - 159 bar surrounding area with a suitable solvent. Ensure all (0 - 2 300 lbf/in²) to port 'P'. hydraulic lines connected to the directional control valve are identified for ease of installation and, with b.
  • Page 448 Braking System - Directional Control Valve Section 250-0090 INSTALLATION 5. Check directional control valve and hydraulic line Note: Tighten all fasteners to torques listed in connections for leaks and tighten as required. Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. 6.
  • Page 449 BRAKING SYSTEM - Monoblock Brake Valve Section 250-0100 SM - 1363 1 - Valve Body 10 - Shuttle Valve 4 - Retainer 7 - Bonded Washer 2 - Orifice Plate 11 - Relief Valve 5 - Disc Filter 8 - Blanking Plug 3 - Conical Filter 12 - Plug 6 - Filter Retainer...
  • Page 450 Braking System - Monoblock Brake Valve Section 250-0100 At the same time, oil enters pressure relief valve (11) SM - 1356 circuit, passing through conical filter (3), disc filter (5) and orifice plate (2) to shuttle valve (10). Oil pressure TO REAR pushes shuttle valve (10) spool across and oil exits SERVICE BRAKES...
  • Page 451 Braking System - Monoblock Brake Valve Section 250-0100 REMOVAL SM - 1353 WARNINGS Hydraulic fluid pressure will remain within the system after engine shut down. Operate the treadle valve continuously until the pressure has dissipated before carrying out any work on the braking system or serious injury could result.
  • Page 452 Braking System - Monoblock Brake Valve Section 250-0100 ASSEMBLY 3. Check oil level in steering and brake control tank Numbers in parentheses refer to Fig. 1, unless and add oil if required. Refer to Section 220-0040, otherwise specified. STEERING AND BRAKE CONTROL TANK for correct fill level, and, use only oil as specified in Section 1.
  • Page 453 BRAKING SYSTEM - Pressure Reducing Valve Section 250-0110 DESCRIPTION SM - 2297 The pressure reducing valve can be identified as item 19 in Section 250-0000, BRAKING SYSTEM SCHEMATIC. Mounted on the inside of the left hand frame rail in front of the body guide, the pressure reducing valve is located in the hydraulic brake circuit between the treadle valve and the front brake callipers.
  • Page 454 Braking System - Pressure Reducing Valve Section 250-0110 7. Secure pressure reducing valve (1) to mounting with WARNING bolts (8) and washers (9). To prevent personal injury and property damage, be sure wheel blocks are properly 8. Remove blanking caps from hydraulic lines and secured and of adequate capacity to do the job install lines to pressure reducing valve (1) as identified safely.
  • Page 455 BRAKING SYSTEM - Retarder Control Valve Section 250-0130 SM - 1272 1 - Adjustment Collar 2 - Actuator Plunger 11 - 'O' Ring 20 - Washer 29 - Jam Nut 3 - Plunger Return Spring 12 - 'O' Ring 21 - Capscrew 30 - Set Screw 4 - Regulator Spring 13 - Regulator Sleeve...
  • Page 456 Braking System - Retarder Control Valve Section 250-0130 SM - 1662 REAR SERVICE BRAKES 'P2' PORT TREADLE VALVE FROM BRAKE MANIFOLD VALVE 12 - Transmission Retarder Cylinder 10 - Retarder Control Valve 18 - Pressure Switch 11 - Directional Control Valve Fig.
  • Page 457 Braking System - Retarder Control Valve Section 250-0130 SM - 1663 REAR SERVICE BRAKES 'P2' PORT TREADLE VALVE FROM BRAKE MANIFOLD VALVE 10 - Retarder Control Valve 12 - Transmission Retarder Cylinder 11 - Directional Control Valve 18 - Pressure Switch Fig.
  • Page 458 Braking System - Retarder Control Valve Section 250-0130 SM - 1664 REAR SERVICE BRAKES 'P2' PORT TREADLE VALVE FROM BRAKE MANIFOLD VALVE 10 - Retarder Control Valve 12 - Transmission Retarder Cylinder 11 - Directional Control Valve 18 - Pressure Switch Fig.
  • Page 459 Braking System - Retarder Control Valve Section 250-0130 SM - 1665 REAR SERVICE BRAKES 'P2' PORT TREADLE VALVE FROM BRAKE MANIFOLD VALVE 10 - Retarder Control Valve 12 - Transmission Retarder Cylinder 11 - Directional Control Valve 18 - Pressure Switch Fig.
  • Page 460 Braking System - Retarder Control Valve Section 250-0130 Valve Body or, the inability to compress spring (31) enough to hold lever (36) in the fully applied position during 1. Remove cap (23) from the top of valve body (18). normal operation. 2.
  • Page 461 Braking System - Retarder Control Valve Section 250-0130 Note: Do not try to disassemble lever (36) from shaft proceed as follows: (34). If shaft (34) or lever (36) are damaged, replace shaft (34), lever (36), ring (35) and spring pin (25). a.
  • Page 462 Braking System - Retarder Control Valve Section 250-0130 Valve Body Seals SM - 1347 1. Install seal (17) in seal groove of valve body (18) first. Position seal (17) in the groove so that 'O' ring inside the seal is facing down toward the bottom of valve body (18).
  • Page 463 Braking System - Retarder Control Valve Section 250-0130 SM - 1349 RETURN 207 bar (3 000 lbf/in SUPPLY BRAKE PRESSURE Fig. 8 - Typical Retarder Control Valve Test Circuit TESTING AND ADJUSTMENTS seated in regulator spring (5) before installing Numbers in parentheses refer to Fig. 1. regulator sleeve (13).
  • Page 464 Braking System - Retarder Control Valve Section 250-0130 Setting Apply Pressure 4. Adjust set screw (27) on top of housing (22) inward until the pressure begins to rise. Measure lever (36) Note: Before actuating the valve, be sure adjustment collar (1) is bottomed to prevent excessive pressure angle and back set screw (27) out until a lever angle from damaging regulator springs (4 &...
  • Page 465 Braking System - Retarder Control Valve Section 250-0130 AND BRAKE CONTROL TANK. Add oil if low. Use b. Start engine and bring hydraulic oil temperature to oils meeting the specifications outlined in Section operating temperature. 300-0020, LUBRICATION SYSTEM. c. Actuate retarder control valve fully and check 5.
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  • Page 467 BRAKING SYSTEM - Shuttle Valve Section 250-0140 DESCRIPTION SM - 1350 TO MONOBLOCK Letters in parentheses refer to Fig. 1. BRAKE VALVE The Shuttle Valve can be identified as item 6 in Section 250-0000, BRAKING SYSTEM SCHEMATIC. FROM 'B2' PORT TREADLE VALVE The shuttle valve allows the distribution of pressure from either the treadle valve, to activate the rear...
  • Page 468 Braking System - Shuttle Valve Section 250-0140 1. Position the vehicle in a level work area, apply the install lines to shuttle valve as identified during removal. parking brake and switch off the engine. 7. Check oil level in steering and brake control tank 2.
  • Page 469 OPERATORS COMPARTMENT - Cab and Mounting Section 260-0010 SM - 2391 1 - Cab Assembly 9 - Rear Glass 17 - Screw 2 - RH Door Assembly 10 - Bolt 18 - Washer 3 - LH Door Assembly 11 - Snubbing Washer 19 - Nut 4 - Front Glass 12 - Rubber Mount...
  • Page 470 Operators Compartment - Cab and Mounting Section 260-0010 the passengers seat keeps the cab interior air fresh order to prevent damage to the electrical and dust free. A sliding window in RH door assembly components. (2) and an electric window in LH door assembly (3) provide additional ventilation.
  • Page 471 Operators Compartment - Cab and Mounting Section 260-0010 Note: Use padded spreader bars when removing cab 5. Remove blanking caps from all braking and assembly (1) with overhead lifting equipment to steering lines and connect lines as identified at prevent damage from concentrated loads at cab removal.

  • Page 472: Removal And Installation

    Operators Compartment - Cab and Mounting Section 260-0010 SM - 2394 19 20 23 22 15 16 25 - Hinge 1 - Gasket 9 - Screw 17 - Fixing Plate 26 - Pin 2 - RH Door Frame 10 - Screw 18 - Lock Cover 27 - Split Pin 3 - Sliding Frame...
  • Page 473 Operators Compartment - Cab and Mounting Section 260-0010 SM - 1994 58 59 12 13 66 67 45 40 41 52 53 1 - Grommet 15 - Cover 42 - Cap 56 - Washer 2 - LH Door 16 - Spacer 43 - Pin 57 - Nut 29 - Inner Door...
  • Page 474 Operators Compartment - Cab and Mounting Section 260-0010 The door assembly can be removed from the cab as feed the wire through the opening. Pierce a second a complete assembly, however, components such as hole in the adhesive on the side directly opposite the the lock, handle and glass assembly can be removed first.
  • Page 475 OPERATORS COMPARTMENT - Driver Seat and Mounting Section 260-0090 SM - 2352 21 - Lap Belt 1 - Seat Assembly 11 - Height Riser Spring 22 - Tether 2 - Seat Frame 12 - Damper 23 - Switch 3 - Latch Height Riser 13 - Suspension Assembly 24 - Bolt 4 - Lumbar Support...
  • Page 476 Operator's Compartment - Driver Seat and Mounting Section 260-0090 the lowest position to allow easier access. The 6. Remove bolts and lockwashers securing lap belt incorporated block out maintains the seat in position (21) to seat assembly. Remove lap belt (21). for driving.
  • Page 477 Operator's Compartment - Driver Seat and Mounting Section 260-0090 MAINTENANCE 4. Position lap belt (21) to seat assembly and secure Numbers in parentheses refer to Fig. 1. using bolts and lockwashers as removed at Removal. The care of the upholstery on seat cover (8) and 5.
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  • Page 479 OPERATORS COMPARTMENT - Passenger Seat and Mounting Section 260-0110 SM - 1992 31 24 17 18 16 15 9 - Hinge 1 - Seat Cushion 17 - Nut 25 - Lap Belt 2 - Seat Frame 26 - Cotter Pin 10 - Spring 18 - Lockwasher 3 - Back Cushion...
  • Page 480 Operator's Compartment - Passenger Seat and Mounting Section 260-0110 arrangement. Located within seat base (8) are the 8. Remove cotter pins (26), release the snap hooks major CEC components; battery equalizer box, on lap belt (25) and remove lap belt (25) halves from electronic control unit (ECU) and CEC interface box.
  • Page 481 Operator's Compartment - Passenger Seat and Mounting Section 260-0110 5. Install pivot pin (13) through mounting hole in seat latch. Lengthen or shorten the belt halves until the base (8) and secure with washer (19), lockwasher (18) desired length is obtained. and nut (17).
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  • Page 483 OPERATORS COMPARTMENT - Passenger Seat and Mounting Section 260-0110 SM - 2392 1 - Seat Cushion 2 - Seat Frame 10 - Spring 18 - Lockwasher 26 - Bolt 3 - Back Cushion 11 - Latch 19 - Washer 27 - Bolt 4 - Bolt 12 - Pad 20 - Bolt...
  • Page 484 Operator's Compartment - Passenger Seat and Mounting Section 260-0110 arrangement. Located within seat base (8) are the 8. Remove bolts (27), washers (28), lockwashers (29) major CEC components; battery equalizer box, and nuts (30) securing lap belt (25) to seat base (8) electronic control unit (ECU) and CEC interface box.
  • Page 485 Operator's Compartment - Passenger Seat and Mounting Section 260-0110 MAINTENANCE 5. Install pivot pin (13) through mounting hole in seat base (8) and secure with washer (19), lockwasher (18) Numbers in parentheses refer to Fig. 1. and nut (17). The care of the upholstery on seat cushion (1) and 6.
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  • Page 487 OPERATORS COMPARTMENT - Air Conditioning Section 260-0130 SM - 2430 3 - Receiver Drier 5 - Evaporator 1 - Compressor 4 - Expansion Valve 2 - Condenser Fig. 1 - Typical Air Conditioning Flow Diagram DESCRIPTION Compressor Drive Clutch The R-134a compressor systems use an electronically Temperature Control Switch actuated clutch to engage and disengage drive to the A thermostat switch senses the temperature of the...
  • Page 488 Operators Compartment - Air Conditioning Section 260-0130 slow down this radiation of heat. Cooling fins are Blockage of the filter will result in a drop in pressure located on the condenser tubes and fans are used to that will be indicated by a drop in system performance. circulate cool air around the condenser tubes.
  • Page 489 Operators Compartment - Air Conditioning Section 260-0130 REMOVAL 5. When satisfied that the system is completely Numbers in parentheses refer to Fig. 2, unless discharged, tag refrigerant hoses (1 & 2) to aid in otherwise stated. installation and carefully disconnect hoses from adaptors at cab firewall.
  • Page 490 Operators Compartment - Air Conditioning Section 260-0130 SM - 2275A CAB FIREWALL 23 24 32 31 36 34 33 1 - Refrigerant Hose 12 - Bracket 2 - Refrigerant Hose 13 - Compressor 23 - Washer 33 - Nut 3 - Refrigerant Hose 14 - Drive Belt 24 - Nut 34 - Washer...
  • Page 491 Operators Compartment - Air Conditioning Section 260-0130 SM - 2275B 48 - Expansion Valve 43 - Air Conditioning Unit 49 - Adaptor 44 - Cover 50 - Adaptor 45 - Grille 51 - Relay 46 - Filter Element 52 - Thermostat 47 - Evaporator Matrix Fig.
  • Page 492 Operators Compartment - Air Conditioning Section 260-0130 should now be free to slide off of groove in 2. Remove caps from end of refrigerant hoses (1 & 2) compressor (13). and adaptors on cab firewall and connect hoses to ports as tagged at Removal. 17.
  • Page 493 Operators Compartment - Air Conditioning Section 260-0130 mounting hole and secure in place with bolt (41), lockwasher (42), washer (39) and nut (40). Do not WARNINGS tighten at this stage.Install spacer (30) on adjuster If you get the slightest trace of R-134a in block (25).
  • Page 494 Operators Compartment - Air Conditioning Section 260-0130 Refrigerant Oil 8. Inspect and clean outside and inside cab air filters periodically, depending on dust conditions. Replace the outside filter when it becomes saturated to the point it won't come clean. WARNINGS To prevent personal injury always wear rubber gloves when handling refrigerant oils.
  • Page 495 Operators Compartment - Air Conditioning Section 260-0130 throughout the system for leaks. A large leak point will from the system components. If any of the major have an oily or greasy appearance. The refrigerant system components are to be repaired or replaced, carries compressor oil with it and deposits it around the system must also be completely discharged.
  • Page 496 Operators Compartment - Air Conditioning Section 260-0130 CHARGING THE SYSTEM start to register that a vacuum is being drawn. If the gauges do not register the vacuum then a blockage or Note: Refer to all WARNINGS listed under 'Maintenance' prior to charging the system. leak is present.
  • Page 497 Operators Compartment - Air Conditioning Section 260-0130 10. Before disconnecting power supply from vacuum side valve. Allow the system to continue the charging pump, close both high and low side gauges. Remove procedure until the sight glass is clear. If the sight yellow hose from vacuum pump and connect to glass remains clear, with the increased engine speed, R-134a source.
  • Page 498 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS TABLE158 CONDITION PROBLEM REMEDY 1. Belt Trouble Slipping Loose Adjust belt to 12 mm (0.5 in) depression Overcharge Correct the charge Air in system Evacuate and re-charge Excessive wear Pulley not aligned Align Pulley Belt too tight Adjust or replace...
  • Page 499 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS (CONT.) CONDITION PROBLEM REMEDY 3. Noise - Evaporator Rubbing/scraping Fan blade or blower Repair or replace Hissing Low charge/leak Correct charge/repair leak Chatter/knocking Expansion valve Replace Noisy case Loose brackets/screws Tighten Motor squeal Dry bearings...
  • Page 500 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS (CONT.) CONDITION PROBLEM REMEDY 6. Air Conditioning System Trouble - Gauges must be connected High head pressure Overcharge of refrigerant Purge system as necessary Air in system Evacuate and re-charge Condenser clogged Clean condenser Low head pressure...
  • Page 501 BODY - Body and Mounting Section 270-0010 SM - 1996 BODY 9,28,29 FRAME 30,31 32,33 35 36 10 - Body Pad 20 - Shim 30 - Shim 1 - Body Assembly 11 - Bolt 31 - Shim 21 - Body Hinge Pin 2 - Cab Guard Assembly 12 - Washer 22 - Bolt...
  • Page 502 Body - Body and Mounting Section 270-0010 OPERATION WARNING The body control joystick, mounted at the left hand side of the drivers' seat, controls the body control To prevent personal injury and property valve which supplies hydraulic oil to operate the body damage, be sure wheel chocks and lifting hoist cylinders.
  • Page 503 Body - Body and Mounting Section 270-0010 Body Shimming Procedure WARNING Numbers in parentheses refer to Fig. 1. To prevent personal injury and property damage, be sure wheel chocks and lifting Note: Tighten all fasteners to standard torques listed equipment are properly secured and of in Section 300-0080, STANDARD BOLT AND NUT adequate capacity to do the job safely.
  • Page 504 Body - Body and Mounting Section 270-0010 7. Raise and lower body assembly (1) and check for gases. The resulting fire in the heating passages is correct clearance at body hinge pins (21) and body helpful in that it burns away some of the carbon and guides.

  • Page 505: Miscellaneous

    MISCELLANEOUS - Lubrication System Section 300-0020 LUBRICATION AND SERVICE SAFETY PRECAUTIONS Do not allow unauthorized personnel to service or maintain this vehicle. Study the Operator’s Handbook WARNING and Service Manual before starting, operating or These vehicles are equipped with engine and servicing this vehicle.
  • Page 506 Miscellaneous - Lubrication System Section 300-0020 SM - 1997 16 21 5 8 26 10 26 8 10 28 20 4 20 2 24 3 15 25 18 17 Fig. 1 - Lubrication and Service Points LUBRICATION AND SERVICE CHART Interval Ref.
  • Page 507 Miscellaneous - Lubrication System Section 300-0020 LUBRICATION AND SERVICE CHART Interval Ref. No. of Hours Points Identification Service Instructions Points Lubricant Service/Quantities A-Frame Nose Spherical Bushing Lube EP, NLGI See Note Banjo Stabilizer Spherical Bushing Lube EP, NLGI See Note Body Hinge Pins Lube EP, NLGI See Note...
  • Page 508 Miscellaneous - Lubrication System Section 300-0020 MISCELLANEOUS SERVICING Rear Disc Brake Oil Filter(s) - WHEN REQUIRED Replace element(s) when indicator shows oil at the replace element level. Seat Belts - Inspect seat belts and replace if damaged. AFTER FIRST 150 HOURS OF OPERATING NEW Note: Replace seat belts at least once every three OR REBUILT COMPONENTS years, regardless of appearance.
  • Page 509 Miscellaneous - Lubrication System Section 300-0020 Note: Instructions for checking pressure, and EVERY 2 000 HOURS OF OPERATION locations of pressure check points, are contained in Steering Hydraulic Tank Filter - Clean filter the relevant service manual section. If the housing and install new element when indicated, or pressures are outwith the specified settings then after 2 000 hours of operation, whichever comes first.
  • Page 510 Miscellaneous - Lubrication System Section 300-0020 RECOMMENDED LUBRICANTS COMPONENT LUBRICANT VISCOSITY (See Note 1) Engine Engine oil with 1.00 % sulphated ash is Ambient Temp Recommendation recommended. Sulphated ash must not exceed 0° C and above SAE 20W-40 1.85 % limit. API code CE or CF-4. See Note 2. -10° C and above SAE 15W-40 -25°...
  • Page 511 Miscellaneous - Lubrication System Section 300-0020 Note 4 - Typical SAE 10W oils complying with Note 1 - Consult your lubricant supplier for the correct Specification EMS19058 are: viscosity of lubricant to use when ambient temperatures are consistently above or below those listed. KUWAIT TO4 SHELL DONAX TC Note 2 - Cummins Engine Co., does not recommend...
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  • Page 513: Service Tools

    MISCELLANEOUS - Service Tools Section 300-0070 INTRODUCTION Engine Contained in this section are recommended service The following tools are recommended for Engine tools and equipment required for maintenance, Maintenance Procedures and should be used in overhaul and troubleshooting. In certain instances, conjunction with procedures outlined in the engine both Metric and Imperial equivalents of the same tools manufacturers service manual.
  • Page 514 Miscellaneous - Service Tools Section 300-0070 15272182 - Fixture, Cylinder Head Water Test 15270344 - LPS NoFlash Electro Contact Cleaner 15270481 - Cup Plug Driver 15269038 - Portable Printer for use with DDR, 15270482 - Cup Plug Driver complete with 110 V AC Adaptor 15270483 - Cup Plug Driver 15269039 - Portable Printer for use with DDR, 15272185 - Dolly, Valve Seat Staking...
  • Page 515 Miscellaneous - Service Tools Section 300-0070 Accumulators/Ride Cylinder Charging OCDB Brake Packs 09359489 - Charging Assembly 15267573 - Seal Installation Kit 15265300 - Seal Installation Tool The following parts can be assembled for 15265301 - Seal Installation Tool simultaneously charging the rear ride cylinders: 09359489 - Charging Assembly Lubrication 00454145 - Tee Piece...
  • Page 516 Miscellaneous - Service Tools Section 300-0070 SM - 112 ONE-4340 STL. OR EQUIV.-HDN.-GRIND 7/16 11.1 12.7 15.9 19.1 29/32 23.0 25.4 1 1/8 28.6 1 1/4 31.8 1 3/8 34.9 1 1/2 38.1 ONE-4340 APPROX 1 7/8 47.6 STL.-HDN.-GRIND 50.8 2 1/32 51.6 2 1/8...
  • Page 517 Miscellaneous - Service Tools Section 300-0070 SM - 126 0.56 - 3 HOLES EQUALLY SPACED 0.12 0.50 12.7 0.56 14.22 0.62 15.7 1.00 25.4 1.62 41.1 2.00 50.8 2.50 63.5 3.25 82.5 MATERIAL: PLAIN CARBON STEEL 3.31 84.0 9.38 15.88 26.25 Fig.
  • Page 518 CLICK HERE FOR HORIZONTAL DRAWING Miscellaneous - Service Tools Section 300-0070 SM - 134 INCHES INCHES 0.03 0.76 0.72 18.2 0.06 1.52 0.75 19.0 0.12 0.81 20.5 0.130 1.00 25.4 0.139 1.12 28.4 0.177 1.68 42.7 0.18 2.00 50.8 0.19 2.50 63.5 0.22...
  • Page 519 Miscellaneous - Service Tools Section 300-0070 SM - 391 HEAVY WALL TUBING ALUMINIUM RING PRESS RING ON END OF TUBING Fig. 6 - Shaft Seal Driver (Section 220-0050, STEERING PUMP) SM - 393 SM - 390 USE FOR "A" NOMINAL Intermediate shaft bearing installation 100 mm (4 in) PIPE BORE Driveshaft bearing installation...
  • Page 520 THIS PAGE IS INTENTIONALLY LEFT BLANK...

  • Page 521: Standard Bolt And Nut Torque Specifications

    MISCELLANEOUS - Standard Bolt and Nut Torque Specifications Section 300-0080 and to establish a uniform value to which these fasteners can be safely tightened, the following torque WARNING Some fasteners are important attaching parts tables have been compiled. which could affect the performance of vital components and systems, and/or, could result The torque values listed in the tables have been in major repair expense.
  • Page 522 Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ± 10% TABLE145 SAE Symbol SAE Symbol SAE Symbol SAE Symbol GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel 12 Point Cap (SAE GR 2) (SAE GR 5) (SAE GR 7)
  • Page 523 Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 RECOMMENDED MAXIMUM TORQUES (METRIC) ± 10% TABLE146 Class 8.8 Class 9.8 Class 10.9 Class 12.9 lbf ft lbf ft lbf ft lbf ft Size M 1.6 - 0.35 0.20 0.15 0.20 0.15 M 1.6 - 0.20...
  • Page 524 Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 SELF-LOCKING FASTENERS has been used. Do not use a self-locking fastener Self-locking fasteners develop a measured gripping more than five times. action or torque and provide a renewed locking action after being removed and reinstalled to their original The following table shows the minimum torque mating part.

  • Page 525: Unit Storage

    MISCELLANEOUS - Unit Storage Section 300-0090 GENERAL Maintenance Manual for complete information on The storage of machines for short periods of time or storing the engine for periods shorter than 30 days. during the off-season is an important item if major damage to components is to be avoided.
  • Page 526 Miscellaneous - Unit Storage Section 300-0090 EXTENDED STORAGE - Over Six Months 2. BATTERIES - Install batteries and check for a full When a machine is to be stored for a period over SIX charge. Charge batteries as required. MONTHS, the following procedure must be followed: 3.

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