Page 1 CLICK HERE FOR TABLE OF CONTENTS TA30 Articulated Dumptruck Maintenance Manual CLICK HERE TO RETURN TO MAIN LIBRARY INDEX TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED MOTHERWELL, SCOTLAND ML1 5RY REF. NO. SM 799 SM 1936 Rev 3 10-02 Courtesy of Machine.Market...
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Page 3 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 Courtesy of Machine.Market...
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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.
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Page 7: Table Of Contents
TABLE OF CONTENTS Section No. Description SM No. GENERAL INFORMATION 0000 Technical Data - TA30 1937 Rev 1 0010 Welding Procedure 2172 CHASSIS 0010 Frames 1960 Rev 1 0020 Articulation and Oscillation Pivot - Pre May 2000 Production 1975 0020...
Page 8 TABLE OF CONTENTS Section No. Description SM No. COOLING SYSTEM 0000 Cooling System 1983 0040 Radiator, Header Tank and Mounting 1987 0060 Transmission Oil Cooler 1977 0100 Hydraulic Oil Cooler 1976 STEERING SYSTEM 0000 Steering System Schematic 1943 0050 Steering Pump (Refer to Section 230-0050) 0090 Steering Valve...
Page 9: General Information
GENERAL INFORMATION - Technical Data Section 000-0000 SM - 2476 2 615 Max. (8-7) 1 435 Body 2 815 (4-8) Depth (9-3) 45˚ Vehicle Clearance Turning Diameter 5 885 65˚ 17.6 m (58-0) (19-4) 4 840 (15-10) 4 390 (14-5) 3 405 (11-2) 3 310...
Page 10 General Information - Technical Data Section 000-0000 AXLES WHEELS AND TYRES Three axles in permanent all-wheel drive with differential Wheels: .... 5-piece earthmover rims with 12 stud fixing coupling between each axle to prevent driveline wind-up. Size: Heavy duty axles with fully-floating axle shafts and outboard Standard .......
Page 11 General Information - Technical Data Section 000-0000 ELECTRICAL SYSTEM TYPICAL NOISE LEVELS Type ..........24 volt, Negative Ground Operator Ear (ISO 6394) ..........79 dbA Battery ......... Two, 12 Volt, 143 Ah each Accessories ..............24 Volt *Exterior Sound Rating (SAE J88 JUN 86) ..... TBA dbA Alternator ..............
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Page 13 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 14 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 15 CHASSIS - Frames Section 100-0010 SM - 2475 Fig. 1 - General Arrangement of Frame Assemblies DESCRIPTION frame, secures the coupling in position. Wear on the The chassis consists of two separate frame thrust faces of the bushes is compensated by assemblies which provide the articulation of the unit.
Page 16 Chassis - Frames Section 100-0010 Welding WARNING Welding and flame cutting cadmium plated metals produce odourless fumes which are WARNINGS toxic. Recommended industrial hygiene Before any welding is done on a machine, practice for protection of the welding operator disconnect connections at body hydraulics from the cadmium fumes and metallic oxides joystick, all battery connections at both positive requires enclosure ventilation specifically...
Page 17 Chassis - Frames Section 100-0010 To keep rust and corrosion to a minimum, periodic painting of abrasions and other exposed metal areas WARNING on the frames is highly recommended. Welding, burning, heating or dressing surfaces previously painted using polyurethane paint If painting of a frame is required, thoroughly clean the produces fumes which are toxic.
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Page 19 CHASSIS - Articulation and Oscillation Pivot Section 100-0020 SM - 2483 45 14 7,8,9 24 2 2,3,50 LUBRICATION POINT 1 - Pivot 17 - Retainer 2 - Coupling 18 - 'O' Ring 3 - Pipe 33 - Bolt 19 - Spacer 47 - Washer 4 - 'O' Ring 34 - Thrust Nut...
Page 20 Chassis - Articulation and Oscillation Pivot Section 100-0020 PIVOT DRIVESHAFT BEARINGS yoke (27). Remove yoke (27) from shaft (37). Removal 6. Remove bolts (1, Fig. 3), lockwashers (2, Fig. 3), Numbers in parentheses refer to Fig. 1, unless nuts (3, Fig. 3) and protective guard (4, Fig. 3), if fitted, otherwise specified.
Page 21 Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 003 1 - Bolt 9 - Rear Wedge Plate 2 - Lockwasher 10 - LH Torque Plate 3 - Nut 11 - Washer 4 - Guard 12 - Locknut 5 - Disc 13 - Brake Pad 6 - Bolt 14 - Adjuster...
Page 22 Chassis - Articulation and Oscillation Pivot Section 100-0020 20. Remove spacer (19). Note position of seals (29) in SM - 004 pivot (1) housing to aid in 'Installation'. Remove and discard seals (29). Inspection Numbers in parentheses refer to Fig. 1, unless otherwise specified.
Page 23 Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 005 SM - 006 SEAL SEAL HOUSING Fig. 5 - Pivot Housing Inner Seals Fig. 6 - Typical Outer Seal Installation 10. Assemble rear housing (31) and brake yoke/disc 18. Make sure mating surfaces of housing (28) are still assembly (16) onto rear of shaft (37).
Page 24 Chassis - Articulation and Oscillation Pivot Section 100-0020 26. Connect pivot - centre axle driveline (Fig. 2) to has exhausted from the air tanks. brake yoke/disc assembly as noted on 'Removal'. Install caps and secure with lockwashers and bolts. 4. Position levelling jack under centre front portion of the front frame.
Page 25 Chassis - Articulation and Oscillation Pivot Section 100-0020 and use lifting equipment to pull the rear frame away SM - 007 from the front frame. After moving, block the rear frame and wheels securely. 12. Mark all bearing retainers (5, 11, 17 & 21) to aid in 'Installation'.
Page 26 Chassis - Articulation and Oscillation Pivot Section 100-0020 6. Remove bolts (13 & 33), lubricate and coat with 19. Place the battery master switch in the on position, anti-seize compound then install shims (7, 8 & 9) start the engine and allow air pressure in the tanks to beneath appropriate upper retainer (5 for upper build up to correct operating pressure.
Page 27 Chassis - Articulation and Oscillation Pivot Section 100-0020 Note: Take extra care when handling drivelines as assembly to avoid damage to end threads. chips, dents, burrs or deformity on any rotating mass creates vibration and excessive wear during any 18. Replace thrust nut (34) on pivot (1) to protect operation.
Page 28 Chassis - Articulation and Oscillation Pivot Section 100-0020 Centre. Refer to Fig. 9. Drift bushes into housing using lockwashers (14). Torque tighten bolts (36) to 75 Nm hammer with soft packing for protection. (55 lbf ft). 4. Using special tool, which can be fabricated as 10.
Page 29 Chassis - Articulation and Oscillation Pivot Section 100-0020 chips, dents, burrs or deformity on any rotating mass 5. Remove bolts and lockwashers securing lockplate creates vibration and excessive wear during any at the thrust nut and remove the lockplate. operation. 6.
Page 30 Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 844 Dimensions in mm (in) Fig. 11 - Fabrication Details of Thrust Nut Removal and Installation Tool SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Bolt Bolt Bolt Bolt...
Page 31 Chassis - Articulation and Oscillation Pivot Section 100-0020 ARTICULATION AND OSCILLATION felt throughout the frame. PIVOT DIAGNOSIS Noise and vibration caused by the pivot driveshaft Noise from the articulation and oscillation points must be investigated. assembly appear only at certain speeds and generally come and go as these speeds are approached and passed.
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Page 33 CHASSIS - Articulation and Oscillation Pivot Section 100-0020 SM - 2495 14 36 7,8,9 2,3,50 LUBRICATION POINT 57 58 1 - Pivot 33 - Bolt 17 - Retainer 2 - Coupling 18 - 'O' Ring 34 - Thrust Nut 3 - Pipe 49 - Connector 19 - Spacer 35 - Lockplate...
Page 34 Chassis - Articulation and Oscillation Pivot Section 100-0020 PIVOT DRIVESHAFT BEARINGS yoke (27). Remove yoke (27) from shaft (37). Removal 6. Remove bolts (1, Fig. 3), lockwashers (2, Fig. 3), Numbers in parentheses refer to Fig. 1, unless nuts (3, Fig. 3) and protective guard (4, Fig. 3), if fitted, otherwise specified.
Page 35 Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 003 1 - Bolt 9 - Rear Wedge Plate 2 - Lockwasher 10 - LH Torque Plate 3 - Nut 11 - Washer 4 - Guard 12 - Locknut 5 - Disc 13 - Brake Pad 6 - Bolt 14 - Adjuster...
Page 36 Chassis - Articulation and Oscillation Pivot Section 100-0020 20. Remove spacer (19). Note position of seals (29) in SM - 004 pivot (1) housing to aid in 'Installation'. Remove and discard seals (29). Inspection Numbers in parentheses refer to Fig. 1, unless otherwise specified.
Page 37 Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 005 SM - 006 SEAL SEAL HOUSING Fig. 5 - Pivot Housing Inner Seals Fig. 6 - Typical Outer Seal Installation 10. Assemble rear housing (31) and brake yoke/disc 18. Make sure mating surfaces of housing (28) are still assembly (16) onto rear of shaft (37).
Page 38 Chassis - Articulation and Oscillation Pivot Section 100-0020 26. Connect pivot - centre axle driveline (Fig. 2) to has exhausted from the air tanks. brake yoke/disc assembly as noted on 'Removal'. Install caps and secure with lockwashers and bolts. 4. Position levelling jack under centre front portion of the front frame.
Page 39 Chassis - Articulation and Oscillation Pivot Section 100-0020 and use lifting equipment to pull the rear frame away SM - 007 from the front frame. After moving, block the rear frame and wheels securely. 12. Mark all bearing retainers (5, 11, 17 & 21) to aid in 'Installation'.
Page 40 Chassis - Articulation and Oscillation Pivot Section 100-0020 6. Remove bolts (13 & 33), lubricate and coat with 19. Place the battery master switch in the on position, anti-seize compound then install shims (7, 8 & 9) start the engine and allow air pressure in the tanks to beneath appropriate upper retainer (5 for upper build up to correct operating pressure.
Page 41 Chassis - Articulation and Oscillation Pivot Section 100-0020 Note: Take extra care when handling drivelines as assembly to avoid damage to end threads. chips, dents, burrs or deformity on any rotating mass creates vibration and excessive wear during any 18. Replace thrust nut (34) on pivot (1) to protect operation.
Page 42 Chassis - Articulation and Oscillation Pivot Section 100-0020 Centre. Refer to Fig. 9. Drift bushes into housing using lockwashers (14). Torque tighten bolts (36) to 75 Nm hammer with soft packing for protection. (55 lbf ft). 4. Using special tool, which can be fabricated as 10.
Page 43 Chassis - Articulation and Oscillation Pivot Section 100-0020 chips, dents, burrs or deformity on any rotating mass 5. Remove bolts and lockwashers securing lockplate creates vibration and excessive wear during any at the thrust nut and remove the lockplate. operation. 6.
Page 44 Chassis - Articulation and Oscillation Pivot Section 100-0020 SM - 844 Dimensions in mm (in) Fig. 11 - Fabrication Details of Thrust Nut Removal and Installation Tool SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Bolt Bolt Bolt Bolt...
Page 45 Chassis - Articulation and Oscillation Pivot Section 100-0020 ARTICULATION AND OSCILLATION felt throughout the frame. PIVOT DIAGNOSIS Noise and vibration caused by the pivot driveshaft Noise from the articulation and oscillation points must be investigated. assembly appear only at certain speeds and generally come and go as these speeds are approached and passed.
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Page 47 CHASSIS - Hood and Mounting Section 100-0040 SM - 2492 62 63 21 22 59 60 1 - Hood 33 - Washer 17 - Handle - LH 49 - Bolt 2 - Grille 18 - Handle - RH 34 - Locknut 50 - Lockwasher 3 - Grille Subframe 19 - Hood Prop...
Page 48 Chassis - Hood and Mounting Section 100-0040 GOALPOST SUPPORT ASSEMBLY Note: Exercise caution as torsion bars (52) may spring when released from mounting brackets. Removal 6. Remove bolts (49), lockwashers (50) and locknuts Numbers in parentheses refer to Fig. 1. (51) securing hinges (56) to frame and lift hood (1) assembly from the machine.
Page 49 Chassis - Hood and Mounting Section 100-0040 goalpost support (11) assembly to its mounting. Lift 6. Install purge tank to mounting bracket on the right goalpost support (11) assembly from the machine. hand side of goalpost support (11) assembly and secure using mounting hardware as removed during 12.
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Page 51 CHASSIS - Fenders and Mounting Section 100-0070 SM - 2478 16,37 22 23 MTG. ON HYD. TANK 15,35 1 - LH Fender 2 - Support Bracket 20 - Spillguard 29 - Bolt 11 - Grab Handle 3 - Contour Plate 12 - Grip 21 - Bolt 30 - Lockwasher...
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Page 53 ENGINE - Engine and Mounting Section 110-0030 SM - 2479 ENGINE - LHS 21 23 32 31 20 23 25 26 27 RAD. WATER PIPE 11 - Bolt 31 - Bolt 1 - Engine 21 - Bolt 12 - Bolt 32 - Washer 22 - Bolt 2 - Fan Belt...
Page 54 Engine - Engine and Mounting Section 110-0030 REMOVAL 7. With suitable containers in position, open drain Numbers in parentheses refer to Fig. 1. cocks and drain coolant from the radiator and engine. Close all drain cocks securely after draining. WARNINGS 8.
Page 55 Engine - Engine and Mounting Section 110-0030 INSPECTION 19. Check to make certain that all necessary line and Numbers in parentheses refer to Fig. 1. cable disconnections have been made, before lifting engine (1). 1. Inspect rubber mounts (9) for damage and replace if required.
Page 56: Drivelines
Engine - Engine and Mounting Section 110-0030 INSTALLATION proximity switches on engine (1), as identified at Numbers in parentheses refer to Fig. 1. removal. Note: Tighten all fasteners without special torques 9. Connect accelerator cable to engine (1). specified to standard torques listed in section 300-0080, STANDARD BOLT AND NUT TORQUE 10.
Page 57 Engine - Engine and Mounting Section 110-0030 22. Ensure parking brake is applied, disconnect steering lock bar and secure in the 'Stowed' position. WARNING Remove wheel blocks from all road wheels. Personal injury can result from a fan blade failure. Never pull or pry on the fan as this can MAINTENANCE damage the blades and lead to fan failure.
Page 58 Engine - Engine and Mounting Section 110-0030 Clean the area around the lube oil filter head and, Coolant Filter (5) - Check the DCA4 concentration using strap type filter wrench, remove lube oil filter (4). and replace the coolant filter at every oil and filter Discard lube oil filter (4) if it is not required for a failure change interval.
Page 59 Engine - Engine and Mounting Section 110-0030 Fan Belt Adjustment Alternator Belt Adjustment Loosen the idler pulley lock nut and adjust the belt to Loosen the adjustment link locking capscrew and turn the correct tension. Tighten the idler pulley lock nut to the capscrew to adjust belt tension.
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Page 61 ENGINE AND MOUNTING - Kysor DST Fan Section 110-0040 SM - 1903 RAD. WATER PIPE SOLENOID SUPPLY 1 - Bolt 5 - DST Fan Drive 2 - Lockwasher 6 - Solenoid 3 - Nut 7 - Sensor Control Valve 4 - Fan 8 - Nylon Tube Fig.
Page 62 Engine and Mounting - Kysor DST Fan Section 110-0040 REMOVAL and nuts (3). Torque tighten nuts (3) to 27 Nm Numbers in parentheses refer to Fig. 1. (20 lbf ft). 2. Using suitable lifting equipment, position fan (4) WARNING assembly on the machine and secure to engine with To prevent personal injury and property bolts (1).
Page 63 Engine and Mounting - Kysor DST Fan Section 110-0040 Basic Dynamic Test - Fan Drive Operation MAINTENANCE Note: This test is carried out with the machine static Every 10 Hours/Daily and secured at rest. Check the fan for debris or damage. Clean or replace 1.
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Page 65 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 Typical Air Cleaner DESCRIPTION AND OPERATION A mechanical air restriction gauge (16, Fig.
Page 66 Engine - Air Cleaner Section 110-0050 SM - 2472 17 11 S.W.E. TURBO 13 - 'U' Bolt 5 - Lockwasher 1 - Air Cleaner Assembly 9 - Band Clamp 14 - Bracket 6 - Plug 2 - Bracket 10 - Cap 15 - Bolt 7 - Hose 3 - Bolt...
Page 67 Engine - Air Cleaner Section 110-0050 Disassembly MAINTENANCE Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless otherwise specified. otherwise specified. Note: Air cleaner body (1) should be thoroughly cleaned twice a year. Do not apply heat in any form to WARNING air cleaner body (1).
Page 68 Engine - Air Cleaner Section 110-0050 remove cover assembly from air cleaner body (1). Inspection of element on the outside will disclose any holes where concentrated light shines through. Even 2. Remove primary element (2) from air cleaner body (1). the smallest hole will pass dust to the engine and may result in costly engine repairs.
Page 69 Engine - Air Cleaner Section 110-0050 MEASURING AIR RESTRICTION c. With the manometer held vertically and the engine Numbers in parentheses refer to Fig. 2. drawing maximum air, the difference in height of the water columns in the two legs is measured as the air As a dry air cleaner element becomes loaded with cleaner restriction.
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Page 71 TRANSMISSION - Transmission and Mounting Section 120-0010 SM - 2011 26,27 28,29 7 LH 13 RH 15 - Dipstick Tube 23 - Screw 1 - Front Bracket Assembly 8 - Isolation Mount 24 - Gasket 16 - Bracket 2 - Isolation Mount 9 - Lockwasher 25 - Dipstick 17 - Clamp...
Page 72 Transmission - Transmission and Mounting Section 120-0010 SM - 1829 K2 KR KV K4 K3 VIEWED FROM THE REAR DETAIL Y 1 - Retarder Oil Temperature Sender 2 - Main Control Valve 3 - Difflock Warning Light Switch 4 - Lockup Solenoid 5 - Engine Speed Sensor 6 - Output Speed Sensor 7 - Central Gear Train Sensor...
Page 73 Transmission - Transmission and Mounting Section 120-0010 SM - 1826 VALVE BLOCK COVER HOUSING SYSTEM PRESSURE FROM CONTROL UNIT BREATHER 1 - Main Pressure Valve 16+2 bar 5 - Follow-on Slide 2 - Pressure Reduction Valve 9 bar 6 - Proportional Valve (P1 to P6) 3 - Lockup Solenoid 7 - Vibration Damper Y1 to Y6 - Pressure Regulators...
Page 74 Transmission - Transmission and Mounting Section 120-0010 differential lock is released. On activation of the intersection of the clutches to be engaged and differential lock switch, the transmission differential disengaged becomes possible. This creates fast lock solenoid is energised and air pressure is shiftings without traction force interruption.
Page 75 Transmission - Transmission and Mounting 2nd POWER TAKE-OFF SCHEDULE OF MEASURING POINTS CONVERTER Measurements to be carried out with oil at normal operating RETARDER temperature of 80° C and operating at full speed. MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE: 1st POWER TAKE-OFF 51 = Before the Convertor - Opening Pressure 8.5 bar 52 = Behind the Convertor - Opening Pressure 5 bar...
Page 76 Transmission - Transmission and Mounting RV-9 TEMP Denomination of the Position Port NOT SCOPE OF SUPPLY ZF To the heat exchanger WK-M From the heat exchanger AIR RESERVOIR 8 bar To the ZF-filter WK-V From the ZF-filter SCOPE OF SUPPLY ZF Behind the Convertor to heat exchanger Before the Convertor to heat exchanger PRESSURE REDUCTION VALVE...
Page 77 Transmission - Transmission and Mounting Section 120-0010 OPERATION VTS-3 Shift Controller - Operation: The shift EST-37 Automatic Shift Control controller has 3 positions the lever can rest in, Forward, Neutral and Reverse. Within each of these The EST-37 transmission is equipped with an positions, the gear can be changed by pushing the electronic control unit (ECU) which continually lever to the right (+) to upshift or to the left (-) to...
Page 78 Transmission - Transmission and Mounting Section 120-0010 SM - 1828 SM - 2335 IDLE FULL LOAD/ THROTTLE KICK/HOLD DOWN 1 - Bars show gear ranges and full display (as shown) indicates driving in automatic mode. 2 - Display shows actual driving direction. 3 - Display shows actual gear in use.
Page 79 Transmission - Transmission and Mounting Section 120-0010 Note: In cold weather, the transmission oil should be warmed up by running the engine at idle speed with WARNINGS the gear selector in neutral, since the system will not Never allow the machine to coast with the operate satisfactorily if the oil is too cold.
Page 80 Transmission - Transmission and Mounting Section 120-0010 Display during operation - Continued Symbol Meaning Remarks warning sump temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) warning retarder temperature changes between actual gear/direction while driving, in neutral only displayed if no fault is detected (spanner) warning torque converter temperature...
Page 81 Transmission - Transmission and Mounting Section 120-0010 Display during AEB-Mode - Continued Symbol Meaning Remarks ò T transmission oil temperature too high -> cool down transmission transmission temperature not in defined Transmission stays in neutral, you range during calibration have to restart the TCU (ignition off/on) operating mode not NORMAL or Transmission stays in neutral, you transmission temperature sensor defective...
Page 82 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) •check cable from TCU to no reaction, TO GROUND AT TRANSMISSION SUMP TEMPERATURE SENSOR TCU uses default temp. sensor INPUT •check connectors...
Page 83 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) OP-Mode: substitute clutch •check cable from TCU to TO BATTERY VOLTAGE OR O AT INTERNAL SPEED INPUT TCU measures a voltage higher than 7.00 V at speed control sensor •check connectors...
Page 84 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) OP-Mode: substitute clutch •check EEC controller EEC1 TIMEOUT •check wire of CAN-Bus Timeout of CAN-message EEC1 from EEC controller control •...
Page 85 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) •check cable from TCU to TCU shifts to neutral see figure 8 AT CLUTCH the measured resistance value of the valve is out of OP-Mode: limp home gearbox •check connectors from...
Page 86 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) •check cable from TCU to TCU shifts to neutral see figure 8 TO GROUND AT CLUTCH the measured resistance value of the valve is out of OP-Mode: limp home gearbox •check connectors from...
Page 87 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) •check cable from TCU to backup alarm will be on see figure 8 TO GROUND AT RELAY REVERSE WARNING ALARM TCU detected a wrong voltage at the output pin, that until TCU power down backup alarm device...
Page 88 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) •check cable from TCU to no reaction see figure 8 TO GROUND AT DIFFLOCK SOLENOID TCU detected a wrong voltage at the output pin, that OP-Mode: normal difflock solenoid •check connectors from...
Page 89 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) •check pressure at clutch K3 TCU shifts to neutral SLIPPAGE AT CLUTCH •check main press. in system TCU calculates a differential speed at closed clutch K3. OP-Mode: limp home •check sensor gap at internal If this calculated value is out of range, TCU interprets...
Page 90 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) •check pressure at SLIPPAGE AT CONVERTER LOCKUP CLUTCH TCU calculates a differential speed at closed converter converter lockup clutch •check main pressure in the lockup clutch.
Page 91 Transmission - Transmission and Mounting Section 120-0010 Fault MEANING OF CODE TCU reaction Checks Remarks Code possible reason for fault detection (hex) •check fuse VPS1 shift to neutral ERROR AT SWITCH FOR VALVE POWER SUPPLY •check cables from TCU switched on VPS1 and measured VPS1 is off or OP-Mode: TCU shutdown TCU switched off VPS1 and measured VPS1 is still on gearbox to TCU...
Page 92 Transmission - Transmission and Mounting Section 120-0010 8.1 Actuator: ≈ R ≈ R ≈ ∞ open circuit: ≈ R; ≈ 0, R ≈ R or R ≈ R, R ≈ 0 short cut to ground: (for s.c. to ground, G is connected to vehicle ground) ≈...
Page 93 Transmission - Transmission and Mounting Section 120-0010 SM - 2480 1 - Adaptor 13 - Tee Piece 5 - Elbow 9 - Dust Cap 2 - Hose Assembly 6 - Tube Assembly 14 - Diagnostic Nipple 10 - Adaptor 3 - Hose Assembly 7 - Tube Assembly 11 - Elbow 15 - Oil Filter Head...
Page 94 Transmission - Transmission and Mounting Section 120-0010 17. Remove locknut (20), bolt (18), washer (19) and (7) from the transmission. Remove isolation mount (8) clamp (17) securing dipstick tube (15) assembly to from LH bracket (7) and replace if required. bracket (16).
Page 95 Transmission - Transmission and Mounting Section 120-0010 2. If removed, install engine speed sensor, output 2. Lubricate rear isolation mounts (8) with water or a speed sensor, central gear train sensor and turbine suitable rubber lubricant and install in brackets speed sensor (5, 6, 7 &...
Page 96 Transmission - Transmission and Mounting Section 120-0010 14. Remove blanking caps and connect air lines to 27. Check for correct operation of the transmission, retarder solenoid, differential lock solenoid and shift selector and warning lights. pressure reducing valve mounted on front bracket assembly (1), as identified at removal.
Page 97 Transmission - Transmission and Mounting Section 120-0010 3. With parking brake applied, foot on service brake, The internal filter and finger magnet at the lower front engine idling and transmission operating at normal left hand of the sump should be removed and cleaned temperature, select each gear position in turn.
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Page 99: Front Axle Group
DRIVELINES - Front and Rear Drivelines Section 130-0010 SM - 2010 PART OF FRONT ENGINE FRAME TRANSMISSION TRAILER FRONT AXLE 1 - Driveline Assembly 6 - Driveline Assembly 2 - Cross Assembly 7 - Cross Assembly 11 - Bracket 3 - Shaft Seal 8 - Shaft Seal 12 - Bolt 4 - Driveline Assembly...
Page 100: Centre Axle
Drivelines - Front and Rear Drivelines Section 130-0010 SM - 1441 PARKING BRAKE CENTRE AXLE REAR AXLE 6 7 5 6 ARTICULATION AND OSCILLATION PIVOT 1 - Capscrew 4 - Shaft Seal 2 - Driveline Assembly 6 - Cross Assembly 3 - Cross Assembly 5 - Driveline Assembly 7 - Shaft Seal...
Page 101 Drivelines - Front and Rear Drivelines Section 130-0010 6. Support driveline (1) with suitable lifting equipment SM - 088 and remove capscrews (10) securing cross APPLY PRESSURE MAXIMUM PERMISSIBLE assemblies (2) to their mating components. Remove HERE BY HAND GAP IS 0.2 mm (0.008 in) driveline assembly (1).
Page 102 Drivelines - Front and Rear Drivelines Section 130-0010 Note: Do not distort the tube with excessive grip. 3. Position driveline assembly (4) on the vehicle as shown in Fig. 1 and align match marks on cross 2. Install cross assembly (2) to yoke end of driveline assemblies (5) with those on its mating surfaces.
Page 103 Drivelines - Front and Rear Drivelines Section 130-0010 MAINTENANCE With the pry bar, check the universal joints for play. If Every 500 hours, check the universal joints for wear loose, replace the universal joints. Check the splines and replace if required. at the slip joint and replace the yoke if excessively worn.
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Page 105 CENTRE AXLE - Differential Drive Head Section 150-0020 DESCRIPTION and short axle shafts are removed. Refer to Section 160-0030, AXLE GROUP (HUB). The differential assembly is mounted to the axle housing. It comprises of two differentials; one for the normal cross-axle drive function; the other for the thru- 6.
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Page 107 Centre Axle - Differential Drive Head Section 150-0020 LEGEND FOR FIG. 1. 1 - Drive Flange 23 - Shifter Fork Assembly 67 - Adjusting Nut 45 - Bolt 2 - Dust Cover 24 - Thrust Block 46 - Seal Ring 68 - Tapered Bearing 3 - Castle Nut 25 - Tapered Bearing...
Page 108 Centre Axle - Differential Drive Head Section 150-0020 DISASSEMBLY SM - 1109 Numbers in parentheses refer to Fig. 1, unless otherwise specified. 1. If not done so previously, remove bolts (50 & 74) which attach countershaft case (49) to differential housing (73) and lift off the countershaft case assembly.
Page 109 Centre Axle - Differential Drive Head Section 150-0020 12. Press the thru-drive differential case assembly SM - 1113 (13 thru 20) out of intermediate flange (12), as shown in Fig. 7. 13. With a bearing puller, pull ball bearing (10) off the bearing journal of differential case half (14).
Page 110 Centre Axle - Differential Drive Head Section 150-0020 17. Unlock slotted nut (86) and remove it from the SM - 1117 threaded end of differential side gear (22) as shown in Fig. 11. With a soft drift and hammer, drive differential side gear (22) from countershaft case (49).
Page 111 Centre Axle - Differential Drive Head Section 150-0020 INSPECTION SM - 1120 The importance of careful and thorough inspection cannot be overstressed. Thorough inspection and necessary replacement of parts now may eliminate costly and avoidable trouble later. 1. Clean all parts in petroleum base solvent. 2.
Page 112 Centre Axle - Differential Drive Head Section 150-0020 ASSEMBLY SM - 1133 Numbers in parentheses refer to Fig. 1 unless specified otherwise. Note: Tighten all fasteners without special torques specified to torques listed in Section 300-0080, AXLE BOLT AND NUT TORQUE SPECIFICATIONS. Note: During assembly and installation, make sure that mated, punch marked, or otherwise identified parts are returned to their original positions, if still...
Page 113 Centre Axle - Differential Drive Head Section 150-0020 6. Place the assembled bearing retaining bush (58) on SM - 1137 pinion gear (61) as shown in Fig. 21 and install gear (57) chamfered side down. 7. Press or drive the assembled pinion gear (61) into its bore in countershaft case (49) until it is completely seated.
Page 114 Centre Axle - Differential Drive Head Section 150-0020 12. Place spur gear (48) in countershaft case (49). It SM - 1131 will be necessary to mesh this gear with gear (57) already installed. Refer to Fig. 25. Fig. 25 - Installing Spur Gear 13.
Page 115 Centre Axle - Differential Drive Head Section 150-0020 16. Thread slotted nut (86) onto the threaded end of SM - 1124 differential side gear (22). Tighten slotted nut (86) to a torque of 550 Nm (400 lbf ft). Refer to Fig. 29. Fig.
Page 116 Centre Axle - Differential Drive Head Section 150-0020 20. Place 'U' section ring (35) on piston (36) OD. Slide SM - 1127 centring ring (37) and spring (38) on the piston stem. Insert the assembled piston into its bore in differential housing (4).
Page 117 Centre Axle - Differential Drive Head Section 150-0020 24. Place side gear (16) into differential case half (14). SM - 1142 Refer to Fig. 37. Fig. 37 - Insert Side Gear 25. Install pinion gears (18) and thrust washers (17) on SM - 1143 spider (19) arms.
Page 118 Centre Axle - Differential Drive Head Section 150-0020 28. Install differential assembly (13 thru 20) into the SM - 1146 bore of differential housing (4) as shown in Fig. 41. Be sure the teeth on differential case half (20) mesh with shift collar (21) teeth.
Page 119 Centre Axle - Differential Drive Head Section 150-0020 32. Using a seal driver, install shaft seal (6) in bearing SM - 1150 flange (8) with the seal lip facing down. Refer to Fig. Fig. 45 - Installing Shaft Seal 33. Measure the distance ball bearing (10) is above SM - 1151 intermediate flange (12) face as shown in Fig.
Page 120 Centre Axle - Differential Drive Head Section 150-0020 37. If removed, install differential lock nut (39) and bolt SM - 1154 (40). Coat the bolt threads with Loctite 270. Actuate the differential lock with compressed air while threading the bolt with lock nut in differential housing (4) until contact is made.
Page 121 Centre Axle - Differential Drive Head Section 150-0020 47. Alternately, install an internally splined disc SM - 880 (6, Fig. 2) and then an externally splined disc (5, Fig. 2) until all the discs have been installed. Fig. 53 - Installing Thrust Ring 48.
Page 122 Centre Axle - Differential Drive Head Section 150-0020 50. Place cover (3, Fig. 2) on housing (11, Fig. 2), SM - 884 cover threads of bolts (1, Fig. 2) with Loctite 270 and fasten cover and housing together as shown in Fig.
Page 123 Centre Axle - Differential Drive Head Section 150-0020 55. Ring gear runout is measured by mounting a dial SM - 893 indicator gauge on the backside of the ring gear. Carefully rotate the ring gear and read the dial indicator gauge. Maximum allowable run out is 0.08 mm (0.003 in).
Page 124 Centre Axle - Differential Drive Head Section 150-0020 SM - 896 SM - 899 Fig. 64 - Drive Side (Convex) Fig. 67 - Drive Side (Convex) SM - 897 SM - 900 Fig. 68 - Pinion Distance Must Be Increased Fig.
Page 125 Centre Axle - Differential Drive Head Section 150-0020 MAINTENANCE SPECIAL TOOLS Proper lubrication of the differential assembly is The special tools referenced in this section are essential if the differentials are to deliver the service available from your dealer. Refer to Section 300-0070, intended.
Page 126 Centre Axle - Differential Drive Head Section 150-0020 DIAGNOSIS CHART (CONTINUED) CONDITION REASON REMEDY Noise on turns Normal limited slip differential operation Use an EP oil with limited slip additives. Refer to Section 300-0020, LUBRICATION SYSTEM Worn pinion gears or side gears Replace gears Worn or damaged axles (spiders) Replace axles (spiders)
Page 127 REAR AXLE GROUP - Differential Drive Head Section 160-0020 SM - 849 1 - Bearing Adjuster 7 - Side Gear 4 - Drive Flange 2 - Housing 5 - Ring Gear 8 - Differential Case Assembly 3 - Pinion Gear (Drive) 6 - Spider (Pinion) Gear Fig.
Page 128 Rear Axle Group - Differential Drive Head Section 160-0020 SM - 850 1 - Housing 2 - Thrust Washers 5 - Thrust Ring 8 - Differential Axle 3 - Externally Splined Discs 6 - Side Gears 9 - Cover 4 - Internally Splined Discs 7 - Pinion Gears 10 - Bolts Fig.
Page 129 Rear Axle Group - Differential Drive Head Section 160-0020 REMOVAL 8. Index mark differential housing (14) and the axle housing to ensure that differential housing (14) is Numbers in parentheses refer to Fig. 3. installed in the same position. WARNING 9.
Page 130 Rear Axle Group - Differential Drive Head Section 160-0020 SM - 851 1 - Cotter Pin 10 - Adjusting Nut 19 - Washer 11 - Roller Bearing 28 - Externally Splined Plate 2 - Slotted Nut 20 - Bolt 3 - Washer 12 - Roller Bearing 21 - Lockwire 29 - Internally Splined Plate...
Page 131 Rear Axle Group - Differential Drive Head Section 160-0020 DISASSEMBLY SM - 852 Numbers in parentheses refer to Fig. 3. Note: The following removal procedure assumes the complete axle assembly was removed from the vehicle. 1. Punch mark the mounting position of differential housing (14) to the axle housing as shown by arrows in Fig.
Page 132 Rear Axle Group - Differential Drive Head Section 160-0020 5. Punch mark bearing caps (22) and differential SM - 856 housing (14) as shown in Fig. 8. Loosen adjusting nuts (10). Remove bolts (20), washers (19) and bearing caps (22). Fig.
Page 133 Rear Axle Group - Differential Drive Head Section 160-0020 9. Remove bolts (25) from cover (26) as shown in SM - 860 Fig. 12. Fig. 12 - Removing Cover Bolts 10. Punch mark cover (26) and housing (33) as shown SM - 861 by the arrows in Fig.
Page 134 Rear Axle Group - Differential Drive Head Section 160-0020 17. Press pinion gear (17) out of differential housing SM - 864 (14) as shown in Fig. 16. Remove spacing washer (15). Fig. 16 - Pressing Out Pinion Shaft 18. With the special tool shown in Fig. 17 pull the inner SM - 865 race of the bearing off the pinion drive end.
Page 135 Rear Axle Group - Differential Drive Head Section 160-0020 SM - 866 1 Measuring Piston 15269936 2 Thrust Washer 15269935 3 Adaptor Pieces 15269937 4 Measuring Shaft 15269934 Fig. 18 - Determining Shim Thickness 1. Using a feeler gauge, determine the gap between SM - 867 the measuring piston and measuring shaft as shown in Fig.
Page 136 Rear Axle Group - Differential Drive Head Section 160-0020 3. The arrow in Fig. 21 is pointing to a dimension SM - 869 etched on the face of pinion gear (17). For example 159.90 mm (6.295 in). Dimension 'XI' 46.10 mm (1.815 in) (Bearing Thickness) + 159.90 mm (6.295 in) = 206.00 mm (8.110 in)
Page 137 Rear Axle Group - Differential Drive Head Section 160-0020 7. Heat the inner race of tapered roller bearing (16) to SM - 873 approximately 90° C (190° F) and install it on the shaft of pinion gear (17). Be sure it is seated against the shaft shoulder as shown in Fig.
Page 138 Rear Axle Group - Differential Drive Head Section 160-0020 11. Remove slotted nut (2), pull off drive flange (4) and SM - 877 remove pinion gear (17) from differential housing (14). Remove and measure the measuring ring with a micrometer. The thickness of the compressed measuring ring will be the thickness of spacing washer (9).
Page 139 Rear Axle Group - Differential Drive Head Section 160-0020 22. Alternately install an internally splined plate (29) SM - 881 and externally splined plate (28) until all plates are installed. 23. Determine the end play between the plates and the housing as shown in Figs.
Page 140 Rear Axle Group - Differential Drive Head Section 160-0020 27. Place outer races of roller bearings (11 & 12) on SM - 885 both differential ends. Using the special lifting tool install ring gear (18) assembly into differential housing (14), as shown in Fig. 37. Fig.
Page 141 Rear Axle Group - Differential Drive Head Section 160-0020 31. To check the backlash between ring gear (18) and SM - 889 pinion gear (17), mount a dial indicator gauge at right angles to the outer diameter of the ring gear tooth flank as shown in Fig.
Page 142 Rear Axle Group - Differential Drive Head Section 160-0020 GLEASON GEAR TOOTH SYSTEM SM - 895 Ideal tooth-contact pattern shown in Figs. 45 and 46 indicating the pinion distance is correct. If the patterns obtained are the same as that shown in Figs.
Page 143 Rear Axle Group - Differential Drive Head Section 160-0020 SM - 898 Fig. 50 - Coast Side (Concave) SM - 899 Fig. 51 - Drive Side (Convex) SM - 900 Fig. 52 - Pinion Distance must be Increased SM 1969 4-00 Courtesy of Machine.Market...
Page 144 Rear Axle Group - Differential Drive Head Section 160-0020 MAINTENANCE should be investigated before the differential is taken Proper lubrication of the differential assembly is apart. essential if the differentials are to deliver the service intended. Section 300-0020, LUBRICATION SYSTEM Whenever noises such as a grating or rattle are heard gives full information on the proper lubrication intervals coming from the differential, stop the unit immediately.
Page 145: Rear Axle Group
REAR AXLE GROUP - Axle Group (Hub) Section 160-0030 SM - 1781 13 12 1 - Hub Carrier 29 - Slotted Nut 2 - Capscrew 11 - Wheel Bolt 20 - Retainer Ring 30 - Axle Housing 12 - Wheel Nut 3 - Capscrew 21 - Thrust Washer 31 - Brake Disc...
Page 146 Rear Axle Group - Axle Group (Hub) Section 160-0030 REMOVAL AND DISASSEMBLY SM - 1026 Numbers in parentheses refer to Fig. 1. Note: On dismantling, clean all parts in paraffin or other suitable cleaning agent and place on a clean work surface.
Page 147 Rear Axle Group - Axle Group (Hub) Section 160-0030 18. Remove shaft seal (9), roller bearing (6) and SM - 1028 bearing outer race (8) from hub (10) as shown in Fig. 5. 19. If it is necessary to remove hub carrier (1) from axle housing (30), index mark hub carrier and axle housing to aid in installation.
Page 148 Rear Axle Group - Axle Group (Hub) Section 160-0030 4. Install roller bearing (6) in inner bore of hub (10). SM - 1031 Coat outer diameter of shaft seal (9) with Loctite 574 sealing compound and, with the seal lip facing down, press shaft seal (9) into the bore of hub (10) with the special tool shown in Fig.
Page 149 Rear Axle Group - Axle Group (Hub) Section 160-0030 15. Carefully slide axle shaft (28) through the bore of SM - 1035 hub carrier (1) until the axle shaft splines into the differential side gears. Place thrust washer (26) onto grooved pins (27) on hub carrier (1).
Page 150 Rear Axle Group - Axle Group (Hub) Section 160-0030 MAINTENANCE 18. Remove sun gear shaft (17) from driver (25) and position in planet carrier (18) in mesh with planet Proper lubrication of the axle group is essential if axles are to deliver the service intended. Section gears (19).
Page 151 Rear Axle Group - Axle Group (Hub) Section 160-0030 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Capscrew Capscrew Wheel Nut Lock Screw Bolt Plug Screw Capscrew SM 1968 4-00 Courtesy of Machine.Market...
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Page 153 REAR AXLE GROUP - Wheel Rim and Tyre Section 160-0050 SM - 1038 1 - Flanges 2 - 'O' Ring 5 - Wheel Rim 8 - Driver (if used) 3 - Bead Seat Band 9 - Lock Washer 6 - Valve Assembly 4 - Lock Ring 10 - Wheel Nut 7 - Valve Cap...
Page 154 Rear Axle Group - Wheel Rim and Tyre Section 160-0050 REMOVING TYRE AND RIM ASSEMBLY SM - 1039 FROM MACHINE Numbers in parentheses refer to Fig. 1. Note: If tyre and rim assembly is to be replaced pre- assembled, it is not necessary to remove the tyre from the rim.
Page 155 Rear Axle Group - Wheel Rim and Tyre Section 160-0050 14. Using suitable lifting equipment, remove tyre from WARNING rim. This completes the removal of the tubeless tyre. When lifting tyre from the rim, be sure the equipment is of sufficient capacity and properly 15.
Page 156 Rear Axle Group - Wheel Rim and Tyre Section 160-0050 SM - 207 WARNING (cont.) Also, use and servicing of damaged, worn out, or improperly assembled rim assemblies is a very dangerous practice. Failure to comply with the above warnings could result in explosions from tyre pressure causing serious personal injury and property damage.
Page 157 Rear Axle Group - Wheel Rim and Tyre Section 160-0050 MOUNTING TYRE AND RIM ASSEMBLY ON MACHINE Use an air compressor and reservoir located Numbers in parentheses refer to Fig. 1. inside a heated building, when available, so that alcohol, methanol, or other flammable antifreeze liquids are not needed in the air WARNING tanks to prevent moisture freezing in the tank...
Page 158 Rear Axle Group - Wheel Rim and Tyre Section 160-0050 All machines whose tyres are factory inflated with dry SM - 208 nitrogen gas will be identified by a decal on the body or frame. Nitrogen gas improves tyre pressure retention, increases tyre life by reducing carcass oxidation from within, minimizes rim rust and has no detrimental effects on the tyre.
Page 159 Rear Axle Group - Wheel Rim and Tyre Section 160-0050 Re-inflation of a Mounted Tyre SM - 1040 To re-inflate a tyre with dry nitrogen gas which is now inflated with air, proceed as follows: 1. Exhaust the tyre until only air at atmospheric pressure remains in the tyre.
Page 160 Rear Axle Group - Wheel Rim and Tyre Section 160-0050 SM - 1041 WARNING (cont.) AT LEAST AT LEAST The machine should be moved to a remote 15 m (50 ft) 460 m (1 500 lbf ft) area, but only when this can be done with complete safety to the operator operating or towing the machine.
Page 161 Rear Axle Group - Wheel Rim and Tyre Section 160-0050 Inspect Tyres Regularly Punctures 13 mm (0.50 in) or larger, large cuts, or bruise breaks require sectional or reinforced vulcanized A systematic plan for tyre inspection will more than repair. Cover the repair patch with a layer of cushion pay for itself in lowered tyre costs per hour of gum after application to the tubeless tyre to ensure an operation.
Page 162 SERVICE TOOLS for part numbers of general service be used in assembling rim parts. tools required. TYRE INFLATION PRESSURES (BRIDGESTONE) FRONT CENTRE AND REAR MODEL TYRE SIZE lbf/in lbf/in 23.5 R 25** TA30 30/65 R 25 SM 1970 4-00 Courtesy of Machine.Market...
Page 163 Rear Axle Group - 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.
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Page 165: Brake Parts
BRAKE PARTS - Brake Parts - Rear Section 165-0010 SM - 048 3 - Brake Heads 1 - Capscrew 2 - Brake Disc 4 - Bolt 5 - Washer Fig. 1 - Cutaway View of Typical Brake Head and Disc Mounting DESCRIPTION AND OPERATION GENERAL INSPECTION The service brakes are of the calliper disc-type.
Page 166 Brake Parts - Brake Parts - Rear Section 165-0010 SM - 049 1 - Bleeder Valve 5 - Torque Pin 9 - Piston Plug 13 - Packing 10 - Seal 2 - Screw 6 - Bolt 14 - Backup Ring 7 - Washer 11 - Piston 3 - Torque Pin...
Page 167 Brake Parts - Brake Parts - Rear Section 165-0010 BRAKE REMOVAL AND DISASSEMBLY attach a bleeder hose to bleeder valve. Open bleeder valve (1). Use a screwdriver or pry bar inserted Numbers in parentheses refer to Fig. 2, unless between brake disc (2, Fig. 1) and brake pads (4) to otherwise specified.
Page 168 Brake Parts - Brake Parts - Rear Section 165-0010 7. Inspect brake pads (4) per Step 1 in 'General 7. Attach cover plate (8) to torque plate (16) and Inspection' procedure. secure with bolts (6) and washers (7). Tighten bolts (6) to a torque of 380 Nm (280 lbf ft).
Page 169 Brake Parts - Brake Parts - Rear Section 165-0010 BLEEDING Inspect brake head assembly to ensure that all bolts Numbers in parentheses refer to Fig. 2. are tight and there are no leaks. Inspect for boot deterioration. In order to obtain satisfactory braking, the system should be bled as follows to eliminate any air in the Every 250 Hours (Monthly) hydraulic brake lines.
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Page 171 BRAKE PARTS - Brake Parts - Front Section 165-0020 SM - 2477 3 - Brake Head 1 - Capscrew 2 - Brake Disc 4 - Bolt 5 - Washer Fig. 1 - Cutaway View of Typical Brake Head and Disc Mounting DESCRIPTION AND OPERATION GENERAL INSPECTION The service brakes are of the calliper disc-type.
Page 172 Brake Parts - Brake Parts - Front Section 165-0020 SM - 049 1 - Bleeder Valve 5 - Torque Pin 9 - Piston Plug 13 - Packing 10 - Seal 2 - Screw 6 - Bolt 14 - Backup Ring 7 - Washer 11 - Piston 3 - Torque Pin...
Page 173 Brake Parts - Brake Parts - Front Section 165-0020 6. Remove dust cap (15) from bleeder valve (1) and f. Repeat Steps a and b until full braking performance attach a bleeder hose to bleeder valve. Open bleeder (per applicable government regulations) is achieved. valve (1).
Page 174 Brake Parts - Brake Parts - Front Section 165-0020 part number. All parts included in a repair kit should 6. Lubricate seals (10) and install seals and piston be replaced each time a brake head is rebuilt. plugs (9) in open end of piston bores of torque plate (16). 7.
Page 175 Brake Parts - Brake Parts - Front Section 165-0020 MAINTENANCE 4. Install wheel on the vehicle following instructions in Section 160-0050, WHEEL RIM AND TYRE. Numbers in parentheses refer to Fig. 2. Every 10 Hours (Daily) BLEEDING Inspect brake fluid level and add brake fluid if low. Numbers in parentheses refer to Fig.
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Page 177: Parking Brake 0010 Parking Brake And Mounting
PARKING BRAKE - Parking Brake and Mounting Section 170-0010 SM - 1908 14 - Brake Calliper 15 - Brake Pads 9 - Bolt 5 - Washer 1 - Brake Disc 10 - Parking Brake Guard 16 - Slack Adjuster 6 - Nut 2 - Lockwasher 17 - Actuator 11 - Bolt...
Page 178 Parking Brake - Parking Brake and Mounting Section 170-0010 lubricated regularly to avoid unequal wear on brake 7. Support brake calliper (14) assembly and remove pads (15). It is also important that the lubricant does bolts (4), washers (5), blocks (18 & 19) and nuts (6) not contact the disc braking surfaces.
Page 179 Parking Brake - Parking Brake and Mounting Section 170-0010 SM - 1914 1 - Brake Pad 8 - Clevis 15 - Actuator 22 - Thrust Bearing 2 - Bolt 9 - Clevis Pin 16 - Snap Ring 3 - Washer 10 - Cotter Pin 17 - Slack Adjuster 23 - Gasket...
Page 180 Parking Brake - Parking Brake and Mounting Section 170-0010 Note: Care should be taken not to push piston seal (5) 3. Using suitable lifting device, position brake calliper out of seal groove in calliper (7) when assembling cap (14) assembly in position on torque plate (7). Install assembly (25), with piston (6) and power screw shaft torque plate (8) on brake calliper (14) and secure to (21), to calliper (7).
Page 181 Parking Brake - Parking Brake and Mounting Section 170-0010 SERVICE SPECIAL TOOLS Every 1 000 hours check pads and disc for wear. There are no special tools required for procedures Lubricate slack adjuster as described in Section outlined in this section. Refer to Section 300-0070, 300-0020, LUBRICATION SYSTEM.
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Page 183 SUSPENSION SYSTEM - Front Suspension Section 180-0020 SM - 2485 31 34 7 35 15,21 18 17 1 - Shock Absorber 12 - Nut 23 - Bellows 2 - Bolt 13 - Mounting Pin 24 - Clamp Ring 34 - Chain 14 - Wear Washer 25 - Clamp Plate 3 - Washer...
Page 184 Suspension System - Front Suspension Section 180-0020 REMOVAL 12. Remove locknuts (30) securing air spring assemblies (22) to the front frame assembly. Numbers in parentheses refer to Fig. 1. 13. Lower front end of suspension frame (10) WARNING assembly onto a suitable trolley. To prevent personal injury and property damage, be sure wheel blocks, blocking 14.
Page 185 Suspension System - Front Suspension Section 180-0020 4. If damaged, press spherical bearings (16) out of SM - 1171 bores in suspension frame (10). FRONT FRAME ASSEMBLY ASSEMBLY Numbers in parentheses refer to Fig. 1. GAP 'B' WARNING To prevent personal injury and property damage, be sure lifting equipment is properly secured and of adequate capacity to do the job safely.
Page 186 Suspension System - Front Suspension Section 180-0020 pin (13). Half this size to obtain the thickness of shim 15. Lower suspension frame (10) onto chain (34). pack required for Gap 'B' (Fig. 2) at both sides. 16. Install nylon tubes to air spring assemblies (22) Note: Gap 'B' at both sides should be equalised within with the long nylon to LH air spring and short nylon to 0.25 mm (0.01 in) maximum.
Page 187 Suspension System - Front Suspension Section 180-0020 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Bolt Locknut Shock Absorber Locking Nut 68 - 74 50 - 55 Wheel Nuts SM 1979 4-00 Courtesy of Machine.Market...
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Page 189 SUSPENSION SYSTEM - Air Spring Section 180-0021 SM - 1067 1 - Top Clamp Plate 2 - Top Clamp Ring 3 - Bellows 4 - Centre Ring 5 - Bottom Clamp Ring 6 - Bottom Clamp Plate 7 - Bump Stop 8 - Nut Fig.
Page 190 Suspension System - Air Spring Section 180-0021 DISASSEMBLY SM - 1068 Numbers in parentheses refer to Fig. 2. 1. Remove top and bottom clamp plates (4 & 3) and clamp rings (2) from bellows (1). 2. Remove centre ring (5) from bellows (1) convolutions.
Page 191 SUSPENSION SYSTEM - Levelling Valve Section 180-0022 SM - 978 1 - Clamp Ring 34 - Control Lever 12 - Compression Spring 23 - Key 2 - Protection Cap 13 - Piston Pin 24 - Sealing Ring 35 - Clamp 3 - Screw 14 - Grooved Pin 25 - Reducer...
Page 192 Suspension System - Levelling Valve Section 180-0022 DESCRIPTION ADJUSTMENT The levelling valve is an air operated valve mounted to Numbers in parentheses refer to Fig. 1. a chassis crossmember and attached to the front suspension frame. Refer to Section 180-0020, FRONT SUSPENSION.
Page 193 Suspension System - Levelling Valve Section 180-0022 MAINTENANCE 4. If control lever (34) is not in the horizontal (neutral) position, disconnect connecting rod (36) and allow The air suspension levelling valve does not require control lever (34) to return to the horizontal position. any particular maintenance.
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Page 195 SUSPENSION - Rear Suspension Section 180-0040 SM - 1427 13,36 13,37,44 13,36 47,48,49 47,48,49 31 30 34 29 21 39 31 30 21 19 20 14 - Bolt 27 - Bolt 1 - Bracket Assembly 40 - Bolt 15 - Lockwasher 28 - Locknut 41 - Plate 2 - Bracket Assembly...
Page 196 Suspension System - Rear Suspension Section 180-0040 1. Position the vehicle in a level work area, raise the 14. Remove bolts (14) and lockwashers (15) securing body and install the body safety prop to secure the end cap (11) to equaliser beam (6). Remove end body in the partially raised position.
Page 197 Suspension System - Rear Suspension Section 180-0040 27. Remove locknuts (28), hardened washers (32), 7. Apply Loctite 243 to bolts (24) and secure brackets (5) bolts (27), bracket assemblies (2 & 4), plate (41) and to the centre and rear axles with bolts (24) and adaptor plate (42) from the rear axle.
Page 198 Suspension System - Rear Suspension Section 180-0040 12. If removed, install lube fittings (13) in end caps (1). SM - 1428 Lubricate with grease specified in Section 300-0020, LUBRICATION SYSTEM, until excess lube is seen. TYP. 10 PLACES 13. Apply Loctite 243 to bolts (45) and secure interleaf mounts (16) to equaliser beams (6) with bolts (45), lockwashers (23) and locknuts (46).
Page 199 Suspension System - Rear Suspension Section 180-0040 MAINTENANCE 27. Using suitable lifting equipment, position one tyre and rim assembly on one rear wheel and secure with Numbers in parentheses refer to Fig. 1. wheel nuts and lockwashers. Pre-Starting Inspection: Visually check condition and 28.
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Page 201 ELECTRICAL SYSTEM - Circuit Diagrams Section 190-0000 COMPONENT DESIGNATIONS A4 - Radio/Cassette K1 - Starter Relay S4 - W/L Test Switch A5 - Radio/Cassette Speaker K4 - Dir Ind Flasher Unit S5 - Engine Oil Press Switch K5 - Air Cond Compress Clutch S8 - Blower Switch B2 - Coolant Temp Sender K5 - Air Cond Compress Relay...
Page 202: Electrical System
Electrical System - Circuit Diagrams Section 190-0000 FUSES Location Fuse No. Circuit Current Rating Ignition Sensed Relay Contacts (Heater) Keyswitch Cab Fan Ventilator Blower Rear Wash/Wipe Horn Relay Coil, Front Wash/Wipe Fuse Box - Air Seat Compressor Column A Lights Supply Main Beam Wiper Park Front and Rear 7.5A...
Page 203 Electrical System - Circuit Diagrams Section 190-0000 ZF EST-37 ELECTRONIC MODULE HARNESS CABLE ROUTINGS PLUG WIRE PLUG PLUG WIRE PLUG SM 1946 Rev 1 11-00 Courtesy of Machine.Market...
Page 204 Electrical System - Circuit Diagrams SM - 2458A Courtesy of Machine.Market...
Page 205 Electrical System - Circuit Diagrams SM - 2458B Courtesy of Machine.Market...
Page 206 Electrical System - Circuit Diagrams SM - 2458C Courtesy of Machine.Market...
Page 207 Electrical System - Circuit Diagrams SM - 2458D Courtesy of Machine.Market...
Page 208 Electrical System - Circuit Diagrams SM - 2458E Courtesy of Machine.Market...
Page 209 Electrical System - Circuit Diagrams SM - 2458F Courtesy of Machine.Market...
Page 210 Electrical System - Circuit Diagrams SM - 2458G Courtesy of Machine.Market...
Page 211 Electrical System - Circuit Diagrams SM - 2458H Courtesy of Machine.Market...
Page 212 Electrical System - Circuit Diagrams SM - 2458I Courtesy of Machine.Market...
Page 213 BRAKING SYSTEM - Air Braking System Schematic Section 250-0000 SM - 2446 1 - Fan Clutch 15 - Parking Brake Actuator 8 - Park/Emergency Control Valve 2 - Air Compressor 16 - Solenoid Valve 9 - Pressure Protection Valve 3 - Air Drier and Purge Tank Kit 17 - Differential Lock Cylinder 10 - Rear Brake Tank 4 - Treadle Valve...
Page 214 Section 190-0000 SM 1946 4-00 Courtesy of Machine.Market...
Page 215 ELECTRICAL SYSTEM - Switches and Sensors Section 190-0270 SM - 2574 ENGINE FRONT BRAKE 4 WAY PRESSURE TANK PROTECTION VALVE FRONT PRESSURE PARK/EMERGENCY CONVERTOR BRAKE VALVE PRIMARY TANK AIR CLEANER HYDRAULIC MAIN PUMP TANK FUEL TANK 1 - Engine Coolant Temperature Sender 5 - Low Air Pressure Switch 9 - Hydraulic Oil Pressure Switch 2 - Switch - 5 bar Sender...
Page 216 Electrical System - Switches and Sensors Section 190-0270 SM - 2474 RPM x100 km/h STOP TRANS WATER TEMP SERVICE TEMP PRESS PRESS 1 - Engine Oil Pressure W/L 16 - Transmission Stop W/L 17 - Differential Lock Ind/L 2 - Hydraulic Oil Filter Restriction W/L 9 - Tachometer/Hourmeter 3 - Tractor Brakes Overstroke W/L 18 - Headlight Main Beam Ind/L...
Page 217 0.28 bar (4 lbf/in ) and above, TA27 Cummins C Series 17.40 the circuit closes and sends a signal to illuminate the TA30 Cummins M11 16.68 brake lights at the rear of the vehicle. As pressure TA35 DD Series 60 18.66...
Page 218 Electrical System - Switches and Sensors Section 190-0270 Air Cleaner or rear brake system warning light (3 or 7, Fig. 2). An audible alarm also sounds. Refer to Section 250-0260, Air Cleaner Restriction Gauge (10) - Mounted on the air cleaner, the restriction gauge indicates the degree PRESSURE CONVERTER, for instructions on how to reset the pressure converter.
Page 219: Fuel System 0040 Fuel Tank, Lines And Mounting
FUEL SYSTEM - Fuel Tank, Lines and Mounting Section 200-0040 SM - 2454 10 11 1 - Fuel Tank 6 - Fuel Strainer 11 - Cover 16 - Plug 7 - Gasket 2 - Key 12 - Bolt 17 - Drain Plug 8 - Fuel Level Transmitter 13 - Washer 18 - Rubber Pad...
Page 220 Fuel System - Fuel Tank, Lines and Mounting Section 200-0040 SM - 2466 9,10 11 - Plug 6 - Elbow 1 - Fuel Line 12 - Fuel Filter Bracket 7 - Elbow 2 - Fuel Line 13 - Connector 8 - Bolt 14 - Fuel Filter/Water Separator 3 - Fuel Line 9 - Lockwasher...
Page 221 Fuel System - Fuel Tank, Lines and Mounting Section 200-0040 2. Block all road wheels and place the battery master washer (13) and locknut (20), as shown in Fig. 1. switch in the 'Off' position. Tighten locknut (20) until spring compresses to a length of 31.75 mm (1.25 in).
Page 222 Fuel System - Fuel Tank, Lines and Mounting Section 200-0040 From time to time, remove cover (11) and check Install new fuel filter/water separator on the filter head condition of electrical connections at fuel level and tighten by hand until the gasket contacts the filter transmitter (8).
Page 223 COOLING SYSTEM - Cooling System Section 210-0000 SM - 2499 TO RADIATOR (FRONT L.H.) 6 - Coolant Inlet Pipe 12 - Coolant Outlet Pipe 1 - Radiator Assembly 7 - Water Pump 13 - Bleed Nipple 2 - Make-up Line 8 - DCA4 Water Filter 14 - Header Tank 3 - Coolant Outlet Pipe...
Page 224 Cooling System - Cooling System Section 210-0000 Every 10 hours/Daily Aerated coolant is drawn off to header tank (14) from left hand radiator tank and engine vent port through Check coolant level and add if low. Fill the radiator header tank with coolant until the coolant reaches the deaeration lines (11 &...
Page 225 Cooling System - Cooling System Section 210-0000 Every 4 000 hours Drain and flush the cooling system as described WARNING under 'Cleaning The Cooling System' in this section. Do not remove the filler cap from the radiator Fill the cooling system with the correct mixture of header tank or attempt to drain the coolant antifreeze, water and DCA4 liquid as described under until the engine has cooled to below 50°...
Page 226 Cooling System - Cooling System Section 210-0000 DCA4 Test Kit It is recommended to use a low silicate antifreeze The test kit must be used: concentrate that meets ASTM D4985 specifications (less than 0.1% silicate). Low silicate antifreeze must 1. When excessive coolant loss occurs. be mixed with quality water at a 50/50 ratio (40 to 60% working range).
Page 227 Cooling System - Cooling System Section 210-0000 Treatment Instructions 6. It is okay to estimate a value between colour blocks, but if uncertain about the colour match, pick If the concentration is: the lower numbered block. Below 0.3 units per litre - Add both the normal 7.
Page 228 Cooling System - Cooling System Section 210-0000 COOLING SYSTEM DIAGNOSIS CHART CONDITION REASON REMEDY Engine coolant temperature Low coolant level Fill cooling system to correct fill level too high Check for leaks and repair Front of radiator obstructed Remove obstruction and clean radiator preventing free flow of air fins Fan drive belt broken or slipping...
Page 229 COOLING SYSTEM - Radiator, Header Tank and Mounting Section 210-0040 SM - 2497 15 - Adaptor 1 - Radiator Assembly 8 - Rubber Mount 16 - Drain Cock 2 - Fan Guard 17 - Plug 9 - Nut 3 - Fan Shroud 10 - Bolt 18 - Bolt 4 - Fan Cowl...
Page 230 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 2496 13 15 1 - Left Hand Tank 7 - Radiator Core 2 - Right Hand Tank 8 - Gasket 13 - Stud 18 - Lockwasher 14 - Bolt 19 - Nut 3 - Top Support 9 - Stiffening Strip...
Page 231 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 2498 TO ENGINE VENT PORT TO ENGINE WATER PUMP INLET TO TOP OF RADIATOR L.H.S 1 - Header Tank 8 - Locknut 15 - Elbow 2 - Clamp 9 - Clamp 16 - Plate Assembly 3 - Hose...
Page 232 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 DISASSEMBLY 13. Using suitable lifting equipment attached to lifting points on the radiator assembly (1), support radiator Numbers in parentheses refer to Fig. 2, unless assembly. otherwise specified. Note: Under no circumstances should eye bolts be Note: Position radiator assembly on wooden blocks fitted to the bosses on the top of radiator (1) for the with fan shroud (3, Fig.
Page 233 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 INSPECTION bolts (17) and lockwashers (18). Tighten all nuts (19) Numbers in parentheses refer to Fig. 2. and bolts (17). 1. Steam clean all parts thoroughly with a suitable 6. Install fan shroud (3, Fig. 1) and fan cowl (4, Fig. solvent.
Page 234 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 steady bracket on engine with bolt (6), washer (7) system through filler neck in header tank (1) with and locknut (9). Tighten all nuts (9 & 12) and bolts (6 coolant until coolant level stabilizes at the bottom of &...
Page 235 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 Note: If scale deposits within the radiator are 4. Leave radiator core to dry before reinstalling the exceptionally heavy, concentrations up to 200 kg/m³ cooling equipment. may be used. Note: In the case of grossly fouled surfaces which The most convenient method of use is to prepare a are not cleaned adequately in steps 1 through 4, the concentrated solution by mixing the powder in hot...
Page 236 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Bolt SM 1987 4-00 Courtesy of Machine.Market...
Page 237 COOLING SYSTEM - Transmission Oil Cooler Section 210-0060 SM - 2484 TRANSMISSION TO ENGINE RETARDER 27,28 FROM RADIATOR L.H. TANK TO ENGINE FRAME REF. 25 - Oil Return Line 9 - Sleeve 26 - Locknut 1 - Heat Exchanger 17 - Hose 2 - Viton Seal 10 - Clamp 27 - Bolt...
Page 238: Cooling System
Cooling System - Transmission Oil Cooler Section 210-0060 REMOVAL CLEANING AND DISASSEMBLY Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. Note: In the event of a major mechanical failure, the WARNING transmission oil cooler assembly should be cleaned To prevent personal injury and property thoroughly or replaced.
Page 239 Cooling System - Transmission Oil Cooler Section 210-0060 4. Immerse heat exchanger (1) in the cleaning 1. Using suitable lifting equipment, position solution. Cleaning action is noticeable by bubbling transmission oil cooler assembly on mounting points and foaming. The process must be carefully in the inside of the front bumper.
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Page 241 COOLING SYSTEM - Hydraulic Oil Cooler Section 210-0100 SM - 2494 DIVERTOR TUBE ON HYD. TANK 1 - Hydraulic Oil Cooler 6 - Connector 2 - Bracket Assembly 7 - Elbow - 90° 3 - Bracket Assembly 8 - Inlet Line 4 - Bolt 9 - Outlet Line 5 - Hardened Washer...
Page 242 Cooling System - Hydraulic Oil Cooler Section 210-0100 4. Remove mounting hardware securing front grille on Note: Tighten all hydraulic lines fitted with ORFS the hood assembly. Remove front grille from the hood. connections, as described in Section 220-0000, STEERING SYSTEM SCHEMATIC. Renew all 5.
Page 243 STEERING SYSTEM - Steering Schematic Section 220-0000 DESCRIPTION Internally there is a baffle plate which divides the tank Numbers in parentheses refer to Figs. 2 through 5. assembly into a body hoist compartment and a steering compartment. Should oil level drop below this The operation of the steering system is hydrostatic.
Page 244 Steering System - Steering Schematic Section 220-0000 Priority Valve (5) Diagnostic Test Point Refer to Section 220-0105, PRIORITY VALVE. Mounted on the rear right hand side of the tractor frame are diagnostic test points. The steering system The priority valve is mounted off the rear right hand has one diagnostic test point which enables the fender support.
Page 245 Steering System - Steering Schematic Section 220-0000 FILLING AND BLEEDING THE STEERING MAINTENANCE SYSTEM Maintenance instructions, intervals and warnings, in the individual steering and body hydraulic component 1. Fill hydraulic tank to maximum level. Be ready to sections of this manual, should be adhered to at all add oil when the engine is started.
Page 246 Steering System - Steering Schematic Section 220-0000 SM - 2455A COMPONENTS 1 - Hydraulic Tank 2 - Main Hydraulic Pump 3 - Emergency Steering Pump 4 - Steering Valve 5 - Priority Valve 6 - Emergency Valve 7 - Steering Cylinder 8 - Oil Pressure Switch COLOUR CODES - Pressurized Oil...
Page 247 Steering System - Steering Schematic Section 220-0000 SM - 2455B COMPONENTS 1 - Hydraulic Tank 2 - Main Hydraulic Pump 3 - Emergency Steering Pump 4 - Steering Valve 5 - Priority Valve 6 - Emergency Valve 7 - Steering Cylinder 8 - Oil Pressure Switch COLOUR CODES - Pressurized Oil...
Page 248 Steering System - Steering Schematic Section 220-0000 SM - 2455C COMPONENTS 1 - Hydraulic Tank 2 - Main Hydraulic Pump 3 - Emergency Steering Pump 4 - Steering Valve 5 - Priority Valve 6 - Emergency Valve 7 - Steering Cylinder 8 - Oil Pressure Switch COLOUR CODES - Pressurized Oil...
Page 249 Steering System - Steering Schematic Section 220-0000 SM - 2455D COMPONENTS 1 - Hydraulic Tank 2 - Main Hydraulic Pump 3 - Emergency Steering Pump 4 - Steering Valve 5 - Priority Valve 6 - Emergency Valve 7 - Steering Cylinder 8 - Oil Pressure Switch COLOUR CODES - Pressurized Oil...
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Page 251 STEERING SYSTEM - Steering Valve Section 220-0090 SM - 2016 7 - Valve Housing 13 - Bearing Race 19 - Gerotor Gear 1 - Capscrew 8 - Sleeve 14 - 'O' Ring 20 - Retainer 2 - End Cap 9 - Ball - Check 15 - Dust Seal 21 - 'O' Ring 3 - 'O' Ring...
Page 252 Steering System - Steering Valve Section 220-0090 Turning action of the steering wheel is transmitted SM - 282 through the steering column to sleeve (8) and POCKETS driveshaft (6), which is fastened to the sleeve with centring pin (10). Rotation of driveshaft (6) causes gerotor gear (19) to rotate in gerotor housing (4).
Page 253 Steering System - Steering Valve Section 220-0090 SM - 2493 1 - Steering Valve 10 - Bolt 2 - Locknut 11 - Lockwasher 19 - Bellows 27 - Bracket Assembly 3 - Washer 12 - Nut 20 - Steering Shaft 28 - Bolt 4 - Rubber Mount 13 - Steering Wheel &...
Page 254 Steering System - Steering Valve Section 220-0090 SM - 2017 17 18 1 - Capscrew 7 - Valve Housing 13 - Bearing Race 19 - Gerotor Gear 2 - End Cap 8 - Sleeve 14 - 'O' Ring 20 - Retainer 3 - 'O' Ring 9 - Ball - Check 15 - Dust Seal...
Page 255 Steering System - Steering Valve Section 220-0090 before these parts are fully disengaged and the pin is SM - 2019 not horizontal, the pin can drop and lockup can occur. 2. Remove cap screws (1) securing end cap (2), gerotor housing (4) and spacer plate (5) to valve housing (7).
Page 256 Steering System - Steering Valve Section 220-0090 through the straws and out of the valve housing (7). SM - 2022 PORT FACE Refer to Fig. 10. 15. Remove and discard 'O' ring (14), seal (17) and backup ring (18) from valve housing (7). 16.
Page 257 Steering System - Steering Valve Section 220-0090 SM - 2027 SM - 2024 6 - Drive Shaft 8 - Sleeve 9 - Ball Check 10 - Pin 16 - Spool Fig. 12 - Installing Spool and Ball Checks SM - 2025 6 - Drive Shaft 8 - Sleeve 9 - Ball Check...
Page 258 Steering System - Steering Valve Section 220-0090 SM - 2029 SM - 2028 Fig. 16 - Compressing Centering Spring Fig. 17 - Installing Spool and Sleeve Assembly SM - 2030 1 - Capscrew 4 - Gerotor Housing 19 - Gerotor Gear 5 - Spacer Plate 21 - 'O' Ring 2 - End Cap...
Page 259 Steering System - Steering Valve Section 220-0090 5. Remove plugs from steering valve ports and caps SM - 313 from steering lines and install steering lines to steering valve (1), as identified at removal. 6. Fill hydraulic tank with hydraulic oil, as specified in Section 300-0020, LUBRICATION SYSTEM.
Page 260 Steering System - Steering Valve Section 220-0090 Hydraulic Oil SPECIAL TOOLS The steering system should be kept filled with Refer to Section 300-0070, SERVICE TOOLS, for part hydraulic oil as specified in Section 300-0020, number of the special tool referenced in this section. LUBRICATION SYSTEM.
Page 261: Steering System
STEERING SYSTEM - Priority Valve Section 220-0105 SM - 1954 METERING EDGE 5 - Washer 9 - Damping Orifice 1 - Valve Body 6 - Plug 10 - Case 2 - Spool 7 - 'O' Ring 11 - 'O' Ring 3 - Spring 8 - Damping Orifice 12 - Damping Orifice...
Page 262 Steering System - Priority Valve Section 220-0105 OPERATION 5. Clean priority valve housing (1) and surrounding Numbers in parentheses refer to Fig. 1. area with a suitable solvent. Identify and tag all hydraulic lines connected to priority valve, to aid in Steering valve in neutral position 'Installation'.
Page 263 Steering System - Priority Valve Section 220-0105 Relief Valve Valve Body 1. Clean the entire priority valve assembly with a 1. If removed, secure priority valve to mounting suitable solvent and dry thoroughly. Remove caps bracket using mounting hardware as removed at from valve housing (1) ports.
Page 264 Steering System - Priority Valve Section 220-0105 6. Check priority valve and hydraulic line connections port 'T', relief valve. Remove adaptor from port and for leaks and tighten as required. cap hydraulic line to prevent ingress of dirt. 7. Install front right hand wheel on the machine, as 4.
Page 265 STEERING SYSTEM - Steering Cylinder Section 220-0120 SM - 2467 12,13 PART OF PART OF FRAME FRAME ORIENTATION OF CUSHION SLEEVE BASE 1 - Cylinder Body 7 - Spherical Bearing 13 - Back Up Ring 19 - Lockwasher 2 - Piston Rod 8 - Circlip 14 - Rod Seal 20 - Hardened Washer...
Page 266 Steering System - Steering Cylinder Section 220-0120 REMOVAL DISASSEMBLY Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. WARNING WARNING To prevent personal injury and property To prevent personal injury and property damage, be sure lifting equipment is properly damage, be sure wheel blocks, blocking secured and of adequate capacity to do the job materials and lifting equipment are properly...
Page 267 Steering System - Steering Cylinder Section 220-0120 INSPECTION 8. Insert piston grub screw (5), through wear ring groove in piston (3), into groove machined in piston Numbers in parentheses refer to Fig. 1 rod (2). Tighten grub screw (5) to a torque of 49 Nm 1.
Page 268 Steering System - Steering Cylinder Section 220-0120 4. Connect hydraulic lines to steering cylinder ports, as start the engine and operate the steering, from lock to tagged during removal. lock several times, to purge air out of the hydraulic lines. Check hydraulic lines and fittings for leaks. 5.
Page 269 Steering System - Steering Cylinder Section 220-0120 SM - 633 SILVER STEEL DOM TUBE OUTER SHIELD TO BE SECURED TO INNER BODY WITH 2BA CAPSCREWS Dimensions in mm (inches) Fig. 3 - Piston Torque Tool SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO.
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Page 271 STEERING SYSTEM - Emergency Valve Section 220-0140 SM - 2279 SECTIONAL VIEW OF PILOT CARTRIDGE 5 - Cage 9 - 'O' Ring 1 - Valve Body 2 - Pilot Cartridge 6 - Spool 10 - 'O' Ring 13 - Backup Washer 11 - 'O' Ring 14 - Backup Washer 3 - Relief Valve...
Page 272 Steering System - Emergency Valve Section 220-0140 REMOVAL INSTALLATION Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT WARNING TORQUE SPECIFICATIONS. To prevent personal injury and property damage, be sure wheel blocks are properly Note: Tighten all hydraulic lines fitted with ORFS secured and of adequate capacity to do the job connections, as described in Section 220-0000,...
Page 273 BODY SYSTEM - Body System Schematic Section 230-0000 DESCRIPTION The main hydraulic pump is a multiple gear type pump which operates in the one direction only (it is Numbers in parentheses refer to Fig. 2 through 5. assembled for right hand (clockwise) rotation, as The body system schematic primarily covers operation viewed from the driveshaft end).
Page 274 Body System - Body System Schematic Section 230-0000 Body Cylinders (5) SM - 1335 FITTING Refer to Section 230-0130, BODY CYLINDER. TUBE There are two single stage, double acting body hoist cylinders on the vehicle. The cylinder base end is connected to the trailer frame and the piston rod end is connected at the body.
Page 275: Body System
Body System - Body System Schematic Section 230-0000 Non-contact Infrared Thermometer pull the trigger, and read the temperature. Since there The infrared thermometer can be used to spot heat is no need to touch what you are measuring, problems early in electrical, mechanical and hydraulic temperatures of hard-to-reach or moving components systems.
Page 276 Body System - Body System Schematic Section 230-0000 SM - 2459A T2 U2 (PORT LS) TO STEERING (PORT P) VALVE TO EMERGENCY VALVE (PORT CE) COMPONENTS COLOUR CODES 5 - Body Cylinder - Pressurized Oil 1 - Hydraulic Tank 2 - Main Hydraulic Pump 6 - Accumulator Blue - Exhaust or Return Oil...
Page 277 Body System - Body System Schematic Section 230-0000 SM - 2459B T2 U2 (PORT LS) TO STEERING (PORT P) VALVE TO EMERGENCY VALVE (PORT CE) COMPONENTS COLOUR CODES 5 - Body Cylinder - Pressurized Oil 1 - Hydraulic Tank 2 - Main Hydraulic Pump 6 - Accumulator Blue - Exhaust or Return Oil...
Page 278 Body System - Body System Schematic Section 230-0000 SM - 2459C T2 U2 (PORT LS) TO STEERING (PORT P) VALVE TO EMERGENCY VALVE (PORT CE) COMPONENTS COLOUR CODES 5 - Body Cylinder - Pressurized Oil 1 - Hydraulic Tank 2 - Main Hydraulic Pump 6 - Accumulator Blue - Exhaust or Return Oil...
Page 279 Body System - Body System Schematic Section 230-0000 SM - 2459D T2 U2 (PORT LS) TO STEERING (PORT P) VALVE TO EMERGENCY VALVE (PORT CE) COMPONENTS COLOUR CODES 1 - Hydraulic Tank 5 - Body Cylinder - Pressurized Oil 6 - Accumulator Blue - Exhaust or Return Oil 2 - Main Hydraulic Pump...
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Page 281 BODY SYSTEM - Hydraulic Tank Section 230-0040 SM - 2461 11,12 11 - Relief Valve 31 - Isolation Mount 1 - Tank Assembly 21 - Sight Gauge 12 - Adaptor Plate 32 - Bolt 2 - Filler Cap 22 - Breather 3 - Bolt 13 - Filter Element 23 - Coupling...
Page 282 Body System - Hydraulic Tank Section 230-0040 SM - 1913 Fig. 2 - Hydraulic Tank Port Locations - Viewed from Underside of Hydraulic Tank Internally there is a baffle plate which divides tank A tube connected at port 'E' allows return oil from the assembly (1) into a steering compartment and a body body control valve to enter tank assembly (1).
Page 283 Body System - Hydraulic Tank Section 230-0040 Replacing Hydraulic Oil 2.75 bar (40 lbf/in²) restriction, indicating filter element (13) requires to be changed. The hydraulic tank should be drained, cleaned and hydraulic oil changed every 2 000 hours. Refer to Temperature switch (28), installed in access cover (7), Section 300-0020, LUBRICATION SYSTEM, for opens when a temperature of 50°...
Page 284 Body System - Hydraulic Tank Section 230-0040 8. If damaged, remove and replace rods (10) from tank suitable container. Remove drain tube connection and assembly (1). reinstall cap. 9. Install new gasket (14), new filter element (13), 6. Unscrew and remove both carrier assemblies adaptor plate (12) and relief valve (11) over rods (10) (15 through 20) from the interior of tank assembly (1).
Page 285 Body System - Hydraulic Tank Section 230-0040 TANK ASSEMBLY 9. Secure a suitable lifting device on tank assembly (1) Numbers in parentheses refer to Fig. 1. and remove bolts (32), washers (33) and locknuts (34) securing tank assembly (1) to tank mountings on the frame.
Page 286 Body System - Hydraulic Tank Section 230-0040 4. Install sight gauges (21) on tank assembly (1). 4. Install all hydraulic lines and fittings to tank assembly (1) as tagged at 'Removal'. Connect all 5. If removed, install bolts (29), washers (36 & 37), wiring lines to tank assembly (1) as disconnected at lockwashers (35), bracket (30), nuts (41) and isolation 'Removal'.
Page 287 BODY SYSTEM - Main Hydraulic Pump Section 230-0050 SM - 1897 13 8 9 8.5 mm APPLY GREASE SEALANT POSITION 4 mm 1 - Body Housing 7 - Bearing 13 - Wear Plate 18 - Seal 2 - Front Cover 8 - Wear Plate Seal 3 - Mounting Flange 14 - Wear Plate...
Page 288 Body System - Main Hydraulic Pump Section 230-0050 As driveshaft and gear (11) rotates, driven gear (12) 6. Support pump assembly with suitable lifting rotates in the opposite direction. Pockets between the equipment. Remove nuts (4) and lockwashers (5) drive and driven gear teeth carry oil from inlet port 'A', securing pump assembly to the transmission PTO.
Page 289 Body System - Main Hydraulic Pump Section 230-0050 10. Remove wear plate (14) and wear plate seal (8) SM - 1865 from body housing (1). Note the position of wear plate seal (8) in wear plate (14) groove, for proper assembly.
Page 290 Body System - Main Hydraulic Pump Section 230-0050 Note: Ensure bearings (7) are pressed to insertion SM - 1866 depth indicated in Fig. 4. 2. Install new lip seals (20) and location sleeve (19) to front cover (2), as shown in Fig. 1. BEARING (ITEM 7) 3.
Page 291 Body System - Main Hydraulic Pump Section 230-0050 SM - 1868 3. Remove cap from the inlet line and install a new 'O' ring in the split flange fitting. Secure inlet line to inlet port 'A' on the pump with bolts and lockwashers, as removed during removal.
Page 292 Body System - Main Hydraulic Pump Section 230-0050 Note: Always use accurate pressure gauges when fresh hydraulic oil installed to eliminate all metal adjusting the relief valve. particles or foreign matter. Check pump mounting and hydraulic line connections Refer to Section 300-0020, LUBRICATION SYSTEM, for leaks.
Page 293 BODY SYSTEM - Body Control Valve Section 230-0060 SM - 2464 13,14 13,14 34 35 15,16 38 39 1 - Control Spool 14 - Capscrew 27 - Cap 2 - Retainer 15 - Shim 28 - Valve Housing 3 - 'O' Ring 16 - Shim 29 - Locknut 4 - Spool Cap...
Page 294 Body System - Body Control Valve Section 230-0060 the pressure reducing valves (13). Refer to Section valve (37) assembly, into the right hand side of control 230-0081, BODY CONTROL JOYSTICK. The body spool (1), unseats check valve plunger, flows out of control joystick has a pre-feel ramp which controls the port 'D' and into the base end of the cylinders.
Page 295 Body System - Body Control Valve Section 230-0060 Should oil at the inlet side of the valve exceed 7. Support body control valve with a suitable lifting 221 bar (3 200 lbf/in²), pilot poppet (33) will be forced device and remove mounting hardware securing body off its seat.
Page 296 Body System - Body Control Valve Section 230-0060 7. Remove capscrews (12) securing end cap (10) to BOTH parts should be replaced by new parts. valve housing (28). Remove end cap (10). Note: Do not lap or grind poppet (33) to relief valve 8.
Page 297 Body System - Body Control Valve Section 230-0060 Relief Valve Note: Be sure to use new 'O' rings with the split flange 1. Install new 'O' rings (38 & 39) on relief valve (37) fittings. assembly. Install relief valve (37) assembly into relief valve bore in valve housing (28).
Page 298 Body System - Body Control Valve Section 230-0060 SERVICE TOOLS steering lock bar in the stowed position. There are no special tools required for the procedures outlined in this section. Refer to Section 300-0070, MAINTENANCE SERVICE TOOLS, for part numbers of general Relief valve pressure should be checked on a regular service tools and adhesives.
Page 299 BODY SYSTEM - Body Control Joystick Section 230-0081 DESCRIPTION SM - 2718 The body control joystick is mounted on the right hand side dash panel, between the transmission shift controller and the document location. OPERATION The body control joystick controls the hydraulic control valve operation, by means of electrical signals to the pressure reducing valves, which in turn operates the body hoist cylinders.
Page 300 Body System - Body Control Joystick Section 230-0081 1. Position the vehicle in a level work area, apply the bracket on the underside of the right hand dash panel parking brake and switch off the engine. with screws (2). 2. Press and hold down body hoist bleed down switch Note: Ensure identifying mark on the body control joystick and operate the body control joystick continually to casing is orientated towards the rear of the cab.
Page 301 BODY SYSTEM - Pilot Supply Valve Section 230-0121 SM - 1941 21 - 'O' Ring 1 - Valve Body 6 - Control Spool 11 - Spacer 16 - Plug 22 - Reducer 7 - Plug 2 - Spring Cover 12 - Pilot 17 - 'O' Ring 23 - Adaptor 8 - 'O' Ring...
Page 302 Body System - Pilot Supply Valve Section 230-0121 REMOVAL 3. Remove plug (7) and 'O' ring (8) from valve body Numbers in parentheses refer to Fig. 1. (1). Remove valve seat (9), 'O' ring (10) and spacer (11) from valve body (1). Discard 'O' rings (8 & 10). WARNINGS 4.
Page 303 BODY SYSTEM - Pilot Supply Valve Section 230-0121 6. Install adaptors (23) and tee pieces (26) in valve 3. Fill hydraulic oil tank with hydraulic oil as specified body (1) and reducer (22). in Section 300-0020, LUBRICATION SYSTEM. Refer to Section 230-0040, HYDRAULIC TANK, for hydraulic oil levels.
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Page 305 BODY SYSTEM - Body Cylinder Section 230-0130 SM - 2468 22,6 17,18 18 19 FRAME MOUNTING BODY MOUNTING GROOVE THIS SIDE ORIENTATION OF CUSHION SLEEVE 1 - Cylinder Body 8 - 'O' Ring 22 - Nylon Ring 15 - Grub Screw 2 - Piston Rod 9 - 'O' Ring 16 - 'O' Ring...
Page 306 Body System - Body Cylinder Section 230-0130 DISASSEMBLY WARNING Numbers in parentheses refer to Fig. 1. Exercise extreme caution when lowering the cylinders from the body. The cylinders will WARNING swing out sharply as they leave their To prevent personal injury and property mountings.
Page 307 Body System - Body Cylinder Section 230-0130 INSPECTION 6. Ensure cushion sleeve (18) and circlip (19) are Numbers in parentheses refer to Fig. 1 secure in piston (12). 1. Clean all parts of the cylinder with a suitable solvent 7. Insert new piston seal (13) and new wear rings (14) and dry with clean, lint-free cloths.
Page 308 Body System - Body Cylinder Section 230-0130 3. Install spacers (25) in rod end of cylinder, align start the engine, operate the body and check cylinder lines spherical bearing with bores in body and install upper for leaks. Tighten lines and fittings as required. pin (24) through mounting bores, spacers (25) and cylinder.
Page 309 Body System - Body Cylinder Section 230-0130 SM - 2470 89 (3.5) 38.1 (1.5) SILVER STEEL EN3B MILD STEEL OUTER SHELL TO BE SECURED DOM TUBE 10.16 25.4 TO INNER BODY WITH 2BA CAP SCREWS (0.4) (1.0) Dimensions in mm (in) Fig.
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Page 311 BRAKING SYSTEM - Air Braking System Schematic Section 250-0000 SM - 2446 1 - Fan Clutch 15 - Parking Brake Actuator 8 - Park/Emergency Control Valve 2 - Air Compressor 16 - Solenoid Valve 9 - Pressure Protection Valve 3 - Air Drier and Purge Tank Kit 17 - Differential Lock Cylinder 10 - Rear Brake Tank 4 - Treadle Valve...
Page 312 Braking System - Air Braking System Schematic Section 250-0000 DESCRIPTION Solenoid Valve (16) - When the solenoid valve is The air brake system is an integral part of the service activated by the differential lock switch, air pressure brake system. The system is used to supply air from the primary tank is directed to the differential lock pressure for operating the front and rear pressure cylinders.
Page 313 Braking System - Air Braking System Schematic Section 250-0000 Air compression is controlled by unloader valve on air Treadle Valve (4) - Directs and controls air to the front drier (3) stopping and starting delivery of air from air pressure converter and rear relay emergency valve compressor (2), when maximum 8.4 bar (122 lbf/in²) which controls air delivery to the rear pressure and minimum 6.5 bar (95 lbf/in²) pressures are...
Page 314 Braking System - Air Braking System Schematic Section 250-0000 Parking Brake Actuator (15) - Applies disc type compressor (2) when maximum 8.4 bar (122 lbf/in²) parking brake when park/emergency control valve and minimum 6.5 bar (95 lbf/in ) pressures are lever is moved into the 'PARK' position by exhausting reached.
Page 315 Braking System - Air Braking System Schematic Section 250-0000 to flow into the air chamber part of rear pressure 5. Never exceed recommended pressure and always converter (13). This applies pressure to the brake wear safety glasses when working. hydraulic fluid to apply the rear service brakes. At the same time, port 'A' is vented through port 'C', allowing 6.
Page 316 Braking System - Air Braking System Schematic Section 250-0000 Emergency Brake Holding Ability 1. Move park/emergency control lever to WARNING 'EMERGENCY' position and move transmission gear If the machine moves during the above shift selector to 1st gear. checks, stop the machine, apply the parking brake and do not operate until the fault has 2.
Page 317: Braking System
Braking System - Air Braking System Schematic Section 250-0000 BRAKING SYSTEM DIAGNOSIS (Continued) CONDITION REASON REMEDY Brakes do not apply Defective treadle valve Repair or replace faulty component as with normal treadle recommended in Section 250-0070, TREADLE valve application VALVE. Defective relay emergency valve Repair or replace faulty component as recommended in Section 250-0280, RELAY...
Page 318 Braking System - Air Braking System Schematic Section 250-0000 BRAKING SYSTEM DIAGNOSIS (Continued) CONDITION REASON REMEDY Air pressure too low Pressure gauge registering Replace gauge and/or gauge sender unit. incorrectly Defective compressor Repair or replace air compressor. Refer to ENGINE MAINTENANCE MANUAL. Excessive leakage.
Page 319 Braking System - Air Braking System Schematic Section 250-0000 BRAKING SYSTEM DIAGNOSIS (Continued) CONDITION REASON REMEDY Air pressure rises to Worn compressor Repair or replace. Refer to ENGINE normal reading too MAINTENANCE MANUAL. slowly Excessive carbon in compressor Clean the head and lines. Refer to ENGINE cylinder head or discharge line.
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Page 321 BRAKING SYSTEM - Hydraulic Braking System Schematic Section 250-0000 SM - 2491 FRONT 1 - Brake Head Assembly 2 - Pressure Converter 3 - Brake Fluid Reservoir Fig. 1 - Hydraulic Braking System Schematic DESCRIPTION When the brake is actuated, the hydraulic pressure forces the pistons against the brake pads which are in Numbers in parentheses refer to Fig.
Page 322 Braking System - Hydraulic Braking System Schematic Section 250-0000 2. Start up the engine, place the park/emergency 5. Apply brake and open bleeder valve. After fluid flow control valve in the 'Emergency' position, block all road stops, close the bleeder valve and release the brake. wheels and place the steering lock bar in the 'Locked' position.
Page 323 BRAKING SYSTEM - Treadle Valve Section 250-0070 SM - 2368 No. 1 DELIVERY PORT No. 1 SUPPLY PORT No. 2 DELIVERY PORT No. 2 SUPPLY PORT 1 - Valve Body 2 - Inlet Valve EXHAUST 3 - Inlet Valve Seat 4 - Exhaust Valve Seat 13 - Primary Piston 22 - Passage...
Page 324 Braking System - Treadle Valve Section 250-0070 OPERATION When the brake application force is reduced primary piston (13) will rise. Inlet/exhaust valve (10) remains Numbers in parentheses refer to Fig. 1. closed but exhaust valve seat (12) will uncover exhaust passage (6) until the No. 1 delivery pressure When treadle is pressed down, force is exerted on spring seat (16), rubber graduating spring (17) and falls sufficiently to restore the balance of forces on...
Page 325 Braking System - Treadle Valve Section 250-0070 ASSEMBLY AND INSTALLATION Thereafter, relay piston (5) will operate the inlet/ exhaust valve (2) as previously described. Numbers in parentheses refer to Fig. 1. Apart from the reduced vehicle braking efficiency, the Note: Tighten all fasteners to standard torques listed effect of a loss of air pressure from No.
Page 326 Braking System - Treadle Valve Section 250-0070 MAINTENANCE Coat valve body and exhaust port 'J' with soap suds Numbers in parentheses refer to Fig. 1. to check for leakage and make and hold a full pressure brake application. Any leakage from the Every 250 hours exhaust port 'J' must not exceed a 25 mm (1 in) Lubricate treadle roller and pin (29) with engine oil as...
Page 327: Operators Compartment
BRAKING SYSTEM - Air Tanks and Mounting Section 250-0170 SM - 819 10 - Lockwasher 1 - Primary Tank 4 - Guard 11 - Nut 7 - Lockwasher 2 - Front Brake Tank 5 - 'U' Bolt 8 - Drain Cock 12 - Bolt 6 - Nut 3 - Rear Brake Tank...
Page 328 Braking System - Air Tanks and Mounting Section 250-0170 REMOVAL 1. Install rear brake tank (3) on mounting brackets on Numbers in parentheses refer to Fig. 1. trailer frame and secure with 'U' bolts (5), lockwashers (7) and nuts (6). 1.
Page 329 BRAKING SYSTEM - Park/Emergency Control Valve Section 250-0190 SM - 1947 1 - Control Lever 5 - Graduating Spring 9 - Plunger 'Upright Side' 13 - Handle 14 - Return Spring 2 - Pivot 6 - Inlet Valve 10 - Outer Circlip 3 - Cam 11 - Washer 15 - Locking Sleeve...
Page 330 Braking System - Park/Emergency Control Valve Section 250-0190 Port 'C' - Supply to relay emergency valve (rear) lifted by the control lever (1) and the pivot (2) allowing Port 'D' - Exhaust the 'upright side' plunger (9) and the 'inverse side' plunger (4) to lift and allowing the air pressure in the The valve comprises an aluminium cover and an brake chambers to exhaust.
Page 331 Braking System - Park/Emergency Control Valve Section 250-0190 INSTALLATION When control lever (1) is moved to the 'Release' Numbers in parentheses refer to Fig. 1. position, the pressure reading at port 'A' should be the same as the inlet pressure at port 'B' and there should Note: Tighten all fasteners to standard torques listed be no pressure at port 'C'.
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Page 333 BRAKING SYSTEM - Air Drier Section 250-0200 SM - 1942 1 - Air Drier 4 - Unloader Valve 7 - Orifice 2 - Air Compressor 5 - Desiccant Cartridge 8 - Purge Tank 3 - Safety Valve 6 - Check Valve Fig.
Page 334 Braking System - Air Drier Section 250-0200 SM - 2280 1 - Purge Tank 2 - Desiccant C - Exhaust 3 - Oil Filter D - Output to Compressor Unloading 7 - Purge Valve 4 - Unloader Valve A - Supply from Compressor Device 5 - Check Valve E - Delivery to Purge Tank...
Page 335 Braking System - Air Drier Section 250-0200 SM - 1945 15 14 CHECK VALVE UNLOADER VALVE EXHAUST 1 - Adjusting Bush 6 - Control Rod 16 - Safety Valve Body 11 - Check Valve Guide 2 - Protection Cap 7 - 'O' Ring 12 - Circlip 17 - Adjusting Screw 3 - Valve Retaining Cap...
Page 336 Braking System - Air Drier Section 250-0200 UNLOADER VALVE CHECK VALVE Disassembly/assembly Disassembly/assembly Numbers in parentheses refer to Fig. 4, unless Numbers in parentheses refer to Fig. 4. otherwise specified. Note: Check valve components should be replaced as Note: Unloader valve components should be replaced a complete assembly when removed from air drier as a complete assembly when removed from air drier assembly.
Page 337 Braking System - Air Drier Section 250-0200 Testing SM - 1946 Operating Test - The valve must open (exhaust) when the pressure applied at the supply port 'P-1' is above 10.75 bar (156 lbf/in²). The valve should exhaust sharply, with a 'pop' action. If the valve does not relieve, ball (20) must be stuck on its seat.
Page 338: Body
Braking System - Air Drier Section 250-0200 3. Remove and discard the bonded rubber/metal purge 4. Connect all air lines to the air drier body, as tagged valve (17) and nylon purge valve housing (12). at 'Removal'. 4. Remove and discard return spring (11). 5.
Page 339 Braking System - Air Drier Section 250-0200 AIR DRIER DIAGNOSIS SM - 1953 The following table lists some of the conditions which Shank should be about 8 in long could prove responsible for air drier malfunctioning. and fitted with Tee handle approx.
Page 340 Braking System - Air Drier Section 250-0200 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ins Bolt 5.1 - 6.2 45 - 55 SM 1985 Rev 1 11-00 Courtesy of Machine.Market...
Page 341 BRAKING SYSTEM - Pressure Converter Section 250-0260 SM - 821 1 - Air Cylinder Body 9 - Air Piston 17 - Contact Assembly 25 - Hydraulic Piston 2 - Nut 10 - Return Spring 18 - Shim (if used) 26 - Valve Insert 3 - Washer 11 - Push Rod 19 - Nut...
Page 342 Braking System - Pressure Converter Section 250-0260 SM - 822 8 - 'O' Ring 9 - Air Piston 10 - Return Spring 11 - Push Rod 12 - End Cap 13 - Seal Ring 14 - 'O' Ring 15 - Indicator Rod 16 - Bleeder Screw 17 - Contact Assembly 18 - Shim (if used)
Page 343 Braking System - Pressure Converter Section 250-0260 1. If required, to remove the rear pressure converter, 3. Remove contact assembly (17) and shim (18), if raise body and secure in place with the body safety used, from hydraulic cylinder body (21). prop.
Page 344 Braking System - Pressure Converter Section 250-0260 2. Inspect cleaned parts for nicks, scratches, grooves, 9. Screw bushing (31) into hydraulic cylinder body (21). wear, pits, corrosion or foreign material which could Torque tighten bushing (31) to 7 - 40 Nm (5 - 30 lbf ft). cause leaks.
Page 345 Braking System - Pressure Converter Section 250-0260 MAINTENANCE hydraulic cylinder body (21). Note: Maintenance and adjustment of the brake 3. Install hydraulic line in port 'D' of end cap (12). system is contained in Section 165-0010, BRAKE PARTS. 4. Install breather hose assembly in port 'B' of hydraulic cylinder body (21).
Page 346 Braking System - Pressure Converter Section 250-0260 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft 1 & 2 7 - 14 5 - 10 1 & 2 End Cap 80 - 105 60 - 80 1 & 2 Bleeder Screw 14 - 28 10 - 20...
Page 347 BRAKING SYSTEM - Air Breather Section 250-0270 DESCRIPTION AND OPERATION SM - 823 There are two non-pressurised air breathers used in the air system, one on each of the brake pressure converters. Air displaced on the atmospheric side of the air piston in the pressure converter exhausts through the air breather.
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Page 349 BRAKING SYSTEM - Relay Emergency Valve Section 250-0280 SM - 2258 1 - Valve Body - Upper 7 - Inlet/Exhaust Valve 13 - 'O' Ring 19 - Valve Rubber 2 - 'O' Ring 8 - 'O' Ring 20 - Rivet 14 - Circlip 3 - Piston - Upper 9 - Valve Body - Lower...
Page 350 Braking System - Relay Emergency Valve Section 250-0280 supplied from the treadle valve to both the service SM - 2457 diaphragm of the spring brake chamber and to chamber 'B' of relay emergency valve via port '41'. This forces piston (2) down to close exhaust seat (7) and open inlet seat (6) thereby reinstating air pressure to the pressure converters to compress the power spring and prevent its force compounding that from the...
Page 351 Braking System - Relay Emergency Valve Section 250-0280 7. Secure relay emergency valve (1) to its mounting Note: Limited repair of the relay emergency valve is using locknuts (2) and washers (3). by replacement of parts only. Refer to vehicle Parts Book for part numbers of kits.
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Page 353 BRAKING SYSTEM - Air Pressure Protection Valve Section 250-0290 SM - 2448 SM - 2447 Rear Brake Front Tank and Rear Front Brake Treadle Tank Tank Tank Valve 11,12 Primary Auxiliary 1 - Pressure Protection Valve 7 - Tee Piece Park/Emergency Primary Tank...
Page 354 Braking System - Air Pressure Protection Valve Section 250-0290 SM - 2450 SM - 2449 A - Piston A - Piston M - Valve Body M - Valve Body B - Spring Retainer B - Spring Retainer C - Circlip X - Connection Point C - Circlip X - Connection Point...
Page 355 Braking System - Air Pressure Protection Valve Section 250-0290 (8 & 13) from pressure protection valve (1) ports. WARNING To prevent personal injury and property 6. If removed, replace all 'O' rings and install elbows damage, be sure wheel blocks are properly (5 &...
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Page 357 OPERATORS COMPARTMENT - Cab and Mounting Section 260-0010 SM - 2471 14,16,17 15,16,17 18,19,20 FRONT MOUNTING REAR MOUNTING 1 - Cab Assembly 8 - Ball Bearing 15 - Hinge 22 - Spring 9 - Hardened Washer 23 - Hardened Washer 2 - Isolation Mount 16 - Bolt 3 - Washer...
Page 358 Operators Compartment - Cab and Mounting Section 260-0010 REMOVAL WARNING Numbers in parentheses refer to Fig. 1. Before disconnecting any air conditioner lines, Note: Identify and tag all cables, harnesses, lines and refer to Section 260-0130, AIR CONDITIONING. linkages disconnected from cab assembly (1) during Refrigerant will rapidly freeze all objects with removal to aid in installation.
Page 359 Operators Compartment - Cab and Mounting Section 260-0010 16. Attach suitable slings to the cab lifting points and 5. Reconnect ball joint to lock mechanism and secure raise lifting equipment to take up the slack. hood release cable using clips removed during removal.
Page 360 Operators Compartment - Cab and Mounting Section 260-0010 MIRROR ARMS 4. Repeat steps 1, 2 and 3 for other mirror arm bracket (11). Removal Numbers in parentheses refer to Fig. 1. REPLACING GLASS Note: When replacing broken glass, it is the user’s WARNING responsibility to ensure that the replacement glass To prevent personal injury and property...
Page 361 Operators Compartment - Cab and Mounting Section 260-0010 9. Position glass onto panel opening, pressing firmly leakage inside the cab. Care should be taken to note so that adhesive bonds sufficiently to allow the glass to whether the leak is between adhesive and glass. Then be moved or straightened up as required.
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Page 363 OPERATORS COMPARTMENT - Driver Seat and Mounting Section 260-0090 SM - 2486 30 - Air Spring 1 - Seat Frame 31 - Pop-out Button 2 - Backrest Cushion 32 - Suspension Skirt 12 - Bushing 21 - Compressor 3 - Seat Cushion 33 - Allen Screw 13 - Plug 22 - Connecting Cable...
Page 364 Operator's Compartment - Driver Seat and Mounting Section 260-0090 When unoccupied, the seat sinks to the lowest position 7. Set damper adjustment (G) position to suit driving to allow easier access. conditions, (4 positions; forward position - hardest setting, rearmost position - softest setting). A retractable lap belt (9) is secured to the seat assembly using nuts and spacers.
Page 365 Operator's Compartment - Driver Seat and Mounting Section 260-0090 Vertical Shock Absorber 3. Pull up and remove backrest (6) from seat frame (1). Numbers in parentheses refer to Fig. 3. 4. Remove screws (5) securing backrest cushion (2) to seat frame (1). Remove backrest cushion (2). Note: Remove seat assembly as described in 'Disassembly' 5.
Page 366 Operator's Compartment - Driver Seat and Mounting Section 260-0090 4. Identify and tag and disconnect electrical plug 3. Pull suspension assembly up to its highest position connections (7 & 8). Unfasten cable tie on the rocker. and block securely. 5. Pull suspension assembly up to its highest position 4.
Page 367 Operator's Compartment - Driver Seat and Mounting Section 260-0090 INSPECTION INSTALLATION Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. 1. Inspect air lines, shock absorbers (15 & 26), Note: Tighten all fasteners without special torques compressor (21), level controller (28) and air spring specified to torques listed in Section 300-0080, (30) for leaks and damage and replace if required.
Page 368 Operator's Compartment - Driver Seat and Mounting Section 260-0090 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Allen Screw SM 1981 4-00 Courtesy of Machine.Market...
Page 369 OPERATORS COMPARTMENT - Air Conditioning Section 260-0130 SM - 2430 3 - Receiver Drier 5 - Evaporator 1 - Compressor 2 - Condenser 4 - Expansion Valve 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 370 Operators Compartment - Air Conditioning Section 260-0130 slow down this radiation of heat. Cooling fins are A filter screen is located in the receiver drier to stop located on the condenser tubes and fans are used to solid contaminates from leaving the unit. Blockage of circulate cool air around the condenser tubes.
Page 371 Operators Compartment - Air Conditioning Section 260-0130 REMOVAL 6. When satisfied that the system is completely Numbers in parentheses refer to Fig. 2, unless discharged, tag refrigerant hoses (5 & 6) to aid in otherwise stated. installation and carefully disconnect hoses from air conditioner (1).
Page 372 Operators Compartment - Air Conditioning Section 260-0130 SM - 2481B AIR CONDITIONER OUTER BOX 34 33 30 - Lockwasher 20 - Adjuster Bracket 11 - Condenser 31 - Bolt 1 - Air Conditioner 21 - Bolt 2 - Screw 12 - Compressor 32 - Bolt 22 - Lockwasher 3 - Lockwasher...
Page 373 Operators Compartment - Air Conditioning Section 260-0130 SM - 2481A 44 43 42 MOUNTING DETAIL INSIDE CAB EXPLODED VIEW ON FRONT OF AIR CONDITIONER BOX 4 - Harness 45 - Cover 40 - Harness 46 - Blower Unit 41 - Harness 47 - Bolt 42 - Bolt 48 - Lockwasher...
Page 374 Operators Compartment - Air Conditioning Section 260-0130 18. Support compressor (12) and remove bolts (32), 2. Connect harness (4, Fig. 3) and attach control washers (33) and locknuts (34) securing compressor cable (49, Fig. 3) to water valve (50, Fig. 3). (12) to bracket (19).
Page 375 Operators Compartment - Air Conditioning Section 260-0130 15. Remove caps from end of refrigerant hoses (6 & 7) 1. Periodically clean the condenser coil of debris and and ports on compressor (12) and connect hoses to dirt using water or air pressure. A partially blocked ports as tagged at removal.
Page 376 Operators Compartment - Air Conditioning Section 260-0130 - Do not over tension belts. being used. The quantity added should be calculated - Keep belts free from foreign material that may using the following equation: cause slippage. - Inspect the V-drive periodically. Re-tension belts if Amount of oil to add in fl oz.
Page 377 Operators Compartment - Air Conditioning Section 260-0130 DISCHARGING THE SYSTEM 1. Position the vehicle in a level work area, apply the parking brake and switch off the engine. Note: Refer to all WARNINGS listed under 'Maintenance' prior to discharging the system. 2.
Page 378 Operators Compartment - Air Conditioning Section 260-0130 11. Connect the service hose (yellow) to the R-134a 2. Pull on handle to release hood catch and raise the cylinder. Open the cylinder valve and then purge air hood. from the hose at the manifold connection. 3.
Page 379 Operators Compartment - Air Conditioning Section 260-0130 Final Charging Of The System remove the yellow supply hose. Remove both the low 1. Start the engine and run at engine idle speed. pressure (blue) hose and high pressure (red) hose from the filling ports on the compressor. 2.
Page 380 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS 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 381 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS (CONTINUED) 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 382 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS (CONTINUED) 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 383 BODY - Body and Mounting Section 270-0010 SM - 1909 LIFTING POINT LIFTING POINT 5 - Shim 1 - Body 6 - Shim 9 - Shim 12 - Plate 2 - Bushing 10 - Locknut 7 - Washer 13 - Washer 3 - Hinge Pin 8 - Bolt 11 - Spacer...
Page 384 Body - Body and Mounting Section 270-0010 started downward from the fully raised position by gravity. When the body starts lowering by gravity, the WARNING joystick can be released and internal valve springs will Exercise extreme caution when lowering move the joystick to the 'HOLD' position. the cylinders from the body.
Page 385 Body - Body and Mounting Section 270-0010 INSTALLATION BODY SHIMMING PROCEDURE Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners to standard torques listed Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.
Page 386 Body - Body and Mounting Section 270-0010 MAINTENANCE SM - 1630 64 DIA HOLE Lubricate the body hinge pins and body cylinder pins BURN at the intervals stated and with lubricant specified in Section 300-0020, LUBRICATION SYSTEM. Lubricate slowly until excess lube is seen. SPECIAL TOOLS Special tools can be fabricated as shown in Fig.
Page 387 MISCELLANEOUS - Lubrication System Section 300-0020 LUBRICATION AND SERVICE SAFETY PRECAUTIONS Do not allow unauthorized personnel to service or maintain this vehicle. Study the Operators Handbook WARNING These vehicles are equipped with engine and and Maintenance Manual before starting, operating or servicing this vehicle.
Page 388 Miscellaneous - Lubrication System Section 300-0020 SM - 2482 5 19 1 21 10 24 12 10 23 11 8 23 28 27 16 11 7 15 10 12 26 11 9 Fig. 1 - Lubrication and Servicing Points LUBRICATION AND SERVICE CHART Interval Ref.
Page 389: Miscellaneous
Miscellaneous - Lubrication System Section 300-0020 LUBRICATION AND SERVICE CHART Interval Ref. No. of Hours Points Identification Service Instructions Points Lubricant Service/Quantities Engine Drain oil and refill. See Page 6 Engine Crankcase Breather Clean. Transmission Breather Clean. Fuel Filter/Water Separator Replace.
Page 390 Miscellaneous - Lubrication System Section 300-0020 AFTER FIRST 100 HOURS OF OPERATING NEW MISCELLANEOUS SERVICING OR REBUILT COMPONENTS WHEN REQUIRED Transmission - Drain oil, replace filter, clean Seat Belts - Inspect for damage and replace if internal filter and finger magnet. Refill transmission. required.
Page 391 Miscellaneous - Lubrication System Section 300-0020 Hydraulic Oil Filter - Clean filter housing and install necessarily have to be changed. If concentration is: new element when filter restriction indicator light illuminates, or after 2 000 hours of operation, Below 0.3 units per litre (1.2 units per US gallon) whichever comes first.
Page 392 Miscellaneous - Lubrication System Section 300-0020 SERVICE CAPACITIES Service Capacities TA30 Identification Lubricant litres US gal Engine Crankcase and Filters 10.5 Transmission and Filters (dry fill) 13.8 Transmission and Filters (wet fill) Hydraulic System (Hoist & Steering) 52.8 Cooling System Coolant 15.6...
Page 393 Miscellaneous - Lubrication System Section 300-0020 Notes on Recommended Lubricants and Note 3 - Hydraulic Transmission Oil meeting Lubricant Grade Selection Tables Specification EMS19058 is suitable for use in the Note 1 - The use of low viscosity oils, such as 10W or hydraulic system.
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Page 395 MISCELLANEOUS - Service Tools Section 300-0070 INTRODUCTION 15270006 - Connecting Rod Checking Fixture 15269956 - Standard Puller Contained in this section are recommended service tools and equipment required for maintenance, 15269958 - Piston Ring Expander overhaul and troubleshooting. In certain instances, 15270078 - Manometer both Metric and Imperial equivalents of the same 15269959 - Main Bearing Cap Puller...
Page 396 Miscellaneous - Service Tools Section 300-0070 15274061 - Injector Protrusion Comparator 15274109 - Torque Angle Gauge 15274062 - Tube, Fuel Line Sight #12 15274110 - Small Bushing Driver Set 15274063 - Pilot, Oil Seal Puller Drills 15274111 - Kit,CNG Wastegate Test 15274064 - Kit, Turbo Rebuild 15274112 - Fixture, Cam Follower Assy R/I 15274065 - Digital Tachometer Kit...
Page 397 Miscellaneous - Service Tools Section 300-0070 Axles and Differentials 15270114 - Digital Depth Gauge 15269893 - Pin Spanner - M95 x 1.5 15270115 - Set of Eye Bolts 15269894 - Wheel Bolt Puller - Basic Set 15270116 - Adjusting Screws - M8 15269895 - Insert - M22 x 1.5 15270117 - Adjusting Screws - M5 15269896 - Driver...
Page 398 Miscellaneous - Service Tools Section 300-0070 Adhesives and Sealants 15270244 - Loctite 592 - Pipe Sealer with Teflon 15023696 - Loctite 635 15269103 - Loctite 221 09362529 - Loctite 225 09371048 - Loctite 638 09029849 - Loctite 243 15269107 - Loctite 641 15269108 - Loctite Superclean Safety Solvent 706 09244598 - Loctite 270 15229541 - Loctite Activator 'N'...
Page 399 Miscellaneous - Service Tools Section 300-0070 SM - 633 SILVER STEEL DOM TUBE OUTER SHIELD TO BE SECURED TO INNER BODY WITH 2BA CAPSCREWS Dimensions in mm (inches) Fig. 3 - Piston Torque Tool (Section 220-0120, STEERING CYLINDER) SM - 2469 (1.9680) (0.984) 160 (6.299)
Page 400 Miscellaneous - Service Tools Section 300-0070 SM - 2470 89 (3.5) 38.1 (1.5) SILVER STEEL EN3B MILD STEEL OUTER SHELL TO BE SECURED DOM TUBE 10.16 25.4 TO INNER BODY WITH 2BA CAP SCREWS (0.4) (1.0) Dimensions in mm (in) Fig.
Page 401 Miscellaneous - Service Tools Section 300-0070 SM - 1630 SM - 1953 64 DIA HOLE BURN Shank should be about 8 in long and fitted with Tee handle approx. 4 in long Machined Length 1.00 in 2 PLACES 2 PLACES 40˚...
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Page 403 MISCELLANEOUS - Axle Bolt and Nut Torque Specifications Section 300-0080 TORQUE LIMITS IN Nm (lbf ft) Friction coefficient total 0.125 for screws and nuts without after treatment as well as for phosphated nuts. Tighten by hand! If nothing special is indicated, select correct Torque Limits from the following tabulations - Metric ISO Thread DIN 13 TABLE161...
Page 404 Miscellaneous - Axle Bolt and Nut Torque Specifications Section 300-0080 Friction coefficient total 0.14 for screws and nuts without after treatment as well as for phosphated nuts. Tighten by hand! If nothing special is indicated, select correct Torque Limits from the following tabulations - Metric ISO Thread DIN 13 TABLE163 10.9...
Page 405 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 tables have been compiled. Some fasteners are important attaching parts which could affect the performance of vital The torque values listed in the tables have been components and systems, and/or, could result in major repair expense.
Page 406 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 407 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 408 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 409 MISCELLANEOUS - Unit Storage Section 300-0090 GENERAL 8. ENGINE - Consult the relevant Engine Maintenance The storage of machines for short periods of time or Manual for complete information on storing the engine during the off-season is an important item if major for periods shorter than 30 days.
Page 410 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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