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Alexander Dennis SUPER Dart SLF EURO 2 Service Manual

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SERVICE MANUAL
EURO 2
Publication Number: 2141
COVERING EURO 2 CHASSIS MODELS
SFD466BR1*GW3
SFD466BR1*GW4
SFD476BR1*GW4
SFD476BR1B*GW4
SFD476BR1B*GW3
SFD477BR1*GW3
SFD477BR1B*GW3
Date: JUNE 1999 (01/03)

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  • Page 1 SERVICE MANUAL EURO 2 COVERING EURO 2 CHASSIS MODELS SFD466BR1*GW3 SFD466BR1*GW4 SFD476BR1*GW4 SFD476BR1B*GW4 SFD476BR1B*GW3 SFD477BR1*GW3 SFD477BR1B*GW3 Publication Number: 2141 Date: JUNE 1999 (01/03)
  • Page 2 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without prior written permission of Alexander Dennis. Dart SPD-Pub No.2141-06/99...
  • Page 3 6.3 EXHAUST SYSTEM 6.4 CRT EXHAUST SYSTEM 7.1 FUEL SYSTEM 7.2 GEARBOX - ALLISON 7.3 GEARBOX - VOITH 8.1 HYDRAULIC SYSTEM 8.2 DRIVE SHAFT Alexander Dennis 9.1 STEERING Dennis Way 9.2 AIR SUSPENSION SYSTEM GUILDFORD Surrey GU1 1AF England Tel: (01483) 571271 10.1 FRONT AIR SUSPENSION...
  • Page 4 Dart SPD-Pub No.2141-06/99...
  • Page 5 SERVICE MANUAL INTRODUCTION SECTION 1.1 Vin Plate ..........Page 1.1.2 Using this book .
  • Page 6 INDTRODUCTION SERVICE MANUAL AMENDED: The Dart SLF can be supplied in lengths to suit 11.2 metre bodies. The exact vehicle specification is identified by the Vehicle Identification Number stamped on the Vehicle Identification Plate, a example of which is shown below: DENNIS GUILDFORD, ENGLAND 51486...

  • Page 7: Table Of Contents

    SERVICE MANUAL MAINTENANCE AMENDED: USING THIS MANUAL Structure The manual is divided into 10 Sections. These sections are separated by blue numbered dividers. Each of the manual's 10 Sections contains separate Sub-sections. An index listing both the Sections and Sub-sections is at the front of the manual, following the cover page.
  • Page 8 Dart SPD-Pub No.2141-06/99...
  • Page 9 SERVICE MANUAL SERVICE CENTRES SECTION 1.2 Regional Service Centres ....... . .Page 1.2.2 - 4 Training .
  • Page 10 SERVICE CENTRES SERVICE MANUAL AMENDED:050804 SKELMERSDALE SKELMERSDALE PARTS CENTRE: Unit 2. Priorswood Place. East Pimbo. Skelmersdale.WN8 9QB TELEPHONE: 01695 556888 FAX: 01695 556999 OUT OF HOURS CONTACT : +44 (0) 7771 973396 GUILDFORD GUILDFORD PARTS CENTRE: Dennis Way. Guildford. Surrey. GU1 1AF. TELEPHONE: 01483 599334/335/336/337 FAX: 01483 887277 OUT OF HOURS CONTACT :...
  • Page 11 SERVICE MANUAL MAINTENANCE AMENDED:050804 SOUTH EAST REGIONAL PARTS MANAGER MARK BOWLEY E-MAIL : mark.bowley@alexander-dennis.com MOBILE : 07770 645212 MIDLANDS AND SOUTH WEST REGIONAL PARTS MANAGER SIMON McFALL E-MAIL : simon.mcfall@alexander-dennis.com MOBILE : 07979 705519 NORTH REGIONAL PARTS MANAGER MATT SHENTON E-MAIL : matt.shenton@alexander-dennis.com MOBILE :...
  • Page 12 MAINTENANCE SERVICE MANUAL AMENDED:050804 BARRHEAD BARRHEAD SERVICE CENTRE: 101 Kelburn Street. Barrhead. Glasgow. G78 1LD TELEPHONE: 0141 881 5625 FAX: 0141 881 5625 OUT OF HOURS CONTACT : +44 (0) 7733 018747 BRISTOL BRISTOL SERVICE CENTRE: Folly Lane. St Philips. Bristol. BS2 0RH TELEPHONE: 0117 955 0444 FAX : 0117 955 0666 OUT OF HOURS CONTACT :...
  • Page 13 SERVICE MANUAL SERVICE CENTRES AMENDED:050804 LONDON - WEST REGIONAL SERVICE MANAGER JOHN CHAVES E-MAIL : john.chaves@alexander-dennis.com MOBILE : 07774 108840 LONDON - SOUTH REGIONAL SERVICE MANAGER STEVE EDMONDS E-MAIL : steve.edmonds@alexander-dennis.com MOBILE : 07831 704251 SOUTH EAST REGIONAL SERVICE MANAGER STEVE HARDY E-MAIL : steve.hardy@alexander-dennis.com...
  • Page 14 MAINTENANCE SERVICE MANUAL AMENDED: FALKIRK PARTS TECHNICAL - BODY: 91 Glasgow Road. Falkirk. FK1 4JB. TELEPHONE: 01324 616335 FAX: 01324 633120 GUILDFORD PARTS TECHNICAL - CHASSIS: Dennis Way. Guildford. Surrey. GU1 1AF TEL: 01483 825027 FAX: 01483 451458 FALKIRK TECHNICAL SERVICE - BODY: 91 Glasgow Road.
  • Page 15 SERVICE MANUAL HEALTH & SAFETY NOTES SECTION 1.3 Moving the vehicle ........Page 1.3.2 Working on the vehicle .

  • Page 16: Moving The Vehicle

    HEALTH & SAFETY NOTES SERVICE MANUAL AMENDED:110700 PLEASE READ FOR YOUR OWN SAFETY MOVING THE VEHICLE During movement of the vehicle chassis the hazards involved are those normally associated with all forms of powered transport. Before driving the vehicle, operators should familiarise themselves with the vehicle operator’s handbook. With the chassis in the unbodied condition, the following areas may present hazards additional to those normally encountered on a vehicle: •...

  • Page 17: Hazardous Materials

    SERVICE MANUAL HEALTH & SAFETY AMENDED:110700 PLEASE READ FOR YOUR OWN SAFETY HAZARDOUS MATERIALS Certain components on the vehicle contain, or can produce, material which must be handled cautiously. These materials are as follows: Those which must not be taken internally or contact the eyes, skin, or mouth Battery acid Diluted sulphuric acid can cause skin burns, eye damage and internal damage if ingested.

  • Page 18: Points To Remember

    HEALTH & SAFETY NOTES SERVICE MANUAL AMENDED:110700 PLEASE READ FOR YOUR OWN SAFETY Those which may cause noxious fumes if allowed to burn: Mineral oil (engine and gearbox) These do not present a fire or explosive hazard under normal circumstances. Hydraulic Fluids These do not present a fire or explosive hazard under normal circumstances.
  • Page 19 SERVICE MANUAL HEALTH & SAFETY NOTES AMENDED:110700 PLEASE READ FOR YOUR OWN SAFETY CHASSIS JACKING POINTS Note: It is not permissible to jack on any part of the frame other than the proper jacking points. it is recommended that the vehicle is supported on stands as soon as there is sufficient clearance under the vehicle.

  • Page 20: Supporting The Vehicle For Maintenance Purposes

    SERVICE MANUAL HEALTH & SAFETY NOTES AMENDED:110700 PLEASE READ FOR YOUR OWN SAFETY SUPPORTING VEHICLE FOR MAINTENANCE PURPOSES When it is necessary to elevate the vehicle to carry out maintenance it is strongly recommended that the wheel type lifts are used and that they remain in position to provide a stable and safe platform whilst carrying out maintenance / inspection tasks beneath the vehicle.
  • Page 21 SERVICE MANUAL MAINTENANCE AMENDED:110700 PLEASE READ FOR YOUR OWN SAFETY CHASSIS SUPPORT SUPER DART SLF DART SLF Dart SPD-Pub No.2141-06/99 1.3.7...
  • Page 22 Dart SPD-Pub No.2141-06/99...
  • Page 23 SERVICE MANUAL SERVICE SCHEDULE SECTION 1.4 Special tools and diagnostic equipment .......Page 1.4.2 Servicing schedule .

  • Page 24: Special Tools And Diagnostic Equipment

    SERVICE SCHEDULE SERVICE MANUAL AMENDED: SPD Dart SLF special tools and diagnostic equipment Braking System Brake chamber lock-nut spanner B90680 Brake chamber lock-nut spanner after chassis 1507 B89440 Brake tube cutter 610224 Pressure gauges 0 - 1 0 bar * 4 local supply Test hoses with ISO test connectors * 4 local supply...
  • Page 25 SERVICE MANUAL SERVICE SCHEDULE AMENDED: SERVICE .........FREQUENCY Daily .
  • Page 26 SERVICE SCHEDULE SERVICE MANUAL AMENDED: SYSTEM SERVICE NOTE DAILY FIRST AIR CLEANER Check for leaks and security of mountings Check the restriction indicator AIR CONDITIONING Check belt tension Check belt condition Check compressor for security and oil leaks FRONT AXLE Check hub bearing end play Check oil seals for leakage Check for wear in swivel pins...
  • Page 27 SERVICE MANUAL SERVICE SCHEDULE AMENDED:020801 SYSTEM SERVICE NOTE DAILY FIRST BRAKING SYSTEM (see section Test & Check List) Check all systems function correctly and correct operating pressure are being attained and the low pressure buzzer is operating Check all air line connections and mountings for leakage and security and all rubber components for signs of cracking or hardening...
  • Page 28 SERVICE SCHEDULE SERVICE MANUAL AMENDED: SYSTEM SERVICE NOTE DAILY FIRST GEARBOX - ALLISON B300R Check the oil level Check idling speed of engine Change sump filter and oil Initial change at 6,000 miles (8,000 km) and then every 24,000 miles (40,000 km) Check gearbox breather is not blocked Check tightness of all fixings...
  • Page 29 SERVICE MANUAL SERVICE SCHEDULE AMENDED:130901 SYSTEM SERVICE NOTE DAILY FIRST AIR SUSPENSION Check spring mountings, tighten if necessary Check shock absorber and mountings Check the ride height Remove dirt and grease deposits from air spring units Check air system for leaks (suspension) Inspect clean / change air suspension line air filter ENGINE AND ANCILLARIES...
  • Page 30 MAINTENANCE SERVICE MANUAL AMENDED:150300 SYSTEM SERVICE NOTE DAILY FIRST WHEELS AND TYRES Visually check all wheel nuts and check tyres are free from damage, cuts and foreign matter Check tyre pressures including spare if fitted Check tread depth is within legal limit Check valves are positioned at 180 degrees to each other on twin wheel GENERAL...
  • Page 31 SERVICE MANUAL MAINTENANCE AMENDED:140300 Vehicle Capacity Specification Recommended Component In litres Brand (approx) Engine 16.4 API:CF-4/SG or CG-4/SH Total Rubia 4400 15W-40 15W40 Gearbox Allison B300R 28.2 Dexron III Total Fluid III Oil change 22.0 Total Fluid ATX Gearbox Voith 25-28 Dexron III Total Fluid III...

  • Page 32: Engine Oil Level Checking

    MAINTENANCE SERVICE MANUAL AMENDED: Preventive maintenance begins with a day to day awareness of the condition of the vehicle. ENGINE OIL LEVEL - CHECKING DAILY CHECK The engine oil dipstick is situated at the rear right hand side of the vehicle, next to the fuel filler and above the engine oil filler.
  • Page 33 SERVICE MANUAL MAINTENANCE AMENDED:140300 VOITH GEARBOX OIL LEVEL - CHECKING MONTHLY CHECK The gearbox filler and dipstick are accessed at the rear engine compartment or through a floor hatch inside the vehicle. 1. The vehicle should be on level ground with the engine idling, neutral gear selected and the parking brake applied.

  • Page 34: Coolant Level Checking

    MAINTENANCE SERVICE MANUAL AMENDED: COOLANT LEVEL CHECKING DAILY CHECK The coolant filler cap is above the radiator at the rear of the vehicle. Remove the filler cap slowly to relieve coolant system pressure. WARNING! Check the coolant only when the engine is stopped. Wait until the temperature is below 50 degrees centigrade (120 degrees Fahrenheit) before removing the pressure cap.

  • Page 35: Hydraulic System Filter

    SERVICE MANUAL MAINTENANCE AMENDED: HYDRAULIC SYSTEM FILTER The return line filter is of the canister type and incorporates an indicator in the filter head. The indicator should be checked, with the engine running, at the recommended intervals and the cartridge changed when the indicator changes from Green to Red.

  • Page 36: Drive Belt Inspection

    MAINTENANCE SERVICE MANUAL AMENDED: DRIVE BELT INSPECTION Visually inspect the belt. Check the belt for intersecting cracks. Transverse cracks (across the belt width) are acceptable. Longitudinal cracks (direction of belt length) intersecting with transverse cracks are NOT acceptable. Renew the belt if it is frayed or has pieces of material missing. RENEWING THE DRIVE BELT 1.

  • Page 37: Air Cleaner Restriction Indicator

    SERVICE MANUAL MAINTENANCE AMENDED: AIR CLEANER RESTRICTION INDICATOR The restriction indicator is situated at the rear of the vehicle, above the air cleaner. The indicator is operated by the depression between the air cleaner and the engine, and at a preset figure, the red warning indicator will remain locked up in a visible position after the engine has stopped running.

  • Page 38: Releasing Spring Brake Actuators

    MAINTENANCE SERVICE MANUAL AMENDED: RELEASING SPRING BRAKE ACTUATORS • Place chocks behind and in front of the wheels. • Remove the cap from the end of both rear spring actuators. • Unscrew the release bolts of both actuators until the brake shoes release from the drums. •...
  • Page 39 SERVICE MANUAL AIR CLEANER SECTION 2.1 Air Cleaner diagram ..........Page 2.1.2 Maintenance .
  • Page 40 AIR CLEANER SERVICE MANUAL AMENDED: Air Cleaner Clip Mounting band Intake pipe Restriction indicator Elbow Elbow Clip Clip Compressor intake pipe Hump hose Hose - intake pipe Air Cleaner Dart SPD-Pub No.2141-06/99 2.1.2...
  • Page 41 SERVICE MANUAL AIR CLEANER AMENDED: MAINTENANCE Access is obtained through the rear engine door. The element should be changed if the restriction indicator (fitted above the rear of the filter) shows red. It is not recommended that treated elements should be washed as this removes the active chemical. In a case of necessity the element can be cleaned by blowing through with air at a max 100 p.s.i.
  • Page 42 AIR CLEANER SERVICE MANUAL AMENDED: RESTRICTION INDICATOR The restriction indicator gives a warning that the air cleaner filter is too clogged for further service. The indicator is operated by the depression between the air cleaner and the engine, and at a preset figure, the red warning indicator will remain locked up in a visible position after the engine has stopped running.
  • Page 43 SERVICE MANUAL FRONT AXLE SECTION 2.2 Diagram ..........Page 2.2.2 Description .
  • Page 44 S46LF FRONT AXLE SERVICE MANUAL AMENDED: Fig 1 S46LF Axle Dart SPD-Pub No.2141-06/99 2.2.2...

  • Page 45: Description

    SERVICE MANUAL S46LF FRONT AXLE AMENDED: 010300 DESCRIPTION The axle is of the 'Reversed Elliot' type, comprising a girder section axle bed or beam with stub axles. Each stub axle is carried on a parallel king pin with fully greased phosphor bronze bushes at top and bottom jaws.
  • Page 46 S46LF FRONT AXLE SERVICE MANUAL AMENDED: 010300 CHECK PERMISSIBLE SLACKNESS IN SWIVEL (KING) PINS EVERY 40,000 KM (25,000MILES): Aspects to be considered are: Lateral slackness Vertical slackness Before commencing checks, apply parking brake, raise wheels off the ground and support axle on stands. Checking lateral slackness Whilst this is being carried out the brake must be applied.
  • Page 47 SERVICE MANUAL S46LF FRONT AXLE AMENDED: 010300 Radial end float (radial travel) Radial end float at right angles to axis of ball pin as shown in Fig. 4 should be within limits of 0.4mm to 0.8mm max. using a test force of 6000N.
  • Page 48 S46LF FRONT AXLE SERVICE MANUAL AMENDED: 010300 If there is corrosion of the ball pin or the sealing boot has deteriorated through ageing or is damaged, replace the ball joint in question, or the complete tie rod or drag link as appropriate. If there is corrosion of the steering lever area which is in contact with the sealing boot, clean and eliminate all surface irregularities.

  • Page 49: Removal And Dismantling Of Hub / Brake Units

    SERVICE MANUAL S46LF FRONT AXLE AMENDED: Removing and Dismantling of Hub / Brake Units 1. Loosen but do not remove, wheel nuts (6) then jack up axle and support on axle stands. 2. Remove wheel nuts (6) and road wheels. 3.

  • Page 50: Inspection

    S46LF FRONT AXLE SERVICE MANUAL AMENDED: 120701 Inspection Clean and inspect all parts for wear and / or damage. Any parts found defective in any way should be removed. Re-assembling Axle Stub / Axle Build Unit 1. Check tightness in turn of bottom lever studs (40 & 41), 190 - 210 lbs ft. (258 - 285 Nm). 2.

  • Page 51: Swivel Setting And Adjustment

    SERVICE MANUAL S46LF FRONT AXLE AMENDED: 010300 Swivel Setting and Adjustment 1. Mount a dial test indicator on axle bed (28) and position pointer on top swivel jaw (14). See fig 8. Fig. 8 2. Position a suitable pry bar between axle bed (28) and swivel (14) to check for lift. The correct reading should be within the limits 0.002"...
  • Page 52 S46LF FRONT AXLE SERVICE MANUAL AMENDED: 010300 4. Assemble bottom cap (45) onto swivel (14) securing with washers and setscrews (43 & 44) then tighten setscrews to 26 - 32 lbf ft. (35 - 43Nm). Bottom cap must be assemblied to swivel within 5 minutes after applying Loctite. 5.

  • Page 53: Fitting Brake And Hub Units

    SERVICE MANUAL S46LF FRONT AXLE AMENDED: 010300 Fitting Brake and Hub Units 1. Fit brake assembly (12) onto its register on stub (14) and secure in place with washers and nuts (49 & 50) also bolts, washers and nuts (10, 15 &16). Tighten nuts to 85 -103 lbs ft.

  • Page 54: Hub Bearing Setting

    S46LF FRONT AXLE SERVICE MANUAL AMENDED: 010300 Hub Bearing Setting 1. Rotate hub whilst shock loading the assembly by knocking hub flange backwards and forwards along axle stub using a hide mallet. It is very important to 'shock load' the hub in this way because: •...

  • Page 55: Final Assembly

    SERVICE MANUAL S46LF FRONT AXLE AMENDED: 010300 Final Assembly 1. Smear inside of hub cap (53) with a thin ( " thick) film of grease (Shell Retinax LX or equivalent). 2. Clean hub cap and hub mating faces (53 & 8) with Loctite Superclean Safety Fluid 706 or similar chlorinated cleaning fluid then apply a complete bead of Loctite Superflex or equivalent sealant to hub cap face.
  • Page 56 S46LF FRONT AXLE SERVICE MANUAL AMENDED: 010300 6. Check wheel alignment as follows (Fig.14) Set axle in straight ahead position. At a point level with wheel centre, measure distance over brake drums (4), both in front and behind axle centre. iii) Front measurement 'B' should be 0.0"...

  • Page 57: Lubrication Instructions

    SERVICE MANUAL S46LF FRONT AXLE AMENDED: 010300 TIGHTENING TORQUE TABLE - S46LF AXLE Item No. Description Torque lb ft Torque Nm Wheel nut 285 - 315 lbs ft 385 - 425 Nm Brake backplate nut 85 - 103 lbs ft 115 - 140 Nm Top cap setscrew 26 - 32 lbs ft...
  • Page 58 S46LF FRONT AXLE SERVICE MANUAL AMENDED: 010300 Mobil Mobilgrease MP Energrease L2 Grease Specification Castrol Castrol LMX Lithium based roller bearing grease NLGI - No 2. Esso Unirex EP2 Shell Retinax LX Recommendation For Correct Amount of Grease in Wheel Hub - See Fig 16. Texaco Multifak Multi Purpose 2 (UK) Marfak HD2(o/seas)
  • Page 59 SERVICE MANUAL REAR AXLE SECTION 3.1 Ring gear and pinion identification diagram ......Page 3.1.2 Ring gear and pinion identification .
  • Page 60 REAR AXLE SERVICE MANUAL AMENDED: Differential Carrier Assembly Dart SPD-Pub No.2141-06/99 3.1.2...
  • Page 61 SERVICE MANUAL REAR AXLE AMENDED: RING GEAR AND PINION IDENTIFICATION Ring gear and drive pinion are matched parts and must be renewed as a set, the part number being listed in the parts catalogue. To aid in identifying gear sets, parts are stamped with such information as number of pinion and ring gear teeth, individual part number and matched set number (refer to drawing below).
  • Page 62 Dart SPD-Pub No.2141-06/99...
  • Page 63 SERVICE MANUAL REAR AXLE SERVICE SECTION 3.2 Lubrication ..........Page 3.2.3 Oil change intervals .
  • Page 64 Dart SPD-Pub No.2141-06/99...

  • Page 65: Lubrication

    SERVICE MANUAL REAR AXLE SERVICE AMENDED: LUBRICATION Proper lubrication is vital for optimal drive axle service life. The importance of the following procedures cannot be overstated. The recommended multigrade gear lubricant is 85W-140. Synthetic lubricants are approved provided they meet MIL-L-2105C. Oil additives are NOT APPROVED for use in Eaton axles.

  • Page 66: Wheel Bearing Adjustment

    REAR AXLE SERVICE SERVICE MANUAL AMENDED: 5. Once the axle is levelled and wheel ends are assembled, add oil through the filler hole in the axle housing cover until fluid is level with the bottom of the filler hole. Always use the upper plug i.e. the larger plug mounted on the axle centre line. Do not remove the lower plug.

  • Page 67: Cleaning

    SERVICE MANUAL REAR AXLE SERVICE AMENDED: CLEANING Proper cleaning requires complete disassembly. The differential carrier assembly may be steam cleaned only while mounted in the housing provided all openings are plugged. Wash castings or other rough parts in solvent or clean in hot solution tanks using mild alkali solutions, heating parts thoroughly before rinsing.
  • Page 68 Dart SPD-Pub No.2141-06/99...
  • Page 69 SERVICE MANUAL REAR AXLE OVERHAUL SECTION 3.3 Removal / Disassembly Differential carrier assembly removal ......Page 3.3.3 Disassemble differential carrier .
  • Page 70 Dart SPD-Pub No.2141-06/99...

  • Page 71: Differential Carrier Assembly Removal

    SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: OVERHAUL Do not strike the axle shaft flange with a hammer. Do not use chisels or wedges to loosen shaft or dowels. Do not lie under carrier while removing fasteners or after fasteners are removed. Use transmission jack to support and remove differential carrier assembly.
  • Page 72 REAR AXLE OVERHAUL SERVICE MANUAL AMENDED: 3. Punch mark differential bearing caps. If reusing gear set, also punch mark bearing adjusters for reference during reassembly. 4. Remove cap screws, flat washers and bearing caps. 5. Remove bearing adjuster and bearing cups. Using a chain hoist, lift ring gear and differential assembly out of carrier.

  • Page 73: Disassemble Drive Pinion

    SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: DISASSEMBLE DRIVE PINION Caution: During the following yoke removal procedure, do not allow the pinion to drop on a hard surface. 1. If Pinion nut was loosened during earlier disassembly, clamp yoke in vice jaws. Use brass pads to prevent damage.
  • Page 74 REAR AXLE OVERHAUL SERVICE MANUAL AMENDED: 4. Remove and retain bearing spacer from pinion. 5. Using a bearing cup remover, remove inner bearing cup. Note: Bearing cup remover, part number J-3940 (Kent Moore Co.) or equivalent can be used to remove inner bearing cup. 6.

  • Page 75: Disassemble Wheel Differential

    SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: DISASSEMBLE WHEEL DIFFERENTIAL Caution: During following procedure, place differential assembly on malleable surface to prevent damage when ring gear falls off its mounting position. 1. Remove nuts and bolts fastening ring gear to differential cases, allowing gear to fall free. If gear does not fall, tap outer diameter with soft mallet to loosen.

  • Page 76: Assemble Wheel Differential

    REAR AXLE OVERHAUL SERVICE MANUAL AMENDED: ASSEMBLE WHEEL DIFFERENTIAL Lubricate differential parts with gear oil during assembly. 1. Press bearing cone on flanged differential case. 2. Press bearing cone on plain differential case. Bearing Cone Installation To prevent bearing damage, use suitable sleeve that only contacts bearing inner race. 3.

  • Page 77: Assemble Drive Pinion

    SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: ASSEMBLE DRIVE PINION Lubricate parts with gear oil during reassembly. When installing bearing cones and pilot bearing, use properly-sized sleeves that only contact the inner bearing race. 1. Before installing cups, check for burrs on bearing surfaces and remove.

  • Page 78: Pinion Bearing Preload Adjustment

    REAR AXLE OVERHAUL SERVICE MANUAL AMENDED: PINION BEARING PRELOAD ADJUSTMENT (TRIAL BUILD - UP) Pinion bearing spacer thickness should be predetermined using a trial build-up. This procedure will result in proper bearing preload in three out of four cases, saving time in subsequent procedures. 1.
  • Page 79 SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: Oil seal drag test The pinion seal used in the axle creates a small amount of drag which can affect pinion bearing preload measured at pinion final assembly. The drag attributable to these seals must be determined through the following procedure.
  • Page 80 REAR AXLE OVERHAUL SERVICE MANUAL AMENDED: PINION BEARING PRELOAD TEST When oil seal drag has been determined, the pinion bearing preload should be measured using either of the two following methods. The press method should be used only if a press is available having a calibrated load cell to accurately indicate press load in tons.

  • Page 81: Install Drive Pinion

    SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: INSTALL DRIVE PINION 1. Place shim pack on carrier. If gear is to be reused, install same quantity and size of shims removed during disassembly. When installing a new gear set, use nominal shim pack of 0.024in. (0.61mm) thickness.

  • Page 82: Adjust Differential Bearing Preload

    REAR AXLE OVERHAUL SERVICE MANUAL AMENDED: ADJUST DIFFERENTIAL BEARING PRELOAD Correct differential bearing preload ensures proper location of these bearings under load and helps position the ring gear for proper gear tooth contact. Before performing the following adjustments, make sure there is adequate clearance between the ring gear and thrust screw if still installed.

  • Page 83: Adjust Ring Gear Backlash

    SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: ADJUST RING GEAR BACKLASH Check backlash as described below and adjust if necessary. Measure backlash with a dial indicator. For new gearing this should be 0.008-0.017 in. (0.20-0.43mm). The indicator should be positioned on a ring gear tooth, at the extreme heel end, perpendicular to the tooth surface.

  • Page 84: Adjust Ring Gear Tooth Contact For Standard Pattern Eaton Axles

    REAR AXLE OVERHAUL SERVICE MANUAL AMENDED: ADJUST RING GEAR TOOTH CONTACT FOR STANDARD PATTERN EATON AXLES After differential bearing preload and gear backlash adjustment is complete, check gear tooth contact pattern and adjust if necessary Correct Tooth Contact Pattern (New Gearing) Paint ring gear teeth with marking compound and roll the gear to obtain a contact pattern as shown in the drawings.
  • Page 85 SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: Adjust pinion position If the contact pattern shows incorrect tooth depth contact, change drive pinion position by altering the shim pack under the cage and cup assembly. Used gears should achieve proper contact with the same shims removed from the axle at disassembly.

  • Page 86: Adjust Ring Gear Tooth Contact For K Pattern Eaton Axles

    REAR AXLE SERVICE MANUAL AMENDED: ADJUST RING GEAR TOOTH CONTACT FOR K PATTERN EATON AXLES CORRECT PATTERN Before adjusting crownwheel position in the following procedures, loosen the thrust screw locknut and back off the thrust screw to allow crownwheel movement. New Gearing Paint crownwheel teeth with marking compound and roll the gear to obtain a contact pattern.
  • Page 87 SERVICE MANUAL REAR AXLE AMENDED: Adjust pinion position If the gear pattern shows incorrect tooth depth contact, change drive pinion position by altering the shim pack. Used gears should achieve proper contact with the same shims removed from the axle at disassembly.

  • Page 88: Install Differential Carrier Assembly

    REAR AXLE OVERHAUL SERVICE MANUAL AMENDED: INSTALL / ADJUST RING GEAR THRUST SCREW 1. Thread thrust screw into the carrier until firm contact with the backface of the ring gear is made. 2. Loosen the thrust screw ¼ turn to obtain the correct adjustment of 0.020"...
  • Page 89 SERVICE MANUAL REAR AXLE OVERHAUL AMENDED: TORQUE CHART Fastener Metric Class lb - ft Threaded Size Differential case cap screw M12 x 1.75 10.9 136 - 149 100 - 110 Ring gear nut M14 x 1.5 230 - 258 170 - 190 Pinion bearing cage cap screw M14 x 2.0 10.9...
  • Page 90 Dart SPD-Pub No.2141-06/99...
  • Page 91 SERVICE MANUAL REAR AXLE HUB OVERHAUL SECTION 3.4 Rear hub diagram .........Page 3.4.2 Hub dismantling .
  • Page 92 REAR AXLE HUB OVERHAUL SERVICE MANUAL AMENDED: Hub seal Spring washer Hub bearing - inner Stud Hub assembly Wheel nut Hub bearing - outer Wheel bolt Adjustable nut - inner Brake drum Adjustable lock washer Axle casing Adjustable nut - outer Grease shield Axle shaft Retaining bolt...
  • Page 93 SERVICE MANUAL REAR AXLE HUB OVERHAUL AMENDED: HUB DISMANTLING • Support and raise the vehicle. Release the spring brakes. • Remove the wheel nuts and the road wheel. • Remove the nuts and washers and withdraw the axle shaft. • Remove the brake drum retaining screws and jack off the brake drum using tapped holes provided.
  • Page 94 REAR AXLE HUB OVERHAUL SERVICE MANUAL AMENDED: TORQUE REQUIREMENT This section gives the torque requirements for bolts, nuts and setscrews. Correct tightening torque values are extremely important to assure long axle life and dependable performance. Over-tightening of attaching parts is just harmful as under-tightening. Torque Settings Fixing lb.
  • Page 95 SERVICE MANUAL BRAKING SYSTEM SECTION 4.1 Braking system diagram ......... . .Page 4.1.2 Description .
  • Page 96 BRAKING SYSTEM SERVICE MANUAL AMENDED: 200799 FRONT FRONT BRAKE BRAKE CHAMBER CHAMBER TO THROTTLE PEDAL FOOTBRAKE VALVE AIR 1 STOP SWITCHES AIR 2 RETARDER PRESSURE SWITCHES PRIMARY HANDBRAKE VALVE SECONDARY TO STEERING INSTRUMENT COLUMN CLAMP PANEL PARK SOLENOID VALVE STEERING COLUMN AUX &...

  • Page 97: Description

    SERVICE MANUAL BRAKING SYSTEM AMENDED: DESCRIPTION The braking system is fully air operated, the front wheel brakes being applied by diaphragm actuators while the rear actuators can be spring-applied in addition to pneumatic operation. A compressor, driven by the engine, connects to a cartridge-type air drier. In addition to drying and filtering the air, the dryer purge cycle is used as an unloading device, diverting the compressor output to atmosphere when the pressure in the reservoirs in high.
  • Page 98 BRAKING SYSTEM SERVICE MANUAL AMENDED: Component locations Dart SPD-Pub No.2141-06/99 4.1.4...
  • Page 99 SERVICE MANUAL BRAKING SYSTEM AMENDED:041200 BRAKE SYSTEM COMPONENTS COMPRESSOR F This compressor is an engine driven single or twin cylinder unit, with a balanced crankshaft and reed type valve. The cylinder head is cooled by water from the vehicle cooling system and is lubricated by oil from the engine lubrication system.
  • Page 100 BRAKING SYSTEM SERVICE MANUAL AMENDED:041200 ITEM DESCRIPTION PART NO DETAILS Brake Assemblies Front brake assembly LH 654975 Perrot single leading shoe Front brake assembly RH 654974 360mm x 170mm Rear brake assembly LH 654973 Torque settings: Rear brake assembly RH 654972 For brake brackets, hub to drum etc, see front and...

  • Page 101: Test And Check List

    SERVICE MANUAL BRAKING SYSTEM AMENDED: TEST AND CHECK LIST IMPORTANT Before working on or around vehicle air systems and components, the following precautions should be observed. • Stop the engine before working under a vehicle. • Always chock the wheels because depleting vehicle air system pressure may cause the vehicle to roll.
  • Page 102 BRAKING SYSTEM SERVICE MANUAL AMENDED: TEST PROCEDURE FOR VEHICLE BRAKING SYSTEM TEST 1 Govemor/Unloader Cut-Out Low pressure Warning Pressure Build-Up 1. Drain all reservoirs to 'O' bar. 2. Start engine (run at fast idle). Low pressure warning light should be on, buzzer should sound. 3.
  • Page 103 SERVICE MANUAL BRAKING SYSTEM AMENDED: TEST 2 Leakage (Reservoir Air Supply) (Full pressure Engine stopped) 1. Allow pressure to stabilise for at least 1 minute. 2. Observe dash gauge pressures for 2 minutes and note any pressure drop. 0. 15 bar maximum for each reservoir. Make all necessary repairs before proceeding to Test 3 - see Check List 2 for common corrections.
  • Page 104 BRAKING SYSTEM SERVICE MANUAL AMENDED: Check list 3 If there is excessive leakage in the service side of the system, One or more of the following devices could be causing the problem: NOTE: A leak detector or soap solution will aid in locating the faulty component. •...
  • Page 105 SERVICE MANUAL BRAKING SYSTEM AMENDED: TEST 5 Secondary/Emergency System (Full Pressure, Engine Stopped) 1 Drain front axle reservoir to 'O' bar. Remaining reservoir pressures should not fall below the close setting of the reservoir protection valve(s). (See Data Sheet). 2. Without recharging front reservoir make a brake application. Rear axle brakes should apply and release.

  • Page 106: Quick Release Valve

    BRAKING SYSTEM SERVICE MANUAL AMENDED: QUICK RELEASE VALVE DESCRIPTION Quick release valves are installed in air brake systems adjacent to the brake actuators to hasten the exhaust of the air from the actuators when the applied pressure is released. If they are not used, air must travel back through relatively long lines to exhaust at the brake valve, which is normally located some distance from the brakes.
  • Page 107 SERVICE MANUAL BRAKING SYSTEM AMENDED: MAINTENANCE Every 3 months, or 10,000 miles, check Quick Release Valve as follows: 1. Apply vehicle brakes and ensure that when they are released the air pressure is quickly exhausted through the valve exhaust ports. 2.
  • Page 108 BRAKING SYSTEM SERVICE MANUAL AMENDED: Back plate Lining Rubber plug Rivet Rubber plug Brake release spring Expander unit Brake release spring Brake shoe complete Hold down spring Fig. 1 Brake Assembly Dart SPD-Pub No.2141-06/99 4.1.14...

  • Page 109: Wheel Brake

    SERVICE MANUAL BRAKING SYSTEM AMENDED: WHEEL BRAKE Description of Brake assembly (Figs. 1 and 2) The brake is a single leading shoe unit with a wedge-type expander and sliding shoes. The expander is operated by an external air cylinder screwed to a spigot on the inner face of the brake. On the rear brakes, a spring in the actuator applies the brakes while the vehicle is at rest.
  • Page 110 BRAKING SYSTEM SERVICE MANUAL AMENDED: Piston Roller Strap plate Wedge Spring plate Return spring Washer Adjuster screw Adjuster nut Hollow screw Lock plate Spring Spring Plunger Seal Hose clip Adjuster spring Adjuster washer Adjuster screw Brake shoe locator Adjuster seal securing spring Fig.
  • Page 111 SERVICE MANUAL BRAKING SYSTEM AMENDED: Description of Expander (Fig. 3) The expander unit is secured to the brake plate by four screws. The spigot on the housing (1) is threaded to accept the actuating cylinder and projects out towards the axle centreline. The inner end of the wedge (4) contacts plunger in the actuator while the inner, tapered end (B) is located between two rollers (2) which are in contact with the pistons (1).
  • Page 112 BRAKING SYSTEM SERVICE MANUAL AMENDED: To remove the brake shoes, first disconnect the upper and lower tension springs (Figs. 6 and 7). Fig. 6 Fig. 7 Slide the brake shoe across the brake backplate and out of the hold down spring (Figs. 8 and 9). Fig.
  • Page 113 SERVICE MANUAL BRAKING SYSTEM AMENDED: Check that the flexible gaiters are in good condition. Every second time the brakes are relined, take off the flexible seals lock plates and take out the screws. Clean the internal components, check that they are in good condition and lubricate them with Texaco Thermatex EP 1 or an equivalent grease.
  • Page 114 BRAKING SYSTEM SERVICE MANUAL AMENDED: Check that the wedge (Fig. 12) is projecting approx 60.5mm from the spigot. Fig. 13 Fig. 12 Screw the cylinder in fully, then back off as far as the connecting lines. Tighten the locknut to 300 - 330 Assembly Set the expander adjuster to the minimum value.
  • Page 115 SERVICE MANUAL BRAKING SYSTEM AMENDED: Checking correct operation Slowly apply the brake at the pedal; check at the inspection holes that the shoes are touching the drum. When the pedal is released, the brake shoes must return to their initial positions immediately. If the brakes bind, check as follows: Wedge does not move back Cause:...

  • Page 116: Front Brake Actuator

    BRAKING SYSTEM SERVICE MANUAL AMENDED: FRONT BRAKE ACTUATOR Description The front brake actuator body has a threaded spigot welded to it which screws into the brake unit and is locked by an attachment lock nut. The spigot is bored to take a push rod carrying two seals. An air chamber is fitted to the open end of the body and is secured by a clamp ring which also locates a flexible diaphragm between the two components.

  • Page 117: Rear Brake Actuator

    SERVICE MANUAL BRAKING SYSTEM AMENDED: REAR BRAKE ACTUATOR Description The rear brake actuator body has a threaded hollow spigot welded to it which screws into the brake unit and is locked by an attachment locknut. The spigot bore takes a push rod with two seals. An air chamber, fitted to the open end of the body, is secured by a clamp ring which also locates a flexible diaphragm.
  • Page 118 BRAKING SYSTEM SERVICE MANUAL AMENDED: Servicing Servicing is limited to renewing the diaphragm or the complete spring end. To dismantle the unit proceed as follows. 1 Compress the piston spring by turning the spring wind-off bolt counter-clockwise until it extends 50mm.

  • Page 119: Compressor

    SERVICE MANUAL BRAKING SYSTEM AMENDED: COMPRESSOR Description This compressor is a single cylinder, single stage machine with a balanced crankshaft and reed type air valve. The cylinder head is cooled by water from the vehicle cooling system. The compressor is lubricated by oil from the engines lubrication system.
  • Page 120 BRAKING SYSTEM SERVICE MANUAL AMENDED: Mounting flange Crankcase Reed-valve plate Cylinder head Air inlet port Water connections Inlet valve Air delivery valve Air delivery port Gaskets Piston Piston rings Oil control ring Gudgeon pin Circlips Crankshaft Thrust washer Bearing bushes End cover Drive dog Lubrication port...
  • Page 121 SERVICE MANUAL BRAKING SYSTEM AMENDED: Dismantling cylinder head and valve plate (See Fig 3) 1. Remove the four Cylinder Head Bolts and Washers (A). 2. Remove the Cylinder Head Cover (B) and discard Gasket (1). 3. Remove Cylinder Head (C) and discard Gasket (2). 4.

  • Page 122: Air Dryer

    BRAKING SYSTEM SERVICE MANUAL AMENDED: AIR DRYER 1. Dessicant cartridge 2. Purge valve assembly 3. Unloader valve assembly 4. Pressure relief valve AD6 Air Dryer AD6S Air Dryer with spin on canister with replacement cartridge Dart SPD-Pub No.2141-06/99 4.1.28...
  • Page 123 SERVICE MANUAL BRAKING SYSTEM AMENDED: Description The air dryer removes any air or water vapour which passes through the condenser unit, controls the unloading pressure of the two compressors and provides a safety valve. A non-serviceable dessicant cartridge, which screws into the top of the dryer body, is filled with micro- crystalline pellets, each having many minute pores to give a very large surface area.
  • Page 124 BRAKING SYSTEM SERVICE MANUAL AMENDED: Operation The Charge Cycle begins when the warm contaminated supply air enters the dryer body and passes up into the desiccant cartridge. As the air enters the cartridge it begins to cool and the resulting condensate collects in the bottom of the body as a mixture of water and oil.
  • Page 125 SERVICE MANUAL BRAKING SYSTEM AMENDED: Removing “Spin on" canister assembly - AD6. Use a strap wrench to remove the canister assembly. The strap must be located as close to the bottom of the canister as possible. Dismantling cartridge assembly - AD6S 1.
  • Page 126 BRAKING SYSTEM SERVICE MANUAL AMENDED: Dismantling purge valve assembly 1. Remove 4 screws (C), housing (D), and discard gasket (3). 2. Using suitable circlip pliers, remove circlip (F). 3. Remove retaining ring (H). 4. Remove and discard 'O' Ring (5) which is situated in recess. 5.
  • Page 127 SERVICE MANUAL BRAKING SYSTEM AMENDED: 4. Place the purge valve assembly in the bore and push home. 5. Grease recess to accept new 'O' Ring (5). 6. Lightly grease the new 'O' Ring (5) and carefully manoeuvre it into recess. This may require some pressure but use something which is both blunt and smooth.
  • Page 128 BRAKING SYSTEM SERVICE MANUAL AMENDED: Assembling unloader assembly 1. Fit new lower bonded valve (16). 2. Fit new pilot valve piston bush (9). 3. Replace pilot valve piston (M). 4. Fit new upper bonded valve (16) 5. Replace control rod (L). 6.
  • Page 129 SERVICE MANUAL BRAKING SYSTEM AMENDED: NOTES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 130 BRAKING SYSTEM SERVICE MANUAL AMENDED: DUAL FOOTBRAKE VALVE Description The E.6 Dual footbrake valve provides the driver with a graduated braking control for applying and releasing a service brake system that is split into two separate circuits, each with its own reservoir. Should one circuit fail, the other circuit will remain intact and be capable of stopping the vehicle.
  • Page 131 SERVICE MANUAL BRAKING SYSTEM AMENDED: OPERATION Refer to Figure 1 The brake application force is transmitted through seat Q and the rubber graduating spring R to piston N. As N descends, its exhaust valve seat M closes exhaust passage F in valve K. The continued movement of N then pushes K off inlet valve seat L.
  • Page 132 BRAKING SYSTEM SERVICE MANUAL AMENDED: Fig. 2 Dual Footbrake Valve The numbered items are supplied in the Service kit. For alphabetical references, see instructions. Dart SPD-Pub No.2141-06/99 4.1.38...
  • Page 133 SERVICE MANUAL BRAKING SYSTEM AMENDED: To Dismantle Refer to Figure 2 1 Unscrew four screws to remove exhaust cover A. Remove inlet/exhaust valve assembly (1). 2. With the valve lightly gripped and horizontal in a vice hold locknut (2), insert screw driver into slot stem B and unscrew, taking care not to damage the valve seats at G.
  • Page 134 BRAKING SYSTEM SERVICE MANUAL AMENDED: To Test 1. Set up valve on a test rig on the vehicle. Ensure at least 5.5 bar (80 psi) is available. Connect air supply ports. Use soap and water solution to test for leaks at delivery ports, exhaust cover and body joints.
  • Page 135 SERVICE MANUAL BRAKING SYSTEM AMENDED: HAND CONTROL VALVE Description The valve controls the flow of air which releases the parking brake The control lever is spring loaded in the OFF position but will lock in the PARK position. Operation When the valve handle is in the brake 'OFF' position the vehicle spring brakes are held off by the maintenance of air pressure in the spring brake actuators.
  • Page 136 BRAKING SYSTEM SERVICE MANUAL AMENDED:140300 FOOTBRAKE VALVE - VOITH Dart SPD-Pub No.2141-06/99 4.1.42...
  • Page 137 SERVICE MANUAL BRAKING SYSTEM AMENDED:140300 FOOTBRAKE VALVE - VOITH- (Microswitch Type) PEDAL ASSEMBLY - DISMANTLING 1. Remove the four nuts (20) and separate and remove the upper and lower section (1) and the micro switch assembly and remove large seal (18) from the valve 2.
  • Page 138 Dart SPD-Pub No.2141-06/99...
  • Page 139 SERVICE MANUAL PIPE CONNECTORS SECTION 4.2 Plastic pipe fitting type PA ........Page 4.2.2 Pipe removal .
  • Page 140 PIPE CONNECTORS SERVICE MANUAL AMENDED: INTRODUCTION This section describes the pipe connector used on the Dart bus chassis. No modification may be made, nor may any air piping be relocated without the express permission of Dennis. WARNING Before working on any piping, ensure that any internal pressure has been released. PLASTIC PIPE FITTING TYPE PA In this type of fitting, the pipe pushes on to an internal spigot where it is locked in position by a toothed grab ring.
  • Page 141 SERVICE MANUAL PIPE CONNECTORS AMENDED: Pipe assembly In order to avoid any abnormal strain on the fitting and consequently guarantee a better performance, it is important to follow the minimum bend radius and the minimum straight length indicated in the table below. Diameter R minimum L minimum...
  • Page 142 PIPE CONNECTORS SERVICE MANUAL AMENDED: METAL PIPE FITTING TYPE MA In this type of connection, the pipe end has a conical flare and is secured to the fitting with a nut, a sleeve pressing the pipe into close contact with the cone on the fitting to form a good seal. The fitting can be secured to the valve, etc, either by a taper male NPTF thread or by a straight JIC thread.
  • Page 143 SERVICE MANUAL PIPE CONNECTORS AMENDED: NYLON BRAKING TUBE REPAIR Should damage occur to the nylon brake tubing it is permissable to carry out a repair using a in line double connector. Suitable in line connectors are available from Dennis. Part No Pipe O/D Length 655416-1...
  • Page 144 Dart SPD-Pub No.2141-06/99...
  • Page 145 SERVICE MANUAL COOLING SYSTEM SECTION 5.1 Diagram ............Page 5.1.2 Description .
  • Page 146 COOLING SYSTEM SERVICE MANUAL AMENDED:140300 HEADER TANK RADIATOR HEATER VOITH CONNECTION ONLY ENGINE COOLANT TEMPERATURE SENSOR HIGH COOLANT TEMP SWITCH ALLISON GEARBOX ALLISON GEARBOX OIL COOLER ARRANGEMENT OIL COOLER VOITH GEARBOX VOITH GEARBOX OIL COOLER ARRANGEMENT OIL COOLER Dart SPD-Pub No.2141-06/99 5.1.2...

  • Page 147: Description

    SERVICE MANUAL COOLING SYSTEM AMENDED: 140300 COOLING SYSTEM Description The engine is cooled by water passing through a radiator on the offside beside the engine. The engine water pump draws water from the bottom of the radiator through a pipe run which includes the gearbox oil cooler.

  • Page 148: Coolant

    COOLING SYSTEM SERVICE MANUAL AMENDED: COOLANT The recommended Ethylene Glycol antifreeze is Total Universal at a dilution of 50% (1:1) This will give protection down to -37°C and will also ensure the correct degree of anti-corrosion protection. The radiator header tank should be topped up to the bottom of the filler neck with the correct strength solution. soft water in the coolant mixture.
  • Page 149 SERVICE MANUAL ELECTRICAL EQUIPMENT SECTION 5.2 Description ..........Page 5.2.2 Precautions .

  • Page 150: Description

    ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: DESCRIPTION The 24 volt electrical system is wired NEGATIVE earth and current is delivered by two 12 volt batteries and an alternator. Routine maintenance and any fault finding and correction should only be carried out by a skilled automotive electrical engineer as it is highly probable that permanent damage may be done by tampering with the equipment.

  • Page 151: Safety Precautions

    SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Safety Precautions The charging, handling and use of lead-acid batteries is not dangerous providing appropriate care is taken. It is vital to ensure that no source of ignition can exist close to batteries. 1 Do not smoke. 2.

  • Page 152: Starter

    ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: STARTER Description By operation of a solenoid the starter pinion is engaged with the flywheel ring gear before the starter is energised, after which the pinion can be retained in mesh for as long as is necessary to start the engine. When the engine is firing and the pinion is being driven at high speed by the flywheel, the armature is protected against over-speeding by the freewheel action of a roller or plate...

  • Page 153: Preliminary Checks

    SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Preliminary Checks Check all connections within the charging system. Inspect alternator drive belt for signs of splitting or wear. Renew if required. Test 1: Battery Test Using a high discharge tester, check that the battery is at least 70% charged. The full battery test procedure is outlined in Section 1.
  • Page 154 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Test 5: Checking Voltage Regulator Setting Before checking regulator, it is essential that a battery in a well charged condition fitted to the vehicle. 1. Disconnect the battery earth cable. 2. Connect an ammeter between the starter solenoid terminal and the alternator main output cable. Connect a voltmeter across the battery terminals.

  • Page 155: Electronic Control Unit

    SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: "ALADIN' ELECTRONIC CONTROL UNIT- Description The Dart SLF electrical system, is fitted with an electronic control unit which manages and monitors the majority of the vehicles electrical and electronic components. The advantages of the "ALADIN" unit is that most of the relays, fuses and circuit breakers can be eliminated, with the added advantage of reducing number of cables and connectors used in wiring a vehicle.

  • Page 156: Diagnostic System

    ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: PRINCIPLE OF OPERATION The "ALADIN" unit is basically a microcontroller, monitoring three types of input: 1. Digital Switch on/off inputs, e.g. fog light switch. 2. Analogue Sensor signals, eg temperature sensor 3. Pulsed Speed signals, eg tachograph or speedometer Based on the input conditions, the controller decides which outputs to switch on or off.
  • Page 157 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Faults detectable Flash code Stored Stop w/l Coolant temp. w/l Rear module Oil pressure w/l Engine run relay Direction ind. w/l Direction ind. w/1 RHS Fog lamps rear Stop lamps Coolant level w/l Battery master switch Motor starter relay Ignition solenoid Dipped beam RHS...
  • Page 158 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: DIAGNOSTIC FLASH CODE EXAMPLES TIME INTERVALS T1 = 2 seconds T2 = 700 ms T3 = 3 seconds T4 = 350 ms T5 = 1 second FAULT REGISTERED Dart SPD-Pub No.2141-06/99 5.2.10...
  • Page 159 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: VIEWING THE FAULT CODE When the diagnostic system detects a fault, the diagnostic switch will be continuously illuminated. The fault will be stored until it is accessed and displayed; once the fault is read it is cancelled and cannot be recalled again unless the fault is present when that output is operated.
  • Page 160 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: ELECTRICAL DISTRIBUTION CENTRE - (E.D.C.) - FRONT - ALLISON GEARBOX Relays Fuses 1. Reverse lights 1. Kneeling system (Orange) 2. Do not shift - W/L 2. Horn (Red) 3. Gearbox temperature W/L 3. Gearbox systems 10A (Red) 4.
  • Page 161 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: 140300F ELECTRICAL DISTRIBUTION CENTRE - (E.D.C.) - FRONT - VOITH GEARBOX VOITH ALADIN CHASSIS CONTROL MODULE GEARBOX ECU JUNCTION ALADIN DIAGNOSTIC SOCKET & SWITCH Relays Fuses 1. Ignition 1. Kneeling system 5A (Orange) 2. Kneel inhibit - handbrake off 2.
  • Page 162 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: REAR JUNCTION BOX - (R.J.B.) Relays 1. Radiator fan 2. Start inhibit - pod door 3. Start inhibit - gearbox neutral Fuses 1. Kneeling system (Orange) 2. Cooling fan (Violet) 3. Coolant module (Orange) Battery Carrier Area Fuses 1.
  • Page 163 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: WARNING LIGHT UNIT 1. Centre door indicator 2. Emergency exit indicator 3. Front fog light indicator Green 4. High beam warning light Blue 5. Not used 6. Charge warning light - alternator 7. Bus stop indicator 8.

  • Page 164: F Instrument Panel

    ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: INSTRUMENT PANEL 1. Master switch 2. Retarder switch 3. Fuel gauge 4. Tachometer / Speedometer 5. Ignition switch 6. Air pressure gauge 1 7. Air pressure gauge 2 8. Hazard warning switch 9. Rear fog light switch 10.
  • Page 165 ELECTRICAL SYSTEM SERVICE MANUAL AMENDED: NOTES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 166 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: ALTERNATOR AC203R - 180 AMP Description The AC203R 180 alternator is designed specially for heavy duty applications. The machine is of the revolving field and stationary armature type. The AC203R 180 differs from previous AC203 types in that it has a parallel, as opposed to a tapered drive shaft on which is mounted an external fan.
  • Page 167 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Workshop Tests Performance AC203R/180 Cutting in speed 1,000 rpm Output at max. load (28V) 180A at 5000 rpm Regulated voltage 27.5 - 28.5V Stator Volt Drop Test (with winding 1.2 ± 0.1V at 20° and carrying 40A DC) Rotor Resistance (with rotor at 20°) 9.5 ±...
  • Page 168 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.20...
  • Page 169 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Dart SPD-Pub No.2141-06/99 5.2.21...
  • Page 170 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.22...
  • Page 171 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: 091199 Dart SPD-Pub No.2141-06/99 5.2.23...
  • Page 172 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.24...
  • Page 173 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Dart SPD-Pub No.2141-06/99 5.2.25...
  • Page 174 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.26...
  • Page 175 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Dart SPD-Pub No.2141-06/99 5.2.27...
  • Page 176 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.28...
  • Page 177 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Dart SPD-Pub No.2141-06/99 5.2.29...
  • Page 178 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.30...
  • Page 179 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Dart SPD-Pub No.2141-06/99 5.2.31...
  • Page 180 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.32...
  • Page 181 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Dart SPD-Pub No.2141-06/99 5.2.33...
  • Page 182 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.34...
  • Page 183 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: +15 AFTER BATTERY MASTER SWITCH +15 AFTER BATTERY +30 BATTERY DIRECT +30 MASTER SWITCH CN2.2 +30 BATTERY DIRECT BATTERY CN1.46 MASTER RELAY STARTER SOLENOID STARTER CN1.33 STARTER BATTERY MASTER SWITCH CN1.37 SOLENOID RELAY FUEL FUEL FLOW CN1.25 IGNITION...
  • Page 184 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Rear box Dart SPD-Pub No.2141-06/99 5.2.36...
  • Page 185 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Dart SPD-Pub No.2141-06/99 5.2.37...
  • Page 186 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 5.2.38...
  • Page 187 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED: Dart SPD-Pub No.2141-06/99 5.2.39...
  • Page 188 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED:210300 Dart SPD-Pub No.2141-06/99 5.2.40...
  • Page 189 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED:210300 Dart SPD-Pub No.2141-06/99 5.2.41...
  • Page 190 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED:210300 Dart SPD-Pub No.2141-06/99 5.2.42...
  • Page 191 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED:210300 Dart SPD-Pub No.2141-06/99 5.2.43...
  • Page 192 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED:210300 Dart SPD-Pub No.2141-06/99 5.2.44...
  • Page 193 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED:210300 Dart SPD-Pub No.2141-06/99 5.2.45...
  • Page 194 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED:210300 Dart SPD-Pub No.2141-06/99 5.2.46...
  • Page 195 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED:210300 Dart SPD-Pub No.2141-06/99 5.2.47...
  • Page 196 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED:150300 Dart SPD-Pub No.2141-06/99 5.2.48...
  • Page 197 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED:150300 Dart SPD-Pub No.2141-06/99 5.2.49...
  • Page 198 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED:150300 Dart SPD-Pub No.2141-06/99 5.2.50...
  • Page 199 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED:150300 Dart SPD-Pub No.2141-06/99 5.2.51...
  • Page 200 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED:150402 NEUTRAL INTERLOCK WIRING DIAGRAM IGNITION FEED RELAY INTERLOCK SOLENOID FT./BRK SWS H/BRK SW. ALADIN I/PUT REVERSE LIGHT SWITCH REVERSE LIGHT OUTPUT SIDE LIGHT SUPPLY NEGATIVE SELECTOR ILLUMINATION IGNITION SUPPLY Dart SPD-Pub No.2141-06/99 5.2.52...
  • Page 201 SERVICE MANUAL ELECTRICAL EQUIPMENT AMENDED:150402 REPLACEMENT SPEEDOMETER WITH DIGITAL ODOMETER When a speedometer is being replaced with one having a digital odometer there is an alteration to the connecting harness. An adaptor harness is supplied with the new speedo which needs the following additional wiring information.
  • Page 202 ELECTRICAL EQUIPMENT SERVICE MANUAL AMENDED:150402 SPEEDOMETER CALIBRATION SWITCH SETTINGS VEHICLE MPH/ AXLE GEARBOX TYPE SWITCH POSITIONS RATIO ANALOGUE DIGITAL FSUPER DART 4.11:1 ALLISON B300R 1110001011 1100101001 FSUPER DART 4.88:1 ALLISON B300R 1110010001 1100101001 FSUPER DART 4.88:1 ALLISON B300R 0011010011 1001101110 FSUPER DART 4.11:1 ALLISON B300R...

  • Page 203: Engine Controls

    SERVICE MANUAL ENGINE CONTROLS SECTION 6.1 Engine controls diagram ......... . .Page 6.1.2 Description .
  • Page 204 ENGINE CONTROLS SERVICE MANUAL AMENDED: CABLE THROTTLE 1. Engine control bracket 11. Bracket - stop control 2. Bracket - control support 12. Rod - stop control - split pin type 3. Accelerator cable 13. Pin - split 4. Lever - engine controls 14.
  • Page 205 SERVICE MANUAL ENGINE CONTROLS AMENDED: DESCRIPTION The engine speed is regulated by the fuel control lever which is connected to the lever below the accelerator pedal on the drivers floor by a Bowden-type cable. The engine can be shut down by a stop control at the rear of the vehicle, connected to the stop lever on the fuel pump by a rod.
  • Page 206 ENGINE CONTROLS SERVICE MANUAL AMENDED:200803 THROTTLE PEDAL FROM AIR DRYER THROTTLE CONTROL CYLINDER INLET QUICK RELEASE EXHAUST VALE EXHAUST PORT FACES DOWNWARDS AIR THROTTLE SYSTEM DIAGRAM 1. Engine control bracket 9. Lever - engine controls 2. Throttle control cylinder 10. Pivot bolt 3.
  • Page 207 SERVICE MANUAL ENGINE CONTROLS AMENDED:190100 AIR THROTTLE CONTROLS Description The air throttle control system replaces the conventional cable operated throttle (fuel pump) and gearbox modulator cable. The benefit of this cable over cable are likely to be lighter throttle pressure, better response and a smoother gear change.
  • Page 208 Dart SPD-Pub No.2141-06/99...
  • Page 209 SERVICE MANUAL CRT EXHAUST SYSTEM SECTION 6.4 General Description ........Page 6.4.3 How does your CRT™...
  • Page 210 CRT EXHAUST SYSTEM SERVICE MANUAL AMENDED:200803 Flexible pipe Clip Flexible mounting Tailpipe Inlet with CRT Filter Outlet Catalyst Cradle Test mount Point EURO 2 CRT Dart SPD-Pub No.2141-06/99...

  • Page 211: General Description

    SERVICE MANUAL CRT EXHAUST SYSTEM AMENDED:200803 GENERAL DESCRIPTION How does your CRT™ look? Your CRT is made up of four major components: · The Inlet Module, · The Catalyst Module, · The Filter Module and · The Outlet Module. The diagram below shows a typical configuration. NOTE: The diagram may not accurately represent your CRT™, however the four major parts will always be assembled in the order shown, even if one or more is combined.

  • Page 212: How Does Your Crt™ Work

    CRT EXHAUST SYSTEM SERVICE MANUAL AMENDED:200803 How does your CRT™ work? This ingenious device contains a specially formulated, highly active catalyst and a wall-flow ceramic filter housed within a modular unit which is in itself an excellent sound attenuator. The patented process promotes continuous cleaning or regeneration of the filter, preventing large accumulations of soot and resultant severe fluctuations in back pressure.

  • Page 213: How Do I Measure Back Pressure

    SERVICE MANUAL CRT EXHAUST SYSTEM AMENDED:200803 How do I measure Back Pressure (BP)? There are two ways of measuring BP, both with the vehicle stationary: 1. If your CRT™ does not have an on board indicator fitted (or, if it has, and you specify that a standard hand held workshop gauge is to be used): Remove the Allen screw from the Service Port plug and connect a damped pressure gauge with a suitable pressure range (0 to 250 mbar).

  • Page 214: What Records Should I Keep

    CRT EXHAUST SYSTEM SERVICE MANUAL AMENDED:200803 What is critical about a 'Routine CRT™ Service Interval'? (continued) If the smoke reading exceeds the limits set by the engine manufacturer then the engine will require adjustment before the vehicle goes back into service. Note: If you do not know what the manufacturer's limits for your engine are then Eminox recommends the following limits depending on the euro level of your engine: Euro 0...

  • Page 215: Re-Assembling The Crt

    SERVICE MANUAL CRT EXHAUST SYSTEM AMENDED:200803 DISMANTLING AND RE-ASSEMBLING THE CRT™ (continued) When the Filter Module is to be removed for cleaning or exchange it may be possible to release it as a single unit by disconnecting its holding Vee Clamps and easing away the adjacent Module and pipework. When the CRT™...

  • Page 216: Checks On Re-Assembled Crt

    CRT EXHAUST SYSTEM SERVICE MANUAL AMENDED:200803 Checks on re-assembled CRT™. Having replaced the CRT™ and all exhaust pipes, connect the garage exhaust extractor and start the engine. Run at idle speed for five minutes, then gradually increase to full rpm and then shut off engine. Remove the extractor unit and check the security of CRT™...

  • Page 217: How Do I Service The Filter

    SERVICE MANUAL CRT EXHAUST SYSTEM AMENDED:200803 How do I service the Filter? The normal cleaning treatment for a Filter that has been removed at the correct service interval, or before the BP limit is reached, is to use an industrial vacuum cleaner suitable for hazardous materials to extract the loose contents of the filter.

  • Page 218: What Do I Do If The Filter Is Not Clean

    CRT EXHAUST SYSTEM SERVICE MANUAL AMENDED:200803 What do I do if the Filter is not clean? The re-installation of a Filter that is not fully clean can have detrimental effects on engine performance, and will result in a shorter interval before the next service is required. If the BP measured after re-installation is suspect it is recommended that a service exchange Filter is purchased from Eminox Ltd.
  • Page 219 SERVICE MANUAL CRT EXHAUST SYSTEM AMENDED:200803 Chassis Engine Euro level Max. Dyn. Max. Static Cleaned Filter (mbar) (mbar) (mbar) limit Trident 2 C series Trident 2 Dart B series B series Dart 4 ISBe Dart 6 ISBe Enviro300 ISBe Sabre The Max.
  • Page 220 Dart SPD-Pub No.2141-06/99...

  • Page 221: Engine & Mounting

    SERVICE MANUAL ENGINE AND MOUNTINGS SECTION 6.2 Engine mounting diagram ........Page 6.2.2 Specification .
  • Page 222 ENGINE AND MOUNTINGS SERVICE MANUAL AMENDED: Engine Mounting Side Engine Mounting Rear Side mounting bracket Stud Anti-vibration mounting Screw Washer Washer Anti-vibration mounting Bolt Distance tube Rebound washer Thrust washer Bolt Rebound washer Washer Bolt Backing washer Engine Mounting Dart SPD-Pub No.2141-06/99 6.2.2...
  • Page 223 SERVICE MANUAL ENGINE AND MOUNTINGS AMENDED: 160701 SPECIFICATION Type ..........Cummins B160-20 or B180-20 Capacity .
  • Page 224 ENGINE AND MOUNTINGS SERVICE MANUAL AMENDED: 160701 MAINTENANCE Carry out all service and Routine maintenance requirements according to the engine manufacturers operators manual. Refer to instructions on pages 6.2.6 - 6.2.7 for oil drain intervals. Check oil level .......Daily, First, A, B & C Service Intervals Change fuel filter .
  • Page 225 SERVICE MANUAL ENGINE AND MOUNTINGS AMENDED: DESCRIPTION The vehicle is powered by a Cummins 6BT 5.9, six cylinder, turbo-charged diesel engine developing 97kw (130 bhp) or 108 kw (145 bhp). It drives the rear axle through a 4-speed Allison AT545 automatic gearbox. The servicing and spare parts for engine and gearbox are covered in their own manuals.
  • Page 226 ENGINE AND MOUNTINGS SERVICE MANUAL AMENDED: 160701 OIL DRAIN INTERVAL PROCEDURE Oil drain intervals for ISB Euro 2 engine powered Buses can be determined by carrying out the following procedure: Determine the vehicle speed category(s), representative of the vehicles(s) operation, detailed within table 1.
  • Page 227 SERVICE MANUAL ENGINE AND MOUNTINGS AMENDED: 160701 OIL DRAIN INTERVAL PROCEDURE (Continued) TABLE 1 Vehicle Speed Category Oil Type Drain Interval whichever < 10 kph 10 - 15 kph 15 - 20 kph 20 - 30 kph 30 - 40 kph >40kph occurs first API CH4...
  • Page 228 Dart SPD-Pub No.2141-06/99...

  • Page 229: Exhaust System

    SERVICE MANUAL EXHAUST SYSTEM SECTION 6.3 Exhaust system diagram ........Page 6.3.2 Description .
  • Page 230 EXHAUST SYSTEM SERVICE MANUAL AMENDED: 1. Tailpipe 7. Elbow - flex to silencer 2. Clamp - tailpipe 8. Pipe - flexible 3. Silencer 9. Elbow, turbo charger to flex pipe 4. Bracket - silencer mounting - front 10. Clamp - flexible pipe 5.
  • Page 231 SERVICE MANUAL EXHAUST SYSTEM AMENDED: MAINTENANCE Check security of all pipe clamps ......A, B & C Service Intervals Inspect anti-vibration rubber mounts for sign of damage or separation .
  • Page 232 Dart SPD-Pub No.2141-06/99...

  • Page 233: Fuel System

    SERVICE MANUAL FUEL SYSTEM SECTION 7.1 Fuel system diagram ..........Page 7.1.2 Fuel tank .
  • Page 234 FUEL SYSTEM SERVICE MANUAL AMENDED: Dart SLF-Pub No.2141-06/99 7.1.2...

  • Page 235: Fuel Tank

    SERVICE MANUAL FUEL SYSTEM AMENDED: IMPORTANT FUEL TYPE CRT Vehicles fitted with a CRT Exhaust system (Continuously Regenerating Trap) MUST be run on a low sulphur diesel fuel (such as City diesel) with a sulphur content of no greater than 50 ppm.

  • Page 236: Filler Cap

    FUEL SYSTEM SERVICE MANUAL AMENDED: TO DRAIN Remove the drain plug at the bottom of the unit to allow accumulated water and foreign matter to drain. Replace and re-tighten drain plug. Prime the sedimenter by manually operating the lift pump at the engine. TO INSPECT AND OVERHAUL Drain the sedimenter as described above.
  • Page 237 SERVICE MANUAL FUEL SYSTEM AMENDED: DISMANTLING Check that the engine runs properly. Remove throttle linkage from fuel pump. Remove return spring from top of spindle and throttle linkage. Take off emergency stop lever (bottom of pump) Take off small vacuum pipe top of fuel pump taking care not to lose washers. Remove fuel feed pipe banjo bolt at back of fuel pump.

  • Page 238: Replacement Throttle Lever

    FUEL SYSTEM SERVICE MANUAL AMENDED: REPLACEMENT THROTTLE LEVER Parts kit available under part number ZZ11324 This procedure can be followed if the throttle lever is found to be worn. The throttle lever on the top of the pump incorporates a spring loaded mechanism which prevents excessive throttle cable travel being transferred to the internal components of the pump.
  • Page 239 SERVICE MANUAL GEARBOX - ALLISON SECTION 7.2 B300R Gearbox installation ....... . .Page 7.2.2 Description .

  • Page 240: Gearbox

    GEARBOX SERVICE MANUAL AMENDED: 1. Bracket - rear support 8. Solenoid 2. Leaf spring - rear support 9. Silencer 3. Clamp plate 10. Pressure protection valve 4. Mounting rubber 11. Hose elbow 5. Accumulator assembly 12. Pipe assembly - radiator to cooler 6.
  • Page 241 SERVICE MANUAL GEARBOX AMENDED: DESCRIPTION The Allison B300R World Transmission is a 4 speed, Automatic gearbox with an integral retarder. The gearbox is electronically controlled by the World Transmission Electronic Control system (WTEC). This controls the five main elements of Electronic Control Unit (ECU) engine throttlesensor, speed sensors, shift selector (keypad or lever) and control module.
  • Page 242 GEARBOX SERVICE MANUAL AMENDED: CHECKING OIL LEVEL HOT RUN • Ensure the oil has reached normal operatng temperature (71°C - 93°C, 160°F - 200°F). • Park the vehicle on a level surface and allow it to idle (500 - 800 rpm) in Neutral. •...
  • Page 243 SERVICE MANUAL GEARBOX AMENDED: Transmission Check Light The transmission electronic system is programmed to inform you if operating parameters have been exceeded and automatically take action to protect the operator, vehicle, and transmission. To do this, the ECU turns on the Transmission check light on the instrument panel. A diagnostic code will be registered when the light is active.
  • Page 244 GEARBOX SERVICE MANUAL AMENDED: DIAGNOSTIC CODES The code list or queue position is the first item displayed, followed by the main code and the subcode. Each item is displayed for about one second. The display cycles continuously until the next code list position is accessed by pressing the MODE button.
  • Page 245 SERVICE MANUAL GEARBOX AMENDED: Main Code Sub Code Description Output speed sensor, detected at 0 output rpm, Low Output speed sensor, detected at 0 output rpm, 1st Output speed sensor, detected at 0 output rpm, 2nd Output speed sensor, detected at 0 output rpm, 3rd Output speed sensor, detected at 0 output rpm, 4th Output speed sensor, detected at 0 output rpm, 5th Output speed sensor, detected at 0 output rpm, 6th...
  • Page 246 GEARBOX SERVICE MANUAL AMENDED: Main Code Sub Code Description Short-to-ground, A solenoid circuit Short-to-ground, B solenoid circuit Short-to-ground, C solenoid circuit Short-to-ground, D solenoid circuit Short-to-ground, E solenoid circuit Short-to-ground, F solenoid circuit Short-to-ground, G solenoid circuit Short-to-ground, H solenoid circuit Short-to-ground, J solenoid circuit Short-to-ground, N solenoid circuit Open circuit, A solenoid circuit...
  • Page 247 SERVICE MANUAL GEARBOX AMENDED: Main Code Sub Code Description Offgoing C3PS test (during shift), Low to 1 Offgoing C3PS test (during shift),Low to N1 Offgoing C3PS test (during shift), 3 to 2 Offgoing C3PS test (during shift), 3 to 4 Offgoing C3PS test (during shift), 5 to 4 Offgoing C3PS test (during shift), 5 to 6 Offgoing C3PS test (during shift), R to 1...
  • Page 248 GEARBOX SERVICE MANUAL AMENDED: Main Code Sub Code Description Oncoming ratio test, (during shift) 4 to 2 (cont'd) Oncoming ratio test (after shift) 4 to 3 Oncoming ratio test (after shift) 4 to 5 Oncoming ratio test, (during shift) 4 to 6 Oncoming ratio test, (during shift) 5 to 3 Oncoming ratio test (after shift) 5 to 4 Oncoming ratio test (after shift) 5 to 6...
  • Page 249 SERVICE MANUAL GEARBOX AMENDED: Main Code Sub Code Description Range verification test, L Range verification ratio test, 1st Range verification ratio test, 2nd Range verification ratio test, 3rd Range verification ratio test, 4th Range verification ratio test, 5th Range verification ratio test, 6th Range verification ratio test, R Range verification C3PS test, 1st Range verification C3PS test, 2nd...
  • Page 250 GEARBOX SERVICE MANUAL AMENDED: Main Code Sub Code Description ECU, inoperative A-Hi switch ECU, inoperative F-Hi switch ECU, inoperative N and H-Hi switch ECU, Computer Operating Properly (COP) timeout ECU, write timeout ECU, checksum test ECU, RAM self test Communication chip addressing error ECU, I/O ASIC addressing test SPI output failure SPI input failure...
  • Page 251 SERVICE MANUAL GEARBOX - VOITH SECTION 7.3 Diagram ..........Page 7.3.2 Description .
  • Page 252 GEARBOX - VOITH SERVICE MANUAL AMENDED:150300 SB1215 GEARBOX INSTALLATION Gearbox - Voith D823.3 Mount - tail support Leaf spring - tail support Clamp plate Setscrew Setscrew Washer - spring Mount - anti vibration Washer - spring Washer - plain Dart SPD-Pub No.2141-09/95 7.3.2...

  • Page 253: Description

    SERVICE MANUAL GEARBOX VOITH AMENDED:190601 DESCRIPTION The Voith-DIWA 823.3 is a 3 speed, Automatic gearbox with an integral retarder and heat exchanger (oil cooler). The gearbox is electronically controlled . The main elements of control are the Electronic Control Unit (ECU), engine load sensor, footbrake valve and push button gear selector. The gearbox has a full diagnostic system with the ECU storing two digit main code and two digit sub codes, five codes at a time will be stored.

  • Page 254: Transmission Function

    GEARBOX - VOITH SERVICE MANUAL AMENDED:150300 TRANSMISSION FUNCTION The power of the engine is transmitted in first gear via a “differential torque converter” (torque converter with pre-mounted differential torque unit) and in second and third purely mechanically. The differential torque converter produces a considerably higher efficiency in the lower speed range than a transmission in which the full torque is transmitted via a torque converter without differential.

  • Page 255: Oil And Filter Change

    SERVICE MANUAL GEARBOX VOITH AMENDED:280900 OIL AND FILTER CHANGE 1. Stop the engine 2. With the oil at normal operating temperature, remove the plug and drain off the oil, taking precautions to avoid contact with the hot oil. Undo and remove the plug (2) from the oil pan (allen wrench 12mm) and drain the oil.

  • Page 256: Kickdown Switch Setting

    GEARBOX VOITH SERVICE MANUAL AMENDED:150300 KICKDOWN SWITCH SETTING 1. Nominally set kickdown switch to 52mm dimension. 2. Depress pedal to end of the main travel, as shown, and measure the clearance between the striker and the kickdown switch. 3. If necessary, adjust the kickdown switch to achieve a clearance of 5mm. Dart SPD-Pub No.2141-09/95 7.3.6...

  • Page 257: Hydraulic System

    SERVICE MANUAL HYDRAULIC SYSTEM SECTION 8.1 System diagram ..........Page 8.1.2 Description .
  • Page 258 HYDRAULIC SYSTEM SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 8.1.2...
  • Page 259 SERVICE MANUAL HYDRAULIC SYSTEM AMENDED: DESCRIPTION The hydraulic system provides the power for the steering system and the radiator cooling fan. An engine driven tandem pump draws oil from a reservoir mounted at the rear offside of the vehicle. The pump nearest the compressor supplies the cooling fan, the oil returning via a reservoir mounted filter.
  • Page 260 HYDRAULIC SYSTEM SERVICE MANUAL AMENDED: MAINTENANCE Check hydraulic fluid level ........First, Daily, A B & C Check security of all components as shown on the hydraulic system diagram .
  • Page 261 SERVICE MANUAL HYDRAULIC SYSTEM AMENDED: OIL LEVEL The oil level should be checked with the engine at idle speed. The level must be maintained mid way between the upper and lower marks on the reservoir dipstick. HYDRAULIC RESERVOIR The reservoir is situated at the rear right hand side of the vehicle and incorporates a remote filler and dipstick, a breather and two filters.
  • Page 262 HYDRAULIC SYSTEM SERVICE MANUAL AMENDED: Bearing Mounting flange Bolt Drive shaft Backing ring Cover Pressure loading ring Dowel Body Circlip Solenoid valve Gear Backing washer Cover Sealing ring Shaft seal Key to fan motor Dart SPD-Pub No.2141-06/99 8.1.6...
  • Page 263 SERVICE MANUAL HYDRAULIC SYSTEM AMENDED: FAULT FINDING • If the cooling fan fails to operate at the present temperature; proceed as follows:- • Check that the hydraulic oil level is correct. • Remove and bridge the temperature switch connections. • Start the engine.
  • Page 264 HYDRAULIC SYSTEM SERVICE MANUAL AMENDED: SECTION A - A SECTION B - B SECTION C - C 1. Shaft coupling 11. Body, outer 20. Drive couple 2. Flange 12. 'O'ring 21. Driving gear, inner pump 3. 'O'ring 13. Outer cover, outer pump 22. Body, inner 4.
  • Page 265 SERVICE MANUAL HYDRAULIC SYSTEM AMENDED: TWIN PUMP Twin Hydraulic pump The twin pump consists of two gear pumps each consisting of a body and end covers enclosing meshing gears supported in bearings. The inner pump, driven by the engine is connected to the outer pump by a coupling sleeve.
  • Page 266 HYDRAULIC SYSTEM SERVICE MANUAL AMENDED: REFITTING TANDEM PUMP TO COMPRESSOR It is recommended that the following procedures are followed if it is found necessary to remove and refit the hydraulic tandem pump. 1. It must be ensured that the lubrication hole between the compressor and the tandem pump is clear from sludge or debris.

  • Page 267: Drive Shaft

    SERVICE MANUAL DRIVE SHAFT SECTION 8.2 Diagram ............Page 8.2.2 Description .
  • Page 268 DRIVE SHAFT SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 8.2.2...

  • Page 269: Description

    SERVICE MANUAL DRIVE SHAFT AMENDED:050900 DESCRIPTION The drive shaft connecting the gearbox to the back axle consists of two sections each incorporating a universal joint. One section has internal splines into which the external splines of the other section engages, both sections having a non-metalic coating to reduce sliding friction and to improve spline life. A grease nipple is fitted on the female spline section.

  • Page 270: Assembly

    DRIVE SHAFT SERVICE MANUAL AMENDED: BEARING REMOVAL With the shaft removed, proceed as follows: 1. Using a soft drift, tap the outside of the bearing assembly to loosen the circlips. Do not use excessive force, just sufficient to break the assembly away from the ring. 2 Using circlip pliers, remove the circlip.

  • Page 271: Trouble Shooting

    SERVICE MANUAL DRIVE SHAFT AMENDED: TROUBLE SHOOTING Fault Cause Remedy Vibration such as shudder in Sections out of phase. Re-assemble correctly. low gear, under light load or Wear in U.J. Fit Bearing Kits. at critical speeds. Shaft bent. Renew. Premature wear Improper lubrication.
  • Page 272 Dart SPD-Pub No.2141-06/99...

  • Page 273: Steering

    SERVICE MANUAL STEERING SECTION 9.1 Steering system diagram ........Page 9.1.2 Description .
  • Page 274 STEERING SERVICE MANUAL AMENDED: Steering System Dart SPD-Pub No.2141-06/99 9.1.2...

  • Page 275: Specification

    SERVICE MANUAL STEERING AMENDED: DESCRIPTION The angled steering column is mounted on the drivers floor structure. The base of the column incorporates a bevel box which is connected to the ZF power steering box by a torque shaft with a universal joint at each end.
  • Page 276 STEERING SERVICE MANUAL AMENDED: ADJUSTMENT OF HYDRAULIC STEERING LIMITER Initial adjustment of the hydraulic steering limiter is always performed at the factory on the test bench in accordance with the particular vehicle requirements. An additional adjustment is necessary after installation of the steering system in the vehicle, and at the specified service intervals. Procedure for adjusting hydraulic steering limiter in vehicle using a pressure gauge:.

  • Page 277: Adjustment Of Hydraulic Steering Automatic Limiter

    SERVICE MANUAL STEERING AMENDED: ADJUSTMENT OF HYDRAULIC STEERING AUTOMATIC LIMITER IMPORTANT When setting the automatic limiters, the limiting angle can be increased but over adjustment of the limiting angle will result in the limiter assembly having to be replaced. The construction of the limiter only allows compression of the limiter and not extension.

  • Page 278: Procedure For Fitting Improved Clamp Handwheel

    STEERING SERVICE MANUAL AMENDED: PROCEDURE FOR FITTING IMPROVED CLAMP HANDWHEEL 1. Unscrew the handwheel a couple of turns to release the column and allow it to rest in the fully down position. 2. Remove the decal from the end face of the hand wheel unit, unscrew and remove the M5 screw from the end of the spindle together with its washer.
  • Page 279 SERVICE MANUAL AIR SUSPENSION SYSTEM SECTION 9.2 Air Circuit diagram ........Page 9.2.2 Description .
  • Page 280 AIR SUSPENSION SYSTEM SERVICE MANUAL AMENDED: 1. Levelling valve 13. Tee piece - equal 23. Connector 2. Connector 14. Connector 24. Connector 3. Elbow 15. Elbow 25. Air spring - rear 4. Charging valve 16. Elbow 26. Adaptor - rear air bag 5.
  • Page 281 SERVICE MANUAL AIR SUSPENSION SYSTEM AMENDED: DESCRIPTION The Dart SLF is fitted with air suspension, a function of this is a front kneeling system. The air suspension is supplied from an auxiliary tank, sited on the right hand side of the chassis and forward of the battery carrier.
  • Page 282 AIR SUSPENSION SYSTEM SERVICE MANUAL AMENDED: When the “raise” button is pressed, valves 41, 42 and 43 are energised. Valve 41 changes over to allow the auxiliary air supply to reinflate the front air bags. Valve 42 will open to allow the air through to re- inflate the front air bags.
  • Page 283 SERVICE MANUAL AIR SUSPENSION SYSTEM AMENDED: CHECKING THE RIDE HEIGHT If it is suspected that the normal ride heighting is incorrect, the measurements shown on the illustrations should be checked. Rear Suspension Layout Front suspension layout Dart SPD-Pub No.2141-06/99 9.2.5...
  • Page 284 AIR SUSPENSION SYSTEM SERVICE MANUAL AMENDED: Dart SPD-Pub No.2141-06/99 9.2.6...

  • Page 285: Description

    SERVICE MANUAL AIR SUSPENSION SYSTEM AMENDED: MAIN COMPONENTS LEVELLING VALVE Location The vehicle is fitted with two levelling valves, one at the front and one at the rear. They are bolted to the left side of the chassis ahead of the wheels. Description The levelling valve controls the inflation or exhausting of air bags.

  • Page 286: Specifications

    AIR SUSPENSION SYSTEM SERVICE MANUAL AMENDED: SOLENOID VALVE Location Beneath the drivers seat area mounted on the chassis side member. Description The solenoid valve block has three valves which control the "kneel" and "raise" functions. For the kneel function the solenoid block isolates the levelling system and exhausts through charge valve to reduce the pressure in the air bags.

  • Page 287: Proximity Switch Adjustment

    SERVICE MANUAL AIR SUSPENSION SYSTEM AMENDED:310300 3. With the BLACK button held in, slowly turn out the charge valve adjusting screw until the frame just contacts the bump stops. 4. Turn the adjuster screw OUT a further HALF turn and tighten the lock nut. 5.

  • Page 288: Load Sensing Valve - Setting Procedure

    AIR SUSPENSION SYSTEM SERVICE MANUAL AMENDED: LOAD SENSING VALVE - SETTING PROCEDURE Before setting the valve 1. Read and understand these instructions fully before starting work. 2. The values of the Inlet pressure and the Laden and Unladen Outlet pressures will be needed, along with the corresponding Air Bag pressures.
  • Page 289 SERVICE MANUAL AIR SUSPENSION SYSTEM AMENDED: 16. Repeat steps 13 to 15 as necessary. 17. Release Vl and V2. Setting the Laden brake pressure 18. Apply V2 to give the required Laden Air Bag pressure on PG2. 19. Apply Vl to give the required Inlet pressure on PG1. 20.
  • Page 290 Dart SPD-Pub No.2141-06/99...

  • Page 291: Front Air Suspension

    SERVICE MANUAL FRONT AIR SUSPENSION SECTION 10.1 Assembly diagram ..........Page 10.1.2 Maintenance .
  • Page 292 FRONT AIR SUSPENSION SERVICE MANUAL AMENDED: Road spring Bolt - panhard rod Bush - road spring Nut - panhard rod Bolt Air spring assembly Angle packer Bolt Air spring mounting bracket - LH Spring washer Bolt Damper - c/w mounting kit Mounting kit - comprising: Panhard rod Bump stop...

  • Page 293: Maintenance

    SERVICE MANUAL FRONT AIR SUSPENSION AMENDED: MAINTENANCE Surface damage Any surface damage in the form of scores, dents etc or weld splatter can cause premature failure of the spring due to stress concentration. Surface damage can also destroy the corrosion protection layer. Check the air bags for signs of damage or wear.
  • Page 294 FRONT AIR SUSPENSION SERVICE MANUAL AMENDED: Road spring Bolt - panhard rod Bush - road spring Nut - panhard rod Bolt Air spring assembly Angle packer Bolt Air spring mounting bracket - LH Spring washer Bolt Damper - c/w mounting kit Mounting kit - comprising: Panhard rod Bump stop...

  • Page 295: Removal / Dismantling Procedure

    SERVICE MANUAL FRONT AIR SUSPENSION AMENDED: REMOVAL / DISMANTLING PROCEDURE Warning No work is to be undertaken beneath the vehicle using jacks as a sole means of support. Additional support, capable of accepting the vehicle weight when the jacks are removed, are to be positioned under the framework junction slightly forward of the gearbox side mountings.

  • Page 296: Panhard Rod Adjustment

    FRONT AIR SUSPENSION SERVICE MANUAL AMENDED: 7. Apply liquid soap to the air bag beads and fit air bags. 8. Connect the panhard rod (9). 9. Tighten the front spring mounting bolts to a torque of 586 - 640 Nm (426 - 470 lb. ft.). The vehicle should be at a normal ride height before fully tightening.

  • Page 297: Rear Air Suspension

    SERVICE MANUAL REAR AIR SUSPENSION SECTION 10.2 Rear Air Suspension Assembly Diagram ..... . .Page 10.2.2 Removal / Dismantling Procedure ......Page 10.2.3 Assembly .
  • Page 298 REAR AIR SUSPENSION SERVICE MANUAL AMENDED: Road spring Panhard rod beam assembly 15. Bump stop Bolt Bolt 16. Air spring assembly Bolt 17. Nut 'U' bolt 18. Bolt Nylock nut Panhard rod 19. Spring washer Saddle - spring Bolt 20. Damper Clamp plate 21.
  • Page 299 SERVICE MANUAL REAR AIR SUSPENSION AMENDED: Removal / Dismantling Procedure WARNING No work is to be undertaken beneath the vehicle using jacks as a sole means of support. Additional support, capable of accepting the vehicle weight when the jacks are removed, are to be positioned under the framework.
  • Page 300 FRONT AIR SUSPENSION SERVICE MANUAL AMENDED: Panhard Rod Adjustment With the vehicle set at ride height take suitable measurements between the frame and axle assembly to ensure it sits centrally in the frame. If adjustments are required disconnect the panhard rod and screw the adjustable end in or out to equalise the distances.
  • Page 301 SERVICE MANUAL SHOCK ABSORBER SECTION 10.3 Hydraulic shock absorber diagram ......Page 10.3.2 Description ..........Page 10.3.3 Removal .
  • Page 302 SHOCK ABSORBER SERVICE MANUAL AMENDED: Armalok Nut Outer Washer Rubber Bush Inner Washer Hydraulic shock absorber Dart SPD-Pub No.2141-06/99 10.3.2...
  • Page 303 SERVICE MANUAL SHOCK ABSORBER AMENDED: DESCRIPTION Type - hydraulic - telescopic double acting Four shock absorbers are used on the suspension system, one at each front wheel, one adjacent to each rear air bag and another at either side of the rear axle. The shock absorbers are sealed units and require no servicing, all mountings are rubber bushed.
  • Page 304 Dart SPD-Pub No.2141-06/99...
  • Page 305 SERVICE MANUAL WHEELS AND TYRES SECTION 10.4 Wheel inspection .........Page 10.4.3 Tyre inspection .
  • Page 306 Dart SPD-Pub No.2141-06/99...

  • Page 307: Wheel Inspection

    SERVICE MANUAL WHEELS AND TYRES AMENDED: WHEEL INSPECTION Carefully examine the wheels for corrosion, damage or cracks, particularly in the region of studholes. Examine the studholes for signs of ovality or fretting caused by slack wheel nuts. Examine the stud threads for damage or severe burring, when they must be replaced. If only slight burring exists clean up the threads using a ‘chaser’.

  • Page 308: Replacement Tyres

    WHEELS AND TYRES SERVICE MANUAL AMENDED: WHEEL STUD REMOVAL If a wheel stud breaks due to loose wheel nuts, install a new stud and also renew both adjacent studs which could have become cracked or fatigued due to the original failure. REPLACEMENT TYRES Replacement tyres should be of a similar specification.

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