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Terex TR100 Maintenance Manual

Terex TR100 Maintenance Manual

Mining truck
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Table of Contents

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TR100
Mining Truck
Maintenance Manual
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MAIN LIBRARY INDEX
TECHNICAL PUBLICATIONS DEPARTMENT
TEREX EQUIPMENT LIMITED,
MOTHERWELL, SCOTLAND, ML1 5RY
PART No. 15272903
REF. NO. SM755/783
SM 1616 Rev 8 06-08

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  • Page 1 CLICK HERE FOR TABLE OF CONTENTS TR100 Mining Truck Maintenance Manual CLICK HERE TO RETURN TO MAIN LIBRARY INDEX TECHNICAL PUBLICATIONS DEPARTMENT TEREX EQUIPMENT LIMITED, MOTHERWELL, SCOTLAND, ML1 5RY PART No. 15272903 REF. NO. SM755/783 SM 1616 Rev 8 06-08...
  • Page 3 IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service procedures recommended and described in this publication, are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. The special tools should be used when, and as recommended.
  • Page 4 THIS PAGE IS INTENTIONALLY LEFT BLANK...
  • Page 5 TEREX SERVICE DEPARTMENT TEREX SERVICE DEPARTMENT TEREX SERVICE DEPARTMENT TEREX SERVICE DEPARTMENT TEREX SERVICE DEPARTMENT TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046 TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752...
  • Page 6 THIS PAGE IS INTENTIONALLY LEFT BLANK...
  • Page 7 TABLE OF CONTENTS Section No. Description SM No. GENERAL INFORMATION 0000 TR100 Off-Highway Truck 1618 Rev 1 0010 Welding Procedure 2172 CHASSIS 0010 Chassis, Hood and Fenders - Pre January 2000 Production 1622 0010 Chassis, Hood and Fenders - From January 2000 Production...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS Section No. Description SM No. STEERING SYSTEM 0000 Steering System Schematic 1661 Rev1 0040 Steering and Brake Control Tank 1638 0050 Steering Pump 2356 0050 Steering Pump (new style) 2575 0080 Accumulator 1205 0090 Steering Valve 1640 Rev 1 0110 Double Relief Valve 1208...
  • Page 9 GENERAL INFORMATION - TR100 Mining Truck Section 000-0000 SM - 2034 1 635 Body (5-4) Depth 5 150 (16-11) 4 730 (15-6) 1 220 (4-0) (2-7) 1 755 (5-9) 8 960 Vehicle Clearance Diameter (SAE) 24.5 m (80 ft) 3 420 (11-3)

  • Page 10: Steering System

    General Information - TR100 Mining Truck Section 000-0000 DRIVE AXLE Parking Heavy duty axle with full floating axle shafts, single Application of rear brakes by springs in brake disc pack. Hydraulically released. reduction spiral bevel gear differential and planetary reduction at each wheel.
  • Page 11 General Information - TR100 Mining Truck Section 000-0000 BODY SERVICE CAPACITIES Longitudinal 'V' type floor with integral transverse box- Engine Crankcase and Filters ..134 litres (35.4 US gal) section stiffeners. The body is exhaust heated and rests on Transmission and Filters ..... 100 litres (26 US gal) resilient impact absorption pads.
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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 - Chassis, Hood and Fenders Section 100-0010 SM - 1585 1 - Frame Assembly 11 - Spring Disc 2 - Bushing 5 - Nut 8 - Hardened Washer 6 - Hardened Washer 9 - Bolt 12 - Hardened Washer 3 - Engine Guard 7 - Bolt 10 - Nut...
  • Page 16 Chassis - Chassis, Hood and Fenders Section 100-00100 SM - 1586 1 - Hood Assembly 9 - Baffle Assembly 5 - Bolt 2 - Bracket - LH 6 - Locknut 10 - Bracket 13 - Bolt 3 - Bracket - RH 7 - Hardened Washer 11 - Plate Assembly - Top 14 - Nut...
  • Page 17 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 2035 SECT 'B-B' 36 32 33 40 SECT 'A-A' 40 33 40 21 40 24 1 - Fender Extension 14 - Mirror 39 - Hardened Washer 2 - Fender Assembly - LH 15 - Block 27 - Bolt 40 - Hardened Washer...
  • Page 18 Chassis - Chassis, Hood and Fenders Section 100-00100 SM - 2036 11 7 11 7 12 7 7 12 13 14 22 - Bumper Extension - LH 8 - Hardened Washer 15 - Cable Assembly 23 - Bumper Assembly - RH 1 - Bolt 9 - Washer 16 - Step Assembly - LH...
  • Page 19 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 1589 1 - Radiator Guard 4 - Clamp 7 - Bolt 2 - Grille - Bottom 5 - Clip 8 - Bolt 10 - Bolt 3 - Grille - Top 6 - Button Plug 11 - Hardened Washer 9 - Hardened Washer...
  • Page 20 Chassis - Chassis, Hood and Fenders Section 100-00100 SM - 2037 5,6,7 STEERING TANK - REF. VIEW CC VIEW AA ENLARGED VIEW BB TYP. 35 PLACES LEFT FRONT - ENLARGED ENLARGED LEFT REAR - SHOWN RIGHT REAR - OPPOSITE HAND 5,6,7 5,15 FUEL TANK...
  • Page 21 CHASSIS - Chassis, Hood and Fenders Section 100-0010 SM - 2387 1 - Frame Assembly 5 - Nut 11 - Spring Disc 2 - Bushing 8 - Hardened Washer 6 - Hardened Washer 12 - Hardened Washer 3 - Engine Guard 9 - Bolt 7 - Bolt 13 - Hardened Spacer...
  • Page 22 Chassis - Chassis, Hood and Fenders Section 100-00100 SM - 1586 1 - Hood Assembly 5 - Bolt 9 - Baffle Assembly 2 - Bracket - LH 6 - Locknut 10 - Bracket 13 - Bolt 3 - Bracket - RH 7 - Hardened Washer 11 - Plate Assembly - Top 14 - Nut...
  • Page 23 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 2035 SECT 'B-B' 36 32 33 40 SECT 'A-A' 40 33 40 24 40 21 1 - Fender Extension 14 - Mirror 2 - Fender Assembly - LH 27 - Bolt 39 - Hardened Washer 15 - Block 3 - Fender Assembly - RH...
  • Page 24 Chassis - Chassis, Hood and Fenders Section 100-00100 SM - 2386 7 11 11 7 7 11 11 7 7 12 33,34 28 - Nut 1 - Bolt 29 - Hardened Washer 10 - Rung 19 - Hoodside - RH 2 - Bolt 30 - Locknut 11 - Hardened Washer...
  • Page 25 Chassis - Chassis, Hood and Fenders Section 100-0010 SM - 1589 1 - Radiator Guard 4 - Clamp 7 - Bolt 2 - Grille - Bottom 5 - Clip 8 - Bolt 10 - Bolt 3 - Grille - Top 6 - Button Plug 9 - Hardened Washer 11 - Hardened Washer...
  • Page 26 Chassis - Chassis, Hood and Fenders Section 100-00100 SM - 2388 1 - Mudguard 6 - Lockwasher 2 - Bar 11 - Angle Support 7 - Nut 15 - Bar 3 - Bar 12 - Angle Support 8 - Hardened Washer 16 - Bar 4 - Bolt 13 - Mudflap - RH...
  • Page 27 ENGINE - Engine and Mounting Section 110-0030 SM - 1592 19,20,16 44 20,19,17 21,22 26,3 LHS 2,3 RHS 39,40,41 33 34 52 51 1 - Engine 15 - Rear Mount 29 - Coolant Filter 2 - Reducer Bush 16 - Clamp 30 - Lube Oil Filter 43 - Clip 3 - Drain Cock...
  • Page 28 Engine - Engine and Mounting Section 110-0030 REMOVAL 6. If the vehicle is equipped with an air conditioning system, evacuate refrigerant from the system and Numbers in parentheses refer to Fig. 1. disconnect lines at the compressor. Refer to Section 260-0130, AIR CONDITIONING.
  • Page 29 Engine - Engine and Mounting Section 110-0030 18. Identify all electrical harnesses and cables the chassis, remove disc brake oil cooler and attached to engine (1) assembly for ease of installation transmission oil cooler from crossmember (6) first. and disconnect from engine (1) assembly. Refer to Section 210-0050, DISC BRAKE OIL COOLER, and, Section 210-0060, TRANSMISSION OIL COOLER.
  • Page 30 Engine - Engine and Mounting Section 110-0030 INSTALLATION SM - 1593 Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners without special torques specified to standard torques listed in Section Install coupling with 300-0080, STANDARD BOLT AND NUT TORQUE Part No.
  • Page 31 Engine - Engine and Mounting Section 110-0030 10. Secure support (5) assembly to crossmember (6) 23. Connect throttle control linkage to engine (1) assembly. with bolts (7) and hardened washers (8). Secure rear mounts (15) to chassis mounts with bolts (7), 24.
  • Page 32 Engine - Engine and Mounting Section 110-0030 MAINTENANCE by hand until the gasket contacts the filter head Numbers in parentheses refer to Fig. 1, unless surface. Tighten fuel filters (28) per the filter otherwise specified. manufacturer's instructions. Every 10 Hours (Daily) Note: Mechanical tightening of the filters is not General - Visually check the engine for leaks, loose or recommended, and may result in seal and/or cartridge...
  • Page 33 Engine - Engine and Mounting Section 110-0030 Apply a thin film of clean lubricating oil to the gasket Crankcase Breather - Check and clean the surface of the new filters and fill the filters with clean crankcase breather hose. Remove the breather hose lubricating oil specified in Section 300-0020, and check internally for obstructions or sludge buildup.
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  • Page 35 ENGINE - Air Cleaner Section 110-0050 SM - 1532 1 - Air Cleaner Body 2 - Primary Element 3 - Safety Element 4 - Cover Assembly 5 - Latch 6 - Vacuator Valve Fig. 1 - Exploded View of Air Cleaner DESCRIPTION SM - 1898 Numbers in parentheses refer to Fig.
  • Page 36 Engine - Air Cleaner Section 110-0050 SM - 1693 18,19 1 - Plenum Chamber 6 - Cap Assembly 11 - Clamp 16 - Nipple 2 - LH Tube 7 - Mounting Band 12 - Bolt 17 - Elbow 3 - RH Tube 13 - Nut 18 - Air Restriction Gauge 8 - Hump Hose...
  • Page 37 Engine - Air Cleaner Section 110-0050 Check condition of clamps (10 & 11, Fig. 3), hump however, it should perform satisfactorily through hoses (8 & 9, Fig. 3) and plenum chamber (1, Fig. 3). approximately six cleanings, providing it does not rupture. Tighten/replace as necessary.
  • Page 38 Engine - Air Cleaner Section 110-0050 MEASURING AIR RESTRICTION 8. After primary element (2) is thoroughly dried, Numbers in parentheses refer to Fig. 3. inspect for damage or ruptures, especially close to the end caps. To detect paper ruptures, place a bright light bulb inside the element and rotate element slowly.
  • Page 39 ENGINE - Power Takeoff Section 110-0130 DESCRIPTION AND OPERATION SM - 2042 Numbers in parentheses refer to Fig. 1. The function of the power takeoff (PTO), as the name implies, is to provide the means of mounting and driving auxiliary components. The tandem gear pump for the disc brake cooling system is mounted on the left hand side of the PTO cover (6) and its input shaft is meshed with the...
  • Page 40 Engine - Power Takeoff Section 110-0130 SM - 2043 12,13 12,13 FLYWHEEL HOUSING ADAPTOR 4 - Lockwasher 8 - Breather Cap 12 - Elbow 1 - PTO Assembly 5 - Yoke 9 - Pipe Coupling 13 - Plug 2 - Bolt 10 - Breather Assembly 14 - Plug 6 - Hardened Washer...
  • Page 41 Engine - Power Takeoff Section 110-0130 SM - 2044 13 - Gasket 14 - Drive Gear 1 - Flywheel Cover Case 5 - Oil Seal 9 - Oil Seal 2 - Dowel Pin 6 - PTO Cover 10 - Bearing 15 - Driveshaft 3 - Bolt 11 - Bearing...
  • Page 42 Engine - Power Takeoff Section 110-0130 1. Using suitable lifting equipment, position PTO 1. If removed, install dowel pins (2) in flywheel cover assembly (1) on engine flywheel housing. Secure case (1), as noted at disassembly. PTO assembly (1) to the engine flywheel housing with bolts (2 &...
  • Page 43 Engine - Power Takeoff Section 110-0130 SPECIAL TOOLS To refill: Remove oil level plug (13) from elbow (12) and fill PTO assembly (1) with lubricant specified in There are no special tools required for procedures Section 300-0020, LUBRICATION SYSTEM, until oil outlined in this section.
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  • Page 45 TRANSMISSION - Transmission and Mounting Section 120-0010 SM - 1249 1 - Transmission 2 - Trunnion 11 - Lockwasher 20 - Elbow 29 - Keys 3 - Bolt 12 - Plate 21 - Filler Tube 30 - Padlock 4 - Spacer 13 - Bushing 22 - Clamp 31 - Flange Nut...
  • Page 46 Transmission - Transmission and Mounting Section 120-0010 Torque Converter continuous use of the retarder will raise transmission The torque converter consists of three elements - oil temperature. Short periods of full release, to interrupt pump, turbine, and stator. The pump is the input continuous application, will help prevent overheating.
  • Page 47 Transmission - Transmission and Mounting Section 120-0010 2. Apply the parking brake and switch off the engine. to transmission (1). Cap all open lines and fittings to Turn steering wheel in both directions several times to prevent entry of dirt. relieve pressure in the steering system.

  • Page 48: Steering System Schematic

    Transmission - Transmission and Mounting Section 120-0010 INSTALLATION 3. Remove flange nut (31) and retainer plate (32) securing input flange (33) on transmission (1). Pull Numbers in parentheses refer to Fig. 1. input flange (33) from transmission (1). Note: Tighten all fasteners without special torques 4.
  • Page 49 Transmission - Transmission and Mounting Section 120-0010 10. Connect all electrical connections and cables to 22. Switch the circuit breakers to the 'On' position, transmission (1) as tagged at removal. start the engine and make an operational check of all lines and components disconnected during removal.
  • Page 50 Transmission - Transmission and Mounting Section 120-0010 Visual Level Indicator SM - 1250 A visual level indicator is mounted on the lower left side of the transmission main housing and provides a method of checking the oil level. Refer to Fig. 2. Cold Oil Level Check Before starting the engine, check the visual level indicator or remove the ADD (lower) plug.
  • Page 51 Transmission - Transmission and Mounting Section 120-0010 a. Disconnect battery equalizer ground connection 3. Apply the service brake, release the parking brake from the batteries. Disconnect battery cables from and select fifth gear on the transmission shift selector. terminal posts (ground cable first). Disconnect battery The transmission will shift to fifth gear and deactivate equalizer positive connection.
  • Page 52 Transmission - Transmission and Mounting Section 120-0010 Transmission Commercial Electronic Control (CEC) WARNING Troubleshooting Manual SA 2712A. Be sure to apply the parking brake, switch off the engine and block all road wheels before SPECIAL TOOLS troubleshooting the vehicle. If it is necessary to run the engine, it is imperative that an There are no special tools required for the procedures operator be present in the cab at all times,...
  • Page 53 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY C - Heavy metal debris found Transmission internal failure Completely disassemble, clean and repair in oil transmission. Replace filters and clean lines and oil cooler. D - Coolant found in oil Transmission oil cooler leaking Completely disassemble and thoroughly clean transmission.
  • Page 54 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY M - Vehicle operates in fifth Fifth and sixth gear clutch Overhaul transmission and sixth gears and moves failed (won't release) forward in neutral when engine is accelerated, but stalls in all other gears when engine is accelerated - Electrical Troubleshooting OK...
  • Page 55 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY T - Low engine speed at Low engine output torque Tune engine and check output converter stall Converter element Check for noise at stall; overhaul converter if interference necessary Transmission oil not up to...
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  • Page 57 TRANSMISSION - Transmission and Mounting Section 120-0010 SM - 2389 17 16 12 - Plate 1 - Transmission 13 - P-Clip 23 - Filler Hose 33 - Input Flange 2 - Trunnion 14 - Bolt 24 - Adaptor 34 - Ring 3 - Bolt 15 - Bolt 25 - Gasket...
  • Page 58 Transmission - Transmission and Mounting Section 120-0010 Torque Converter continuous use of the retarder will raise transmission The torque converter consists of three elements - oil temperature. Short periods of full release, to interrupt pump, turbine, and stator. The pump is the input continuous application, will help prevent overheating.
  • Page 59 Transmission - Transmission and Mounting Section 120-0010 2. Apply the parking brake and switch off the engine. 14. Disconnect all remaining hydraulic lines attached Turn steering wheel in both directions several times to to transmission (1). Cap all open lines and fittings to relieve pressure in the steering system.
  • Page 60 Transmission - Transmission and Mounting Section 120-0010 INSTALLATION 3. Remove flange nut (31) and retainer plate (32) securing input flange (33) on transmission (1). Pull Numbers in parentheses refer to Fig. 1. input flange (33) from transmission (1). Note: Tighten all fasteners without special torques 4.
  • Page 61 Transmission - Transmission and Mounting Section 120-0010 8. Connect all electrical connections and cables to 20. Switch the circuit breakers to the 'On' position, transmission (1) as tagged at removal. start the engine and make an operational check of all lines and components disconnected during removal.
  • Page 62 Transmission - Transmission and Mounting Section 120-0010 Visual Level Indicator SM - 1250 A visual level indicator is mounted on the lower left side of the transmission main housing and provides a method of checking the oil level. Refer to Fig. 2. Cold Oil Level Check Before starting the engine, check the visual level indicator or remove the ADD (lower) plug.
  • Page 63 Transmission - Transmission and Mounting Section 120-0010 a. Disconnect battery equalizer ground connection 3. Apply the service brake, release the parking brake from the batteries. Disconnect battery cables from and select fifth gear on the transmission shift selector. terminal posts (ground cable first). Disconnect battery The transmission will shift to fifth gear and deactivate equalizer positive connection.
  • Page 64 Transmission - Transmission and Mounting Section 120-0010 Transmission Commercial Electronic Control (CEC) WARNING Troubleshooting Manual SA 2712A. Be sure to apply the parking brake, switch off the engine and block all road wheels before SPECIAL TOOLS troubleshooting the vehicle. If it is necessary to run the engine, it is imperative that an There are no special tools required for the procedures operator be present in the cab at all times,...
  • Page 65 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY C - Heavy metal debris found Transmission internal failure Completely disassemble, clean and repair in oil transmission. Replace filters and clean lines and oil cooler. D - Coolant found in oil Transmission oil cooler leaking Completely disassemble and thoroughly clean transmission.
  • Page 66 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY M - Vehicle operates in fifth Fifth and sixth gear clutch Overhaul transmission and sixth gears and moves failed (won't release) forward in neutral when engine is accelerated, but stalls in all other gears when engine is accelerated - Electrical Troubleshooting OK...
  • Page 67 Transmission - Transmission and Mounting Section 120-0010 MECHANICAL TROUBLESHOOTING CHART CONDITION REASON REMEDY T - Low engine speed at Low engine output torque Tune engine and check output converter stall Converter element Check for noise at stall; overhaul converter if interference necessary Transmission oil not up to...
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  • Page 69 TRANSMISSION - CEC Plus II Shift System Section 120-0070 DESCRIPTION seconds and then, if the condition fails to correct itself, The CEC (Commercial Electronic Control) shift system locks in gear and prevents any further shifting. The continually monitors the transmission and shift system Check Trans and Do Not Shift lights will both come on.
  • Page 70 Transmission - CEC Plus II Shift System Section 120-0070 SM - 2031 TEST MANUAL AUTO POWER ECONOMY BODY HYD CONTROL VALVE 1 - Electronic Control Unit (ECU) 8 - Check Trans Warning Light 2 - Battery Equalizer 14 - Lockup Valve & Temp Control 9 - Check Trans Switch 3 - CEC Interface Box 15 - Main Control Valve...
  • Page 71 Transmission - CEC Plus II Shift System Section 120-0070 selector in direct response to throttle position and transmission output speed. WARNING Always select Neutral and apply the parking When Reverse is selected the reverse alarm sounds and brake before leaving the operator’s seat. the reverse light illuminates at the rear of the vehicle.
  • Page 72 Transmission - CEC Plus II Shift System Section 120-0070 and hoist interlock pressure switch mechanisms are 9. Check Trans Switch - Is used in conjunction with disengaged! This allows unauthorised selection of the check trans warning light to obtain trouble codes reverse or any forward gear with the body raised, which will indicate shift system malfunctions.
  • Page 73 Transmission - CEC Plus II Shift System CEC COMPONENT DESIGNATIONS F7 - 10 Amp Fuse - CEC (in fuse box) H27 - Check Trans W/L K1 - Starter Relay K17 - Reverse Relay N2 - Voltage Regulator S4 - Test Switch 330A S7 - Park/Emergency Brake Switch S19 - Dipswitch...
  • Page 74 Transmission - CEC Plus II Shift System Section 120-0070 SM - 1968 WARNINGS The ECU can be damaged by improper welding B(306) procedures. W/P(203) Any time the battery equalizer is disconnected from the batteries, remove W/P(203) ground cable first, and reconnect last, to FUSE 3 prevent damaging the component.
  • Page 75 Transmission - CEC Plus II Shift System Section 120-0070 SM - 1969 BATTERIES FUSE 1 B(306) FUSE 2 (235) R(308) CHECK TRANS SHIFT LIGHT SELECTOR B(306) B(306) (87A) Fig. 4 - Circuit Breakers SM - 1970 FROM IGN. SW. W/B(330A) U/G(223) W/U(202A) RELAY 1...
  • Page 76 Transmission - CEC Plus II Shift System Section 120-0070 ECU Operating Power Circuit is completed to ground through line 306. Solenoid in Relay 2 closes Switch allowing current Refer to Fig. 6. When the engine is started, current (24 volts) flows through Line 330 and Fuse 7 to Relay (12 volts) to flow through Fuse 6, Line 87, Switch and 2, energizing solenoid.
  • Page 77 Transmission - CEC Plus II Shift System Section 120-0070 Check Trans Light When the engine is started, a switch in the ECU The Check Trans light has two functions: to warn the closes, allowing current (24 volts) to flow through the operator of a system failure and to flash trouble codes circuit made by Fuse 7, Lines 330, 215, 208 or 209 when the test switch is activated.
  • Page 78 Transmission - CEC Plus II Shift System Section 120-0070 Reverse Alarm ECU and back to ground through Lines 208 or 209 and Refer to Fig. 10. When the shift selector is placed in Line 306. Solenoid closes Switch, allowing current to Reverse, ECU closes circuit allowing current (24 volts) flow through Line 308, Switch and Line 75 to reverse to flow through Line 308 and Fuse 1 to Relay 5,...
  • Page 79 Transmission - CEC Plus II Shift System Section 120-0070 SM - 2032 VANNER EMERGENCY PARK B(306) N.C. B(309) R(222) N.O. N.C. - RUN POSITION N.O. - PARK POSITION BATTERIES Fig. 12 - Parking Brake Interlock Body Up Interlock proximity switch closes. Refer to Fig.
  • Page 80 Transmission - CEC Plus II Shift System Section 120-0070 ECU Electromagnetic Shield - Ground SM - 426 Refer to Fig. 15. Must be grounded to protect ECU. GROUND TO PASSENGER SEAT BOX Fig. 15 - ECU Electromagnetic Shield - Ground Mode Selection Switch 2.
  • Page 81 Transmission - CEC Plus II Shift System Section 120-0070 SM - 427 COUNTS COUNTS COUNTS COUNTS ERROR ERROR ZONE ZONE OPERATING RANGE FULL IDLE THROTTLE 5.08 mm APPROX 45.7 mm (0.2 in) 19.05mm (0.75 in) (1.8 in) 0 mm 48.3 mm STROKE (0 in) (1.9 in)
  • Page 82 208580 17 - 21 Nm (13 - 16 lbf ft). Refer to Section 190-0270, TR70 M6600AR 208580 SWITCHES AND SENSORS. TR100 DP-8963 249120 Speedometer Calibration Hoist Interlock Pressure Switch 1. Determine the impulses/mile required. Reference Located in a tee installed in body hoist control valve.
  • Page 83 Transmission - CEC Plus II Shift System Section 120-0070 Neutral. To obtain reverse gear whilst the body is held For example: FLASH - PAUSE - FLASH - FLASH - in the raise position, move the transmission shift lever FLASH - LONG PAUSE denotes a Code 13. to Neutral, then re-select reverse gear.
  • Page 84 Transmission - CEC Plus II Shift System Section 120-0070 open circuits by moving harnesses with VOM probes Remedy: connected to the applicable terminals. For step-by- 1. Check battery voltage with VOM. Fully charged step procedures for finding shorts or open circuits in batteries should measure 28 ±...
  • Page 85 Transmission - CEC Plus II Shift System Section 120-0070 SM - 432 MAIN VALVE J1B HARNESS J1A HARNESS BODY HARNESS CONNECTORS TO ECU CONNECTORS AT CONNECTOR TO MAIN VALVE SHIFT SELECTOR BODY COVER CONTROL INTERFACE MAIN CONTROL VALVE SOLENOID CONNECTORS DIGITAL DATA LINE CONNECTOR LOCKUP...
  • Page 86 Transmission - CEC Plus II Shift System Section 120-0070 SM - 433 A - J1A HARNESS CONNECTOR TO ECU B - J1B HARNESS CONNECTOR TO ECU D - J1A HARNESS C - J3 HARNESS CONNECTOR TO ECU CONNECTOR TO SHIFT SELECTOR E - J1B HARNESS F - J1B HARNESS D - J1A HARNESS CONNECTOR TO...
  • Page 87 Transmission - CEC Plus II Shift System Section 120-0070 Code 22 - Transmission Output Shaft 3. If fault cannot be found using steps 1 & 2, install a new shift selector and reconnect all harness Speed Sensor connectors. Test drive the vehicle and check for System Response: presence of trouble code.
  • Page 88 Transmission - CEC Plus II Shift System Section 120-0070 Remedy: Note: Solenoids in main valve body are lettered A, B, 1. Check transmission oil level. C, D, E, F and G from left to right. 2. Check cooling system. Remedy: 1.
  • Page 89 Transmission - CEC Plus II Shift System Section 120-0070 Code 61/63 - Splitter High Solenoid (G) 3. If in Step 1 VOM reading was not within limits, remove lockup valve body cover or trim boost valve System Response: body cover and remove connector from solenoid. 1.
  • Page 90 Transmission - CEC Plus II Shift System Section 120-0070 DETERMINING PROM PART NUMBER use the ECU/PROM assembly number to determine The PROM is located inside the ECU and the part the PROM part number. number is printed on the PROM itself. On the ECU is a label with the ECU/PROM assembly number.
  • Page 91 Transmission - CEC Plus II Shift System Section 120-0070 ELECTRICAL TROUBLESHOOTING - No Codes CONDITION REASON REMEDY Transmission stays in Neutral Disconnected or dirty Check and clean harness connectors (will not shift), or will not make connectors a selected shift Faulty wiring harness Check and repair harness Transmission output shaft...
  • Page 92 Transmission - CEC Plus II Shift System Section 120-0070 ELECTRICAL TROUBLESHOOTING - No Codes CONDITION REASON REMEDY Transmission will not make a Extremely low oil level Check oil level and add if low specific shift Extreme oil temperature Refer to Codes 24 and 33 troubleshooting procedures Faulty solenoid circuitry Refer to Codes 41 - 45, 54, 61, 62 or 63...
  • Page 93 Transmission - CEC Plus II Shift System Section 120-0070 SPECIAL TOOLS The following tools are contained in CEC Off-Highway Diagnostic Service Kit - 15269231 TOOL NUMBER TOOL NAME 15269232 Wire Cutter, Stripper and Terminal Crimper 15269233 Jumper Wire Set 15269234 Terminal Crimper 15269235 Terminal Remover - Metri Pack (J1A, J1B, J3 and Shift Selector Connector Terminals)
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  • Page 95 Transmission - C.E.C. 2 Section 120-0070 NNE T R T RES ST R EART E. . . SE E T R TRANS. ARNESS NTER A E A N ST RE . E ARNESS NNE T R 1. Gear Shift Selector 5.
  • Page 96 Transmission - C.E.C. 2 Section 120-0070 Power Module - The Power Module is located on the SM2940 side of the battery box (Fig.3). The Power Module contains ignition run fuses and relays, and a timer relay for the shutdown function of the ECU. The ignition fuses and relays open power to the ECU.
  • Page 97 Transmission - C.E.C. 2 Section 120-0070 SM2667 SM2669 SP AY Fig. 6 - Gear Shift Selector Fig. 7 - Speed Sensors Locations When drive 'D' is selected, the transmission right-of-way to a loaded vehicle, the transmission can automatically upshifts and downshifts through all six be left in the selected range and the vehicle held forward ranges as required by loads and travel speeds.
  • Page 98 Transmission - C.E.C. 2 Section 120-0070 torque converter acts as a fluid coupling, multiplying SM2670 torque when engine speed is significantly higher than transmission output shaft speed. When the mode selection switch is in the Power position, the ECU controls operation of the lockup clutch according to signals received by the throttle position sensor (giving engine speed as a percent of throttle), the transmission output shaft speed sensor,...
  • Page 99 Transmission - C.E.C. 2 Section 120-0070 SM2666 MAIN VALVE BODY MAIN ONNE TOR ALL MODELS (Solenoids A LATE & OVER ONNE TOR VALVE BODY (Solenoids H, I, & J) 8610, 9610, 9810 ONNE TOR ALL MODELS TRIM BOOST ONNE TOR ( Solenoid and sump (Solenoid J) temperature sensor)
  • Page 100 Transmission - C.E.C. 2 Section 120-0070 gear shift selector to neutral, than back to reverse. The 6. Lock in Gear - The Lock in gear feature is designed ECU receives a signal from a pressure switch located to protect the transmission from damage should wheel on the raise circuit on the body control valve.
  • Page 101 Transmission - C.E.C. 2 Section 120-0070 ELECTRICAL DIAGRAMS Transmission ECU Power Diagrams SM3240A Fig. 14 - MAIN POWER SUPPLY & STARTER CIRCUITS module mounted on the trucks battery box (Ref. Fig. Transmission ECM Power 15, 16 & 18). Inside the power module there are 2 Refer to Fig.
  • Page 102 Transmission - C.E.C. 2 Section 120-0070 SM2922 Fig. 15 - SM2923 Fig. 16 - SM2314 Rev 2 10-07...
  • Page 103 Transmission - C.E.C. 2 Section 120-0070 neutral (N). Turning key switch to position '2', against SM2679 spring pressure causes pre lube timer relay (K42) to energise, in doing so starting the prelube motor which will continue to run until the engine oil pressure is sensed between 5-7 Ibf/in², at which time prelube starter relay (K1) will energise and after a 3(s) delay will .
  • Page 104 Transmission - C.E.C. 2 Section 120-0070 SM2930 Fig. 21 - SM2929 Fig. 22 - SM2314 Rev 2 10-07...
  • Page 105 Transmission - C.E.C. 2 Section 120-0070 SM2933 body up relay (4) completes the hold in range signal via wire 163 back to the ECU shifter connector (S), pin 27. 4. Bed Hoist Interlock (Reverse Hoist Interlock) - The ECU shifts the transmission to neutral (N) if the body is raised when the transmission is in a selected reverse gear (R).
  • Page 106 Transmission - C.E.C. 2 Section 120-0070 11. Manual Mode Key - The manual mode key, For all transmission solenoid locations please refer to mounted on the interface box, is defined as (S52) - Fig. 9. All transmission solenoid inputs/outputs are Ref.
  • Page 107 Transmission - C.E.C. 2 Section 120-0070 the Hi-Retard Relay, located inside the centre console (Ref. Fig. 26), is energised completing the Hi-Retard request back to ECU vehicle connector (V), pin 28, wire 178. SM2935 Fig. 27 - SM2937 1. Hi-Retard Temperature Switch (S46) 2.
  • Page 108 Transmission - C.E.C. 2 Section 120-0070 TRANSMISSION ECU CONNECTIONS SM2924 Refer to Fig. 29. The transmission ECU has 3 conections that provide inputs and out puts for transmission functions. The 3 E IC E connections are; CONNECTION (V) Vehicle Connector - Gray Colour (S) Shifter Connector - Black Colour TRANSMISSION CONNECTION...
  • Page 109 Transmission - C.E.C. 2 Section 120-0070 SM2926 BLACK COLOUR WIRE# DESCRIPTION 142-S1 Diagnostic connector (High) 124-S3 Shift Selector Power 146-S4 Ignition Sense (Diagnostic Connector) 170-S5 PSS, Data Bit 1 171-S6 PSS, Data Bit 2 172-S7 PSS, Data Bit 4 173-S8 PSS, Data Bit 8 174-S9 PSS, Parity...
  • Page 110 Transmission - C.E.C. 2 Section 120-0070 SM2925 COLOUR WIRE# DESCRIPTION 102-T1 Solenoid Power, Solenoids F, G & I 121-T2 Solenoid Power, Solenoid K 107-T3 Solenoid Power, Solenoid J or H 120-T4 F Solenoid, Low 103-T5 B Solenoid, Low 129-T6 E Solenoid, Low 104-T7 A Solenoid, Low 111-T8...
  • Page 111 Transmission - C.E.C. 2 Section 120-0070 TROUBLE-SHOOTING 2. For Inactive Codes - Press and hold the mode button for 8 to 10 seconds. Begin troubleshooting by checking the transmission fluid level and ECU input voltage. Remember that Exit Diagnostic Mode some problems may be temperature related.
  • Page 112 Transmission - C.E.C. 2 Section 120-0070 TROUBLE-SHOOTING DIAGNOSTIC CODES Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated. SOL OFF - All Solenoids Off. GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode. SM2314 Rev 2 10-07...
  • Page 113 Transmission - C.E.C. 2 Section 120-0070 TROUBLE-SHOOTING DIAGNOSTIC CODES (CONT.) Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated. SOL OFF - All Solenoids Off. GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode. SM2314 Rev 2 10-07...
  • Page 114 Transmission - C.E.C. 2 Section 120-0070 TROUBLE-SHOOTING DIAGNOSTIC CODES (CONT.) Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated. SOL OFF - All Solenoids Off. GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode. SM2314 Rev 2 10-07...
  • Page 115 M6610 AR-CEC2 104290 • Is the driveline properly connected? TR100 M8610 AR-CEC2 124560 • TR100 with M8610 AR-CEC2 95120 Are there signs of fluid leakage under the vehicle? • 10.5 Planetry What is the origination point of this leak? •...
  • Page 116 Transmission - C.E.C. 2 Section 120-0070 SPECIAL TOOLS The Special Tools listed in the following tables are required for servicing the CEC 2 Shift System and are available from your dealer. SPECIAL TOOLS TOOL NUMBER TOOL NAME 15275098 Diagnostic Data Reader (DDR) Multikit (Includes Reader, Cartridge, Cables) 15275180 CEC 2 Diagnostic Card 15269038...
  • Page 117 Transmission - C.E.C. 2 Section 120-0070 GLOSSARY Detailed below is a glossary of abbreviation used withing the C.E.C. 2 descriptions. Abbreviation Termination Point AGND Analog Return (Ground) ASOL Solenoid A - Main Valve Body Cover BSOL Solenoid B - Main Valve Body Cover CSOL Solenoid C - Main Valve Body Cover DDRD...
  • Page 118 Transmission - C.E.C. 2 Section 120-0070 THIS PAGE IS INTENTIONALLY LEFT BLANK SM2314 Rev 2 10-07...
  • Page 119 TRANSMISSION - Power Takeoff Section 120-0090 SM - 1386 1 - Snap Ring 7 - 'O' Ring 13 - Pipe Plug 8 - Pinion Shaft 14 - Bearing 19 - Lockwasher 2 - Bearing 9 - Bearing 15 - Shim 0.07 mm (0.003 in) 20 - Pipe Plug 3 - Snap Ring 10 - Pinion Gear...
  • Page 120 Transmission - Power Takeoff Section 120-0090 parking brake and switch off the engine. suitable puller tool into the internally splined output shaft (4) and pull output shaft, together with bearing 2. Turn steering wheel in both directions several (14) from driven gear (5). times to relieve pressure in the steering circuit.
  • Page 121 Transmission - Power Takeoff Section 120-0090 8. Install and stake set screw (11) in housing (12). SM - 272 9. Install pipe plug (13) in the end of pinion shaft (8). INSTALLATION Numbers in parentheses refer to Fig. 1. Note: Tighten all fasteners to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS.
  • Page 122 Transmission - Power Takeoff Section 120-0090 assembly in position with bolts (18) and tighten lines and fittings as required. lockwashers (19). 11. Ensure parking brake is applied and remove 8. Remove blanking caps from adaptor (21) and hose wheel chocks from all road wheels. assembly (22) and install hose assembly (22).
  • Page 123 TRANSMISSION - Transmission Oil Filter Section 120-0100 SM - 1568 TRANSMISSION 1 - Adaptor 6 - Bolt 2 - Elbow 7 - Lockwasher 3 - Filter Inlet Line 8 - Bolt 4 - Filter Outlet Line 9 - Lockwasher 10 - Filter Assembly 5 - Plate Assembly Fig.
  • Page 124 Transmission - Transmission Oil Filter Section 120-0100 REMOVAL SM - 1251 Numbers in parentheses refer to Fig. 1, unless otherwise specified. WARNING To prevent personal injury and property damage, be sure wheel blocks are properly secured and of adequate capacity to do the job safely.
  • Page 125 Transmission - Transmission Oil Filter Section 120-0100 7. Start the engine and check for leaks. Tighten lines, 3. With a suitable container under the filter assembly fittings and filter locking collar as required. to catch draining oil, unscrew locking collar on housing (5) and remove housing (5) and element (2).
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  • Page 127 DRIVELINE - Front Driveline Section 130-0010 SM - 1982 ENGINE TRANSMISSION 1 - Driveline Assembly 2 - Universal joint 3 - Capscrew 4 - Capscrew Fig. 1 - Exploded View of Front Driveline Installation DESCRIPTION REMOVAL The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig.
  • Page 128 Driveline - Front Driveline Section 130-0010 2. Turn steering wheel in both directions several times SM - 088 to relieve pressure in the steering circuit. Block all road wheels. APPLY PRESSURE MAXIMUM PERMISSABLE HERE BY HAND GAP IS 0.2 mm (0.008 in) 3.
  • Page 129 Driveline - Front Driveline Section 130-0010 MAINTENANCE other deformity of universal joints will prevent accurate mating with the crosses and bearings. This will cause Lubrication misalignment, which is accompanied by vibration and excessive wear. Lubricate driveline with either a hand-operated or a pressure grease gun.
  • Page 130 Driveline - Front Driveline Section 130-0010 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Capscrew 312 - 325 230 - 240 Capscrew 312 - 325 230 - 240 SM 1657 1-99...
  • Page 131 DRIVELINE - Rear Driveline Section 130-0020 SM - 1983 TRANSMISSION DIFFERENTIAL 1 - Driveline Assembly 2 - Universal joint 3 - Capscrew 4 - Capscrew Fig. 1 - Exploded View of Rear Driveline Installation DESCRIPTION REMOVAL The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig.
  • Page 132 Driveline - Rear Driveline Section 130-0020 2. Turn steering wheel in both directions several times SM - 088 to relieve pressure in the steering circuit. Block all road wheels. APPLY PRESSURE MAXIMUM PERMISSABLE HERE BY HAND GAP IS 0.2 mm (0.008 in) 3.
  • Page 133 Driveline - Rear Driveline Section 130-0020 MAINTENANCE other deformity of universal joints will prevent accurate mating with the crosses and bearings. This will cause Lubrication misalignment, which is accompanied by vibration and excessive wear. Lubricate driveline with either a hand-operated or a pressure grease gun.
  • Page 134 Driveline - Rear Driveline Section 130-0020 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft Capscrew 377 - 417 278 - 308 Capscrew 377 - 417 278 - 308 SM 1658 1-99...
  • Page 135 FRONT AXLE - Wheel, Rim and Tyre Section 140-0040 SM - 228 1 - Clamp 7 - 'O' Ring 4 - Rim 2 - Wheel Nut 5 - Lock Ring 8 - Bead Seat Band 3 - Wheel Stud 6 - Flange 9 - Wheel Fig.
  • Page 136 Front Axle - Wheel, Rim and Tyre Section 140-0040 machine. The tyre and rim may be removed from the SM - 204 machine as an assembly, and transported to a more desirable location for removing the tyre from the rim. WARNING To prevent personal injury and property damage, be sure wheel blocks, blocking...
  • Page 137 Front Axle - Wheel, Rim and Tyre Section 140-0040 Note: If tyre and rim is on machine, and no tyre lifting WARNING equipment is available, 'walk' tyre off rim as follows: When lifting tyre from rim, be sure the force bottom of tyre outward as far as possible; lower equipment is of sufficient capacity and jack enough to allow weight of tyre to rest on ground;...
  • Page 138 Front Axle - Wheel, Rim and Tyre Section 140-0040 distorted, battered, and rusted parts which may have SM - 207 resulted from abusive practices outlined above. Replace any damaged parts with new parts. 4. Discard 'O' ring and replace with new one. Note: Handle 'O' rings carefully, as damage will prevent an airtight seal for tyre inflation.
  • Page 139 Front Axle - Wheel, Rim and Tyre Section 140-0040 SM - 229 BRAKE CALLIPER SEC 165-0020 1 - Lockwire 2 - Bolt 3 - Plate 4 - Shim Pack 5 - Outer Bearing Cone 6 - Outer Bearing Cup 7 - Wheel 8 - Spindle 9 - Inner Bearing Cone 10 - Inner Bearing Cup...
  • Page 140 Front Axle - Wheel, Rim and Tyre Section 140-0040 Inspection BRAKE PARTS. 1. Thoroughly clean all metal components, except 5. Remove bolts (18) and lockwashers (19) which bearing cones, in a suitable solvent. Dry with secure cover (20) to wheel (7). Remove cover (20) compressed air and coat all threaded components with light oil to facilitate assembly.
  • Page 141 Front Axle - Wheel, Rim and Tyre Section 140-0040 evenly to 205° C (400° F). This takes about 1 minute, only two bolts (2) located 180 apart, adjacent to the using a torch with a heating tip. Use a Tempilstik or gauging holes in plate (3).
  • Page 142 Front Axle - Wheel, Rim and Tyre Section 140-0040 SM - 208 WARNING To avoid personal injury and property damage, never stand or sit in front of a mounted tyre during tyre inflation. Use a clip-on air chuck with a long hose and stand to one side while the tyre is being inflated.
  • Page 143 Front Axle - Wheel, Rim and Tyre Section 140-0040 NITROGEN TYRE INFLATION SM - 1040 Note: All Warnings and procedures under 'Tyre Inflation' will apply, except for differences covered by this passage. In certain environments it is recommended that tyres be inflated with dry nitrogen gas, and that the resulting oxygen content of the inflation does not exceed 5%.
  • Page 144 Front Axle - Wheel, Rim and Tyre Section 140-0040 SM - 214 observing the gauge at the pressure regulator. STAY AWAY FROM THE TYRE. e. When desired inflation pressure has been achieved, back off the regulator or close the valve on the compressed gas cylinder.
  • Page 145 Front Axle - Wheel, Rim and Tyre Section 140-0040 until 3/4 of the rim circumference has been covered. SM - 218 Apply pressure at this point until bead breaks loose. AT LEAST 460 m AT LEAST 15 m (50 ft) (1 500 ft) 8.
  • Page 146 Front Axle - Wheel, Rim and Tyre Section 140-0040 Maintain Correct Inflation angle of the skive should be no more than sufficient to expel all foreign material and should extend no deeper The most common cause of tyre damage is improper inflation.
  • Page 147 Front Axle - Wheel, Rim and Tyre Section 140-0040 Store Tyres Properly must be taken not to distort or mutilate the rim parts because they must mate properly to form part of the The best of care given to tyres in service by operators and maintenance personnel can be completely basic air chamber.
  • Page 148 Front Axle - Wheel, Rim and Tyre Section 140-0040 TUBELESS TYRE LEAK DIAGNOSIS Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of leakage, the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be checked using a soap solution.
  • Page 149 REAR AXLE - Differential Section 160-0020 SM - 1291 PINION ASSY RETAINER ASSY YOKE ASSY 1 - Lockwire 12 - Oil Seal 23 - Bearing Cap 2 - Bolts 13 - Cup 24 - Bolt 34 - Dowel Pin 3 - Plate 14 - Cone 25 - Lock 35 - Side Gear...
  • Page 150 Rear Axle - Differential Section 160-0020 assembly when driven by input pinion gear (15). 8. Install chain fall or come-a-long to the loop placed However, side gears (35), into which each axle shaft is on the body just behind the hoist brackets. Attach the inserted, are free to rotate independently about spider other end of the lifting device to eye previously pinion gears (37) with which they are meshed.
  • Page 151 Rear Axle - Differential Section 160-0020 3. Scribe an identifying line on the bearing adjusters (26) SM - 094 and carrier housing bores which these adjusters screw into. If the differential assembly is disassembled, for inspection purposes only, this line will be of assistance when readjusting the preload on the side bearing cups and cones (27 &...
  • Page 152 Rear Axle - Differential Section 160-0020 20. Remove dowel pins (34) from plain case (39) and SM - 096 flanged case (29) only if they are damaged and have to be replaced. Pinion Cage Group Note: Before disassembling, punch identifying marks on retainer (9) and carrier housing (19) for assembly purposes.
  • Page 153 Rear Axle - Differential Section 160-0020 on yoke (5) to provide a smooth contact surface. If the Note: Bearing caps (23) and carrier housing (19) can sleeve is rough or worn, pull it from the yoke and install only be replaced as an assembly. a new one.
  • Page 154 Rear Axle - Differential Section 160-0020 carrier housing (19) as shown in Fig. 6. The plate must SM - 098 lie perfectly flat between the bearing cap mounting GAUGING DISTANCE surfaces and must be clean and free of burrs. MEASURE GAUGING DISTANCE WITH ESTIMATED, OR ORIGINAL e.
  • Page 155 Rear Axle - Differential Section 160-0020 against shoulders of flanged case (29), using the SM - 100 bearing spreader tool shown in Fig. 18. 7. Install other side gear (35) and thrust washer (33), with grooved side of washer mating with machined surface of side gear, in plain case (39).
  • Page 156 Rear Axle - Differential Section 160-0020 Note: Each cap (23) is mated to the carrier housing SM - 102 (19), therefore, they must be returned to their original positions by aligning the identification marks made RING GEAR RUNOUT during disassembly. READING TAKEN AS SHOWN, AND MUST 2.
  • Page 157 Rear Axle - Differential Section 160-0020 ADJUSTMENTS SM - 105 When adjusting a noisy differential that has been in service for some time, more harm than good can result. Changes in adjustment will frequently concentrate the bearing area on a small portion of the teeth which often results in failure.
  • Page 158 Rear Axle - Differential Section 160-0020 SM - 110 SM - 108 MOVE GEAR IN THIS DIRECTION FOR CORRECTION IN FIG. 12 MOVE GEAR IN THIS DIRECTION FOR CORRECTION IN FIG. 13 Fig. 14 - Pinion In Too Far - Add Shims Fig.
  • Page 159 Rear Axle - Differential Section 160-0020 6. Install chain fall or come-a-long to the loop on the Note: Do not operate with only one wheel jacked up. body just behind the hoist brackets. Attach the other Excessive operation in this manner will overheat the end of the lifting device to the eye previously installed differential spider and cause galling or shearing of the in the differential assembly.
  • Page 160 Rear Axle - Differential Section 160-0020 SM - 112 ONE-4340 STL. OR EQUIV.-HDN.-GRIND 7/16 11.1 12.7 15.9 19.1 29/32 23.0 25.4 1 1/8 28.6 1 1/4 31.8 1 3/8 34.9 1 1/2 38.1 1 7/8 47.6 ONE-4340 APPROX STL.-HDN.-GRIND 50.8 2 1/32 51.6 2 1/8...
  • Page 161 Rear Axle - Differential Section 160-0020 DIAGNOSIS CHART CONDITION REASON REMEDY Vibration. Broken gear teeth. Replace damaged gear. Excessive runout of pinion or flanged case. Disassemble, correct or replace faulty part. Continual noise. Bearing worn. Replace worn parts. Gears damaged or worn. Replace gears.
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  • Page 163 REAR AXLE - Differential Section 160-0020 SM - 2403 23 - Bolt 35 - Spider 12 - Oil Seal 24 - Lock 36 - Spider Pinion Gear 1 - Set Screw 13 - Cup 25 - Bearing Adjuster 37 - Bearing 2 - Bolt 14 - Cone 26 - Cup...
  • Page 164 Rear Axle - Differential Section 160-0020 assembly (44) rotate as an assembly when driven by 8. Install chain fall or come-a-long to the loop placed input pinion gear (15). However, side gears (34 & 38), on the body just behind the hoist brackets. Attach the into which each axle shaft is inserted, are free to rotate other end of the lifting device to eye previously independently about spider pinion gears (36) with...
  • Page 165 Rear Axle - Differential Section 160-0020 3. Scribe an identifying line on the bearing adjusters SM - 2404 (25) and carrier housing bores which these adjusters screw into. If the differential assembly is disassembled, for inspection purposes only, this line will be of assistance when readjusting the preload on the side bearing cups and cones (26 &...
  • Page 166 Rear Axle - Differential Section 160-0020 Pinion Cage Group SM - 096 Note: Before disassembling, punch identifying marks on retainer (9) and carrier housing (19) for assembly purposes. 1. Remove bolts (2) and plate (3); pull yoke assembly (5) from pinion gear (15) shaft with care so as not to damage or distort the yoke flange.
  • Page 167 Rear Axle - Differential Section 160-0020 using a torch with a heating tip. Use a Tempilstik or 14. The machined mating surfaces of plain case (28) other temperature gauge to make sure sleeve (6) is and flanged case assembly (44) must be square with hot enough.
  • Page 168 Rear Axle - Differential Section 160-0020 b. Install bearing cone (16) and bearing cone (14) on SM - 099 pinion gear (15). Install cup (13) into retainer (9) until it bottoms against the retainer shoulder. Install pinion gear assembly (14, 15 & 16) and retainer (9) into carrier housing (19).
  • Page 169 Rear Axle - Differential Section 160-0020 2. Install bolts (31) and tighten to 700 Nm (515 lbf ft) SM - 101 torque. Spider and Component Parts Assembly 1. Press thrust washer dowel pins (33) into holes in plain case (28) and flanged case assembly (44), if removed.
  • Page 170 Rear Axle - Differential Section 160-0020 with an easy motion and note the back face runout. SM - 102 The runout is not to exceed 0.08 mm (0.003 in) with the dial indicator position as shown in Fig. 7. RING GEAR RUNOUT READING TAKEN AS 3.
  • Page 171 Rear Axle - Differential Section 160-0020 ADJUSTMENTS SM - 105 When adjusting a noisy differential that has been in service for some time, more harm than good can result. Changes in adjustment will frequently concentrate the bearing area on a small portion of the teeth which often results in failure.
  • Page 172 Rear Axle - Differential Section 160-0020 SM - 110 SM - 108 MOVE GEAR IN THIS DIRECTION FOR CORRECTION IN FIG. 10 MOVE GEAR IN THIS DIRECTION FOR CORRECTION IN FIG. 11 Fig. 12 - Pinion In Too Far - Add Shims Fig.
  • Page 173 Rear Axle - Differential Section 160-0020 6. Install chain fall or come-a-long to the loop on the Note: Do not operate with only one wheel jacked up. body just behind the hoist brackets. Attach the other Excessive operation in this manner will overheat the end of the lifting device to the eye previously installed differential spider and cause galling or shearing of the in the differential assembly.
  • Page 174 Rear Axle - Differential Section 160-0020 SM - 112 ONE-4340 STL. OR EQUIV.-HDN.-GRIND 7/16 11.1 12.7 15.9 19.1 29/32 23.0 25.4 1 1/8 28.6 1 1/4 31.8 1 3/8 34.9 1 1/2 38.1 1 7/8 47.6 ONE-4340 APPROX STL.-HDN.-GRIND 50.8 2 1/32 51.6 2 1/8...
  • Page 175 Rear Axle - Differential Section 160-0020 DIAGNOSIS CHART CONDITION REASON REMEDY Vibration Broken gear teeth Replace damaged gear Excessive run-out of pinion or flanged case Disassemble, correct or replace faulty part Continual noise Bearing worn Replace worn parts Gears damaged or worn Replace gears Noise on drive Ring or pinion gear adjustment tight...
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  • Page 177 REAR AXLE - Axle Group Section 160-0030 SM - 231 1 - Lockwire 2 - Bolt *3 - Magnetic Plug *4 - Plug 5 - Planetary Carrier 6 - Planet Pinion 7 - Pin Retainer 8 - Pinion Pin 9 - Thrust Plate 10 - Thrust Spacer 11 - Bearing 12 - Bearing Spacer...
  • Page 178 Rear Axle - Axle Group Section 160-0030 Second stage sun gear (18) meshes with and rotates second stage planetary pinions (6) which, in turn, are meshed with ring gear (34). Since second stage ring gear (34) is splined to the wheel spindle it cannot turn and forces the second stage planetary carrier (5) to rotate.
  • Page 179 Rear Axle - Axle Group Section 160-0030 SM - 232 30 - Hardened Washer 31 - 'O' Ring 1 - Lockwire 32 - Pin Retainer 2 - Bolt 33 - Pin Retainer 3 - Magnetic Plug 34 - Ring Gear 4 - Plug 35 - Bolt 5 - Planetary Carrier...
  • Page 180 Rear Axle - Axle Group Section 160-0030 12. Slide planet pinions (17), thrust plates (9), thrust SM - 233 spacers (10), bearings (40) and bearing spacers (16) from planetary carrier (20) assembly. Use care to avoid dropping and/or damaging bearings (40). 13.
  • Page 181 Rear Axle - Axle Group Section 160-0030 10. Install assembled planetary carrier (20) and sun SM - 234 gear (18) in planetary carrier (5) carefully meshing sun gear (18) and planet pinion (6) teeth, and ring gear (27) and planet pinion (17). 11.
  • Page 182 Rear Axle - Axle Group Section 160-0030 REAR AXLE Note: Avoid spilling lubricant on tyres, as it will deteriorate the rubber. Description and Operation Numbers in parentheses refer to Fig. 6. 4. Jack up or lift the truck so its weight is no longer resting on the tyres of the axle assembly.
  • Page 183 Rear Axle - Axle Group Section 160-0030 SM - 2563 31 - Lockwasher 1 - Banjo 11 - Split Cup 21 - Washer 32 - Spacers 2 - Spindle - Left 12 - Tapered Pin 22 - Bolt 33 - Stud 3 - Spindle - Right 13 - Washer 23 - Link...
  • Page 184 Rear Axle - Axle Group Section 160-0030 Inspection 5. If removed, install lube fittings (9) in A-frame (4) and link (23). 1. Clean all metal parts in a suitable solvent, using a brush to clean bearings. Dry all parts on a clean 6.
  • Page 185 Rear Axle - Axle Group Section 160-0030 seating is required and accomplished by re-tightening 11. Lubricate the rear axle assembly through lube bolt (15) after the first few hours of operation, and fittings (9) with lubricant specified in Section 300-0020, thereafter, until bolt (15) retains it torque.
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  • Page 187 REAR AXLE - Wheel, Rim and Tyre Section 160-0050 SM - 203 1 - Flange 4 - Clamp 7 - Bead Seat Band 10 - Spacer Band 2 - Wheel Stud 5 - Wedge Band 8 - Lock Ring 11 - Wheel 3 - Nut 6 - 'O' Ring 9 - Rim...
  • Page 188 Rear Axle - Wheel, Rim and Tyre Section 160-0050 SM - 204 WARNING To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly secured and of sufficient capacity to do the job safely.
  • Page 189 Rear Axle - Wheel, Rim and Tyre Section 160-0050 Note: If tyre and rim is on the truck, and no tyre lifting WARNING equipment is available, 'walk' tyre off rim as follows: When lifting tyre from rim, be sure the force bottom of tyre outward as far as possible;...
  • Page 190 Rear Axle - Wheel, Rim and Tyre Section 160-0050 distorted, battered, and rusted parts which may have SM - 207 resulted from abusive practices outlined above. Replace any damaged parts with new parts. 4. Discard 'O' rings and replace with new ones. Note: Handle 'O' rings carefully, as damage will prevent an airtight seal for tyre inflation.
  • Page 191 Rear Axle - Wheel, Rim and Tyre Section 160-0050 SM - 1294 1 - Lockwire 2 - Bolt 5 - Ring Gear 11 - Spindle 8 - Outer Bearing Cup 3 - Plate 6 - Wheel 12 - Wheel Driver 9 - Inner Bearing Cup 4 - Shim Pack 7 - Outer Bearing Cone...
  • Page 192 Rear Axle - Wheel, Rim and Tyre Section 160-0050 steering wheel in both directions several times to compressed air and coat all threaded components with relieve pressure in the steering system. light oil to facilitate assembly. 2. Block all road wheels, except the ones to be raised. 2.
  • Page 193 Rear Axle - Wheel, Rim and Tyre Section 160-0050 BEARING ADJUSTMENT TABLE GAUGING BOLT TORQUE FINAL BOLT TORQUE No. of Bolts lbf ft No. of Bolts lbf ft SYSTEM. Install outer bearing cone (7) on spindle (11) 15. Install planetary gear assembly and fill planetary and seat in outer bearing cup (8).
  • Page 194 Rear Axle - Wheel, Rim and Tyre Section 160-0050 SM - 208 Make sure that paints, lacquers, paint thinners, or similar materials that produce volatile, flammable vapours are not used or stored near the air intake of the compressor that supplies the air for inflating tyres.
  • Page 195 Rear Axle - Wheel, Rim and Tyre Section 160-0050 NITROGEN TYRE INFLATION b. Safety relief valve, 8.6 bar (125 lbf/in²), that will assure an upper limit to the pressure available for tyre Note: All Warnings and procedures under 'Tyre Inflation' will apply, except for differences covered by inflation.
  • Page 196 Rear Axle - Wheel, Rim and Tyre Section 160-0050 adjust the pressure with the tyre gauge in the usual SM - 214 manner. b. If the required service inflation pressure is greater than 4.1 bar (60 lbf/in²), further inflate, with dry nitrogen gas only, to the pressure level required.
  • Page 197 Rear Axle - Wheel, Rim and Tyre Section 160-0050 SM - 218 AT LEAST 460 m AT LEAST 15 m (50 ft) (1 500 ft) Fig. 10 - APPROACH AREA. Do Not Approach Tyre in Shaded Area TYRE EXPLOSION HAZARD WARNINGS There is always a possibility of a tyre Whenever a machines tyre(s) is (are) exposed...
  • Page 198 Rear Axle - Wheel, Rim and Tyre Section 160-0050 TYRE MAINTENANCE A retreaded tyre has the old tread removed entirely and a new tread cured directly onto the body of the Tyre Repairs tyre. A tyre can be recapped or retreaded if the cord body is free of cuts, bruises and separation, and is Prompt repair of tyre injuries will prevent small injuries thoroughly sound, including previous repairs.
  • Page 199 Rear Axle - Wheel, Rim and Tyre Section 160-0050 Prevent Overloading hooks, cables, or chains in contact with the tyre beads Off-the-highway trucks are designed to carry a when lifting these tyres. If forklift trucks are used for maximum allowable payload. Excessive loading will handling they should be equipped with broad, well overstress both the truck and tyres and shorten the life rounded arms to distribute the load and prevent...
  • Page 200 Rear Axle - Wheel, Rim and Tyre Section 160-0050 TUBELESS TYRE LEAK DIAGNOSIS Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of leakage, the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be checked using a soap solution.
  • Page 201 BRAKE PARTS - Brake Parts - Front Section 165-0020 DESCRIPTION AND OPERATION SM - 248 WARNINGS Use only hydraulic oils meeting specifications outlined in Section 300-0020, LUBRICATION SYSTEM. DO NOT use BRAKE FLUID (J1703). Use of improper fluids is destructive to rubber components of brakes resulting in loss of braking and possible catastrophic failure.
  • Page 202 Brake Parts - Brake Parts - Front Section 165-0020 SM - 249 1 - Bolt 5 - Brake Pad 9 - Cap 13 - Packing 2 - Washer 6 - Bleeder Valve 10 - Retainer 14 - Packing Retainer 3 - Thrust Plate 7 - Bolt 11 - Packing 15 - Dust Boot...
  • Page 203 Brake Parts - Brake Parts - Front Section 165-0020 BRAKE REMOVAL AND DISASSEMBLY material next to the brake disc and rotating into position in the brake head. Numbers in parentheses refer to Fig. 2, unless otherwise specified. 8. Install thrust plates (3 & 4) in same position from which removed (with bolt hole furthest from groove in plate to outside diameter of disc).
  • Page 204 Brake Parts - Brake Parts - Front Section 165-0020 7. Inspect brake pads (5) per Step 1 in the 'General washers (8). Tighten bolts (7) to a torque of Inspection Procedure'. 180 - 200 Nm (135 - 150 lbf ft). 8.
  • Page 205 Brake Parts - Brake Parts - Front Section 165-0020 BLEEDING open until oil exhausting from the bleeder valve is Numbers in parentheses refer to Fig. 2. free from air bubbles. Close bleeder valve (6) and release the service brake treadle. Remove bleeder hose.
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  • Page 207 BRAKE PARTS - Brake Parts - Rear Section 165-0030 DESCRIPTION AND OPERATION consisting of rotating friction discs (29) and splined Numbers in parentheses refer to Figs. 1 and 2. plates (30). The rotating discs are compressed between the splined plates and are held stationary, Service Brakes thus keeping the wheels from rotating.
  • Page 208 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 1296 SPINDLE BEARING SECTION E-E 1 - Inner Seal Housing 16 - Hardened Washer 17 - 'O' Ring 2 - 'O' Ring 31 - Service Piston 45 - Socket Head Screw 3 - Face Seal *18 - Dowel 32 - Pin...
  • Page 209 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 114 PORT B PORT D PORT F PORT D SECTION C-C PORT F PORT C SECTION B-B SECTION D-D NOTE: SECTION A-A Shown on Fig. 1. 14 - Spring Housing 28 - Damper Assemblies 38 - 'D' Section Seal 17 - 'O' Ring...
  • Page 210 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 1298 Fig. 3 - Exploded View of Typical Disc Brake Assembly SM 1630 1-99...
  • Page 211 Brake Parts - Brake Parts - Rear Section 165-0030 16 - Hardened Washers 1 - Inner Seal Housing 2 - 'O' Ring 17 - 'O' Ring 31 - Service Piston 45 - Socket Head Screws 46 - Studs 3 - Face Seal 18 - Dowels 32 - Pins 4 - 'O' Rings...
  • Page 212 Brake Parts - Brake Parts - Rear Section 165-0030 8. If necessary, remove plug (49) and 'O' ring (48) SM - 116 from piston housing assembly (41). Discard 'O' ring. 9. If necessary, remove studs (46) and pipe plug (47) from piston housing assembly (41).
  • Page 213 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 120 WARNING Return springs (36) are under compression. To prevent personal injury and property damage, use care when removing bolts (33) and retaining plates (34). 19. Very carefully, remove bolts (33) and retainer plates (34) securing return springs (36) in piston housing assembly (41).
  • Page 214 Brake Parts - Brake Parts - Rear Section 165-0030 at a time. Using a suitable lifting device, lift spring SM - 125 housing (14) from disc housing (25). Refer to Fig. 12. 26. Remove and discard 'O' ring (17) from spring housing (14).
  • Page 215 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 1542 CORRECT INSTALLATION OF 'D' RING 1 - Pipe Plug 4 - Friction Disc 22 - Seal 25 - Disc Housing 5 - Splined Plate 23 - Parking Piston 2 - Retainer Pin 57 - Spacer Ring 6 - Piston Housing...
  • Page 216 Brake Parts - Brake Parts - Rear Section 165-0030 DISC BRAKE WEAR LIMITS THICKNESS NUMBER OFF WORN FRICTION DISCS 66.04 MM (2.60 IN) 59.44 MM (2.34 IN) SPLINED PLATES 28.96 MM (1.14 IN) 27.43 MM (1.08 IN) DAMPER PLATES 13.72 MM (0.54 IN) 11.68 MM (0.46 IN) STACK THICKNESS 108.71 MM (4.28 IN)
  • Page 217 Brake Parts - Brake Parts - Rear Section 165-0030 install in parking piston (23) as shown in Fig. 17. SM - 131 8. Lubricate disc housing seal (24) and area around the seal generously with 'Wynns S.T.P.'. Install parking piston (23) into disc housing (25). 9.
  • Page 218 Brake Parts - Brake Parts - Rear Section 165-0030 coating of oil, of the type used in the system, to the SM - 133 discs. 19. Install friction disc (29) over disc driver (27), aligning teeth of friction disc with splines on disc driver. 20.
  • Page 219 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 137 SM - 138 Fig. 24 - Installing Piston Housing on Disc Housing Fig. 25 - Tightening Piston Housing to Disc Housing SM - 140 DISC BRAKE ASSY PORT F 3/8 NPT PORTABLE ADAPTOR...
  • Page 220 Brake Parts - Brake Parts - Rear Section 165-0030 cavity to 52 bar (750 lbf/in ). See Fig. 27. SM - 139 Open bleeder valve (54, Fig. 2) slightly while pressurizing Port 'D' to release any trapped air. When hydraulic oil only, flows from bleeder valve (54), close the valve and pressurize piston cavity to 52 bar (750 lbf/in Apply and release the pressure ten times to seat the...
  • Page 221 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 450 SM - 451 Fig. 30 - Seal Driver Fig. 29 - Seal Sleeve SM - 452 DISC DRIVER SEAL METALLIC ELEMENT TORIC RING SEAL SPRING DRIVER SEAL PARKING SLEEVE PISTON SPRING...
  • Page 222 Brake Parts - Brake Parts - Rear Section 165-0030 contacting surface of face seal (11). SM - 148 10. Install toric ring in other half of face seal and install in seal housing (10), toric ring side down. Refer to Figs. 32 & 33. Install seal installation tool (Fig.
  • Page 223 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 1486 8,9,10 TO MAIN AIRLINE 14,15 18,19 16,17 1 - Blanking Plate (Port 'B') 11 - Pressure Gauge 6 - Hose Assembly 2 - Blanking Plate (Port 'C') 12 - Shutoff Valve 16 - Hose Assembly 7 - Female Swivel Connector 3 - 'O' Ring...
  • Page 224 Brake Parts - Brake Parts - Rear Section 165-0030 oil specified in Section 300-0020, LUBRICATION WARNING SYSTEM. Refer to SECTION 220-0040, STEERING Loosen bleeder valves carefully. The braking AND BRAKE CONTROL TANK, for correct fill level. system operates at high pressure. Note: If brake discs, service and/or parking pistons, 5.
  • Page 225 Brake Parts - Brake Parts - Rear SPRING COMPRESSOR TOOL MATERIAL: PLAIN CARBON STEEL ITEM #2 - BASE (WELDMENT) 100 SQ. STOCK ITEM #1 - HANDLE .250 DIA. HOLE THRU. KNURL DIA. HOLE ITEM #5 - 'T' HANDLE (WELDMENT) .19 SQ. 8-32 UNC 2B X .38 MIN.
  • Page 226 Brake Parts - Brake Parts - Rear Section 165-0030 SM - 126 0.56 - 3 HOLES EQUALLY SPACED 0.12 0.50 12.7 0.56 14.22 0.62 15.7 1.00 25.4 1.62 41.1 2.00 50.8 2.50 63.5 3.25 82.5 MATERIAL: PLAIN CARBON STEEL 3.31 84.0 9.38 15.88...
  • Page 227 SUSPENSION SYSTEM - Ride Cylinder Section 180-0030 SM - 1544 *1 - Pipe Plug 2 - Relief Valve 3 - Ball Bearing 4 - Bolt 5 - Locknut *6 - Valve Assembly *7 - Check Valve 8 - Hardened Washer 9 - Wiper 10 - Seal 11 - Wear Ring...
  • Page 228 Suspension System - Ride Cylinder Section 180-0030 bearing (3), allowing oil to fill the cavity between piston SM - 1545 rod (24) and tube (18). When the force of piston rod (24) is expended, the compressed nitrogen pushes the piston rod outward to its original position.
  • Page 229 Suspension System - Ride Cylinder Section 180-0030 SM - 1546 1 - Pipe Plug 17 - Bolt 9 - Wiper 2 - Relief Valve 18 - Tube 25 - Wear Ring 10 - Seal 3 - Ball Bearing 19 - Seal Retainer 26 - Bolt 11 - Wear Ring 4 - Bolt...
  • Page 230 Suspension System - Ride Cylinder Section 180-0030 SM - 193 4. Inspect pipe plug (1), check valve (7), valve assembly (6), relief valve (2) and lube fitting (21). Check their seating positions in end cap (20) and tube (18). If threads in any of these parts are damaged, restore the threads.
  • Page 231 Suspension System - Ride Cylinder Section 180-0030 SM - 194 TUBE 'O' RING BACKUP RING WEAR WIPER SEAL INNER SEAL RING SEAL TUBE RETAINER Fig. 5 - Cutaway View of Front Ride Cylinder Tube Assembly the full extended position and tighten bolts (17) to a SM - 195 torque of 95 - 122 Nm (70 - 90 lbf ft).
  • Page 232 Suspension System - Ride Cylinder Section 180-0030 2. Secure ride cylinder assembly (7) to the chassis SM - 196 with hardened washers (5) and bolts (6 & 8). Alternately tighten bolts (6 & 8) to a torque of 1 830 Nm (1 350 lbf ft).
  • Page 233 Suspension System - Ride Cylinder Section 180-0030 a) Modify a spare check valve assembly by Note: Nitrogen leaving the cylinder will often carry oil removing the internal valve and spring or with it. This results from foaming of the oil in the cylinder.
  • Page 234 Suspension System - Ride Cylinder Section 180-0030 8. Close tank valve (6, Fig. 8) and open cylinder valve (4, SM - 1273 Fig. 8). Charge both cylinders to 16.3 bar (240 lbf/in²) by opening tank valve (6, Fig. 8) slowly, closing it occasionally. To check the pressures in the cylinders, close tank valve (6, Fig.
  • Page 235 Suspension System - Ride Cylinder Section 180-0030 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft 6 & 8 Bolt 1 830 1 350 Locknut 260 - 285 190 - 210 Bolt 95 - 122 70 - 90 Bolt Tie Rod Nut 2 030 - 2 300...
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  • Page 237 SUSPENSION SYSTEM - Ride Cylinder - Rear Section 180-0050 SM - 1369 PASSAGE 'A' 7 - Plug 1 - Piston Rod 8 - Ball 18 - Bolt 2 - Spherical Bushing 13 - Bolt 9 - Wiper 19 - Tube 3 - Snap Ring 14 - Backup Ring 4 - Lube Fitting...
  • Page 238 Suspension System - Ride Cylinder - Rear Section 180-0050 SM - 1543 1 - Ride Cylinder 2 - Spacer 5 - Bolt 8 - Anti-seize Lubricant 11 - Locknut 3 - Pin 6 - Bolt 9 - Bolt 12 - Pin Assembly 4 - Bolt Assembly 7 - Lube Fitting 10 - Washer...
  • Page 239 Suspension System - Ride Cylinder - Rear Section 180-0050 SM - 1378 9 - Wiper 1 - Piston Rod 10 - Lube Fitting 24 - Small Ring 2 - Spherical Bushing 17 - Piston 11 - Seal 25 - Valve Core 3 - Snap Ring 18 - Bolt 12 - Seal Retainer...
  • Page 240 Suspension System - Ride Cylinder - Rear Section 180-0050 9. Remove and discard seal (11) and wiper (9) from ASSEMBLY seal retainer (12) inner grooves. Numbers in parentheses refer to Fig. 3. 10. Remove check valve (6) and plug (7) assembly Note: Apply a light coating of clean hydraulic oil to all from piston rod (1).
  • Page 241 Suspension System - Ride Cylinder - Rear Section 180-0050 5. Remove lifting device or 'come-along' from ride Note: Because of close tolerances, care will have to be cylinder (1). taken when assembling piston rod (1) and piston (17) assembly into tube (19). 6.
  • Page 242 Suspension System - Ride Cylinder - Rear Section 180-0050 SM - 160 FRAME 1 - Lube Fitting 2 - Nitrogen Charging Valve SPACER 3 - Plug 35 mm (1.38 in) 4 - Check Valve 5 - Check Valve TOP OF SEAL RETAINER DIMENSION 'A' RIDE POSITION...
  • Page 243 Suspension System - Ride Cylinder - Rear Section 180-0050 SM - 1372 1 - Lube Fitting 2 - Nitrogen Charging Valve 3 - Pipe Plug 4 - Check Valve (upper) 5 - Check Valve (lower) 6 - Ride Cylinder 7 - Hose 8 - Tee Piece 9 - Pressure Gauge 10 - Charging Assembly...
  • Page 244 Suspension System - Ride Cylinder - Rear Section 180-0050 valves (2) as follows: SM - 1273 a. Rotate 'T' handle of valve chucks (12) anticlockwise until they stop. b. Screw the swivel nuts down on nitrogen charging valves (2) until they seat. c.
  • Page 245 Suspension System - Ride Cylinder - Rear Section 180-0050 stops with the truck on a level surface. If there is less additional parts required for simultaneous charging of both than 30 mm (1.25 in) between stops, check for ride cylinders and general service tools required. These machine overload.
  • Page 246 Suspension System - Ride Cylinder - Rear Section 180-0050 THIS PAGE IS INTENTIONALLY BLANK SM 1632 Rev 2 11-07...
  • Page 247 B8 - Fuel Level Sender S16 - Brake Pressure Switch K32 - Retarder Select Solenoid B21 - Trans Oil Temp Sender K41 - Brake Valve Timer (TR100) S18 - Lights Switch B22 - Engine Oil Press Sender K42 - Pre-lube Timer (TR100)
  • Page 248 Electrical System - Circuit Diagrams Section 190-0000 SM 1585 12-98...
  • Page 249 Electrical System - Circuit Diagrams Section 190-0000 SM 1585 12-98...
  • Page 250 Electrical System - Circuit Diagrams Section 190-0000 SM 1585 12-98...
  • Page 251 Electrical System - Circuit Diagrams Section 190-0000 SM 1585 12-98...
  • Page 252 Electrical System - Circuit Diagrams Section 190-0000 SM 1585 12-98...
  • Page 253 Electrical System - Circuit Diagrams Section 190-0000 SM 1585 12-98...
  • Page 254 Electrical System - Circuit Diagrams Section 190-0000 INTERFACE BOX CIRCUIT DIAGRAM SM 1585 12-98...
  • Page 255 Electrical System - Circuit Diagrams Section 190-0000 CEC TRANSMISSION CIRCUIT DIAGRAM SM 1585 12-98...
  • Page 256 Electrical System - Circuit Diagrams Section 190-0000 SM 1585 12-98...
  • Page 257 Electrical System - Circuit Diagrams Section 190-0000 SM 1585 12-98...
  • Page 258 Electrical System - Circuit Diagrams Section 190-0000 Fuses, Relays and Warning Lights CEC Fuses and Relays - Located in Interface Box Fuses, relays and warning lights which were not Fuses - Current Ratings Relay Functions described under 'Component Designations' on the 1 - 8A 1 - ECU Initial Start previous page, are identified in the following tables.
  • Page 259 B19 - Throttle Position Sensor S15 - Direction Indicator Switch K39 - Trans Filter Interlock Relay B21 - Trans Oil Temp Sender K41 - Brake Valve Timer (TR100) S16 - Brake Pressure Switch B22 - Engine Oil Press Sender K42 - Pre-lube Timer (TR100)
  • Page 260 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
  • Page 261 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
  • Page 262 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
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  • Page 264 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
  • Page 265 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
  • Page 266 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
  • Page 267 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
  • Page 268 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
  • Page 269 Electrical System - Circuit Diagrams Section 190-0000 SM 2313 06-04...
  • Page 270 Electrical System - Circuit Diagrams Section 190-0000 Fuses, Relays and Warning Lights WARNING LIGHTS - Located in Dash Panel Fuses, relays and warning lights which were not Front Brake Accumulator Pressure described under 'Component Designations' on the Rear Brake Accumulator Pressure previous page, are identified in the following tables.
  • Page 271 ELECTRICAL SYSTEM - Switches and Sensors Section 190-0270 SM - 2073 RETARDER BRAKE MANIFOLD VALVE VALVE BODY-UP BODY HEADER SWITCH TANK TREADLE VALVE ENGINE FUEL TANK STEERING VALVE HYD TANKS DISC BRAKE COOLING OIL RETURN TUBE RHS OF TRANS TRANSMISSION OIL COOLER INLET PIPE ENGINE...
  • Page 272 Water Temperature Gauge (3, Fig. 2). The gauge TR70 DD Series 2000 12.00 should read in the green zone after the engine has TR100 Cummins KTA 15.72 warmed. If the gauge reads in the red zone, stop the TR100 DD Series 2000 12.00...
  • Page 273 Electrical System - Switches and Sensors Section 190-0270 SM - 1784 STOP 1 - Alternator Charging 9 - Front Brake Accumulator Pressure 17 - Transmission Oil Temperature 2 - Engine Water Temperature 10 - Rear Brake accumulator Pressure 18 - Disc Brake Hydraulic Temperature 3 - Engine Water Level 11 - Low Steering Pressure 19 - Retarder Indicator...
  • Page 274 Electrical System - Switches and Sensors Section 190-0270 Watch for wide deviations from normal readings on the field at the end of the sensor. The passing of each gauge during vehicle operation. If the gauge, on gear tooth generates an electrical pulse which is vehicles which do not have a transmission retarder directed to the ECU.
  • Page 275 Electrical System - Switches and Sensors Section 190-0270 (39 lbf/in²) and above, the circuit should close and brake hydraulic temperature warning light (16, Fig. 3) send a signal to illuminate retarder indicator light when a temperature of 121° C (250° F) is reached. If (19, Fig.
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  • Page 277 ELECTRICAL SYSTEM - Switches and Sensors Section 190-0270 SM - 2073 RETARDER BRAKE MANIFOLD VALVE VALVE BODY-UP BODY HEADER SWITCH TANK TREADLE VALVE ENGINE FUEL TANK STEERING VALVE HYD TANKS DISC BRAKE COOLING OIL RETURN TUBE RHS OF TRANS TRANSMISSION OIL COOLER INLET PIPE ENGINE...
  • Page 278 Cummins QSK 12.00 engine until the fault is corrected. TR70 DD Series 2000 12.00 TR100 Cummins KTA 15.72 Engine Water Level Probe (17) - Located in the (Standard 70 A Alt bottom of the coolant system header tank. Sends a...
  • Page 279 Electrical System - Switches and Sensors Section 190-0270 SM - 3306 1 - Alternator Charging 9 - Front Brake Accumulator Pressure 17 - Transmission Oil Temperature 2 - Engine Water Temperature 10 - Rear Brake accumulator Pressure 18 - Disc Brake Hydraulic Temperature 3 - Engine Water Level 11 - Low Steering Pressure 19 - Retarder Indicator...
  • Page 280 Electrical System - Switches and Sensors Section 190-0270 safe operating temperature. Output Speed Sensor - The output speed sensor (magnetic pick-up) is installed in the rear cover of the The temperature sender sends a signal to the transmission. The magnetic end of the sensor is Transmission Oil Temperature Gauge (5, Fig.
  • Page 281 Electrical System - Switches and Sensors Section 190-0270 the disc brake cooling oil is overheating. The oil should close and send a signal to illuminate the brake temperature switch sends a signal to illuminate disc lights. As pressure drops below 2.7 bar (39 lbf/in²) the brake hydraulic temperature warning light (16, Fig.
  • Page 282 Electrical System - Switches and Sensors Section 190-0270 THIS PAGE IS INTENTIONALLY LEFT BLANK SM 2046 Rev 2 10-07...
  • Page 283 FUEL SYSTEM - Fuel Tank and Mounting Section 200-0010 SM - 1688 CHASSIS 1 - Fuel Tank 9 - Screw 17 - Reducer 25 - Mounting Bracket 2 - Filler Cap 10 - Cover Plate 18 - Elbow 26 - Bolt 19 - Connector 3 - Gasket 11 - 'O' Ring...
  • Page 284 Fuel System - Fuel Tank and Mounting Section 200-0010 REMOVAL SM - 1689 FUEL Numbers in parentheses refer to Fig. 1, unless TANK otherwise specified. WARNING To prevent personal injury and property damage, be sure wheel blocks and lifting equipment are properly secured and of adequate capacity to do the job safely.
  • Page 285 Fuel System - Fuel Tank and Mounting Section 200-0010 clean fuel strainer (14) with clean diesel fuel. 2. If removed, install heavy duty straps (23) to top of mounting brackets (25) with overlap facils inside, as 2. Clean filler cap (2) with clean diesel fuel and ensure shown in Fig.
  • Page 286 Fuel System - Fuel Tank and Mounting Section 200-0010 method at the top of the tank. SM - 1417 The advantages of fast fuelling are: a. Reduces the fill time by around two thirds. b. Reduces foaming which results in a full tank and more running time between fill-ups.
  • Page 287 COOLING SYSTEM - Cooling System Section 210-0000 SM - 1684 ENGINE COOLER PRESSURE REGULATOR WATER PUMP THERMOSTATS CLOSED FULL COOLANT FLOW 8 - Coolant Pipe 1 - Radiator 2 - Engine Water Pump 9 - Make-up Line 15 - Pressurization Line 3 - Engine Oil Cooler 10 - Thermostat Housings 16 - Pressure Regulator...
  • Page 288 Cooling System - Cooling System Section 210-0000 OPERATION The increase in the cooling system pressure provides Numbers in parentheses refer to Fig. 1. additional margin in the systems natural tendency to develop vapour bubbles at the cylinder liner surface The engine water pump (2) draws coolant from the and therefore provides additional protection against radiator bottom tank, through coolant pipe (18) and liner cavitation.
  • Page 289 Cooling System - Cooling System Section 210-0000 reinstalled while the system is hot, normal system leakage at the water pump weep hole. build up to the rated pressure will not take place. This may result in a serious temporary reduction of coolant Note: A minor chemical buildup or streaking at the flow due to cavitation at the water pump inlet, water pump weep hole is normal.
  • Page 290 Cooling System - Cooling System Section 210-0000 under 'Coolant Recommendations'. flushing gun. Note: If engine overheats and fan belt tension and 3. Apply air pressure gradually increasing to a water level are satisfactory, the entire cooling system pressure of 0.7 bar (10 lbf/in²). DO NOT EXCEED may require cleaning with a descaling solvent and THIS PRESSURE.
  • Page 291 Cooling System - Cooling System Section 210-0000 c. Add the correct quantity of DCA4 liquid for the 3. Dip the strip in the coolant sample for one second, cooling system capacity required. Refer to the remove, and shake the strip briskly to remove excess 'Precharge Chart' in this section for DCA4 quantities.
  • Page 292 Cooling System - Cooling System Section 210-0000 SPECIAL TOOL AND TEST KIT amount of DCA4 liquid specified in the 'Service Chart' and the amount specified in the 'Precharge Chart'. Refer to Section 300-0070, SERVICE TOOLS, for Replace the DCA4 coolant filters, as per Engine part numbers of the refractometer and coolant test kit Manufacturers coolant recommendations.
  • Page 293 COOLING SYSTEM - Radiator, Header Tank and Mounting Section 210-0040 SM - 1675 1 - Lockwasher 2 - Washer 8 - Plug 14 - Rubber Seal 20 - Screen 3 - Bolt 9 - Drain Plug 15 - Anti-recirculation Plate 21 - Support Rod 4 - Bolt 10 - Washer...
  • Page 294 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 1676 26 20 46 45 24 21 ENGINE THERMOSTAT HOUSINGS ENGINE RADIATOR PRESSURE ASSEMBLY REGULATOR 13 - Clip 1 - Header Tank 14 - Clip 25 - Lockwasher 36 - Screw 2 - Plate 15 - Clamp...
  • Page 295 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 Header Tank SM - 1677 Numbers in parentheses refer to Fig. 2. 1. With suitable container in position, Slacken clamp (12) and slide make-up line (8) back over coolant tube at the transmission oil cooler.
  • Page 296 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 1678 12,33,31,37 26,32,36,25 DETAIL A - A 31,37,12 34,23, 24,35 18,19 16,17 11,13, 33,37 25,26,36 25,27 32,36 30,38 25,26 32,36 1 - Top Tank 11 - U Bolt 2 - Centre Tank 12 - Lockwasher 21 - Brass Ferrule...
  • Page 297 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 5. Replacement of joule tubes (22) and rubber ferrules plate (32). (20) is as follows: 4. Remove window nut (4) from header tank (1). a. Lightly coat outside diameter of new rubber ferrules (20) and tube holes in tube plates (18 &...
  • Page 298 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 secure with clamps (1, Fig. 3). on header tank (1). Fill with coolant until coolant reaches the bottom of filler neck (27) and holds at that 7. Secure screens (19 & 20) to ring (18) with bolts level.
  • Page 299 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 External Cleaning not cleaned adequately in steps 1 through 4, the Note: If a build up of dirt is apparent during routine following procedure may be used. inspection, the following cleaning procedure should be adopted.
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  • Page 301 COOLING SYSTEM - Radiator, Header Tank and Mounting Section 210-0040 SM - 1675 1 - Lockwasher 2 - Washer 8 - Plug 14 - Rubber Seal 20 - Screen 3 - Bolt 9 - Drain Plug 15 - Anti-recirculation Plate 21 - Support Rod 4 - Bolt 10 - Washer...
  • Page 302 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 1676 26 20 46 45 24 21 ENGINE THERMOSTAT HOUSINGS ENGINE RADIATOR PRESSURE ASSEMBLY REGULATOR 13 - Clip 1 - Header Tank 14 - Clip 25 - Lockwasher 36 - Screw 2 - Plate 15 - Clamp...
  • Page 303 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 14. If necessary, remove locknuts (16) and bolts (5) SM - 2390 securing flexible mounts (11) to chassis mounting brackets. Header Tank Numbers in parentheses refer to Fig. 2. 1. With suitable container in position, Slacken clamp (12) and slide make-up line (8) back over coolant tube at the transmission oil cooler.
  • Page 304 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 SM - 1678 12,33,31,37 26,32,36,25 DETAIL A - A 31,37,12 34,23, 24,35 18,19 16,17 11,13, 33,37 25,26,36 25,27 32,36 30,38 25,26 32,36 1 - Top Tank 11 - U Bolt 2 - Centre Tank 12 - Lockwasher 21 - Brass Ferrule...
  • Page 305 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 c. Remove and discard rubber ferrules (20) from 2. Remove bolts (34) securing adaptor plate (32) and tube plates (18 & 19). float level switch (35) assembly to header tank (1). Remove adaptor plate (32), gasket (33) and float level 4.
  • Page 306 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 Initial Fill and Start-up 4. Install nuts (7) and lockwashers (1) on top end of support rods (21) and secure support rods (21) to Numbers in parentheses refer to Fig. 2, unless otherwise specified.
  • Page 307 Cooling System - Radiator, Header Tank and Mounting Section 210-0040 exceptionally heavy, concentrations up to 200 kg/m³ surfaces, forcing the fouling material out from the may be used. radiator core assembly. The most convenient method of use is to prepare a 4.
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  • Page 309 COOLING SYSTEM - Disc Brake Oil Cooler Section 210-0050 SM - 458 COOLANT INLET PIPE DEAERATION LINE COOLANT OUTLET PIPE OIL INLET LINES OIL OUTLET COOLANT LINES INLET PIPE 1 - Disc Brake Oil Cooler 8 - Sleeve 15 - Oil Inlet Lines 2 - Heat Exchanger 9 - Coolant Inlet Pipe 16 - Oil Outlet Lines...
  • Page 310 Cooling System - Disc Brake Oil Cooler Section 210-0050 1. Position the vehicle in a level work area, apply the Lower disc brake oil cooler (1) and remove to a clean parking brake and shutdown the engine. work area for disassembly. 2.
  • Page 311 Cooling System - Disc Brake Oil Cooler Section 210-0050 and 2/3 water. To each 9.5 litres (2.5 gal) of solution, 1. Using suitable lifting equipment, position disc add 227 g (0.5 lb) of oxalic acid. brake oil cooler (1) to mounting bracket at engine front crossmember and secure with bolts (21) and 4.
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  • Page 313 COOLING SYSTEM - Transmission Oil Cooler Section 210-0060 SM - 791 TO ENGINE WATER PUMP FROM CONVERTOR OUTLET TO CONVERTOR INLET SECTION Y-Y FROM DISC BRAKE OIL COOLER 1 - Cooler Housing 9 - Sleeve 17 - Deaeration Line 25 - Cover 2 - Oil Inlet Pipe 10 - Clamp 18 - Bolt...
  • Page 314 Cooling System - Transmission Oil Cooler Section 210-0060 REMOVAL DISASSEMBLY Numbers and letters in parentheses refer to Fig. 1. Numbers and letters in parentheses refer to Fig. 1. 1. Turn transmission cooler assembly so that bracket WARNING (20) is facing upwards. Remove bolts (21) securing To prevent personal injury and property transmission cooler assembly to bracket (20).
  • Page 315 Cooling System - Transmission Oil Cooler Section 210-0060 2. After cleaning the oil passages, clean the water 3. Secure cooler cores (27) to cover (25) with jam side of cores (27) by immersing in a solution made nuts (24). Torque tighten jam nuts (24) to 95 - 110 Nm as follows: add 227 g (0.5 lb) of oxalic acid to each (70 - 80 lbf ft).
  • Page 316 Cooling System - Transmission Oil Cooler Section 210-0060 SPECIAL TOOLS 9. Ensure all drain cocks on the cooling system are There are no special tools required for procedures securely locked and fill cooling system with coolant outlined in this section. Refer to Section 300-0070, as specified in Section 210-0000, COOLING SYSTEM.

  • Page 317: Steering And Brake Control Tank

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

  • Page 318: Steering Filter

    Steering System - Steering System Schematic Section 220-0000 Double Relief Valve (6) Steering Filter (12) Refer to Section 220-0110, DOUBLE RELIEF VALVE. Refer to Section 220-0150, STEERING FILTER. The double relief valve is installed in the lines The steering filter is located at the front right hand side between the steering cylinders and the steering of the transmission.
  • Page 319 Steering System - Steering System Schematic Section 220-0000 a. Ensure 'O' ring/seal is in place and that joining 2. Turn steering wheel in both directions until the surfaces are clean. If necessary, retain 'O' ring/seal in pressure is relieved in the steering system (pressure place with a light coating of grease or vaseline.
  • Page 320 Steering System - Steering System Schematic Section 220-0000 STEERING SYSTEM DIAGNOSIS CONDITION REASON REMEDY Slow response or hard Wear or damage to front axle Make necessary adjustment and/or replace defective steering. linkage. parts. Refer to Section 220-0120, STEERING CYLINDER AND LINKAGE. Low steering oil level.
  • Page 321 Steering System - Steering System Schematic Section 220-0000 SM 1661 Rev 1 06-08...
  • Page 322 Steering System - Steering System Schematic Section 220-0000 SM 1661 Rev 1 06-08...
  • Page 323 Steering System - Steering System Schematic Section 220-0000 SM 1661 Rev 1 06-08...
  • Page 324 Steering System - Steering System Schematic Section 220-0000 SM 1661 Rev 1 06-08...
  • Page 325 Steering System - Steering System Schematic Section 220-0000 SM 1661 Rev 1 06-08...
  • Page 326 Steering System - Steering System Schematic Section 220-0000 THIS PAGE IS INTENTIONALLY BLANK SM 1661 Rev 1 06-08...
  • Page 327 STEERING SYSTEM - Steering and Brake Control Tank Section 220-0040 SM - 1566 1 - Tank 10 - Filter Assembly 19 - Hardened Washer 28 - Hinge Pin 2 - Latch 11 - Suction Screen 20 - Nut 29 - Cotter Pin 3 - Access Cover 12 - Window Nut 21 - Washer...
  • Page 328 Steering System - Steering and Brake Control Tank Section 220-0040 SM - 1567 SM - 1322 A B D 1 - Tank 2 - Steering Pump 10 - Oil Pressure Switch 9 - Oil Level Switch 11 - Oil Temperature Switch Fig.
  • Page 329 Steering System - Steering and Brake Control Tank Section 220-0040 Operate the treadle valve continuously to discharge SM - 1991 the braking accumulators. Oil should be showing in middle window nut (12). If oil is required, remove filler cap (8) and fill tank (1) with hydraulic oil specified in Section 300-0020, LUBRICATION SYSTEM, until oil shows in middle window nut (12).
  • Page 330 Steering System - Steering and Brake Control Tank Section 220-0040 Removing Suction Screen 9. Fill tank (1) to correct level with hydraulic oil Remove and clean suction screen (11) at interval specified in Section 300-0020, LUBRICATION specified in Section 300-0020, LUBRICATION SYSTEM. SYSTEM.
  • Page 331 Steering System - Steering and Brake Control Tank Section 220-0040 7. Remove locking pin (27) and open hinged cover 3. Install all internal components in tank (1) as (25) to allow access to nuts (20). Support bracket previously described in 'Maintenance'. Renew filter assembly (24) and remove nuts (20) and hardened assembly (10) and gaskets (5 &...
  • Page 332 Steering System - Steering and Brake Control Tank Section 220-0040 SPECIAL TOOLS 8. Remove wheel blocks, start the engine and charge the steering and brake control systems. Check oil There are no special tools required for procedures level as described under 'Checking Oil Level'. outlined in this section.
  • Page 333 STEERING SYSTEM - Steering Pump Section 220-0050 SM - 3342 1 - Retaining Ring 26 - Pin 12 - Plug Assembly 20 - Drive Shaft 29 - End Cover 2 - Shaft Seal 13 - Crush Ring 21 - Rotating Group 32 - Screw 3 - Pump Housing 15 - Swash Plate...
  • Page 334 Steering System - Steering Pump Section 220-0050 SM - 395 PISTON SUB ASSEMBLY OUTLET VALVE PLATE SLOT SWASH PLATE OUTLET PORT INLET DRIVESHAFT PORT SHOE PLATE INTAKE VALVE PLATE SLOT CYLINDER BLOCK BORE Fig. 2 - Pump Rotation and Oil Flow OPERATION SM - 553 Refer to Fig.
  • Page 335 Steering System - Steering Pump Section 220-0050 SM - 377 MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE (MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT) VIEW A VIEW B VIEW C Fig. 4 - Variable Displacement Action minimum displacement position.
  • Page 336 Steering System - Steering Pump Section 220-0050 SM - 3341 13 - Crush Ring / Shim Kit* 1 - Retaining Ring 24 - Bearing 14 - Bearing 2 - Shaft Seal 25 - 'O'-Ring 15 - Bearing Swash Plate 3 - Pump Housing 26 - Pin 16 - Screw 4 - Plug...
  • Page 337 Steering System - Steering Pump Section 220-0050 8. Wash the outside of steering pump (1) thoroughly Pump housing with a suitable solvent and move to a clean work area Numbers in parentheses refer to Figs 6 unless for disassembly. otherwise stated. 1.
  • Page 338 Steering System - Steering Pump Section 220-0050 scratches with 500 grit paper. Remove burrs with an India stone. Pistons should move freely over their respective rods. WARNING The spring located within the cylinder block is under high tension and can cause bodily harm. Swash plate Ensure retaining ring is removed using the 1.
  • Page 339 Steering System - Steering Pump Section 220-0050 Press outer race until it is fully seated on internal face PUMP HOUSING of end cover (29). INNER RACE 6. Taking inner races of tapered bearings (14 & 24), OUTER RACE OF TAPERED lubricate races and driveshaft (20) with clean hydraulic OF TAPERED BEARING (14)
  • Page 340 Steering System - Steering Pump Section 220-0050 Shim installation / Measurement: bolts (2) and lockwashers (3). Note: For shim kit service Part No. refer to SERVICE 3. Remove caps and connect outlet and inlet lines to TOOL section 300-0070 steering pump (1). Before connecting the case drain line, fill steering pump (1) with clean hydraulic oil specified in A.
  • Page 341 Steering System - Steering Pump Section 220-0050 normal system pressure. This is done by backing off If it is, there is either excessive restriction in the case the steering pressure relief valve so that the pump will drain line (obstructed or possibly a kinked line), or the start under no-load conditions.
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  • Page 343 The steering pump is assembled for right-hand TR70 (913) A9131016 (clockwise) rotation, as viewed from drive shaft (1) end (although the rotation cannot be viewed in service, as TR100 (783) A7831370 the shaft is fully enclosed). If a replacement pump TR100 (883) A8831021...
  • Page 344 Steering System - Steering Pump Section 220-0050 SM - 395 PISTON SUB ASSEMBLY OUTLET VALVE PLATE SLOT SWASH PLATE OUTLET PORT INLET DRIVESHAFT PORT SHOE PLATE INTAKE VALVE PLATE SLOT CYLINDER BLOCK BORE Fig. 2 - Pump Rotation and Oil Flow The major pump components comprise the pump casing (19), valve cover (20), compensator (Figure 7), SM553...
  • Page 345 Steering System - Steering Pump Section 220-0050 SM377 MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE (MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT) VIEW A VIEW B VIEW C Fig. 4 - Variable Displacement Action Oil flows from the outlet (pressure) port to the SM 3901 accumulator valve which supplies the steering circuit pressure.
  • Page 346 Steering System - Steering Pump Section 220-0050 SM 3899 34 - O-ring 23 - Retaining Ring 1 - Drive Shaft 12 - Roller 45 - Nut 35 - O-ring 24 - Plug 2 - Roller Bearing 13 - Spacer 46 - Set Screw 36 - O-ring 25 - Plug 3 - Needle Bearing...
  • Page 347 Steering System - Steering Pump Section 220-0050 adapter (4, Figure 5). Discard the gasket (5, Figure 5). Note: The pump compensator assembly can only be Do not remove the pump adapter (4, Figure 5) from its replaced as an assembly. Therefore, no further mounting unless it is to be replaced.
  • Page 348 Steering System - Steering Pump Section 220-0050 INSPECTION shaft (1). Only remove the roller bearing (2) if it is considered to be approaching the end of its useful life. Numbers in parentheses refer to Figures 8-11, Otherwise, leave it installed on the drive shaft (1). individually identified below.
  • Page 349 Steering System - Steering Pump Section 220-0050 2. Measure the end play between each piston and its SM 3919 shoe, identified as 'ä' on Figure 9 below. Assess the clearance in each case, and use the table on Page 6 to determine whether or not to renew the pistons and shoes.
  • Page 350 Steering System - Steering Pump Section 220-0050 (21) and the valve cover (20). approximately flush with the outer lip of the internal bore of the pump casing (19) . 15. Mount the valve plate (21) in the valve cover (20). A spring pin (49) is fitted to the valve cover (20), and Note: Take care not to apply excessive axial pressure locates in a recess in the valve plate (21).
  • Page 351 Steering System - Steering Pump Section 220-0050 few seconds. If the pump does not prime, check to 4. Fill the steering and brake control tank with clean make sure there are no air leaks in the inlet line and hydraulic oil specified in Section 300-0020, Lubrication connections.
  • Page 352 Steering System - Steering Pump Section 220-0050 (2300 lbf/in²) is attained. The case tank pressure SPECIAL TOOLS differential should still not exceed 0.07 - 0.14 bar (1 - 2 Details of recommended manufacturer tools to follow, lbf/in²). Tighten the lock nut on the pressure limiter once confirmation and approval has been given from spool adustment to a torque of 16 Nm (12 lbf ft).
  • Page 353 STEERING SYSTEM - Accumulator Section 220-0080 SM - 171 1 - Charging Valve 1E - Body 1A - Cap 1F - ‘O’ Ring 5 - Backup Ring 9 - Hardened Washer 1B - Core 2 - Shield 6 - 'O’ Ring 10 - Piston 3 - ‘O’...
  • Page 354 Steering System - Accumulator Section 220-0080 and releasing it quickly once or twice. Recheck for the body is completely lowered, apply the parking leakage, if leakage continues then discharge the brake and switch off the engine. accumulator as described under 'Discharging Nitrogen' in this section, then replace the valve core.
  • Page 355 Steering System - Accumulator Section 220-0080 DISCHARGING NITROGEN WARNINGS Numbers in parentheses refer to Fig. 1. Do not use Oxygen or any gas other than Nitrogen to charge an accumulator. Oxygen Make sure charging valve (1) is closed internally by under pressure coming into contact with oil or turning locknut (1D) clockwise.
  • Page 356 Steering System - Accumulator Section 220-0080 5. Insert a suitable wooden dowel through the port SM - 172 end of cylinder (12) to push out piston (10). Remove and discard seal rings (7) and wear rings (11) from FRAME piston (10). INSPECTION Numbers in parentheses refer to Fig.
  • Page 357 Steering System - Accumulator Section 220-0080 clockwise to 11 Nm (100 lbf in) to close charging 4. Install hydraulic line securely to the oil inlet port at valve. Insert valve core (1B), replace valve cap (1A) bottom of accumulator. and tighten finger tight. 5.
  • Page 358 Steering System - Accumulator Section 220-0080 AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE °C °F lbf/in² 47.7 48.8 49.8 50.9 54.1 56.2 57.3 58.3 59.4 60.5 61.5 WARNING This truck is equipped with pre-charged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in Special permits may be required when transporting the truck or cylinders by any method while cylinders are charged.
  • Page 359 STEERING SYSTEM - Steering Valve Section 220-0090 SM - 1560 1 - Cap Screw 6 - Gerotor Gear 11 - Sleeve 16 - Retainer 2 - End Cap 7 - Wear Plate 12 - Spool 17 - 'O' Ring 3 - 'O' Ring 8 - 'O' Ring 13 - Centring Pin 18 - Seal...
  • Page 360 Steering System - Steering Valve Section 220-0090 gerotor gear (6) rotates, oil in gerotor housing (5) SM - 282 pockets (see Fig. 2) is forced out and flows through GEROTOR GEROTOR GEAR HOUSING spool (12) and sleeve (11) to the steering cylinder port. Spool (12) contains porting matched to sleeve (11) and rotates within sleeve (11) to provide directional control of the oil.
  • Page 361 Steering System - Steering Valve Section 220-0090 REMOVAL SM - 1555 Numbers in parentheses refer to Fig. 7. SUPPLY TO RETURN FROM CYLINDERS CYLINDERS WARNINGS Dangerous pressure. To prevent personal injury and property damage, turn steering wheel several times in each direction to relieve pressure in the system.
  • Page 362 Steering System - Steering Valve Section 220-0090 SM - 2564 19 - Bush 1 - Steering Valve 10 - Bolt 20 - Bush 2 - Bolt 11 - Washer 28 - Bracket 21 - Washer 3 - Lockwasher 12 - Nut 29 - Bolt 22 - Bevel Washer 4 - Gasket...
  • Page 363 Steering System - Steering Valve Section 220-0090 SM - 1552 1 - Cap Screw 16 - Retainer 6 - Gerotor Gear 11 - Sleeve 2 - End Cap 17 - 'O' Ring 7 - Wear Plate 12 - Spool 3 - 'O' Ring 18 - Seal 8 - 'O' Ring 13 - Centring Pin...
  • Page 364 Steering System - Steering Valve Section 220-0090 14. Remove spool (12) from sleeve (11) carefully. SM - 297 Remove centring springs (10) from spool (12) by hand. See Fig. 10. INSPECTION 1. Clean all metal parts in a suitable solvent and blow dry with compressed air.
  • Page 365 Steering System - Steering Valve Section 220-0090 a. Insert one centring spring, with extended edge SM - 1559 down, in spring slot of spool (12). Raise spool (12) from sleeve (11) slightly for more clearance. b. Insert 1 centring spring (10) opposite spring located in slot of spool (12).
  • Page 366 Steering System - Steering Valve Section 220-0090 SM - 1554 SM - 621 PORT FACE PIN PARALLEL WITH PORT FACE 14 - Dust Seal 9 - Driveshaft 17 - 'O' Ring 15 - Retaining Ring 13 - Centring Pin 18 - Seal 16 - Retainer Fig.
  • Page 367 Steering System - Steering Valve Section 220-0090 SM - 624 WARNING To prevent personal injury and property damage, be sure wheel blocks, blocking materials and lifting equipment are properly secured and of adequate capacity to do the job safely. 1. Make certain, area of installation is clean. 2.

  • Page 368: Item Name Nm

    Steering System - Steering Valve Section 220-0090 Hydraulic Oil be added to the steering and brake control tank to replenish the oil moving into the circuit. The steering system should be kept filled with hydraulic oil as specified in Section 300-0020, LUBRICATION SYSTEM.
  • Page 369 Steering System - Steering Valve Section 220-0090 STEERING CONTROL DIAGNOSIS CONDITION REASON REMEDY Steering wheel does not centre Binding in steering linkage to valve Align as required Worn gerotor Replace parts Broken centring springs Replace centring springs, drain and flush system Burrs on sleeve or spool Disassemble and repair or replace parts...
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  • Page 371: Plug

    STEERING SYSTEM - Double Relief Valve Section 220-0110 SM - 1326 1 - Valve Body 11 - Backup Ring 16 - Valve 6 - Spring End 2 - Valve 12 - Plug 17 - Valve Seat 7 - Adjustment Screw 3 - Valve Seat 13 - Relief Body 18 - Spring...
  • Page 372 Steering System - Double Relief Valve Section 220-0110 When oil flowing through valve body (1) at port 'B', and SM - 560 out of the opposite side exceeds valve (2) setting, valve (2) is moved off valve seat (3) against the STEERING STEERING pressure of spring (5).
  • Page 373 Steering System - Double Relief Valve Section 220-0110 body (1). Remove and discard 'O' ring (8) and backup 6. Repeat steps 1 through 5 to assemble remaining rings (9) from valve seat (3). valve (16) assembly. 7. Follow steps 1 through 6 to disassemble the 7.
  • Page 374 Steering System - Double Relief Valve Section 220-0110 If oil is discharged through port 'A' only when relief secure in place with mounting hardware. pressure is exceeded, turn adjustment screw (7) out and open needle valve slightly. Continue opening 2. Remove blanking caps from hydraulic lines and needle valve and turning adjustment screw (7) out install lines to double relief valve as identified during until discharge through port 'A' occurs at relief pressure.

  • Page 375: Plug

    STEERING SYSTEM - Steering Cylinder and Linkage Section 220-0120 SM - 1547 27,49 36- LH 37- RH 44,45 46,47 46,47 7- LH 15,16 8- RH 1-3 LH 4-6 RH 11,12,13 20,21,22 24,23 1 - Spindle Assembly - LH 14 - Thrust Washer 2 - Spacer 15 - Locking Pin 27 - Bolt...
  • Page 376 Steering System - Steering Cylinder and Linkage Section 220-0120 REMOVAL Steering Linkage Numbers in parentheses refer to Fig. 1. 1. Remove cotter pins (45) from studs (39) and remove castle nuts (44). WARNINGS 2. With suitable lifting equipment, remove tie rod (35) To prevent personal injury and property assembly from steering arm (7) and bellcrank (10).
  • Page 377 Steering System - Steering Cylinder and Linkage Section 220-0120 1. Remove lube fitting (17) and plug (48) from rod 6. Remove and discard backup ring (5) and 'O' ring (6) end (36). from outer groove of end cap (4). 2. Place tie rod (35) assembly in a vice, or similar 7.
  • Page 378 Steering System - Steering Cylinder and Linkage Section 220-0120 SM - 834 1 - Piston Rod 5 - Backup Ring 9 - Nut 13 - Bushing 2 - Wiper 6 - 'O' Ring 10 - Bolt 14 - Pipe Plug 3 - Seal 7 - Piston 11 - Tube...
  • Page 379 Steering System - Steering Cylinder and Linkage Section 220-0120 Tie Rod Assembly with lube fittings (17 & 18) in bellcrank housing. Numbers in parentheses refer to Fig. 1. 2. Using suitable lifting equipment, install bellcrank (10) 1. Place tie rod (35) in a vice, or similar holding between upper and lower bores of the bellcrank device, and screw rod ends (36 &...
  • Page 380 Steering System - Steering Cylinder and Linkage Section 220-0120 Steering Cylinder SM - 154 FRONT 1. Position seal (25) on steering arm (7) ball joint bore. OF VEHICLE 2. Position spacers (50) to base end of steering cylinder (32) and insert the base end of steering cylinder (32) into the clevis on bellcrank housing.

  • Page 381: Nut

    Steering System - Steering Cylinder and Linkage Section 220-0120 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft 245 - 300 180 - 220 Castle Nut 4 000 - 4 500 3 000 - 3 300 Castle Nut 2 035 - 2 300 1 500 - 1 700 540 - 610...
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  • Page 383 STEERING SYSTEM - Steering Cylinder and Linkage Section 220-0120 SM - 2565 27,49 36- LH 37- RH 44,45 46,47 46,47 7- LH 15,16 8- RH 1-3 LH 4-6 RH 11,12,13 20,21,22 24,23 1 - Spindle Assembly - LH 26 - Spacer 38 - Bolt 2 - Spacer 14 - Thrust Washer...
  • Page 384 Steering System - Steering Cylinder and Linkage Section 220-0120 REMOVAL Steering Linkage Numbers in parentheses refer to Fig. 1. 1. Remove cotter pins (45) from studs (39) and remove castle nuts (44). WARNINGS 2. With suitable lifting equipment, remove tie rod (35) To prevent personal injury and property assembly from steering arm (7) and bellcrank (10).
  • Page 385 Steering System - Steering Cylinder and Linkage Section 220-0120 1. Remove lube fitting (17) and plug (48) from rod from piston (7). end (36). 6. Remove and discard backup ring (5) and 'O' rings 2. Place tie rod (35) assembly in a vice, or similar (6) from outer groove of end cap (4).
  • Page 386 Steering System - Steering Cylinder and Linkage Section 220-0120 SM - 2566 1 - Piston Rod 5 - Backup Ring 9 - Locking Screw 13 - Bushing 2 - Wiper Seal 6 - 'O' Ring 10 - 'O' Ring 14 - Elbow 3 - Wiper Seal 7 - Piston 11 - Tube...
  • Page 387 Steering System - Steering Cylinder and Linkage Section 220-0120 Tie Rod Assembly lube fittings (17 & 18) in bellcrank housing. Numbers in parentheses refer to Fig. 1. 2. Using suitable lifting equipment, install bellcrank (10) between upper and lower bores of the bellcrank 1.
  • Page 388 Steering System - Steering Cylinder and Linkage Section 220-0120 Steering Cylinder SM - 154 FRONT 1. Position seal (25) on steering arm (7) ball joint bore. OF VEHICLE 2. Position spacers (26) to base end of steering cylinder (32) and insert the base end of steering cylinder (32) into the clevis on bellcrank housing.
  • Page 389 Steering System - Steering Cylinder and Linkage Section 220-0120 SPECIAL TORQUE SPECIFICATIONS TORQUE FIG. NO. ITEM NO. ITEM NAME lbf ft 245 - 300 180 - 220 Castle Nut 4 000 - 4 500 3 000 - 3 300 Castle Nut 2 035 - 2 300 1 500 - 1 700 End Cap...
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  • Page 391 STEERING SYSTEM - Accumulator Valve Section 220-0130 SM - 548 11 - 'O' Ring 1 - Poppet 6 - Plug 16 - Pin 2 - Spring 7 - Quad Ring 12 - Plug 17 - Piston 3 - 'O' Ring 13 - Piston 18 - Spring 8 - Relief Valve Cartridge...
  • Page 392 Steering System - Accumulator Valve Section 220-0130 An accumulator two-way valve (13 thru 17) is located SM - 1548 in the centre portion of the assembly. In the operating position, engine running and two-way valve energized SUPPLY TO STEERING RETURN FROM (refer to Fig.
  • Page 393 Steering System - Accumulator Valve Section 220-0130 DISASSEMBLY dissipates, and spring (15) shifts the two-way valve Numbers in parentheses refer to Fig. 4. (13 thru 17) to the de-energised (open) position. This allows oil to flow back from the accumulator through 1.
  • Page 394 Steering System - Accumulator Valve Section 220-0130 SM - 1551 9 - Filter 10 - Breather 11 - 'O' Ring 12 - Spring 13 - Pin 1 - Relief Valve Cartridge 14 - Quad Ring 15 - Piston 2 - 'O' Ring 3 - 'O' Ring 16 - 'O' Ring 4 - Backup Rings...
  • Page 395 Steering System - Accumulator Valve Section 220-0130 tank and add oil if necessary. Refer to Section accumulation of dirt, painting over or plugged with 220-0040, STEERING AND BRAKE CONTROL TANK tape or other material. Check filter (6) for plugging. for correct oil level and, Section 300-0020, LUBRICATION SYSTEM for oil specification.
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  • Page 397 STEERING SYSTEM - Steering Filter Section 220-0150 SM - 627 1 - Housing 4 - 'O' Ring 7 - Indicator Link 2 - Bowl 5 - Magnets 8 - Visual Indicator 'B' - Outlet Port 3 - Element 6 - Bypass Valve 'A' - Inlet Port 'C' - Bypass Port Fig.
  • Page 398 Steering System - Steering Filter Section 220-0150 Element (3) should be changed immediately visual 2. Turn steering wheel in both directions several indicator registers in the yellow 'Needs Cleaning' area. times to relieve any pressure in accumulator and steering system. Block all road wheels. Note: Bypass valve (6) is still not open at this point.

  • Page 399: Body System

    BODY SYSTEM - Body System Schematic Section 230-0000 DESCRIPTION position spool. The four positions of spool (1) are; Numbers in parentheses refer to Figs. 2 through 5. 'Raise', 'Hold', 'Float' and 'Lower' (power down). The spool is detented in the 'Hold' position. The body system schematics primarily cover operation of the body hoist system.
  • Page 400 Body System - Body System Schematic Section 230-0000 Disc Brake Oil Cooler (8) sends a signal to illuminate the warning light on the right hand dash panel when a temperature of Refer to Section 210-0050, DISC BRAKE OIL COOLER. 121° C (250° F) is reached. The disc brake oil cooler is connected in the hydraulic system between disc brake oil filters (7) and disc Pilot Supply Valve (14)
  • Page 401 Body System - Body System Schematic Section 230-0000 Test Point B SM - 1335 Spool Actuation Pressure - Raise Side - Adjacent to FITTING the pilot supply valve, the diagnostic test point is TUBE located in a tee installed in servo line, raise side. Spool in Raise position - Pressure should be 15.9 - 17.8 bar (230 - 258 lbf/in Spool in Hold position - Pressure should be 0 bar...
  • Page 402 Body System - Body System Schematic SM - 2048A TEST E TO OCDB COOLING CIRCUIT COMPONENTS 1 - Body and Disc Brake TO OCDB Cooling Tank COOLING CIRCUIT 2 - Main Hydraulic Pump 3 - Body Control Valve STEERING 4 - Manifold Block CIRCUIT 5 - Body Cylinder 6 - Manifold Relief Valve...
  • Page 403 Body System - Body System Schematic SM - 2048B TEST E TO OCDB COMPONENTS COOLING CIRCUIT 1 - Body and Disc Brake Cooling Tank TO OCDB COOLING CIRCUIT 2 - Main Hydraulic Pump 3 - Body Control Valve STEERING 4 - Manifold Block CIRCUIT 5 - Body Cylinder 6 - Manifold Relief Valve...
  • Page 404 Body System - Body System Schematic SM - 2048C TEST E TO OCDB COOLING CIRCUIT COMPONENTS 1 - Body and Disc Brake TO OCDB Cooling Tank COOLING CIRCUIT 2 - Main Hydraulic Pump 3 - Body Control Valve STEERING 4 - Manifold Block CIRCUIT 5 - Body Cylinder 6 - Manifold Relief Valve...
  • Page 405 Body System - Body System Schematic SM - 2048D TEST E TO OCDB COOLING CIRCUIT COMPONENTS 1 - Body and Disc Brake TO OCDB Cooling Tank COOLING CIRCUIT 2 - Main Hydraulic Pump 3 - Body Control Valve STEERING 4 - Manifold Block CIRCUIT 5 - Body Cylinder 6 - Manifold Relief Valve...
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  • Page 407 BODY SYSTEM - Body and Disc Brake Cooling Tank Section 230-0040 SM - 2053 29 28 1 - Hydraulic Tank 12 - Filter Element 23 - Spring 2 - Access Cover 13 - Gasket 24 - Shim 34 - Tee Piece 3 - Access Cover 25 - Mounting Bracket - LH 14 - Gasket...
  • Page 408 Body System - Body and Disc Brake Cooling Tank Section 230-0040 SM - 2054 SM - 1310 11 - Relief Valve 1 - Hydraulic Tank 12 - Breather 2 - Main Hydraulic Pump 13 - Temperature Switch 10 - Relief Valve 15 - Tandem Pump Fig.
  • Page 409 Body System - Body and Disc Brake Cooling Tank Section 230-0040 300-0020, LUBRICATION SYSTEM, until oil shows in 4. Remove bolts (5), lockwashers (6), access cover (2) bottom window nut (16). Fit filler cap (7). and gasket (14) from hydraulic tank (1). Discard gasket (14).
  • Page 410 Body System - Body and Disc Brake Cooling Tank Section 230-0040 SM - 1991 SM - 464 Fig. 5 - Suction Screen Removal/Installation Tool 9. Assemble relief valve (20) in reverse order to disassembly. Thoroughly clean and dry threads on relief valve (20) and tank port and apply Loctite 1 - Steering and Brake Control Tank 2 - Body and Disc Brake Cooling Tank...
  • Page 411 Body System - Body and Disc Brake Cooling Tank Section 230-0040 TANK ASSEMBLY Disassembly Numbers in parentheses refer to Fig. 1, unless 1. Remove internal components from hydraulic tank (1) otherwise specified. assembly as described in 'MAINTENANCE'. 2. If required, remove rods (10) and window nuts (16) Removal from hydraulic tank (1) assembly.
  • Page 412 Body System - Body and Disc Brake Cooling Tank Section 230-0040 INSTALLATION line securely. Numbers in parentheses refer to Fig. 1, unless otherwise specified. 3. Remove blanking cap from inter-connecting hose assembly (3, Fig. 4) and connect hose to access Note: Tighten all fasteners to torques listed in cover (3).
  • Page 413 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 414 Body System - Main Hydraulic Pump Section 230-0050 DISASSEMBLY As driveshaft and gear (11) rotates, driven gear (12) rotates in the opposite direction. Pockets between the Numbers in parentheses refer to Figs. 1. drive and driven gear teeth carry oil from inlet port 'A', around gear housing (2) ID, to outlet port 'B'.
  • Page 415 Body System - Main Hydraulic Pump Section 230-0050 INSPECTION SM - 1865 Numbers in parentheses refer to Figs. 1. 1. Clean all parts in a suitable solvent and dry with compressed air. OUTLET INLET (SMALL PORT) (LARGE PORT) 2. Check driveshaft and gear (11) and driven gear (12) carefully for wear.
  • Page 416 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 417 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 418 Body System - Main Hydraulic Pump Section 230-0050 Note: Always use accurate pressure gauges when and 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 419 BODY SYSTEM - Body Control Valve Section 230-0060 SM - 2072 23 24 8 - Retainer - Inner Spring 1 - Valve Body 15 - Plug 22 - Poppet 9 - Inner Spring 2 - Spool 16 - Plug 23 - Seal 10 - Outer Spring 3 - Seal 17 - 'O' Ring...

  • Page 420: Body Control Valve

    Body System - Body Control Valve Section 230-0060 The port identifications are as follows: SM - 2068 Port 'A' - Body cylinder 'Lower' circuit RAISE CIRCUIT LOWER CIRCUIT Port 'B' - Body cylinder 'Raise' circuit TO HPCO & Port 'C' - Inlet supply from main hydraulic pump MAN.
  • Page 421 Body System - Body Control Valve Section 230-0060 position, moves the spool to a position within valve SM - 2071 body (1) which allows the body to lower by its own weight. RAISE CIRCUIT LOWER CIRCUIT TO HPCO & Hydraulic oil enters control valve body (1) at port 'C'. MAN.
  • Page 422 Body System - Body Control Valve Section 230-0060 SM - 2067 14,15,16 9,10 6,4,5 OCDB Manifold Block Ports A - Supply from rear section of tandem pump B - Supply to disc brake oil filter (rear) C - Supply to disc brake oil filter (front) D - Supply from front section of tandem pump F - Return to body and disc brake cooling tank 3,4,5...
  • Page 423 Body System - Body Control Valve Section 230-0060 Relief Valve SM - 2429 1. Carefully remove plug (15) and 'O' ring (17) from port 'H' in valve body (1). Discard 'O' ring (17). 2. Remove relief valve (18) and spring (19) from port 'H' in valve body (1).
  • Page 424 Body System - Body Control Valve Section 230-0060 INSPECTION 3. Assemble retainer (5), 'O' ring (6), outer spring Numbers in parentheses refer to Fig. 1. retainer (7), inner spring retainer (8),inner spring (9), outer spring (10) and retainer (11) and install in valve 1.
  • Page 425 Body System - Body Control Valve Section 230-0060 SM - 3509 Fig. 8 - Detail View of Relief Valve 2. Position pressure relief valve (12) to adaptor (11) pressure relief valve (12) and manifold block (17) and and tighten adaptor (11) securely. Be sure pressure hydraulic lines for leaks.
  • Page 426 Body System - Body Control Valve Section 230-0060 reading. Record pressure reading. a. Connect a hydraulic gauge capable of reading 0 - 207 bar (0 - 3 000 lbf/in ) into the diagnostic test Proceed to 'Checking and adjusting Relief valve' point on the rear left hand cab support (Fig.
  • Page 427 BODY SYSTEM - Body Control Joystick Section 230-0081 SM - 1795 7 - Mounting Bracket 4 - Connector 1 - Body Control Joystick 8 - Screw 2 - Bolt 5 - Elbow 9 - Lockwasher 3 - Lockwasher 6 - Elbow 10 - Cover Plate Fig 1.

  • Page 428: Body Control Joystick

    Body System - Body Control Joystick Section 230-0081 operating positions of the joystick from front to rear are 2. Operate the body control joystick (1) continuously to as follows: discharge the pilot valve accumulator. Block all road wheels. 'LOWER' - This position provides hydraulic force to power-down the body.
  • Page 429 BODY SYSTEM - Manifold Relief Valve Section 230-0110 SM - 586 7 - Seals 1 - Manifold Body 3 - Relief Cartridge 5 - 'O' Ring 8 - Connector 2 - Check Cartridge 4 - Plug 6 - Seals 9 - Cap Fig.

  • Page 430: Manifold Relief Valve

    Body System - Manifold Relief Valve Section 230-0110 Refer to Fig. 3. When the body control valve is used SM - 588 to lower the body, oil enters the manifold relief valve TO LOWER TO LOWER at port 'V'. Oil pressure opens check cartridge (2) to PORT ON PORT ON BODY CYLINDER...
  • Page 431 Body System - Manifold Relief Valve Section 230-0110 INSTALLATION 4. If required, remove connector (8) and cap (9) from manifold body (1). Numbers in parentheses refer to Fig. 4, unless otherwise specified. INSPECTION Note: Tighten all fasteners to standard torques listed Numbers in parentheses refer to Fig.
  • Page 432 Body System - Manifold Relief Valve Section 230-0110 pressure gauge. Tighten the lock nut and re-check of parts only. the pressure setting. Install the cap on relief valve cartridge (3, Fig. 1). When carrying out pressure checks on the machine, follow the procedure described in 'Installation'.
  • Page 433 BODY SYSTEM - Pilot Supply Valve Section 230-0121 SM - 1799 6,7,8 TO MANIFOLD BRACKET IN CAB FLOOR TO STEERING TO MANIFOLD TANK BRAKE VALVE 9 - Elbow - 90° 10 - Tee Piece 1 - Valve Body 5 - Seal 2 - Accumulator 6 - Bolt 11 - Diagnostic Fitting...

  • Page 434: Pilot Supply Valve

    Body System - Pilot Supply Valve Section 230-0121 MAINTENANCE disconnect hydraulic lines. Fit blanking caps to all Numbers in parentheses refer to Fig. 1. open lines. The pilot supply valve is a non-serviceable item and 4. Remove bolts (6), lockwashers (7), washers (8) and should be replaced completely, if damaged, as follows: pilot supply valve (1) from mounting bracket (3).

  • Page 435: Body Cylinder

    BODY SYSTEM - Body Cylinder Section 230-0130 SM - 178 BODY MAIN FRAME TORQUE TUBE 1 - Pins 2 - Washer 3 - Lockwasher 4 - Bolt 5 - Cylinder 6 - Lube Fitting Fig. 1 - Exploded View of Body Cylinder Mounting DESCRIPTION 1.
  • Page 436 Body System - Body Cylinder Section 230-0130 SM - 180 8 - Seal 1 - Bolt 9 - Wear Ring 2 - Bushing 15 - Seal 21 - Wear Ring 10 - Wiper 3 - Base 16 - Tube 22 - Wiper 4 - Backup Ring 11 - Wear Ring 17 - Bushing...
  • Page 437 Body System - Body Cylinder Section 230-0130 remove. Remove wear ring (6) from tube (7). new bushings (2 & 17) in base (3) and end (26), respectively, if removed during disassembly. 7. Remove and discard wiper (10), wear ring (9) and seal (8) from tube (7).
  • Page 438 Body System - Body Cylinder Section 230-0130 BODY SYSTEM SCHEMATIC. Renew all 'O' rings 6. Remove body safety pins and operate the body. where used. Check all cylinder lines and fittings for leaks and tighten as required. WARNING 7. Check oil level in the body and disc brake cooling To prevent personal injury and property tank and add oil if low.

  • Page 439: Braking System

    BRAKING SYSTEM - Braking System Schematics Section 250-0000 DESCRIPTION precharged with nitrogen to 55 bar (800 lbf/in ). It Numbers in parentheses refer to Figs. 2 through 8. consists of a charging valve assembly, cylinder assembly and a piston. The charging valve is The hydraulic braking system is of closed centre equipped with a locking feature which, when opened, design wherein constant pressure is stored in...
  • Page 440 Braking System - Braking System Schematics Section 250-0000 The differing maximum operating pressures required for service brakes, or, the retarder control valve, to utilise the front and rear brakes are achieved within the treadle the rear service brakes as a retarder. valve.

  • Page 441: Monoblock Brake Valve

    Braking System - Braking System Schematics Section 250-0000 Monoblock Brake Valve (8) retarder is made by a separate retarder selection switch Refer to Section 250-0100, MONOBLOCK BRAKE on the centre console. Pressing the switch at the rear will VALVE. select the OCDB retarder and pressing the front will select the transmission retarder.

  • Page 442: Brake Dump Valve

    Braking System - Braking System Schematics Section 250-0000 Brake Dump Valve (15) Test Point D This test point is used to record the Rear Service Refer to Section 250-0152, BRAKE DUMP VALVE. Brake Pressure, Residual Brake Pressure and the Retarder Pressure - Taken from port 'TP1' on the Mounted on the rear torque tube, the brake dump monoblock brake valve.
  • Page 443 Braking System - Braking System Schematics Section 250-0000 RELIEVING PRESSURE BLEEDING THE BRAKES If either the front or rear brake assemblies have been serviced, the brakes must be bled to ensure that no air WARNINGS remains in the braking system. The braking system is equipped with accumulators which maintain pressure in the In the interests of safety, it is important that the exact...
  • Page 444 Braking System - Braking System Schematics Section 250-0000 BRAKING SYSTEM DIAGNOSIS CONDITION REASON REMEDY Inadequate braking Low System Pressure Check oil level Check oil condition Check for leakage Check system pressure and adjust as required Treadle valve delivery pressure below Check front and rear brake circuits normal Check treadle valve operation...
  • Page 445 Braking System - Braking System Schematics SM - 2049A OUTLET COMPONENTS 1 - Steering Pump TEST 2 - Accumulators 3 - Brake Manifold Valve 4 - Treadle Valve REF. 5 - Front Brake Callipers BODY HOIST 6 - Shuttle Valve CIRCUIT 7 - Oil Cooled Disc Brakes 8 - Monoblock Brake Valve...
  • Page 446 Braking System - Braking System Schematics SM - 2049B OUTLET COMPONENTS 1 - Steering Pump 2 - Accumulators TEST 3 - Brake Manifold Valve 4 - Treadle Valve REF. 5 - Front Brake Callipers BODY 6 - Shuttle Valve HOIST 7 - Oil Cooled Disc Brakes CIRCUIT 8 - Monoblock Brake Valve...
  • Page 447 Braking System - Braking System Schematics SM - 2049C OUTLET COMPONENTS 1 - Steering Pump 2 - Accumulators TEST 3 - Brake Manifold Valve 4 - Treadle Valve REF. 5 - Front Brake Callipers BODY 6 - Shuttle Valve HOIST 7 - Oil Cooled Disc Brakes CIRCUIT 8 - Monoblock Brake Valve...
  • Page 448 Braking System - Braking System Schematics SM - 2049D OUTLET COMPONENTS 1 - Steering Pump TEST 2 - Accumulators 3 - Brake Manifold Valve REF. 4 - Treadle Valve BODY 5 - Front Brake Callipers HOIST 6 - Shuttle Valve CIRCUIT 7 - Oil Cooled Disc Brakes 8 - Monoblock Brake Valve...
  • Page 449 Braking System - Braking System Schematics SM - 2049E COMPONENTS OUTLET 1 - Steering Pump 2 - Accumulators TEST 3 - Brake Manifold Valve 4 - Treadle Valve 5 - Front Brake Callipers REF. BODY 6 - Shuttle Valve HOIST 7 - Oil Cooled Disc Brakes CIRCUIT 8 - Monoblock Brake Valve...
  • Page 450 Braking System - Braking System Schematics SM - 2049F OUTLET COMPONENTS 1 - Steering Pump TEST 2 - Accumulators 3 - Brake Manifold Valve 4 - Treadle Valve REF. 5 - Front Brake Callipers BODY HOIST 6 - Shuttle Valve CIRCUIT 7 - Oil Cooled Disc Brakes 8 - Monoblock Brake Valve...
  • Page 451 Braking System - Braking System Schematics SM - 2049G OUTLET COMPONENTS 1 - Steering Pump 2 - Accumulators TEST 3 - Brake Manifold Valve 4 - Treadle Valve REF. 5 - Front Brake Callipers BODY 6 - Shuttle Valve HOIST 7 - Oil Cooled Disc Brakes CIRCUIT 8 - Monoblock Brake Valve...
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  • Page 453 BRAKING SYSTEM - Brake Manifold Valve Section 250-0050 SM - 1505 ACC1 ACC2 5,18 1 - Valve Body 6 - Retainer 11 - 'O' Ring 16 - 'O' Ring 2 - Solenoid Cartridge 7 - 'O' Ring 12 - 'O' Ring 17 - Backup Rings 3 - Solenoid Coil 8 - Spring...
  • Page 454 Braking System - Brake Manifold Valve Section 250-0050 SM - 1644 TO DIRECTIONAL TO PORT 'P2' CONTROL VALVE TREADLE VALVE FROM MONOBLOCK BRAKE VALVE FROM STEERING PUMP TO PORT 'P1' TREADLE VALVE ACC1 TO FRONT ACCUMULATOR TO REAR ACCUMULATOR ACC2 19 - Rear Brake Accumulator Pressure Switch 3 - Brake Manifold Valve 18 - Front Brake Accumulator Pressure Switch...
  • Page 455 Braking System - Brake Manifold Valve Section 250-0050 SM - 1645 FROM DIRECTIONAL TO PORT 'P2' CONTROL VALVE TREADLE VALVE TO MONOBLOCK BRAKE VALVE FROM STEERING PUMP TO PORT 'P1' TREADLE VALVE ACC1 TO FRONT ACCUMULATOR TO REAR ACCUMULATOR ACC2 3 - Brake Manifold Valve 19 - Rear Brake Accumulator Pressure Switch 20 - Parking Brake Pressure Switch...
  • Page 456 Braking System - Brake Manifold Valve Section 250-0050 8. If required, note orientation and remove hydraulic SM - 1508 line connectors from ports in valve body (1). ASSEMBLY Numbers in parentheses refer to Fig. 1. 1. Install new 'O' rings (11, 12, 14 & 16) and backup rings (13, 15 &...
  • Page 457 Braking System - Brake Manifold Valve Section 250-0050 MAINTENANCE SPECIAL TOOLS Inspect the brake manifold valve regularly for any There are no special tools required for procedures signs of leakage or damage and repair/replace as outlined in this section. Refer to Section 300-0070, required.
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  • Page 459 BRAKING SYSTEM - Tandem Pump Section 250-0055 SM - 2039 22 - Gear Housing 15 - Gear Housing 1 - Snap Ring 8 - Ring Seals 23 - End Cover 16 - Seals 2 - Spacer 9 - Bearings 24 - Name Plate * 17 - Connecting Shaft 3 - Seal Retainer 10 - Pocket Seals...
  • Page 460 Braking System - Tandem Pump Section 250-0055 SM - 575 SM - 338 TO BRAKE DRIVE GEAR COOLING CIRCUIT TO BRAKE COOLING CIRCUIT INLET OUTLET FROM FROM DRIVEN GEAR TANK TANK Fig. 2 - Typical Pump Operation Fig. 3 - Hydraulic Schematic of Tandem Pump Operation DISASSEMBLY The tandem pump draws oil from the body and disc Numbers in parentheses refer to Figs.
  • Page 461 Braking System - Tandem Pump Section 250-0055 SM - 2040 21 - Driven Gear 13 - Driven Gear 22 - Gear Housing 14 - Seals 23 - End Cover 7 - Plug 15 - Gear Housing 1 - Snap Ring 24 - Name Plate 8 - Ring Seals 2 - Spacer...
  • Page 462 Braking System - Tandem Pump Section 250-0055 3. Tap end cover (23) with a soft hammer and SM - 344 separate from gear housing (22). If end cover (23) must be pried off, use care to avoid damaging machined surfaces of the cover and housing. See Fig.
  • Page 463 Braking System - Tandem Pump Section 250-0055 8. Separate and lift off gear housing (15) with care. SM - 348 See Fig. 12. Remove thrust plate (11) as in Step 4. 9. Mark three meshed gear teeth with a dab of Prussian blue or similar dye and remove the matched driveshaft and gear (12) and driven gear (13) set.
  • Page 464 Braking System - Tandem Pump Section 250-0055 Hydraulic pressure forces the gears against the low SM - 354 pressure side of the housing. As the bearings and gear hubs wear, the housing gear bores wear. Excessive bore cutout, particularly in a short period, indicates excessive pump loading or dirty oil.
  • Page 465 Braking System - Tandem Pump Section 250-0055 10. Smooth all machined surfaces with a medium-grit SM - 357 stone. See Fig. 21. Deburr all bearing bores if required. 11. Clean parts in a suitable solvent and dry with compressed air after smoothing surfaces. ASSEMBLY Numbers in parentheses refer to Figs.
  • Page 466 Braking System - Tandem Pump Section 250-0055 7. With shaft end cover (6) clamped in a soft-jawed SM - 362 vice, insert driveshaft and gear (12) into the shaft end cover bore and push down until the gear is snug against thrust plate (11).
  • Page 467 Braking System - Tandem Pump Section 250-0055 gear housing (22) with a soft hammer until it rests SM - 366 snugly against bearing carrier (18). Refer to Fig. 28. If a new housing is used, make sure the large oil port will be toward the inlet, and the small port toward the outlet side of the pump assembly.
  • Page 468 Braking System - Tandem Pump Section 250-0055 4. Fill body and disc brake cooling tank to the proper SM - 371 level. Refer to Section 230-0040, BODY AND DISC BRAKE COOLING TANK. Refer to Section 300-0020, LUBRICATION SYSTEM, for correct oil specifications.
  • Page 469 BRAKING SYSTEM - Accumulator Section 250-0060 SM - 277 1 - Charging Valve 8 - Wear Rings 1A - Cap 4 - Protector 1E - Body 9 - 'O' Ring 1B - Core 1F - 'O' Ring 5 - Piston 10 - End Cap 1C - 'O' Ring 2 - Screw...
  • Page 470 Braking System - Accumulator Section 250-0060 core (1B). Attempt to reseat the valve core by SM - 1273 depressing and releasing it quickly once or twice. Recheck for leakage, if leakage continues then discharge the accumulator as described under 'Discharging Nitrogen' in this section, then replace the valve core.
  • Page 471 Braking System - Accumulator Section 250-0060 DISCHARGING NITROGEN WARNINGS Numbers in parentheses refer to Fig. 1, unless Do not use Oxygen or any gas other than otherwise specified. Nitrogen to charge an accumulator. Oxygen under pressure coming into contact with oil or Make sure charging valve (1) is closed internally by grease will cause a violent explosion.
  • Page 472 Braking System - Accumulator Section 250-0060 DISASSEMBLY SM - 278 Numbers in parentheses refer to Fig. 1. WARNING Accumulators are charged with Nitrogen. The service pressure is 55 bar (800 lbf/in ) at C (70 F). Do not attempt to remove any valves or fittings until all nitrogen pressure is completely relieved to prevent personal injury and property damage.
  • Page 473 Braking System - Accumulator Section 250-0060 6. Test accumulator hydraulically for leakage or 5. Charge the accumulator with Nitrogen gas as failure at 255 - 276 bar (3 700 - 4 000 lbf/in described under the heading 'Charging the Discharge after testing. Accumulator' in this section.
  • Page 474 Braking System - Accumulator Section 250-0060 AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE °C °F lbf/in² 47.7 48.8 49.8 50.9 54.1 56.2 57.3 58.3 59.4 60.5 61.5 WARNING This truck is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in Special permits may be required when transporting the truck or cylinders by any method while cylinders are charged.
  • Page 475 BRAKING SYSTEM - Treadle Valve Section 250-0070 SM - 1267 1 - Adjustment Collar 2 - Actuator Plunger 16 - Reaction Plunger 3 - Glyde Ring Assembly 30 - Nut 43 - Screw 17 - Wiper Seal 4 - Plunger Return Spring 31 - Washer 44 - Retainer Plate 18 - Backup Ring...
  • Page 476 Braking System - Treadle Valve Section 250-0070 SM - 1616 SM - 1617 FROM TO FRONT FRONT BRAKE CIRCUIT BRAKES FROM TO REAR REAR BRAKE BRAKE CIRCUIT CIRCUIT FROM FROM BRAKE BRAKE MANIFOLD MANIFOLD FROM FROM 4 - Treadle Valve 4 - Treadle Valve BRAKE BRAKE...
  • Page 477 Braking System - Treadle Valve Section 250-0070 SM - 1618 SM - 1619 FROM FRONT TO FRONT BRAKE CIRCUIT BRAKE CIRCUIT FROM TO TANK FROM TO REAR REAR VIA BRAKE BRAKE BRAKE BRAKE MANIFOLD MANIFOLD CIRCUIT CIRCUIT SOLENOID SOLENOID FROM FROM BRAKE BRAKE...
  • Page 478 Braking System - Treadle Valve Section 250-0070 REMOVAL 5. Remove pivot pin (38) from actuator base (46) with Numbers in parentheses refer to Fig. 1. a punch and hammer. Remove actuator cam (36) assembly and inspect for any abnormal wear or cracks.
  • Page 479 Braking System - Treadle Valve Section 250-0070 SUB-ASSEMBLY 18. Turn valve body (20) on its side on the work bench and remove regulator sleeves (14) from valve body (20). Numbers in parentheses refer to Fig. 1. 19. Remove regulator spools (8), reaction Note: All metal parts should be thoroughly cleaned plungers (16) and spool return springs (15) from with a suitable solvent, dried, and lubricated with a...
  • Page 480 Braking System - Treadle Valve Section 250-0070 centre. Install threaded inserts (52) by tapping lightly SM - 1235 with a small hammer until their flanges become flush with pedal (50) surface. Be sure pedal (50) is supported to prevent breaking. 4.
  • Page 481 Braking System - Treadle Valve Section 250-0070 ASSEMBLY SM - 1237 Numbers in parentheses refer to Fig. 1. 1. Lightly lubricate glyde ring assembly (3) and install the 'B1' actuator plunger (2) into the 'B1' circuit. Be GLYDE RING ASSEMBLY careful not to damage or cut the glyde ring during installation.
  • Page 482 Braking System - Treadle Valve Section 250-0070 SM - 499 PILOT 159 bar (2 300 lbf/in²) RETURN SUPPLY SUPPLY FRONT REAR BRAKE BRAKE PRESSURE PRESSURE SIMULATED BRAKE VOLUME Fig. 9 - Typical Test Fixture 17. Install stop light pressure switch (55) and lockup SM - 1238 drop out pressure switch (54) in plate (21) and tighten SCREWDRIVER...
  • Page 483 Braking System - Treadle Valve Section 250-0070 FINAL ASSEMBLY 4. Attach tank return line to 'T' port of valve body (20). Numbers in parentheses refer to Fig. 1. 5. Attach output ports 'B1' and 'B2' to test lines. Check that all ports are used. Note: Tighten all fasteners without special torques specified to standard torques listed in Section 300-0080, STANDARD BOLT AND NUT TORQUE...
  • Page 484 Braking System - Treadle Valve Section 250-0070 2. Remove blanking caps and connect hydraulic lines SM - 1239 to the treadle valve assembly as noted at removal. 3. Connect electrical connections to stop light pressure switch (55) and lockup drop out pressure switch (54) as noted at removal.
  • Page 485 Braking System - Treadle Valve Section 250-0070 raised or lowered by an in service (in situ) adjustment. 17. Assemble actuator cap (41), boot (42) and retainer plate (44) to actuator base (46) and secure with 5. Remove pedal (50) from actuator cam (36) by capscrews (43).
  • Page 486 Braking System - Treadle Valve Section 250-0070 SPECIAL TOOLS Every 1 000 Hours Check front and rear brake pressures at diagnostic There are no special tools required for procedures test points. If the pressures are outwith the specified outlined in this section. Refer to Section 300-0070, SERVICE TOOLS, for part numbers of general service pressure range, inspect the valve and take relevant tools, sealants and adhesives required.
  • Page 487 BRAKING SYSTEM - Directional Control Valve Section 250-0090 SM - 1509 1 - Valve Body 5 - Spring End Cap 9 - Allen Bolt 2 - End Cover 6 - Slide Washer 10 - Allen Bolt 13 - Sub Plate 3 - Spool 14 - Connector 7 - Spring...
  • Page 488 Braking System - Directional Control Valve Section 250-0090 SM - 1511 SM - 1510 TO 'PX' PORT FROM 'PX' PORT TREADLE VALVE TREADLE VALVE BRAKE BRAKE MANIFOLD MANIFOLD VALVE VALVE Fig. 3 - Directional Control Valve - De-energized Fig. 2 - Directional Control Valve - Energized OPERATION A controlled bleed down of the applied service brakes to the steering and brake control tank occurs through...
  • Page 489 Braking System - Directional Control Valve Section 250-0090 3. Clean directional control valve assembly and a. Install hydraulic supply capable of 0 - 159 bar surrounding area with a suitable solvent. Ensure all (0 - 2 300 lbf/in²) to port 'P'. hydraulic lines connected to the directional control valve are identified for ease of installation and, with b.
  • Page 490 Braking System - Directional Control Valve Section 250-0090 INSTALLATION 5. Check directional control valve and hydraulic line Note: Tighten all fasteners to torques listed in connections for leaks and tighten as required. Section 300-0080, STANDARD BOLT AND NUT TORQUE SPECIFICATIONS. 6.
  • Page 491 BRAKING SYSTEM - Monoblock Brake Valve Section 250-0100 SM - 1363 1 - Valve Body 10 - Shuttle Valve 4 - Retainer 7 - Bonded Washer 2 - Orifice Plate 11 - Relief Valve 5 - Disc Filter 8 - Blanking Plug 3 - Conical Filter 12 - Plug 6 - Filter Retainer...
  • Page 492 Braking System - Monoblock Brake Valve Section 250-0100 At the same time, oil enters pressure relief valve (11) SM - 1356 circuit, passing through conical filter (3), disc filter (5) and orifice plate (2) to shuttle valve (10). Oil pressure TO REAR pushes shuttle valve (10) spool across and oil exits SERVICE BRAKES...
  • Page 493 Braking System - Monoblock Brake Valve Section 250-0100 REMOVAL SM - 1353 WARNINGS Hydraulic fluid pressure will remain within the system after engine shut down. Operate the treadle valve continuously until the pressure has dissipated before carrying out any work on the braking system or serious injury could result.
  • Page 494 Braking System - Monoblock Brake Valve Section 250-0100 ASSEMBLY 3. Check oil level in steering and brake control tank Numbers in parentheses refer to Fig. 1, unless and add oil if required. Refer to Section 220-0040, otherwise specified. STEERING AND BRAKE CONTROL TANK for correct fill level, and, use only oil as specified in Section 1.
  • Page 495 BRAKING SYSTEM - Pressure Reducing Valve Section 250-0110 DESCRIPTION SM - 2567 The pressure reducing valve can be identified as item 14 in Section 250-0000, BRAKING SYSTEM SCHEMATIC. Mounted on the inside of the left hand frame rail under the body control valve, the pressure reducing valve is located in the hydraulic brake circuit between the treadle valve and the front brake callipers.
  • Page 496 Braking System - Pressure Reducing Valve Section 250-0110 7. Secure pressure reducing valve (1) to mounting WARNING with bolts (10) and washers (11). To prevent personal injury and property damage, be sure wheel blocks are properly 8. Remove blanking caps from hydraulic lines and secured and of adequate capacity to do the job install lines to pressure reducing valve (1) as identified safely.
  • Page 497 BRAKING SYSTEM - Retarder Control Valve Section 250-0130 SM - 1272 1 - Adjustment Collar 2 - Actuator Plunger 11 - 'O' Ring 20 - Washer 29 - Jam Nut 3 - Plunger Return Spring 12 - 'O' Ring 21 - Capscrew 30 - Set Screw 4 - Regulator Spring 13 - Regulator Sleeve...
  • Page 498 Braking System - Retarder Control Valve Section 250-0130 SM - 1646 REAR SERVICE BRAKES 'P2' PORT TREADLE VALVE FROM BRAKE MANIFOLD VALVE 10 - Retarder Control Valve 12 - Transmission Retarder Cylinder 11 - Directional Control Valve 21 - Pressure Switch Fig.
  • Page 499 Braking System - Retarder Control Valve Section 250-0130 SM - 1647 REAR SERVICE BRAKES 'P2' PORT TREADLE VALVE FROM BRAKE MANIFOLD VALVE 10 - Retarder Control Valve 12 - Transmission Retarder Cylinder 11 - Directional Control Valve 21 - Pressure Switch Fig.
  • Page 500 Braking System - Retarder Control Valve Section 250-0130 SM - 1648 REAR SERVICE BRAKES 'P2' PORT TREADLE VALVE FROM BRAKE MANIFOLD VALVE 10 - Retarder Control Valve 12 - Transmission Retarder Cylinder 11 - Directional Control Valve 21 - Pressure Switch Fig.
  • Page 501 Braking System - Retarder Control Valve Section 250-0130 SM - 1649 REAR SERVICE BRAKES 'P2' PORT TREADLE VALVE FROM BRAKE MANIFOLD VALVE 10 - Retarder Control Valve 12 - Transmission Retarder Cylinder 11 - Directional Control Valve 21 - Pressure Switch Fig.

  • Page 502: Body

    Braking System - Retarder Control Valve Section 250-0130 Valve Body lever (36) in the fully applied position during normal operation. 1. Remove cap (23) from the top of valve body (18). 2. Loosen the socket head capscrew from adjustment REMOVAL collar (1) and unscrew adjustment collar (1).
  • Page 503 Braking System - Retarder Control Valve Section 250-0130 Actuator sub-assembly from housing (22). 1. If new lever (36) and shaft (34) are being fitted proceed as follows: Note: Do not try to disassemble lever (36) from shaft (34). If shaft (34) or lever (36) are damaged, replace shaft (34), lever (36), ring (35) and spring pin (25).
  • Page 504 Braking System - Retarder Control Valve Section 250-0130 the actuation cavity with EP, NLGI grease until cam SM - 1347 (24) is covered. Refer to Section 300-0020, LUBRICATION SYSTEM for grease specification. Valve Body Seals 1. Install seal (17) in seal groove of valve body (18) first.
  • Page 505 Braking System - Retarder Control Valve Section 250-0130 SM - 1349 RETURN 207 bar (3 000 lbf/in SUPPLY BRAKE PRESSURE Fig. 8 - Typical Retarder Control Valve Test Circuit TESTING AND ADJUSTMENTS 6. Install regulator sleeve (13) assembly in valve Numbers in parentheses refer to Fig.
  • Page 506 Braking System - Retarder Control Valve Section 250-0130 collar (1) is bottomed to prevent excessive pressure angle and back set screw (27) out until a lever angle of from damaging regulator springs (4 & 5). 6° is achieved. 1. Gradually increase pressure in order to check for Note: Failure to comply with this specification may leaks.
  • Page 507 Braking System - Retarder Control Valve Section 250-0130 5. Remove wheel blocks, start the engine and bring c. Actuate retarder control valve fully and check hydraulic fluid to operating temperature. reading on pressure gauge. Pressure reading should be 33 ± 1.7 bar (480 ± 25 lbf/in 6.
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  • Page 509 BRAKING SYSTEM - Shuttle Valve Section 250-0140 DESCRIPTION SM - 1350 TO MONOBLOCK Letters in parentheses refer to Fig. 1. BRAKE VALVE The Shuttle Valve can be identified as item 6 in Section 250-0000, BRAKING SYSTEM SCHEMATIC. FROM 'B2' PORT TREADLE VALVE The shuttle valve allows the distribution of pressure from either the treadle valve, to activate the rear...
  • Page 510 Braking System - Shuttle Valve Section 250-0140 1. Position the vehicle in a level work area, apply the install lines to shuttle valve as identified during removal. parking brake and switch off the engine. 7. Check oil level in steering and brake control tank 2.
  • Page 511 BRAKING SYSTEM - Parking Brake Valve Section 250-0151 DESCRIPTION SM - 1653 The parking brake valve can be identified as item 13 in Section 250-0000, BRAKING SYSTEM SCHEMATIC. Mounted off the cab rear crossmember, the parking brake valve is located in the hydraulic brake circuit between the treadle valve and the front brake pressure reducing valve.
  • Page 512 Braking System - Parking Brake Valve Section 250-0151 Note: Tighten all hydraulic lines fitted with ORFS 6. Note location and orientation of elbows (10 & 11) connections, as described in Section 250-0000, and remove from parking brake valve (1) for use on BRAKING SYSTEM SCHEMATIC.
  • Page 513 BRAKING SYSTEM - Brake Dump Valve Section 250-0152 DESCRIPTION SM - 1671 The parking brake valve can be identified as item 15 in Section 250-0000, BRAKING SYSTEM SCHEMATIC. Mounted on the rear torque tube, the brake dump valve is located in the hydraulic brake circuit between the monoblock brake valve and the oil cooled disc brakes (See Fig.
  • Page 514 Braking System - Brake Dump Valve Section 250-0152 3. Clean brake dump valve (1) and surrounding area during removal. with a suitable solvent. Ensure all hydraulic lines connected to brake dump valve (1) are identified for 9. Check oil level in the steering and brake control ease of installation and, with suitable containers tank and add oil if required.
  • Page 515 OPERATORS COMPARTMENT - Cab and Mounting Section 260-0010 SM - 2391 1 - Cab Assembly 8 - LH Cover 15 - Insert 2 - RH Door Assembly 9 - Rear Glass 16 - Catch Assembly 3 - LH Door Assembly 10 - Bolt 17 - Screw 4 - Front Glass...
  • Page 516 Operators Compartment - Cab and Mounting Section 260-0010 passengers seat keeps the cab interior air fresh and 4. Disconnect the electrical cables in the following dust free. A sliding window in RH door assembly (2) order to prevent damage to the electrical components. and an electric window in LH door assembly (3) provide additional ventilation.
  • Page 517 Operators Compartment - Cab and Mounting Section 260-0010 Note: Use padded spreader bars when removing cab 5. Remove blanking caps from all braking and steering assembly (1) with overhead lifting equipment to lines and connect lines as identified at removal. prevent damage from concentrated loads at cab lifting Tighten all lines securely.
  • Page 518 Operators Compartment - Cab and Mounting Section 260-0010 SM - 2394 19 20 23 22 15 16 25 - Hinge 1 - Gasket 9 - Screw 17 - Fixing Plate 26 - Pin 2 - RH Door Frame 10 - Screw 18 - Lock Cover 27 - Split Pin 3 - Sliding Frame...
  • Page 519 Operators Compartment - Cab and Mounting Section 260-0010 SM - 1994 58 59 12 13 66 67 45 40 41 52 53 1 - Grommet 15 - Cover 42 - Cap 56 - Washer 2 - LH Door 16 - Spacer 43 - Pin 57 - Nut 29 - Inner Door...
  • Page 520 Operators Compartment - Cab and Mounting Section 260-0010 The door assembly can be removed from the cab as a glass. Unscrew one handle of the special tool and feed complete assembly, however, components such as the wire through the opening. Pierce a second hole in the lock, handle and glass assembly can be removed the adhesive on the side directly opposite the first.
  • Page 521 OPERATORS COMPARTMENT - Driver Seat and Mounting Section 260-0090 SM - 3267 22 - Tether 1 - Seat Assembly 12 - Damper 23 - air Pipes 2 - Seat Frame 13 - Suspension Assembly 24 - Bolt 3 - Reel Cover 14 - Upstop/Bumpstop 25 - Washer 4 - Lumbar Support...
  • Page 522 Operator's Compartment - Driver Seat and Mounting Section 260-0090 the lowest position to allow easier access. The 6. Remove bolts and lockwashers securing belt (21) to incorporated block out maintains the seat in position seat assembly. Remove lap belt (21). for driving.
  • Page 523 Operator's Compartment - Driver Seat and Mounting Section 260-0090 MAINTENANCE 4. Position seat belt (21) to seat assembly and secure Numbers in parentheses refer to Fig. 1. using bolts and lockwashers as removed at Removal. The care of the upholstery on seat cover (8) and 5.
  • Page 525 OPERATORS COMPARTMENT - Passenger Seat and Mounting Section 260-0110 SM - 1992 31 24 17 18 16 15 9 - Hinge 1 - Seat Cushion 17 - Nut 25 - Lap Belt 2 - Seat Frame 26 - Cotter Pin 10 - Spring 18 - Lockwasher 3 - Back Cushion...
  • Page 526 Operator's Compartment - Passenger Seat and Mounting Section 260-0110 arrangement. Located within seat base (8) are the 8. Remove cotter pins (26), release the snap hooks major CEC components; battery equalizer box, on lap belt (25) and remove lap belt (25) halves from electronic control unit (ECU) and CEC interface box.
  • Page 527 Operator's Compartment - Passenger Seat and Mounting Section 260-0110 5. Install pivot pin (13) through mounting hole in seat latch. Lengthen or shorten the belt halves until the base (8) and secure with washer (19), lockwasher (18) desired length is obtained. and nut (17).
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  • Page 529 OPERATORS COMPARTMENT - Passenger Seat and Mounting Section 260-0110 SM - 2392 1 - Seat Cushion 2 - Seat Frame 10 - Spring 18 - Lockwasher 26 - Bolt 3 - Back Cushion 11 - Latch 19 - Washer 27 - Bolt 4 - Bolt 12 - Pad 20 - Bolt...
  • Page 530 Operator's Compartment - Passenger Seat and Mounting Section 260-0110 arrangement. Located within seat base (8) are the 8. Remove bolts (27), washers (28), lockwashers (29) major CEC components; battery equalizer box, and nuts (30) securing lap belt (25) to seat base (8) electronic control unit (ECU) and CEC interface box.
  • Page 531 Operator's Compartment - Passenger Seat and Mounting Section 260-0110 MAINTENANCE 5. Install pivot pin (13) through mounting hole in seat base (8) and secure with washer (19), lockwasher (18) Numbers in parentheses refer to Fig. 1. and nut (17). The care of the upholstery on seat cushion (1) and 6.
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  • Page 533 OPERATORS COMPARTMENT - Air Conditioning Section 260-0130 SM - 2430 3 - Receiver Drier 5 - Evaporator 1 - Compressor 4 - Expansion Valve 2 - Condenser Fig. 1 - Typical Air Conditioning Flow Diagram DESCRIPTION Compressor Drive Clutch The R-134a compressor systems use an electronically Temperature Control Switch actuated clutch to engage and disengage drive to the A thermostat switch senses the temperature of the...
  • Page 534 Operators Compartment - Air Conditioning Section 260-0130 slow down this radiation of heat. Cooling fins are Blockage of the filter will result in a drop in pressure located on the condenser tubes and fans are used to that will be indicated by a drop in system performance. circulate cool air around the condenser tubes.
  • Page 535 Operators Compartment - Air Conditioning Section 260-0130 REMOVAL 5. When satisfied that the system is completely Numbers in parentheses refer to Fig. 2, unless discharged, tag refrigerant hoses (1 & 2) to aid in otherwise stated. installation and carefully disconnect hoses from adaptors at cab firewall.
  • Page 536 Operators Compartment - Air Conditioning Section 260-0130 SM - 2393A 24 25 24 23 12 12 29 28 34 35 1 - Refrigerant Hose 2 - Refrigerant Hose 3 - Refrigerant Hose 4 - Refrigerant Hose 18 - Bolt 5 - Condenser 19 - Bracket 36 35 6 - Bolt...
  • Page 537 Operators Compartment - Air Conditioning Section 260-0130 SM - 2393B 55 - Expansion Valve 50 - Air Conditioning Unit 56 - Adaptor 51 - Cover 57 - Adaptor 52 - Grille 58 - Relay 53 - Filter Element 59 - Thermostat 54 - Evaporator Matrix Fig.
  • Page 538 Operators Compartment - Air Conditioning Section 260-0130 adjuster bracket (49). Drive belt (14) should now be (50, Fig. 3) and secure using quarter-turn screws. free to slide off of groove in compressor (13). 2. Remove caps from end of refrigerant hoses (1 & 2) 17.
  • Page 539 Operators Compartment - Air Conditioning Section 260-0130 on adjuster rod (31), locate in pivot block (37) and secure in place with washer (36), lockwasher (35) and WARNINGS nut (34). Do not tighten at this stage. If you get the slightest trace of R-134a in your eye, flood the eye immediately with cool 14.
  • Page 540 Operators Compartment - Air Conditioning Section 260-0130 Refrigerant Oil 8. Inspect and clean outside and inside cab air filters periodically, depending on dust conditions. Replace the outside filter when it becomes saturated to the point it won't come clean. WARNINGS To prevent personal injury always wear rubber gloves when handling refrigerant oils.
  • Page 541 Operators Compartment - Air Conditioning Section 260-0130 throughout the system for leaks. A large leak point will from the system components. If any of the major have an oily or greasy appearance. The refrigerant system components are to be repaired or replaced, carries compressor oil with it and deposits it around the system must also be completely discharged.
  • Page 542 Operators Compartment - Air Conditioning Section 260-0130 CHARGING THE SYSTEM start to register that a vacuum is being drawn. If the gauges do not register the vacuum then a blockage or Note: Refer to all WARNINGS listed under 'Maintenance' prior to charging the system. leak is present.
  • Page 543 Operators Compartment - Air Conditioning Section 260-0130 10. Before disconnecting power supply from vacuum side valve. Allow the system to continue the charging pump, close both high and low side gauges. Remove procedure until the sight glass is clear. If the sight yellow hose from vacuum pump and connect to glass remains clear, with the increased engine speed, R-134a source.
  • Page 544 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS TABLE158 CONDITION PROBLEM REMEDY 1. Belt Trouble Slipping Loose Adjust belt to 12 mm (0.5 in) depression Overcharge Correct the charge Air in system Evacuate and re-charge Excessive wear Pulley not aligned Align Pulley Belt too tight Adjust or replace...
  • Page 545 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS (CONT.) CONDITION PROBLEM REMEDY 3. Noise - Evaporator Rubbing/scraping Fan blade or blower Repair or replace Hissing Low charge/leak Correct charge/repair leak Chatter/knocking Expansion valve Replace Noisy case Loose brackets/screws Tighten Motor squeal Dry bearings...
  • Page 546 Operators Compartment - Air Conditioning Section 260-0130 AIR CONDITIONING DIAGNOSIS (CONT.) CONDITION PROBLEM REMEDY 6. Air Conditioning System Trouble - Gauges must be connected High head pressure Overcharge of refrigerant Purge system as necessary Air in system Evacuate and re-charge Condenser clogged Clean condenser Low head pressure...
  • Page 547 BODY - Body and Mounting Section 270-0010 SM - 2038 BODY 16,38 FRAME 19,20 21,22 11 - Bolt 21 - Shim 31 - Locknut 1 - Body Assembly 12 - Shim 22 - Shim 32 - Washer 2 - Cab Guard Assembly 13 - Body Safety Pin 23 - Shim 33 - Cap...
  • Page 548 Body - Body and Mounting Section 270-0010 OPERATION WARNING The body control joystick, mounted at the left hand side of the drivers' seat, controls the body control To prevent personal injury and property valve which supplies hydraulic oil to operate the body damage, be sure wheel chocks and lifting hoist cylinders.
  • Page 549 Body - Body and Mounting Section 270-0010 Body Shimming Procedure WARNING Numbers in parentheses refer to Fig. 1. To prevent personal injury and property damage, be sure wheel chocks and lifting Note: Tighten all fasteners to standard torques listed equipment are properly secured and of in Section 300-0080, STANDARD BOLT AND NUT adequate capacity to do the job safely.
  • Page 550 Body - Body and Mounting Section 270-0010 7. Raise and lower body assembly (1) and check for gases. The resulting fire in the heating passages is correct clearance at body hinge pins (10) and body helpful in that it burns away some of the carbon and guides.
  • Page 551 Miscellaneous - Lubrication System Section 300-0020 LUBRICATION AND SERVICE SAFETY PRECAUTIONS Do not allow unauthorized personnel to service or maintain this vehicle. Study the Operator’s Handbook WARNING and Maintenance Manual before starting, operating or These trucks are equipped with engine and servicing this vehicle.
  • Page 552 Miscellaneous - Lubrication System Section 300-0020 LUBRICATION AND SERVICING (CONTINUED) WARNING Trucks filled with Allison TranSynd RD oil should only be filled with TranSynd RD oil at For non TranSynd RD filled transmissions refer to the drain and refill intervals. Use of other / mixing service schedule detailed from page 4 onwards.
  • Page 553 Miscellaneous - Lubrication System Section 300-0020 SM - 2041 Fig. 1 - Lubrication and Service Points LUBRICATION AND SERVICE CHART Interval Ref. No. of Hours Points Identification Service Instructions Points Lubricant Service/Quantities Engine Check oil level. Add if low. As Required Transmission Check oil level.
  • Page 554 Miscellaneous - Lubrication System Section 300-0020 LUBRICATION AND SERVICE CHART Interval Ref. No. of Hours Points Identification Service Instructions Points Lubricant Service/Quantities Steering Pivot Pin Lube. EP, NLGI See Note A-Frame Nose Spherical Bushing Lube. EP, NLGI See Note Banjo Stabilizer Spherical Bushing Lube.
  • Page 555 Miscellaneous - Lubrication System Section 300-0020 MISCELLANEOUS SERVICING Note: Any time a significant amount of coolant is WHEN REQUIRED added, the DCA4 concentration MUST be checked. If the concentration is low, engine damage will result. Seat Belts - Inspect seat belts and replace if Conversely, over-inhibiting antifreeze solutions can damaged.
  • Page 556 Miscellaneous - Lubrication System Section 300-0020 glazed or shiny surface which indicates belt slippage. EVERY 2000 HOURS OF OPERATION Correctly installed and tensioned belts will show even Steering Hydraulic Tank Filter - Clean filter housing pulley and belt wear. Refer to Section 110-0030, and install new element when indicated, or after 2000 Engine and Mounting for drive belt tension and hours of operation, whichever comes first.
  • Page 557 Miscellaneous - Lubrication System Section 300-0020 SERVICE CAPACITIES Ref. Service Capacities Points Identification Lubricant litres US gal Engine Crankcase and Filters 35.4 Transmission and Filters* TranSynd RD Main Hydraulic Tank 78.5 Main Hydraulic System Steering Hydraulic Tank Steering Hydraulic System Cooling System Coolant 80.3...
  • Page 558 Miscellaneous - Lubrication System Section 300-0020 RECOMMENDED LUBRICANTS COMPONENT LUBRICANT VISCOSITY (See Note 1) Engine Engine oil with 1.00 % sulphated ash is Ambient Temp Recommendation recommended. Sulphated ash must not exceed 0° C and above SAE 20W-40 1.85 % limit. API code CE or CF-4. See Note 2. -10°...
  • Page 559 Miscellaneous - Lubrication System Section 300-0020 Note 1 - Consult your lubricant supplier for the correct Note 4 - Typical SAE 10W oils complying with viscosity of lubricant to use when ambient temperatures Specification EMS19058 are: are consistently above or below those listed. KUWAIT TO4 Note 2 - Cummins Engine Co., does not recommend SHELL DONAX TC...
  • Page 560 Miscellaneous - Lubrication System Section 300-0020 THIS PAGE IS INTENTIONALLY BLANK SM1654 Rev 7 07-08...
  • Page 561 MISCELLANEOUS - Service Tools Section 300-0070 INTRODUCTION Engine Contained in this section are recommended service tools The following tools are recommended for Engine and equipment required for maintenance, overhaul and Maintenance Procedures and should be used in troubleshooting. In certain instances, both Metric and conjunction with procedures outlined in the engine Imperial equivalents of the same tools are listed.
  • Page 562 Miscellaneous - Service Tools Section 300-0070 Accumulators/Ride Cylinder Charging 15269040 - Printer Paper for use in above printers - 5 rolls 09359489 - Charging Assembly The following tools are contained in CEC The following parts can be assembled for Off-Highway Diagnostic Service Kit - 15269231: simultaneously charging the rear ride cylinders: 15269232 - Wire Cutter, Stripper and Terminal 09359489 - Charging Assembly...
  • Page 563 Miscellaneous - Service Tools Section 300-0070 Adhesives and Sealants 09371048 - Loctite 638 15269103 - Loctite 221 15269107 - Loctite 641 09362529 - Loctite 225 15304830 - Loctite 5205 (Ref. Sec. 160-0020) 09029849 - Loctite 243 15305445 - Loctite 7063 Cleaning Agent 09244598 - Loctite 270 15269108 - Loctite Superclean Safety Solvent 706 09985300 - Loctite 271...
  • Page 564 Miscellaneous - Service Tools Section 300-0070 SM - 126 0.56 - 3 HOLES EQUALLY SPACED 0.12 0.50 12.7 0.56 14.22 0.62 15.7 1.00 25.4 1.62 41.1 2.00 50.8 2.50 63.5 3.25 82.5 MATERIAL: PLAIN CARBON STEEL 3.31 84.0 9.38 15.88 26.25 Fig.
  • Page 565 Miscellaneous - Service Tools SPRING COMPRESSOR TOOL MATERIAL: PLAIN CARBON STEEL ITEM #2 - BASE (WELDMENT) 100 SQ. STOCK ITEM #1 - HANDLE .250 DIA. HOLE THRU. KNURL DIA. HOLE ITEM #5 - 'T' HANDLE (WELDMENT) .19 SQ. 8-32 UNC 2B X .38 MIN. FULL STOCK THD.
  • Page 566 Miscellaneous - Service Tools Section 300-0070 SM - 625 Note: Break all sharp corners 4 mm (0.015 in) Fig. 6 - Centring Spring Installation Tool (Section 220-0090, STEERING VALVE) SM - 403 HEAVY WALL TUBING ALUMINIUM RING PRESS RING ON END OF TUBING Fig.
  • Page 567 Miscellaneous - Service Tools Section 300-0070 SM - 404 ALUMINIUM ROUND STOCK BRG. RACE ITEM NO. mm (in) mm (in) mm (in) 100 (4.0) 25 (1.00) 50 (2.00) 100 (4.0) 40 (1.55) 70 (2.75) Fig. 8 - Bearing Race Installation Tool (Section 220-0050, STEERING PUMP) SM - 647 6 mm (0.25 in) ø...
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  • Page 569 MISCELLANEOUS - Standard Bolt and Nut Torque Specifications Section 300-0080 fasteners can be safely tightened, the following torque tables have been compiled. WARNING Some fasteners are important attaching parts which could affect the performance of vital The torque values listed in the tables have been established over a period of years and cover all components and systems, and/or, could result conditions of assembly.
  • Page 570 Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ±10% TABLE 145 Size SAE Symbol SAE Symbol SAE Symbol SAE Symbol 12 Point Cap Screws GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel (SAE GR 2) (SAE GR 5) (SAE GR 7)
  • Page 571 Miscellaneous - Standard Bolt and Nut Torque Specifications Section 300-0080 RECOMMENDED MAXIMUM TORQUES (METRIC) ±10% TABLE 146 Class 8.8 Class 9.8 Class 10.9 Class 12.9 Size Nm lbf ft Nm lbf ft Nm lbf ft lbf ft 0.20 0.15 M1.6 - 0.35 0.20 0.15 0.40 0.30...
  • Page 572 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 573 MISCELLANEOUS - Unit Storage Section 300-0090 GENERAL Maintenance Manual for complete information on The storage of machines for short periods of time or storing the engine for periods shorter than 30 days. during the off-season is an important item if major damage to components is to be avoided.
  • Page 574 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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