Centaur 950 Service Manual
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Centaur 950 Service Manual

2001 - present offroad vehicle
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Table of Contents

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Models:
Ontario Drive & Gear
(519) 662-2840 FAX (519) 662-2421
Service Manual
2001 - Present
CENTAUR 950
CENTAUR 950D
CENTAUR 950DT
01/09
www.centaur8x8.ca

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Summary of Contents for Centaur CENTAUR 950

  • Page 1 Service Manual 2001 - Present Models: CENTAUR 950 CENTAUR 950D CENTAUR 950DT Ontario Drive & Gear 01/09 www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 3 Centaur Service Manual How to use this manual This manual is divided into general sections which are identi- Service Guide fied by a 2 letter designation. Find the section you want in the guide General Information....GI on this page, and then turn to the Engine........

  • Page 5: Table Of Contents

    Centaur Service Manual General Information SECTION GI General Information Table of Contents General Instructions................GI-2 Model Identification................GI-3 Identification and Location of Controls..........GI-3 Information Labels................. GI-4 CE Marked Centaurs................GI-4 Centaur Specifications................GI-5 Maintenance Chart................. GI-6 Trouble Shooting Chart................GI-7 Torque Specifications................

  • Page 6: General Instructions

    General Information General Information Centaur Service Manual Centaur Service Manual General Instructions Read the servicing instructions in this manual through once before attempting each procedure to familiarize yourself with what is involved. This manual contains servic- ing operations with warnings to the mechanic about potential hazards that can result in personal injury or property damage.

  • Page 7: Model Identification

    Centaur Service Manual General Information Model Identification The vehicle identification plate is fastened to the upper frame to the right of the passenger’s knee. Photo Below The model and serial numbers are stamped into it. Model identification starts with “V”, followed by four numbers and a letter, either G (for gas), D (for diesel), or DT (for turbo diesel).

  • Page 8: Information Labels

    General Information General Information Centaur Service Manual Centaur Service Manual CE marked Centaurs include: • CE marked serial number label • horn, activated from driver’s compartment • the weighted root mean square value for vibration of the vehicle does not exceed 2.5 m/s2 •...
  • Page 9 Centaur Service Manual General Information Ontario Drive & Gear Limited. www.centaur8x8.ca GI-5 (519) 662-2840 FAX (519) 662-2421...
  • Page 10 General Information General Information Centaur Service Manual Centaur Service Manual MAINTENANCE INFORMATION BEFORE EVERY AFTER INITIAL EACH 10hrs. 25hrs. 25hrs. 50hrs. 100hrs. 150hrs. 300hrs. CHECK STEERING LOCKOUT OPERATION CHECK COOLANT LEVEL CHECK FAN BELT TENSION CHECK FUEL LEVEL CHECK TIRE INFLATION CHECK ACCELERATOR PEDAL OPERATION CHECK BRAKE PEDAL OPERATION CHECK STEERING WHEEL TRAVEL...

  • Page 11: Trouble Shooting

    Centaur Service Manual General Information TROUBLE SHOOTING MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION (SYMPTOM) Electric starter inoperative 1. Loose electrical connections 1. Clean and re-tighten electrical connections. 2. Battery charge low or dead 2. Recharge battery or replace as necessary. 3. Faulty starter motor 3.
  • Page 12 General Information General Information Centaur Service Manual Centaur Service Manual TROUBLE SHOOTING MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION (SYMPTOM) Water leaks into lower body 1. Leak has developed at the axle 1. Replace the flange gasket. assembly 2. Lower body is cut or punctured 2.
  • Page 13 Centaur Service Manual General Information Centaur Torque Specifications Section TR Side Cover Bolts..............29.8Nm 22FT. LBS. Hydrostatic Pump Bridge Block Bolts to Transmission..27.1Nm 20FT. LBS. Hydrostatic Drive Sprocket Bushing Set Screws....20.3Nm 25FT. LBS. Section EN Exhaust Manifold to Engine........... 19.0Nm 14FT.
  • Page 14 General Information General Information Centaur Service Manual Centaur Service Manual Master Cylinder Lid Screws................Snug by Hand Section VR Trailer Hitch Mounting Bolts...........27.1Nm 20FT. LBS. Tow Hook Mounting Bolts............33.9Nm 25FT. LBS. Section WA Wheel Nuts................88.2Nm 65FT. LBS. Axle Flange Nuts..............

  • Page 15: General Information

    Centaur Service Manual General Information Flat Rate Schedule Wheels, Axles & Chains Re & Re Drive Chain Front......... .30min. Middle........1hr. Rear.......... .30min. Re & Re Slider Block (Chain Tensioners)......1hr. (Frt & Rear) 1 ½ hr. (Mid) Re & Re Drive Sprocket or Seal (Transmission)....8 hrs. Re &...
  • Page 16 General Information General Information Centaur Service Manual Centaur Service Manual Re & Re Belt Sprocket and Bushing (Hydrostatic Pump)... 3 hrs. Re & Re Transmission............12 hrs. Disassemble and Assemble Transmission......7 hrs Steering Re & Re Steering Assembly..........4hrs Re &...
  • Page 17 Centaur Service Manual General Information Re & Re Driver Clutch............1 hr. Re & Re Driven Clutch............2 hrs Brake System Re & Re Brake Pads (Hydraulic).......... 1 ½ hrs. Re & Re Brake Pads ( Mechanical Parking)......1 ½ hrs. Re &...
  • Page 18 General Information General Information Centaur Service Manual Centaur Service Manual Brand Type Model Cornwell 15/16” ½ D Socket P3230 5/8” ½ D Socket 34020 Proto 16mm ½” D Socket 7416M Proto 19mm ½” D Socket 7419M SK Universal 24mm ½” D Socket 34374 SK Shallow 13mm ½”...
  • Page 19 Centaur Service Manual General Information Philips # 2 82007 Max tech Roberts #1 ————— Maglite Mini Maglite Everst 24oz Ball Pein Hammer ISO-9002 Everst 12oz Ball Pein Hammer ————— ————— Rubber Mallet ————— Stanley Utility Knife 10-989 Bond HUS Gorilla Grip Allen Keys —————...
  • Page 20 General Information General Information Centaur Service Manual Centaur Service Manual 5 Pce. File Set-Fine Flat-90160 5 Pce. File Set Sq. - 90163 5 Pce. File Set Tri. - 90162 Thumb Ratchet 1/4” 49270 Proto 5.5mm Socket 1/4” 6905.5m Craftsman 12mm Socket 1/4” 41338 Bond HUS 1/16”...
  • Page 21 Centaur Service Manual General Information Punches - 1/4” 6908 Punches - 5/16” 6108 Punches - 1/4” 6107 Punches - 3-16” 6106 Punches - 5-32” 6105 Punches - 1/8” 6104 Punches - 3-32” 6103 Pop Tool Huck Gun (Rivets) 045610 Pop Tool Huck Gun (Skid plate Rivets) —————...

  • Page 22: Special Tools

    General Information General Information Centaur Service Manual Centaur Service Manual SPECIAL TOOLS 7R VICE GRIP MODIFICATION As detailed in Section 7, a pair of modified 7R Vice Grips is required to hold the ends of the drive chain together while inserting the connecting link. This tool can also be used to hold the ends of the idler chain together while inserting the connecting link.
  • Page 23 Centaur Service Manual General Information Planet Shaft and Gear Removal For 805-100 Axle Reassembly (Transmission) 658-32 AXLE SERVICE ASM 658-28 PLANET GEAR PULLER ASM Bearing Race Installation Seal Installation (805-100 Axle Assembly) (805-100 Axle Assembly) 658-22 DRIVER, AXLE SEAL 658-21 DRIVER, AXLE BRG. RACE Driver Clutch Removal Driven Clutch Disassembly 658-20 TOOL, DRIVEN CLUTCH SERVICE...
  • Page 24 General Information Centaur Service Manual Ontario Drive & Gear Limited www.centaur8x8.ca GI-20 (519) 662-2840 FAX (519) 662-2421...
  • Page 25 Centaur Service Manual Engine System SECTION EN Engine System Table of Contents Engine Illustration 950D & 950G ............EN-2 Engine Parts List 950D & 950G ............EN-3 Engine Illustration Turbo Diesel (950DT) ..........EN-4 Engine Parts List Turbo Diesel (950DT)..........EN-5 General Instructions................EN-6 Fueling the Vehicle ................EN-7 Throttle Control Cable Assembly ............EN-9 Adjusting the Throttle ................EN-9...

  • Page 26: Engine Illustration 950D & 950G

    Engine System Centaur Service Manual Engine 950D & 950G EN-2 Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 27 Centaur Service Manual Engine System Engine 950D & 950G Ref. Qty. Part # Description 809-162 Tube, Rad Hose Extender 810-89 Hose, Intake 1-7/8”Dia.ID x 9”(26HP Diesel) 810-88 Hose, Intake 1-7/8”Dia.ID x 4.5”(3HP Gas) 100-12 Clamp Gear 1.5” HF-28/30 835008 Filter, Air - B&SD Engine 820263 Filter 811-112...
  • Page 28 Engine System Centaur Service Manual E n g i n e - 9 5 0 D T EN-4 Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 29 Centaur Service Manual Engine System E n g i n e - 9 5 0 D T Ref. Qty. Part # Description 809-162 Tube, Rad Hose Extender 810-109 Hose, Intake 1-7/8”Dia.ID x 33” - DT 848-17 Clamp Gear 1.5” HF-28/30 835008 Filter, Air - B&SD Engine 820263...

  • Page 30: General Instructions

    Engine System Centaur Service Manual General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.

  • Page 31: Fueling The Vehicle

    Centaur Service Manual Engine System Fueling The Vehicle Gasoline and diesel fuel are extremely flammable and can explode under certain conditions. Do not add fuel while the engine is running or hot. If fuel is spilled in, on or around the vehicle, wipe it up immediately. Flush out any fuel spilled in the vehicle with water and allow it to drain out through the drain plug holes.
  • Page 32 Engine System Centaur Service Manual Centaur 950 - Gasoline Use clean, fresh, unleaded gasoline with a minimum of 85 octane. Purchase fuel in quantity that can be used within 30 days to assure fuel freshness. We recommend the use of Briggs &...

  • Page 33: Adjusting The Throttle

    Centaur Service Manual Engine System Throttle Control Vehicle speed is controlled by the accelerator pedal. To increase vehicle speed, press on the accelerator pedal. To decrease vehicle speed, remove pressure on the accelerator pedal. Adjusting The Throttle Cable Assembly With the engine stopped, push accelerator to the floor plate and secure. At the engine check that the throttle arm is fully open.

  • Page 34: Stopping The Engine

    Engine System Centaur Service Manual battery power recover. Never attempt to restart the engine until it completely stops. Always remove key from switch when leaving vehicle unattended or when vehicle is not in use. Release the key as soon as the engine starts: the key will automatically return to the “RUN”...

  • Page 35: Oil, Filter And Lubrication Information

    Centaur Service Manual Engine System Oil, Filter And Lubrication Information ENGINE OIL INFORMATION Checking the Engine Oil Level To check the oil during an operating period, shut the engine off, let it cool down and allow the oil time to drain into the sump before checking the oil level. Position the vehicle so the engine is level.

  • Page 36: Changing The Engine Oil

    Engine System Centaur Service Manual Changing Engine Oil During the initial engine break-in period, change the oil after the first 25 hours of operation. After the break-in period, change the engine oil every 150 operating hours, or more frequently if the vehicle is operated in dusty or dirty conditions. Draining the Engine Oil Each engine is equipped with a drain plug for draining the oil.

  • Page 37: Filter Information ( Oil, Air And Fuel

    Centaur Service Manual Engine System Filter Information Air Filter The Centaur is equipped with a filter element housed in an air cleaner assembly located above the clutch. Check the paper air filter element every 100 hours of operation or more often under extremely dusty or dirty conditions.
  • Page 38 Engine System Centaur Service Manual fuel flows from filter. Tighten drain plug. Bleed air from fuel line. Start engine. Make sure warning light goes out. Check for leaks. To replace fuel filter element: Disconnect sensor wire. Remove drain plug and discard O-ring. Remove fuel filter with filter wrench.
  • Page 39 Centaur Service Manual Engine System Removing The Radiator (Gasoline and N.A. 26 H.P Diesel Engines) Remove the engine access cover and drain the coolant from the radiator by removing the spring clamp and rubber plug from the lower drain spout. Photo EN-1 Before disconnecting any radiator coolant hoses from the liquid cooled system, be prepared to collect any antifreeze that may still be present in the system, even after you have drained the radiator itself.
  • Page 40 Engine System Centaur Service Manual EN-4 EN-5 Lift the radiator assembly from the body. Photo EN-6 Remove the 4 fasteners securing the plastic shroud to the radiator. Remove the 2 bolts fastening the radiator side brackets. Photo EN-7 EN-6 EN-7 Installing The Radiator (Gas or N.A.
  • Page 41 Centaur Service Manual Engine System Reconnect the lower rad hose and extension to the engine and tighten all hose clamps securely. Photo EN-9 After the lower rad hose has been reconnected to the engine, check the gap between the hose, and the top of the poly chain belt of the hydrostatic pump.
  • Page 42 Engine System Centaur Service Manual Turbo Diesel Radiator (950DT) The radiator on the turbo diesel CENTAUR, is a larger capacity radiator, and is installed and configured differently than ones used on the gas (950G) or regular 26 H.P diesel (950D) model versions.
  • Page 43 Centaur Service Manual Engine System Remove the hardware fastening the radiator brackets at 2 locations to the upper frame. Take note of the spacers used on the left mount and be sure that they are reinstalled during assembly. Photo EN-13 Unbolt the radiator bracket at the main vehicle frame at 2 locations.
  • Page 44 Engine System Centaur Service Manual Install the 2 side brackets to the radiator using 4 bolts and flat washers. Install the radiator assembly to the vehicle and bolt into place using the specified hardware detailed in the Centaur Parts Manual. Bolt the radiator at 2 locations on the main vehicle frame as well as the 2 lo- cations on the upper frame.

  • Page 45: Removing The Engine

    Centaur Service Manual Engine System Always disconnect the battery from the electrical system when working on or around engine wiring. Removing the engine Remove the engine cover to access the engine and transmission compartment. Disconnect the battery wiring and remove the battery. Photo EN-18 Remove the transmission cover located in the rear cargo department.
  • Page 46 Engine System Centaur Service Manual Slip the over flow bottle and cap from it’s mount. Photo EN-20 Disconnect the emergency brake cable at the cam by removing the cotter pin and clevis pin. Photo EN-21 Remove both nuts of the “U” bolt mounting bracket and remove the cable. Photo EN- EN-20 EN-21 EN-22...
  • Page 47 Centaur Service Manual Engine System (Diesel Model) Disconnect the throttle cable assembly at the engine linkage. Remove the cotter pin and clevis pin to free the cable. Photo EN-24 10. Remove the tie-wraps that secure the wire harness to the battery holder. Photo EN-25 EN-24 11.
  • Page 48 Engine System Centaur Service Manual EN-29 EN-28 14. Remove the hydrostatic drive belt. Photo EN-29 15. Disconnect the air intake hose at the filter and move it out of the way. Photo EN-30 EN-30 Cut all tie-wraps where necessary to free wiring.
  • Page 49 Centaur Service Manual Engine System 18. Disconnect the trigger coil wiring at the plug. Photo EN-33 This wiring is for ignition timing, as well as the pickup for the tachometer on the gas model. On the diesel, this wiring reads the impulse for the tachometer rpm’s only. Blue connects to the orange/black stripe of the engine harness, and green connects to brown of the harness.
  • Page 50 Engine System Centaur Service Manual EN-38 EN-37 23. Pull back the conduit to locate the connector of the green fuel shut off wire from the carburetor to the harness, and disconnect it. (Gasoline Engine Only) Photo EN-38 24. Disconnect the coil wiring. (Gasoline Engine Only) Blue wire #3 cylinder, Orange wire #2 cylinder and the Red wire to the #1 cylinder.
  • Page 51 Centaur Service Manual Engine System EN-42 EN-41 28. Insert a 6” length of 3/8” steel rod into the opening where the previous mounting bolt was just removed. Photo EN-43 29. Thread a 9/16”-18 x 1 1/8” bolt back into the clutch and tighten it with an impact. As the bolt makes contact with the 3/8”...
  • Page 52 Engine System Centaur Service Manual EN-46 EN-47 32. Disconnect the fuel line to the carburetor (Gas Models) Photo EN-48 33. Disconnect the fuel line inlet and return on the injector pump. (Diesel Models) Photo EN-49 EN-48 EN-49 34. Disconnect the muffler from the mani- fold pipe by removing the 2 springs that fasten them together.
  • Page 53 Centaur Service Manual Engine System EN-52 EN-51 36. Remove the 8 bolts securing the engine to transmission. There are 4 on the front mounting bracket and 4 on the rear mounting bracket. Photo EN-53 Before removing the last 2 mounting bolts, make sure that the engine is supported by an overhead hoist clipped into the engine lift hooks.
  • Page 54 Engine System Centaur Service Manual IMPORTANT When removing the rear bracket, take note of any spacers that have been used between the engine bracket and engine block. Both gasoline and diesel models have (1) spacer on the right hand side of this bracket. Photo EN-55 The gasoline model Centaur has an additional spacer on the left hand side.
  • Page 55 Centaur Service Manual Engine System 42. Remove the air filter intake hose. Remove both gear clamps that fastening it at each end. Photo EN-60 43. Remove the 2 bolts and locknuts securing the air filter and housing. Photo EN-61 44. Unfasten the 3 bolts securing the clutch guard and remove it. Photo EN-62 45.

  • Page 56: Engine Sub-Assembly

    Engine System Centaur Service Manual 47. Remove the upper rad hose and extension tube connected to the top of the thermo- stat. Photo EN-64 48. Remove the lower rad hose and extender tube that is connected to the outlet side of the cooling system.
  • Page 57 Centaur Service Manual Engine System Install the upper rad hose and extension tube to the top of the thermostat. Photo EN-67 Mount the PTO to the flywheel. Apply blue LOCTITE 242 to the threads of each of the 6 fasteners and torque to specifications. Photo EN-68 Reattach the clutch guard with the 3 mounting bolts and blue LOCTITE 242.
  • Page 58 Engine System Centaur Service Manual Install the intake hose from the air filter to the engine and secure each end with a gear clamp. Photo EN-71 There are 2 different lengths of hose depending on the type of engine you have. The gas model Centaur has a 4 ½”...

  • Page 59: Reinstalling The Engine To The Vehicle

    Centaur Service Manual Engine System 10. Install the front and rear engine mounting brackets. These are mounted to the engine block by a total of 15 bolts and lock washers. There are 7 securing the rear bracket and 8 fastening the front bracket. When fastening the rear bracket, make sure to reinstall the shims required between the engine bracket and engine block.
  • Page 60 Engine System Centaur Service Manual EN-77 EN-78 With a new manifold gasket installed, reconnect the exhaust pipe to the engine using the 4 nuts and lock washers required. Photo EN-78 Re-attach the muffler and secure it with the 2 exhaust connector springs. Photo EN- Reconnect the fuel line to the carburetor on the gas model.
  • Page 61 Centaur Service Manual Engine System Install The Driver Clutch To The Engine When mounting the driver clutch to the engine, the drive belt needs to be installed at the same time. Slip the drive belt over the driven clutch at the transmission and then over the driver.
  • Page 62 Engine System Centaur Service Manual Blue Wire to #3 coil (terminal closest to firewall) then yellow ignition wire. Orange wire to #2 coil (terminal closest to firewall) then yellow ignition wire. Red wire to the #1 coil (terminal closest to firewall) then yellow ignition wire. Photo EN-83 10.
  • Page 63 Centaur Service Manual Engine System EN-87 EN-88 EN-89 EN-90 Replug the green starter relay wire back into the relay. Photo EN-88 Reconnect the trigger coil wiring at the plug. Photo EN-89 . This wiring is for ignition timing, as well as the pickup for the tachometer on the gas model. On the diesel model, this wiring reads the impulse for the tachometer rpm’s only.
  • Page 64 Engine System Centaur Service Manual 17. Connect the temperature gauge sensor wire (Pink/red stripe), and the temperature warning light wire (red/white stripe) Photo EN-91 18. Tie-wrap all wiring as necessary to keep away from any hot or moving components. Installing The Hydrostatic Pump Drive Belt 19.
  • Page 65 Centaur Service Manual Engine System 23. Bolt the battery frame back into position using the specified 3 bolts and flat washers. Photo EN-95 24. Install the battery and tie wrap the engine wire harness to the battery frame. Photo EN-96 25.
  • Page 66 Engine System Centaur Service Manual 27. Mount the emergency brake cable to the bracket of the engine cover support using the “U” bolt mounting bracket. Photo EN-99 28. Reattach the emergency brake cable to the cam with the clevis pin and a new cotter pin.
  • Page 67 Centaur Service Manual Engine System SECTION EN Supplement Pages Engine System Ontario Drive & Gear ltd. www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 68 Centaur Service Manual Engine System Engine - 950G From Serial # T12271 EN-2(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 69 Engine System Engine System Centaur Service Manual Centaur Service Manual Engine - 950G From Serial # T12271 Ref. Qty. Part # Description Ref. Qty. Part # Description 809-162 Tube, Rad Hose Extender 807-111 Muffler, Centaur - 950G 810-88 Hose, Intake 1-7/8"Dia.ID x 807-124 Brace, Exhaust - Shield 4.5"...
  • Page 70 Centaur Service Manual Engine System Engine - 950DT From Serial # T12271 EN-4(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 71 Engine System Engine System Centaur Service Manual Centaur Service Manual Engine - 950DT From Serial # T12271 Ref. Qty. Part # Description Ref. Qty. Part # Description 807-127 Cap, Tailpipe 607-103 Spark Arrestor 807-110 Muffler, Centaur 810-109 Hose, Intake 1-7/8"Dia.ID x 807-124 Brace, Exhaust Shield 33"...
  • Page 72 Centaur Service Manual Engine System Engine - 950G From Serial # T12318 EN-6(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 73 Engine System Engine System Centaur Service Manual Centaur Service Manual Engine - 950G From Serial # T12318 Ref. Qty. Part # Description Ref. Qty. Part # Description 809-162 Tube, Rad Hose Extender 807-131 Muffler, 950G & 954G - 810-88 Hose, Intake 1-7/8"Dia.ID x Side Exhaust 4.5"...
  • Page 74 Centaur Service Manual Engine System Engine - 950DT From Serial # T12318 EN-8(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 75 Engine System Engine System Centaur Service Manual Centaur Service Manual Engine - 950DT From Serial # T12318 Ref. Qty. Part # Description Ref. Qty. Part # Description 117-10 Locknut, 10-24 N/I Zn 607-103 Spark Arrestor 807-130 Muffler, 950 & 954DT - Side 810-109 Hose, Intake 1-7/8"Dia.ID x Exhaust...
  • Page 76 Centaur Service Manual Engine System Engine - 34G From Serial # T12384 Ontario Drive & Gear Limited www.centaur8x8.ca EN-10(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 77 Engine System Engine System Centaur Service Manual Centaur Service Manual Engine - 34G From Serial # T12384 Ref. Qty. Part # Description Ref. Qty. Part # Description 809-195 Tube, Lower Rad - Bent -Cent. 807-131 Muffler - Side Exhaust -Gas 810-88 Hose, Intake 1-7/8"Dia.ID x4.5"...
  • Page 78 Centaur Service Manual Engine System Engine - 34DT From Serial # T12384 Ontario Drive & Gear Limited www.centaur8x8.ca EN-12(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 79 Engine System Engine System Centaur Service Manual Centaur Service Manual Engine - 34DT From Serial # T12384 Ref. Qty. Part # Description Ref. Qty. Part # Description 610-119SA Drive Belt - 34 HP 607-103 Spark Arrestor 117-10 Locknut, 10-24 N/I Zn 810-109 Hose, Intake 1-7/8"Dia.ID x 807-130...
  • Page 80 Centaur Service Manual Engine System Engine - 34G From Serial # T12433 Ontario Drive & Gear Limited www.centaur8x8.ca EN-14(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 81 Engine System Engine System Centaur Service Manual Centaur Service Manual Engine - 34G From Serial # T12433 Ref. Qty. Part # Description Ref. Qty. Part # Description 809-195 Tube, Lower Rad - Bent -Cent. 848-16 Clamp Gear - 1.25" Dia HF- 810-88 Hose, Intake 1-7/8"Dia.ID x4.5"...
  • Page 82 Centaur Service Manual Engine System Engine - 34DT From Serial # T12433 Ontario Drive & Gear Limited www.centaur8x8.ca EN-16(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 83 Engine System Engine System Centaur Service Manual Centaur Service Manual Engine - 34DT From Serial # T12433 Ref. Qty. Part # Description Ref. Qty. Part # Description 108-24 Washer .34x.70x.06 Zn 607-103 Spark Arrestor 112-137 HHCS M10x1,25x20mm Zn 810-109 Hose, Intake 1-7/8"Dia.ID x 848-16 Clamp Gear - 1.25"...
  • Page 84 Centaur Service Manual Engine System Ontario Drive & Gear Limited www.centaur8x8.ca EN-18(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 85 Centaur Service Manual Electrical System SECTION ES Electrical System Table of Contents Wiring Diagram (Dash Harness) .............. ES-2 Wiring Diagram (Engine Harness) ............ES-3 Parts List (Wiring) ..................ES-4 Electrical System Illustration (From Serial #..11191) ......FS2(A) Electrical System Parts List (From Serial #..11191) ......FS-3(A) General Instructions ..................
  • Page 86 Electrical System Electrical System Centaur Service Manual Centaur Service Manual Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421 ES-2...
  • Page 87 Centaur Service Manual Electrical System Ontario Drive & Gear Limited www.centaur8x8.ca ES-3 (519) 662-2840 FAX (519) 662-2421...
  • Page 88 Electrical System Electrical System Centaur Service Manual Centaur Service Manual Ref. Qty. Part # Description 613-79 Outlet, 12 Volt DC 127-93 Plug, Black Nylon - 3/8” ID 634-08 Light, Indicator 126-93 Clamp, Nylon wire - ½” ID 120-13 Rivet - 3/16 x 5/8 Black 120-04 Washer, .19x.5x.08 Zn 103-25...

  • Page 89: General Instructions

    Centaur Service Manual Electrical System General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.
  • Page 90 Electrical System Electrical System Centaur Service Manual Centaur Service Manual Electrical System To prevent damage to the electrical system: • Never weld on the vehicle without first disconnecting both positive and negative bat- tery cables. Make sure the part you are welding is properly grounded. •...

  • Page 91: Charging The Battery

    Centaur Service Manual Electrical System Charging the Battery If the battery loses its electrical charge, remove the battery from the Centaur and recharge it with a 12 volt battery charger at the rate of 10-12 amps maximum. The battery should remain on charge until the specific gravity reaches 1.265 on a hydrometer.

  • Page 92: Removing The Dash

    Electrical System Electrical System Centaur Service Manual Centaur Service Manual Dash Wiring The dash wiring of the Gas CENTAUR and Diesel CENTAUR vehicles are similar in many ways with the exception of a few differences obviously to accomodate the diesel setup. Refer to the wiring tables on page ES-15 through 17, to identify each colour coded wire and what they control on the CENTAURS electrical system.
  • Page 93 Centaur Service Manual Electrical System Lay the dash into the drivers compartment while disconnecting the necessary wiring to free the dash from the vehicle. Photo ES-5 Unplug the connector that houses the 6 gauge positive and negative cable connection to the battery. Photo ES-6 Disconnect the main dash wire harness from the engine harness.
  • Page 94 Electrical System Electrical System Centaur Service Manual Centaur Service Manual ES-9 ES-10 10. Disconnect the wiring from the windshield wiper switch. Photo ES-11 11. Unplug the headlamp wiring feeds for both high and low beam. Photo ES-12 ES-11 ES-12 12. Remove the dash from the vehicle. Photo ES-13 The procedure for removing the the dash from the gas vehicle is the same with the exception of the choke cable which needs to be disconnected AT THE ENGINE.

  • Page 95: Installing The Dash

    Centaur Service Manual Electrical System Installing The Dash Lay the assembled dash in front of the seat of the CENTAUR to reconnect all wiring before mounting it in place. Photo ES-15 Reconnect the front headlamp wiring. The pink and white wiring from the headlamps will plug into the pink and white wiring from the dash.
  • Page 96 Electrical System Electrical System Centaur Service Manual Centaur Service Manual Reconnect the cargo compartment light. This wire runs in a separate conduit from the rear cargo headlamp. On some models this wire is colour coded pink, later models will be orange. Plug this wire into the orange wiring of the harness. Photo ES-19 Plug all brown ground wires back into the ground bar which is riveted to the dash.

  • Page 97: Replacing A Headlamp/Bulb

    Centaur Service Manual Electrical System 10. Fasten the dash along the front with the self tapping screws and secure tightly. Avoid over tightening the screws or you may strip them. Photo ES-25 11. Install the cover plate at the shift box. Photo ES-26 12.

  • Page 98: Removing The Starter Motor

    Electrical System Electrical System Centaur Service Manual Centaur Service Manual ES-28 ES-29 To remove the bulb from the lens turn the bulb 1/4 turn counter-clockwise and pull straight out. Photo ES-30 Removing the Starter Motor Disconnect the wiring from the battery and remove from the vehicle.

  • Page 99: Colour Code Wire Chart For The Centaur Electrical System

    Centaur Service Manual Electrical System Colour Code Wire Chart for the CENTAUR Electrical System NOTE* Number in circle corresponds to photo’s on pages ES-18,19 & 20 Electrical Component Associated Wire Colour Code Sensor Wire from Tank (Green/Yellow Stripe) Ground Wire (Brown) Gas Gauge Ignition Wire...
  • Page 100 Electrical System Electrical System Centaur Service Manual Centaur Service Manual Colour Code Wire Chart for the CENTAUR Wire System Electrical Component Associated Wire Colour Code Power (Red) Power- Switch Side to Horn (Purple) Horn Ground at Horn (Brown) Sensor Wire from Engine (Red/White Stripe) High Temp.
  • Page 101 Centaur Service Manual Electrical System Electrical Component Associated Wire Colour Code Power to Solenoids (Yellow from Ignition) Fuel Shut Off (Both Gas & Diesel Models) Ground to Firewall (Brown) Power to Coils (Yellow from Ignition) Engine Timing (Red #1 coil) Ignition Coils (Gas only) (Orange #2 coil) (Blue #3 coil)

  • Page 102: Electrical Components Of The Centaur Vehicle (Photo's

    Electrical System Electrical System Centaur Service Manual Centaur Service Manual Electrical Components of the CENTAUR Vehicle Temperature Gauge and Warning Light Alternator Wiring Trigger Coil at Crank Shaft Pulley Starter Relay Starter Main Cable Fuel Shut Off (GasOnly)& Oil Pressure Ontario Drive &...
  • Page 103 Centaur Service Manual Electrical System Electrical Components of the CENTAUR Vehicle Fuel Shut Off (Gasoline Models) Ignition Coils (Gasoline Models) Electric Fuel Pump (Gasoline Model) Fuel Gauge Fuel Filter System (Diesel Models) Glow Plug Preheat (Diesel Models) Ontario Drive & Gear Limited www.centaur8x8.ca ES-19 (519) 662-2840 FAX (519) 662-2421...
  • Page 104 Electrical System Electrical System Centaur Service Manual Centaur Service Manual Electrical Components of the CENTAUR Vehicle Fuel Shut off (Diesel) Horn Rear Cargo Light Interior Light Back Up Alarm Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421 ES-20...

  • Page 105: Diesel Powered Centaur Wiring At Firewall

    Centaur Service Manual Electrical System Diesel Powered CENTAUR Wiring at Firewall (Glow Plug Timer & Relay) There are (5) grounds to the firewall 1.Ground from glow plug timer 2.Ground from trigger coil 3.Ground from fuel filter system 4.Ground from battery 5.Ground from fuel float Ontario Drive &...
  • Page 106 Electrical System Electrical System Centaur Service Manual Centaur Service Manual Gas Powered CENTAUR at the Firewall (Ignition Module) There are (4) grounds to the firewall 1.Ground from Electric Fuel Pump 2.Ground from Igniter Box 3.Ground from battery 4.Ground from fuel float Ontario Drive &...
  • Page 107 Centaur Service Manual Electrical System Wiring of Micro Switches for Reverse Alarm System and Neutral Safety This view of the micro switches is taken from the front of the shifter assembly. You must remove the front left low beam headlamp to view the wiring (correctly) from this perspective. Ontario Drive &...
  • Page 108 Electrical System Electrical System Centaur Service Manual Centaur Service Manual Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421 ES-24...
  • Page 109 Centaur Service Manual Electrical System Ontario Drive & Gear Limited www.centaur8x8.ca ES-25 (519) 662-2840 FAX (519) 662-2421...

  • Page 110: Calibrating The Tachometer

    Electrical System Electrical System Centaur Service Manual Centaur Service Manual Calibrating the Tachometer The tachometer is initially calibrated at the factory during production, but if for some reason it needs to be re-calibrated or replaced with a new one, these procedures must be followed to achieve the correct RPM readout from the engine which powers the CENTAUR vehicle.
  • Page 111 Centaur Service Manual Electrical System Upon releasing the contact, the LED will begin flashing digits starting from the right. The first digits will be .00 As long as the contact remains unpressed, the digits will blink 4 times then move on to the next number. Leave the first set of digits at .00 and wait until the “5”...
  • Page 115 Centaur Service Manual Electrical System SECTION ES Supplement Pages Electrical System Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 116 Electrical System Centaur Service Manual Electrical System From Serial # ..11191 ES-2(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 117 Centaur Service Manual Electrical System Electrical System From Serial # ..11191 Ref. Qty. Part # Description 613-90 Outlet, 12 Volt DC 127-93 Plug, Black Nylon - 3/8" ID 634-08 Light, Indicator 126-93 Clamp, Nylon wire - ½" ID 120-13 Rivet - 3/16 x 5/8 Black 120-04 Washer, .19x.5x.08 Zn 103-25...
  • Page 118 Electrical System Centaur Service Manual Electrical System From Serial # ..12340 ES-4(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 119 Centaur Service Manual Electrical System Electrical System From Serial # ..12340 Ref. Qty. Part # Description 613-90 Outlet, 12 Volt DC 127-90 Plug, Black Nylon - 3/8" ID 634-08 Light, Indicator 126-93 Clamp, Nylon wire - ½" ID 120-13 Rivet - 3/16 x 5/8 Black 120-04 Washer, .19x.5x.08 Zn 103-25...
  • Page 120 Electrical System Centaur Service Manual ES-6(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 121 Centaur Service Manual Brake System SECTION BR Brake System Table of Contents Hydraulic Brake Caliper Illustration and Parts List ......BR-3 Mechanical Brake Caliper Illustration and Parts List ......BR-4 General Instructions ................BR-5 Brake System Maintenance ..............BR-6 Brake Pad Inspection ................BR-7 Removing Brake Pads (Hydraulic) ............BR-7 Installing Brake Pads (Hydraulic) ............BR-8 Servicing Mechanical Brake Calipers (Parking Brake) ......BR-9 Brake Caliper Removal (Mechanical) ...........BR-9...
  • Page 122 Brake System Centaur Service Manual SECTION BR Brake System Table of Contents Continued MasterCylinder Servicing ..............BR-30 Master Cylinder Reassembl ..............BR-30 Master Cylinder Installation ..............BR-31 Inspecting the Hydraulic Brake Line ...........BR-33 Replacing the Hydraulic Brake Line ............BR-34 Brake Fluid Inspection ................BR-35 Changing the Brake Fluid ..............BR-36 Ontario Drive &...
  • Page 123 Centaur Service Manual Brake System Hydraulic Caliper Ref. Qty. Part # Description 166-01RM Caliper, Brake- w/o pads (incl. Refs 3,4,5,6,8 -11) 161-01 O-Ring Kit, Caliper (incl. Refs 4 & 5) 160-40 SHCS M8 x 1,25 x 40 Zinc Seal, Rubber-5mm (see Ref 2) Seal, Piston-41mm (see Ref 2) 168-05 Piston 41mm...
  • Page 124 Brake System Centaur Service Manual Mechanical (Emergency Brake) Ref. Qty. Part # Description 112-20 HHCS M8x1,25x25mm Zinc 108-05 Lockwasher 5/16 Split-Ring Zinc 103-29 HHCS 5/16-24x2.75 GR8 Zinc 103-16 HHCS 5/16-24x3.75 GR8 Zinc 610-111 Hub, Disc Brake - Splined (note c) 610-116 Hub, Disc Brake - Splined (note b) 107-02...

  • Page 125: General Instructions

    Centaur Service Manual Brake System General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.

  • Page 126: Brake System Maintenance

    Brake System Centaur Service Manual Brake System Maintenance Regular maintenance of the brake system is essential to both good vehicle per- formance and personal safety. Poorly maintained brakes can result in a decrease in braking efficiency, vehicle performance or damaged brake discs. Maintenance schedule Every 25 hours of vehicle operation, perform the servicing procedure, Brake Pad Inspection ( Mechanical) on page BR-7...

  • Page 127: Brake Pad Inspection

    Centaur Service Manual Brake System Brake Pad Inspection Replace the brake pads if: • Pad thickness is less than 0.10” (Hydraulic Brake Pads) • Pad thickness is worn to (1/8”) 3mm. ( Mechanical Parking Brake Pad). • The pads are glazed over and brake performance is affected. •...

  • Page 128: Installing Brake Pads (Hydraulic

    Brake System Centaur Service Manual Installing Brake Pads When replacing worn or contaminated pads, replace both pads in the brake caliper assembly even if both pads do not require replacing. Using one new and one old brake pad in a caliper assembly may BR-3 provide poor braking performance.

  • Page 129: Servicing Mechanical Brake Calipers (Parking Brake

    Centaur Service Manual Brake System Servicing Mechanical Brake Calipers ( Parking Brake) Inspect the parking/emergency brake system periodically to ensure proper performance. Service either by cable/caliper adjustment or brake pad replacement The mechanical brake caliper assembly or pads need adjustment or servicing when: •...

  • Page 130: Brake Pad Removal (Mechanical

    Brake System Centaur Service Manual BR-4 BR-5 BR-6 BR-7 Remove the inside caliper from the bracket and slip the second compression spring off as well. Brake Pad Removal ( Mechanical) Perform the servicing procedure, Brake Caliper Removal on page BR-9 Using a drill and a 1/8”...

  • Page 131: Brake Pad Installation (Mechanical

    Centaur Service Manual Brake System When replacing worn or contaminated pads, replace both pads in the brake caliper assembly even if both pads do not require replacing. Using one new and one old brake pad in a caliper assembly may provide poor braking performance. Brake Pad Installation ( Mechanical) Rivet the new pads to the caliper using a pop riveting tool capable of drawing them tightly into place.
  • Page 132 Brake System Centaur Service Manual BR-12 BR-11 BR-14 BR-13 Install the mechanical brake caliper assembly to the mounting boss on the transmission using 2 bolts and 2 lock washers. LOCTITE the threads with blue 242 LOCTITE. Torque to specifications Photo BR-15 Reattach the parking cable linkage to the brake cam and fasten with the clevis pin and cotter pin.

  • Page 133: Brake Disc Inspection

    Centaur Service Manual Brake System BR-15 BR-16 Brake Disc Inspection Maintenance Schedule - Inspect every 50 Hours Brake Disc Condition Corrective Action Servicing Procedure Page Rust or Pitting Brake Disc Removal BR-14 Bends or Cracks Replace Immediately Brake Disc Installation BR-15 Scratches or Scoring Glazing...

  • Page 134: Brake Disc Removal/Hub Removal

    Brake System Centaur Service Manual Brake Disc Removal/Hub Removal Remove the engine hood assembly Raise the vehicle off the ground. Disconnect the emergency brake cable at the mechanical caliper by removing the cot- ter pin that secures the clevis pin to the brake cam. Photo BR-16 (previous page) Remove the 3 locknuts holding the mechanical calipers together and remove the cam.

  • Page 135: Brake Disc/Hub Installation

    Centaur Service Manual Brake System BR-19 BR-20 Lower the vehicle to the ground and put it into gear. Remove the 4 hex head fasteners and lock washers that attach the brake disc to the hub. Photo BR-20 Remove the disc and perform the procedure, Brake Disc Inspection on page BR-13 10.
  • Page 136 Brake System Centaur Service Manual Attach the new or cleaned brake disc using 4 M6 capscrews and lock washers. LOCTITE the threads of the bolts with blue loctite 242 or equivalent and torque to specifications. Photo BR-22 Remount the hydraulic caliper to the transmission by aligning the access hole in the brake disc with that of the threaded mounting boss on the transmission.
  • Page 137 Centaur Service Manual Brake System Fasten with the 3 locknuts. 2 are threaded to the brake cam as jam nuts, and 1 is threaded on the rear bolt as the adjustment lock. Reattach the emergency cable linkage to the brake cam and fasten with the clevis pin and cotter pin.

  • Page 138: Adjusting The Parking Brake Cable

    Brake System Centaur Service Manual Using 2 open ended wrenches, tighten the outer nut of the cam, to the inner jam nut. Photo BR-30 Re-check the rear locknut and bolt to see if it still turns freely by hand and adjust ac- cordingly.

  • Page 139: Hydraulic Brake Calipers

    Centaur Service Manual Brake System Start up and drive the vehicle for 10 minutes. Stop the engine and check that the parking brake caliper has not been dragging. A strong “brake material” smell and a very hot brake disc would indicate that the parking brake caliper is adjusted too tight. Re-adjust if necessary.

  • Page 140: Remove Hydraulic Brake Caliper

    Brake System Centaur Service Manual Remove Hydraulic Brake Caliper Remove the engine hood assembly. Raise the vehicle off the ground Disconnect the steel brake line at the caliper. Photo BR-32 Be aware of the brake fluid present in the system. Use a rag or small container to collect any fluid that may drain from the system Line up the hole provided in the brake disc, with the hex mounting bolts that secure the hydraulic brake caliper to the transmission housing.
  • Page 141 Centaur Service Manual Brake System Remove the piston from each half by applying compressed air (Max. 20 psi or less), to the hydraulic hose inlet. Place a rag in between the caliper to absorb the shock of the piston when it pops from the caliper. Photo BR-34 Work on a CLEAN dry surface.

  • Page 142: Hydraulic Brake Caliper Reassembly

    Brake System Centaur Service Manual Remove the bleed screws and check the steel ball from the caliper casting. Photo BR-38 Clean all components with alcohol or a mild soap solution. Use compressed air to blow out the caliper castings. This will free up any dirt or other con- BR-38 taminants you couldn’t reach with the cloth.
  • Page 143 Centaur Service Manual Brake System Place the caliper castings on a clean workbench so that the interior is facing up. Photo BR-39 Insert the rubber seals into each half of the caliper casting. Photo BR-40 Do not scratch or tear the seals during installation. Any damaged seal must be replaced immediately.

  • Page 144: Hydraulic Brakecaliper Installation

    Brake System Centaur Service Manual Reinstall the 4 socket head bolts which hold the caliper assembly together. Use blue LOCTITE on the threads of the fasteners. Torque the bolts to the specified torque. Photo BR- 43 Place the check ball, bleeding screw and rubber plug back into the threaded mount of the caliper casting.

  • Page 145: Bleeding The Hydraulic Brake System

    Centaur Service Manual Brake System Bleeding the Hydraulic Brake System Clean the master cylinder casing and caliper casting and fittings. This will prevent dirt from contaminating the brake system. Contaminants in the brake fluid can damage components or cause premature wear to them. This will result in a loss of braking effectiveness.
  • Page 146 Brake System Centaur Service Manual Add only fresh clean Dot 5 silicon brake fluid. Old fluid will contaminate the system, and other types of brake fluid may not be compatible with the brake system’s components. Remove the rubber plug from the bleeding screw . With the bleed screw still tight, purge any air from the system by pumping the brake pedal at the front of the vehicle.

  • Page 147: Master Cylinder Removal

    Centaur Service Manual Brake System Master Cylinder Removal Clean the master cylinder casting and caliper casting and fittings. This will prevent dirt from contaminating the brake system. Contaminants in the brake fluid can damage components or cause premature wear. This will result in a loss of braking effectiveness.

  • Page 148: Master Cylinder Disassembly

    Brake System Centaur Service Manual Loosen the bolt that secures the brake pedal assembly at the steering box lower adjuster assembly, Photo BR-50, and push the brake pedal sideways to the right and free of the welded rod stop. Rotate the brake pedal up. Remove the 2 locknuts from the bolts that fasten the master cylinder into position, and slide the bolts out.
  • Page 149 Centaur Service Manual Brake System Remove the Brake line fitting and union, along with the copper sealing washers. Dis- card the copper washers. Always use new washers when restoring the brake line to the brake system. Remove the piston and return spring. Photo BR-54 Do not use a gripping tool to pull out the piston as this will scratch or damage the surface.

  • Page 150: Mastercylinder Servicing

    Brake System Centaur Service Manual Master Cylinder Servicing Thoroughly inspect all components of the master cylinder assembly and replace any worn, cracked or broken parts. Use only genuine CENTAUR parts Inspect the condition of the piston. Replace the piston immediately if it is: •...

  • Page 151: Master Cylinder Installation

    Centaur Service Manual Brake System Install the compression spring on to the piston. Make sure the small end of the spring is mated to the piston. Photo BR-56 Install the piston into the piston bore. Slide the end with the primary seal in first. Photo BR-57 Install the brake line fitting to the master cylinder using 3 new copper washers.
  • Page 152 Brake System Centaur Service Manual Be sure that the flat washer spacers are installed to the inside of the mounting bolts before pushing them completely through the throttle brake supports . Photo BR-61 illustrates the master cylinder mounting in it’s sub-assembly stage to illustrate more clearly where these washers are installed.

  • Page 153: Inspecting The Hydraulic Brake Line

    Centaur Service Manual Brake System BR-64 BR-65 Connect the throttle cable linkage at the pedal and slip the gas pedal assembly back through the throttle brake supports making sure the 3 spacers are installed to the inside. Place the outside washer on the other end and secure it with a new cotter pin. Do not reuse the old cotter pin.

  • Page 154: Replacing The Hydraulic Brake Line

    Brake System Centaur Service Manual Replacing the Hydraulic Brake Line Photo BR-69 &70 illustrate the routing of the steel brake line from the front master cylinder to the rear caliper. The steel line is in 2 sections with 1 union at the master cylinder and 1 close to the Upper Frame - Cross Frame Assembly.

  • Page 155: Brake Fluid Inspection

    Centaur Service Manual Brake System Brake Fluid Inspection Do not allow brake fluid to contact your eyes, clothes, or painted surfaces. Brake fluid is extremely corrosive and can cause severe personal injury. Wear protective eye goggles, gloves and clothing. If brake fluid contacts your eyes, consult a physician immediately.

  • Page 156: Changing The Brake Fluid

    Brake System Centaur Service Manual Inspect the condition of the brake fluid and replace if: • the fluid appears cloudy • the fluid appears discoloured • the fluid contains particles of dirt, rust, water, or other contaminants • the level is below the viewing window If any of these conditions are noted, Perform the servicing procedure, Changing the Brake Fluid below Changing the Brake Fluid...
  • Page 157 Centaur Service Manual Brake System SECTION BR Supplement Pages Brake System Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 158 Brake System Centaur Service Manual Brake System From Serial # ..12340 EN-2(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 159 Centaur Service Manual Brake System Brake System From Serial # ..12340 Ref. Qty. Part # Description 166-10 Caliper, Hydraulic Brake - L 161-01 O-Ring Kit, Caliper (incl. Refs 4 & 5) 160-40 SHCS M8 x 1,25 x 40 Zn Seal, Rubber-5mm (see Ref 2) Seal, Piston-41mm (see Ref 2) 168-05 Piston 41mm...
  • Page 160 Brake System Centaur Service Manual EN-4(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 161 Centaur Service Manual Clutch System SECTION CS Clutch System Table of Contents Driven and Driver Clutch Illustration (Prior to S/N 0301191)..CS-2 Driven and Driver Clutch Parts List (Prior to S/N 0301191).... CS-2 Driven and Driver Clutch Illustration (From S/N 0301191)..Sup. CS-2(A) Driven and Driver Clutch Parts List (From S/N 0301191)..Sup.
  • Page 162 Clutch System Clutch System Centaur Service Manual Centaur Service Manual Clutches Ref. Qty. Part # Description 0405-0041 Flange, Fixed 0410-0006 Flange, Sliding Spring Guide Washer V10-48-103-18 Spring, Standard Diesel (26 h.p) V10-57-077-22 Spring, Gas & Turbo Diesel (31 h.p) 0440-0002 Spring Cover 420-2453-700 Lockwasher...

  • Page 163: General Instructions

    Centaur Service Manual Clutch System General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.

  • Page 164: Maintenance Information

    Clutch System Clutch System Centaur Service Manual Centaur Service Manual Maintenance Information The maintenance information provided in this manual refers to a CENTAUR vehicle operating under normal conditions and use. Service more often when the vehicle is used under heavy duty applications.

  • Page 165: Removing The Drive Belt

    Centaur Service Manual Clutch System Check the condition of the belt in the table below and perform the necessary servicing procedure. Belt Condition Problem Servicing Procedure Driver Clutch Servicing Clutch Malfunction Glazed Sides Lubricant Contamination Driven Clutch Servicing Replacing the Drive Belt Wrong Drive Belt Torn Underchords Replacing the Drive Belt...

  • Page 166: Driver Clutch Removal

    Clutch System Clutch System Centaur Service Manual Centaur Service Manual Inspect the exterior of the driver clutch. Remove and service the driver clutch if: • the clutch plates have tracking grooves caused by drive belt action. • the clutch plates are bent or cracked. •...

  • Page 167: Disassembling The Driver Clutch

    Centaur Service Manual Clutch System CS-4 CS-5 Disassembling The Driver Clutch IMPORTANT The driver clutch weights and spring, have been calibrated by the manufacturer to give optimum results for the model CENTAUR it is installed on. This is a fixed setting and there is no need for further adjustment.
  • Page 168 Clutch System Clutch System Centaur Service Manual Centaur Service Manual CS-8 CS-9 This cap is under spring tension and will fly apart if precautions are not taken to hold it down while the screws are removed. Be sure to always wear eye protection when servicing the clutches, or any other vehicle component for that matter, with the potential of flying parts.

  • Page 169: Assembling The Driver Clutch

    Centaur Service Manual Clutch System Assembling The Driver Clutch Lay the movable face on a clean workbench and install the spring guide washer. Photo CS-11 Referring to your CENTAUR parts manual, place the correct spring for the model you are working on into the movable face. Photo CS-12 Apply blue 242 LOCTITE to each thread of the (3) fasteners that secure the spring cap to the movable face.
  • Page 170 Clutch System Clutch System Centaur Service Manual Centaur Service Manual CS-15 CS-16 Install the cap over the weights and blocks making sure that the blocks are aligned with the guides riveted into the cap. Photo CS-17 Before installing and tightening the flat washer and nut, be certain that hexagon shaped hole in the cap is mated to the one at the base of the threaded shaft.

  • Page 171: Installing The Driver Clutch

    Centaur Service Manual Clutch System Installing The Driver Clutch 10. When mounting the driver clutch to the engine, the drive belt needs to be installed at the same time. Slip the drive belt over the driven clutch at the transmission and then over the driver.

  • Page 172: Driven Clutch Disassembly

    Clutch System Clutch System Centaur Service Manual Centaur Service Manual Remove the engine access hood. Perform the servicing procedure, Drive Chain Removal on page WA-7 Remove the bolt, lock washer and flat washer securing the clutch to the input shaft and slide it free of the vehicle.
  • Page 173 Centaur Service Manual Clutch System Remove the cam and key from the key way. Photo CS-25 Slide the movable face from the fixed pulley. Photo CS-26 Remove the retaining ring and spacer from the shaft of the fixed pulley. Photo CS-27 10.

  • Page 174: Driven Clutch Reassembly

    Clutch System Clutch System Centaur Service Manual Centaur Service Manual CS-29 CS-30 CS-31 CS-32 14. Perform the servicing procedure, Driven Clutch Inspection on page CS-11 Driven Clutch Reassembly Press each of the new cam shoes back into the movable face clutch. Originally, the larger bushing of the movable face was staked to secure it into place.
  • Page 175 Centaur Service Manual Clutch System CS-33 CS-34 CS-35 CS-36 Slip the movable face back on to the fixed pulley. Photo CS-37 Slide the small key to the key way of the fixed shaft. Photo CS-38 CS-37 CS-38 There are 4 spring tension adjustment holes in the cam that are numbered 1 through 4. Insert the one end of the cam spring into the number 1 hole.
  • Page 176 Clutch System Clutch System Centaur Service Manual Centaur Service Manual 10. There are 3 holes within the movable face pulley, one of which is drilled bigger to accept the other end of the spring. Photo CS-40 11. Install the cam and spring to the fixed face shaft, lining up the other end of the cam spring with the hole in the movable face.

  • Page 177: Testing The Spring Load Of The Driven Clutch

    Centaur Service Manual Clutch System CS-43 CS-44 13. Slip the 3 spacers over the end of the fixed shaft and install the retaining ring. Make sure that the retaining ring is seated to the groove. Failure to guarantee that it is seated, could result in personal injury while handling the clutch or damage to the vehicle once installed.
  • Page 178 Clutch System Centaur Service Manual Installing The Driven Clutch to the Transmission Apply anti-seize compound to the input shaft of the transmission and slide the key on to the key way. Install the driven clutch to the input, lining up the key ways and securing it with the specified hardware as listed in your CENTAUR parts manual.

  • Page 179: Clutch System

    Centaur Service Manual Clutch System SECTION CS Supplement Pages Clutch System Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 180 Clutch System Centaur Service Manual Ref. Qty. Part # Description 0405-0066 Flange, Fixed 0410-0025 Flange, Sliding 0150-1014 Spring Guide Washer 0151-1005 Spring 0440-0005 Spring Cover 420-2453-700 Lockwasher 0080-0021 Screw, Cap 0130-3008 Block 0135-2035 Weight (400gr) 0115-3042 0080-0162 Washer, Zinc V16J1 5105-0018 Flange, Fixed as req...
  • Page 181 Centaur Service Manual Wheels, Axles & Chains SECTION WA Wheels, Axles and Chains Table of Contents Frame and Lower Body Illustration (Prior to S/N 0301191) ..WA-3 Frame and Lower Body Parts List (Prior to S/N 0301191) ..... WA-4 Frame and Lower Body Illustration (From S/N 0301191)..Sup. WA-2(A) Frame and Lower Body Parts List (From S/N 0301191)..Sup.
  • Page 182 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Table of Contents Removing a Drive Sprocket(Axles) (Prior to S/N 0301191) ...... WA-19 Removing a Drive Sprocket(Axles) (From S/N 0301191) ....Sup. WA -15(A) Installing the Drive Sprocket (Prior to S/N 0301191)........ WA-20 Installing the Drive Sprocket (From S/N 0301191)....
  • Page 183 Centaur Service Manual Wheels, Axles & Chains Ontario Drive & Gear Limited www.centaur8x8.ca WA-3 (519) 662-2840 FAX (519) 662-2421...
  • Page 184 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Frame and Body Prior to mid December of 2001 Before S/N 0112076 Prior to mid December of 2001 Before S/N 0112076 Ontario Drive & Gear Limited www.centaur8x8.ca WA-4 (519) 662-2840 FAX (519) 662-2421...
  • Page 185 Centaur Service Manual Wheels, Axles & Chains Ref. Qty. Part # Description 805-120 Cap, Bearing Dust - 2.0 Plated 108-40 Washer .68x1.77x.16 Zinc 117-72 Locknut, Nylon - M16 x 1,5 Zn 805-113 Sprocket Asm, Rear 805-108 Bushing, 1.97 Od, 1.82 Id x .46 117-62 Nut, Hex M10x1,5 Zinc 108-67...
  • Page 186 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Axle Assembly Ref. Qty. Part # Description 102-27 Seal, Oil 50x72x8 Dbl Lip 101-76 Bearing, Tapered Roller 32008X 805-101SA Housing Asm, Axle 127-85 Plug, Drain - M10 x 1,0 805-106 Axle -17T Spline 112-81...

  • Page 187: General Instructions

    Centaur Service Manual Wheels, Axles & Chains General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.

  • Page 188: Drive Chain Maintenance

    Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Drive Chain Maintenance Regular maintenance of the drive chains is essential to both good vehicle perform- ance and personal safety. Poorly maintained chains can result in rusted, corroded or seized up chains, damaged sprockets, and costly repair bills.

  • Page 189: Drive Chain Removal

    Centaur Service Manual Wheels, Axles & Chains Drive Chain Removal Remove the related floor pan(s) to access the desired chain(s) to be repaired or re- placed. If you are removing the chains on the middle front and/or middle rear axles to service the sprockets or axles, the Lower Baffle in front of the gas tank, and the Transmission Cover behind the transmission, will need to be removed to gain easier access to the components of these assemblies(Sprockets, dustcaps, axle flange bolts etc.).

  • Page 190: Drive Chain Inspection

    Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Drive Chain Inspection: Please refer to Roller Chain Tension on Supplement Page WA-8(a) at the end of section WA for a guide to assessing adequate chain slack. Roller chain “stretch”...

  • Page 191: Drive Chain Lubrication

    Centaur Service Manual Wheels, Axles & Chains The front and middle/front chains are tightened in this manner: Snug up the chain tensioner bolt. Insert a suitable piece of square stock metal into the top of the chain tensioners guide. This will make contact with the square nut be- low and allow it to be pushed further down while striking it with a mallet from the top.

  • Page 192: Drive Chain Cleaning

    Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Drive Chain Cleaning Maintenance Information - Clean every 100 operating hours. Perform the servicing procedure, Drive Chain Removal on Page WA- 7 until all of the drive chains have been removed. Clean all drive chains by soaking in a strong solvent bath such as varsol.

  • Page 193: Quickadjust Chain Tensioners

    Centaur Service Manual Wheels, Axles & Chains To Replace a Slider Block Remove the floor pans. Loosen the 16mm tensioner bolt and re- move. Remove the washer and slider block from the bolt as illustrated to right. Remove the bushing from within the WA-7 slider block.
  • Page 194 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Removing and Installing the Front and Rear Chain Tensioners (Quick Adjust) Perform the servicing procedure, Drive Chain Removal on page WA-7 Front Chain Tensioners Remove the 2 jam nuts located at the bottom of the threaded tension rod on the front 4 chain tensioners and slide the assembly up and out of the guide.
  • Page 195 Centaur Service Manual Wheels, Axles & Chains Drop both front and rear chain tensioner assemblies into the welded chain tensioner guides of the frame, lining up the machined slots of the chain adjuster spindles with the channel in the frame guide. Photo WA-13 The front 4 chain tensioner assemblies requires 2 jam nuts to be installed to the lower part of the tensioner rod.
  • Page 196 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Remove the hydraulic brake caliper by lining up the hole provided in the brake disc, with the (2) hex mounting bolts that secure the hydraulic brake caliper to the transmis- sion housing.
  • Page 197 Centaur Service Manual Wheels, Axles & Chains WA-18 WA-19 Remove the (4) mounting bolts and locknuts securing the transmission to the left and right hand side transmission mount bracket assemblies. Photo WA-19 You will need to disconnect the rear shifter cables at the transmission before moving the engine/transmission to a work bench area.
  • Page 198 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual 12. Remove the retaining ring and discard. Photo WA-21 13. Remove the (2) sprocket assemblies on each output shaft of the transmission. Transmission Drive Sprocket Installation WA-21 14.
  • Page 199 Centaur Service Manual Wheels, Axles & Chains 18. Gently lower the power pack down into the vehicle lining up the mounting holes of the transmission, with those of the rear left and righthand side mounting brackets, and the single mount bracket to the front. Secure with the specified hardware. 19.
  • Page 200 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual 23. Reattach the steering cable linkage at the lever using the clevis pin and a new cotter pin. Photo WA-26 24. Reinstall the left and right hand side transmission covers. Photo WA-27 WA-26 WA-27 25.
  • Page 201 Centaur Service Manual Wheels, Axles & Chains Perform the servicing procedure, Drive Chain Removal on page WA-7 Pry the dust cap off the sprocket end and discard. Photo WA-30 on page WA-20 Remove the locknut and flat washer securing the sprocket to the spline of the inner axle - 17T spline.
  • Page 202 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual The Centaur axle assembly is a sealed unit partly filled with 80W/90 gear lube Hypoy- C or a suitable 80W/90 gear oil with an EP rating for Extreme Pressure. Remove the tire from the axle to be disassembled.
  • Page 203 Centaur Service Manual Wheels, Axles & Chains WA-31 WA-32 WA-33 WA-34 Remove the axle assembly from the vehicle. Set aside the mounting hardware and inner flange for reassembly later. Axle Disassembly Secure the axle assembly in a vise with aluminum jaws for ease of disassembly. Photo WA-35 10.
  • Page 204 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual WA-36 WA-37 WA-38 WA-39 14. Remove the inner axle - 17T spline from the outer housing. Photo WA-40 15. Remove the outer seal. Photo WA-41` 16. Remove the tapered bearing from the wheel hub side. Photo WA-42 WA-40 WA-41 Ontario Drive &...
  • Page 205 Centaur Service Manual Wheels, Axles & Chains WA-42 WA-43 17. Remove the inner bearing races from both ends of the housing. Using a long punch and hammer, tap the races from behind through the machined notches within the housing cover. Photo WA-43 18.
  • Page 206 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Press the tapered bearing on and up to the shoulder of the inner axle 17T spline. Orient the bearing as in Photo WA-47. WA-46 WA-47 Install both bearing races into each end of the axle housing using a press and suitable installation tool.
  • Page 207 Centaur Service Manual Wheels, Axles & Chains WA-50 WA-51 WA-52 IMPORTANT WA-53 Always make sure that all races, seals and bearings have been properly seated to their respective shoulders within the housing. Failure to observe this could result in premature wear, leaks, or an extra rework job not planned on.
  • Page 208 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Assemble the hub to the splined end of the axle shaft. Apply a light coat of white axle grease to the “V” seal on the hub. Rotate the housing in a back and forth motion to seat the seal properly and prevent any deforming of it while it mates into the oil seal within the housing.
  • Page 209 Centaur Service Manual Wheels, Axles & Chains WA-58 WA-59 11. Place the assembly into an aluminum jawed vice and install the inner seal (sprocket side). Photo WA-59 Seat properly to the shoulder. 12. Install a new gasket to the outer sealing flange of the housing assembly and insert the entire unit back through the vehicle frame.
  • Page 210 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual WA-64 WA-63 13. Completely install the axle by seating the outer flange to the lower body. On Vehicles manufactured prior to serial number 0301191:  Secure the axle assembly by installing the M10 lockwashers and hex nuts to the car- riage bolts.
  • Page 211 Centaur Service Manual Wheels, Axles & Chains 18. Fill the axle assemblies with 200 ml 80/90 Hypoy-C gear oil or a 80/90 EP gear oil rated for Extreme Pressure. 19. Reinstall the tire and torque the nuts to specifications. Axle Bearing Lubrication The Centaur axle assemblies are partly filled with 80W90 Gear Lube HYP0Y-C.
  • Page 212 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Continue with the chisel, striking behind the sleeve, forcing the sleeve off of the sprocket’s shoulder. Tap evenly around the sleeve to prevent any binding as it moves towards the edge of the sprocket.
  • Page 213 Centaur Service Manual Wheels, Axles & Chains Place the steel sleeve over the hub with the chamfer facing up, and set it into the arbor press. Photo WA-72 Press the sleeve on as far as the press will allow. Photo WA-73 Place a second steel sleeve as an extension of the arbor press, to the top of the first sleeve.
  • Page 214 Wheels, Axles & Chains Centaur Service Manual Ontario Drive & Gear Limited www.centaur8x8.ca WA-34 (519) 662-2840 FAX (519) 662-2421...
  • Page 215 Centaur Service Manual Wheels, Axles & Chains SECTION WA Supplement Pages Wheels, Axles & Chains Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 216 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Frame and Body Vehicles manufactured from serial number 0301191 WA-2(A) Ontario Drive & Gear Limited. www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 217 Centaur Service Manual Wheels, Axles & Chains Frame and Body Vehicles manufactured from serial number 0301191 Ref. Qty. Part # Description 805-120 Cap, Bearing Dust - 2.0 Plated 108-40 Washer .68x1.77x.16 Zn 117-72 Locknut, Nylon - M16 x 1,5 Zn 805-113 Sprocket Asm, Rear 805-108...
  • Page 218 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Frame and Body Vehicles manufactured from serial number ...11191 WA-4(A) Ontario Drive & Gear Limited. www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 219 Centaur Service Manual Wheels, Axles & Chains Frame and Body Vehicles manufactured from serial number ...11191 Ref. Qty. Part # Description 805-120 Cap, Bearing Dust - 2.0 Plated 108-40 Washer .68x1.77x.16 Zn 117-72 Locknut, Nylon - M16 x 1,5 Zn 805-113 Sprocket Asm, Rear 805-108...
  • Page 220 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Frame and Body Vehicles manufactured from serial number ...12280 WA-6(A) Ontario Drive & Gear Limited. www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 221 Centaur Service Manual Wheels, Axles & Chains Frame and Body Vehicles manufactured from serial number ...12280 Ref. Qty. Part # Description 805-120 Cap, Bearing Dust - 2.0 Plated 108-40 Washer .68 x 1.77 x .16 Zn 117-72 Locknut, Nylon - M16 x 1,5 Zn 805-126 Sprocket Asm, Rear -S80 x 18T 805-108...
  • Page 222 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Frame and Body Vehicles manufactured from serial number ...12340 Ontario Drive & Gear Limited. WA-8(A) www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 223 Centaur Service Manual Wheels, Axles & Chains Frame and Body Vehicles manufactured from serial number ...12340 Ref. Qty. Part # Description 805-120 Cap, Bearing Dust - 2.0 Plated 108-40 Washer .68 x 1.77 x .16 Zn 117-72 Locknut, Nylon - M16 x 1,5 Zn 805-126 Sprocket Asm, Rear -S80 x 18T 805-108...
  • Page 224 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Chain Tensioners Vehicles manufactured from serial number ...12280 WA-10(A) Ontario Drive & Gear Limited. www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 225 Centaur Service Manual Wheels, Axles & Chains Chain Tensioners Vehicles manufactured from serial number ...12280 Ref. Qty. Part # Description 100-105 Pin, Cotter 3/16 x 1.75” Zn 108-67 Lockwasher M10 Split Ring Zn 806-126 Flange 108-72 Washer, 0.938 x 1.75 x 0.125” Zn 108-34 Washer .47 x .94 x .06 Zn 606-40...
  • Page 226 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Chain Tensioners Vehicles manufactured from serial number ...12448 Ontario Drive & Gear Limited. WA-12(A) www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 227 Centaur Service Manual Wheels, Axles & Chains Chain Tensioners Vehicles manufactured from serial number...12448 Ref. Qty. Part # Description 100-105 Pin, Cotter 3/16 x 1.75" Zn 108-67 Lockwasher M10 Split Ring Zn 806-126 Flange 108-72 Washer, 0.938 x 1.75 x 0.125” Zn 108-34 Washer .47 x .94 x .06 Zn 606-40...
  • Page 228 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Roller Chain Tension Initial tension for roller chain power transmission is not as critical as for belt transmissions. Generally, roller chain is used with adequate slack. Slack on the lower side is most desirable.
  • Page 229 Centaur Service Manual Wheels, Axles & Chains For the following cases, slack should be about 2%. Vertical power transmission (idler is required) Distance between the shafts is over 1m (3.3’) Heavy loads and frequent starting Sudden backward rotation The chain will elongate slightly from the beginning of initial driving from 0.05% to 0.1% of the full length.
  • Page 230 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Removing and Installing the Chain Tensioners (From Serial # 12280) Perform the servicing procedure, Drive Chain Removal on page WA-7. On the inside of the frame, remove the (4) 112-133 bolts and (4) 108-67 lock- washers that are securing the 806-126 flange and tensioner assembly in place.
  • Page 231 Centaur Service Manual Wheels, Axles & Chains WA-5 WA-4 Note: Be sure to orientate the 806-126 flange correctly for each assembly. The front 2 and back 2 should have it angled up. The middle 4 should have it angled down. Figure WA-6.
  • Page 232 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual Check to ensure that when the spring is activated the 2 slider blocks are in contact. Photo WA-7. On the inside of the frame, using (4) 112-133 bolts and (4) 108-67 lockwashers, secure the 806-126 flange and tensioner assembly in place.
  • Page 233 Centaur Service Manual Wheels, Axles & Chains Removing a drive sprocket ( Centaurs manufactured from 0301191 ) Refer to steps 1 through 4 on page WA-18 & 19. Slide the sprocket forward a little to access the (4) bolts and lockwashers securing the inner axle flange to the frame.
  • Page 234 Wheels, Axles & Chains Wheels, Axles & Chains Centaur Service Manual Centaur Service Manual WA-12 WA-13 As the assembly is inserted through the lower body, slip the inner flange over the hous- ing, and the drive sprocket on to the splined end. The sprocket will not fit on to the axle assembly once it has been fully installed.
  • Page 235 Centaur Service Manual Wheels, Axles & Chains WA-17 WA-18 12. Secure each sprocket with a flat washer & nylon locknut. Apply 242 blue LOCTITE to each of the threads first. Torque to 55 FT. LBS. Photo WA-18. 13. Apply some LOCTITE 30509 instant gasket to the 805-120 dust cap’s sealing edge and install each dust cap with an installation tool.
  • Page 236 Wheels, Axles & Chains Centaur Service Manual Ontario Drive & Gear Limited. WA-22(A) www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 237 Centaur Service Manual Steering System SECTION ST Steering System Table of Contents Steering System Illustration ( Prior to S/N 0301191)......ST-2 Steering System Parts List ( Prior to S/N 0301191)......ST-3 Steering System Illustration (From S/N 0301191)....Sup. ST-2(A) Steering System Parts List (From S/N 0301191)......Sup. ST-3(A) Steering System Illustration (From S/N ..12340)....Sup.
  • Page 238 Steering System Centaur Service Manual Earlier Models (1 Spring Pin Only) Ref. #7 Ontario Drive & Gear Limited www.centaur8x8.ca ST-2 ST-2 (519) 662-2840 FAX (519) 662-2421...
  • Page 239 Centaur Service Manual Steering System Ref. Qty. Part # Description 117-76 Locknut, Nylon M16 x 2,0 Zinc 809-133 Steering Wheel 106-07 Retaining Ring SH-0075-PA 106-19 Retaining Ring SE-0074-ZD (from S/N 0105059) 108-16 Washer .79 x 1.00 x .06 Zinc 105-16 Bushing, Oilite -3/4 x 1/2 809-134 Spacer, Stepped...
  • Page 240 Steering System Centaur Service Manual General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.
  • Page 241 Centaur Service Manual Steering System Disassembling The Steering Assembly The steering wheel assembly houses the master cylinder, brake pedal and gas pedal together in one unit. Although you may service parts of the assembly without removing it from the vehicle, you may find it easier to work on if you do. These instructions will illustrate the disassembly of the steering system.
  • Page 242 Steering System Centaur Service Manual Loosen the brake line fitting at the master cylinder a few turns. Do not completely free it from the master cylinder. Photo ST-4 At the time of production, the brake line is attached first to the master cylinder, then bent and formed to the upper frame assemblies.
  • Page 243 Centaur Service Manual Steering System ST-7 ST-8 On vehicles manufactured prior to S/N 0301191:  13. Remove the outside retaining ring on the steering tube at the steering column, and slip off the 3 flat washers that are installed against the oilite bushing.. Photo ST-8 ST-9 ST-10 Vehicles manufactured from serial numbers S/N0110072 have 2 flat washers and 1 “O”...
  • Page 244 Steering System Centaur Service Manual ST-12 ST-11 16. Remove the inner retaining ring. Photo ST-11 17. Remove the master cylinder. This is secured by 2 bolts and locknuts. There are 4 spacers used between master cylinder and throttle/brake supports. Photo ST-12 18.
  • Page 245 Centaur Service Manual Steering System Reassembling the Steering Assembly Install the throttle pedal to the two supports. Use 4 Spacers. 3 are to the inside at the gas pedal linkage and 1 is to the outside secured with a cotter pin. Photo ST-14 Using 1 bolt, install a cable bracket into the lower hole of the brake support.
  • Page 246 Steering System Centaur Service Manual Using the spring clip, attach the brake pedal pushrod to the pedal if it had been previously removed. Photo ST-18 Next, attach the brake pedal and plunger pin assembly to the throttle/brake as- sembly supports. Photo ST-19 Keep ST-18 in mind the 2 washers that are installed between the pedal assembly on the right...
  • Page 247 Centaur Service Manual Steering System wards the oilite bushing of the steering wheel housing Photo ST-22 ST-27 ST-22 ST-23 12. Slip the steering tube through the oilite bushing of the steering wheel housing and connect the rear of it to the pin located in the back of the housing. Photo ST-23 ST-24 ST-25 13.
  • Page 248 Steering System Centaur Service Manual 16. If the spring pin was removed from the steering tube during disassembly, install it into the hole drilled at the end of the tube. Make sure the pin protrudes from the hole about 1/8”, pointing upwards to the top of the steering column. Photo ST-26 17.
  • Page 249 Centaur Service Manual Steering System ST-31 ST-30 22. Perform the servicing procedure, Bleed- ing the Hydraulic Brake System on page BR-25 in the Brake Section of this service manual. 23. Reconnect both the steering cable link- age at the steering shaft, and the throttle cable to the gas pedal.
  • Page 250 Steering System Centaur Service Manual Steering Lock Adjustment With the arm rest DOWN ensure that the steering lock pin is not engaged or making contact with the adjustable lock plate on the hydrostat unit. Adjust if neccessary for sufficient clearance between the two. See Adjusting the Steering Lock Pin on page ST-16 for UPRIGHT armrest adjustment.
  • Page 251 Centaur Service Manual Steering System ST-35 ST-36 ST-37 ST-38 Pop the shock from the ball stud with a quick blow from behind with your hand. Photo ST-38 Remove the retaining ring securing the arm rest assembly to the pivot point and slide it from the shaft to free it from the vehicle.
  • Page 252 Steering System Centaur Service Manual ST-41 ST-42 The other end of the steering lock system is located at the steering lever assembly on the hydrostatic pump. This consists of a spring loaded locking pin mounted to a bracket on the upper frame cross brace assembly.
  • Page 253 Centaur Service Manual Steering System ST-43 ST-44 Generally, when the cable is fastened at the bracket on the upper cross brace assembly, if it is installed with an equal amount of threads on either side of the welded tab, the cable will be properly set.
  • Page 254 Steering System Centaur Service Manual Apply anti-seize compound to the pivot post of the steering arm rest lock assembly. With the shock connected at both ends, compress the gas shock by maneuvering the arm rest up and on to the pivot pin at the ROP.

  • Page 255: Steering System

    Centaur Service Manual Steering System SECTION ST Supplement Pages Steering System Ontario Drive & Gear ltd. www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 256 Steering System Steering System Centaur Service Manual Centaur Service Manual Steering System From Serial No. 0301191 Ontario Drive & Gear Limited www.centaur8x8.ca ST-2(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 257 Centaur Service Manual Steering System Steering System From Serial No. 0301191 Ref. Qty. Part # Description 117-76 Locknut, Nylon M16 x 2,0 Zn 809-133 Steering Wheel 106-07 Retaining Ring SH-0075-PA 106-19 Retaining Ring SE-0074-ZD 108-16 Washer .79 x 1.00 x .06 Zn 105-16 Bushing, Oilite -3/4 x 1/2 112-141...
  • Page 258 Steering System Steering System Centaur Service Manual Centaur Service Manual Steering System From Serial No..12340 Ontario Drive & Gear Limited www.centaur8x8.ca ST-4(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 259 Centaur Service Manual Steering System Steering System From Serial No..12340 Ref. Qty. Part # Description 117-76 Locknut, Nylon M16 x 2,0 Zn 809-133SA Steering Wheel 106-07 Retaining Ring SH-0075-PA 106-19 Retaining Ring SE-0074-ZD 108-16 Washer .79 x 1.00 x .06 Zn 105-16 Bushing, Oilite -3/4 x 1/2 112-141...
  • Page 260 Steering System Steering System Centaur Service Manual Centaur Service Manual Disassembling the Steering Column  On vehicles manufactured from S/N 0301191: Remove the outside retaining ring on the steering shaft at the steering column. Photo ST-1 Slip the washer and O-ring from the steering shaft. Photo ST-2 ST-1 ST-2 Pull the steering shaft from the columns welded steering tube.
  • Page 261 Centaur Service Manual Steering System ST-5 ST-6 ST-7 ST-8 Install the O-ring, flatwasher and secure with a retaining ring. Photos ST-8, 9 & 10 ST-9 ST-10 Install the spring pin to the end of the steering shaft where the steering wheel is attached. Photo ST- Attach the steering wheel aligning one of the keyways with the roll pin and orienting the steering wheel as in Photo ST-12 Ontario Drive &...
  • Page 262 Steering System Steering System Centaur Service Manual Centaur Service Manual ST-11 ST-12 ST-13 ST-14 Secure the steering wheel with the locknut. Ensure that the threaded end of the shaft extends at least one thread past the nylon insert of the locknut. Photo ST-13 Snap the steering wheel cover over the mounting nut.
  • Page 263 Centaur Service Manual Steering System 10. Assemble (2) shoulder bolts with a flat washer and nylon washer as in Photo ST-17 11. Attach the steering column assembly to the centaur steering compartment using the (2) shoulder bolts. Photo ST-18 ST-17 ST-18 12.
  • Page 264 Centaur Service Manual Fuel System SECTION FS Fuel System Table of Contents Fuel System Illustration ..............FS-2 Fuel System Parts List ................ FS-3 Fuel System Illustration ..............FS-2(A) Fuel System Parts List ................ FS-3(A) General Instructions ................FS-4 Removing the Fuel Tank ..............FS-5 Assembling the Swing Arm to the Fuel Tank ........
  • Page 265 Fuel System Fuel System Centaur Service Manual Centaur Service Manual Ontario Drive & Gear Limited www.centaur8x8.ca FS-2 FS-2 (519) 662-2840 FAX (519) 662-2421...

  • Page 266: Fuel System

    Centaur Service Manual Fuel System Fuel System (Gasoline and Diesel) Ontario Drive & Gear Limited www.centaur8x8.ca FS-3 (519) 662-2840 FAX (519) 662-2421...
  • Page 267 Fuel System Fuel System Centaur Service Manual Centaur Service Manual Ref. Qty. Part # Description 112-97 HHCS M6x1x25mm Zn 108-08 Washer, .26x.62x.04 Zn 108-26 Washer .43x1.02x.09 Zn 117-60 Locknut, Nylon M10x1,5 Zn 112-20 HHCS M8x1,25x25mm Zn 108-24 Washer .34x.70x.06 Zn 117-77 Locknut, Nylon M8x1,25 Zn 808-126...

  • Page 268: General Instructions

    Centaur Service Manual Fuel System General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.

  • Page 269: Removing The Fuel Tank

    Fuel System Fuel System Centaur Service Manual Centaur Service Manual Removing The Fuel Tank Siphon the contents of the fuel tank so that it is dry. Disconnect and remove the battery from the vehicle. Remove the 2 bolts, 2 flat washers and 2 locknuts that secure the seat to the left and right side seat support assemblies.
  • Page 270 Centaur Service Manual Fuel System FS-5 FS-6 FS-7 FS-8 Disconnect the wiring at the swing arm on the fuel tank (Fuel gauge sensor). The green wire with the yellow stripe is the sensor wire attached to the center post, and the brown is the ground attached to the side post.
  • Page 271 Fuel System Fuel System Centaur Service Manual Centaur Service Manual 11. Remove the 4 bolts, flat washers and locknuts that fasten the front fuel tank bracket assembly to the left and right hand side seat supports. Photo FS-10 You may leave the lower part of the front bracket connected at the floor but it is a good idea to loosen each of the bolts off.

  • Page 272: Assembling The Swing Arm To The Fuel Tank

    Centaur Service Manual Fuel System Assembling The Swing Arm To The Fuel Tank Refer to Photo FS-14 to assemble the swing arm correctly when installing it back into the tank. When assembling the float system back into the tank, ensure that the plate with the marking “Float Side”...
  • Page 273 Fuel System Fuel System Centaur Service Manual Centaur Service Manual Reconnect the filler hose and gear clamp at the mouth of the tank as well as the fuel line(s) at the pickup and (return tubes)Diesel. Secure the tank by installing the 4 bolts, 8 flat washers and 4 locknuts at the right and left hand side seat support assemblies.
  • Page 274 Centaur Service Manual Fuel System Reinstall the lower front baffle to the front of the tank and secure tightly. Photo FS-21 Set the seat back into the cab and re-fasten it to the left and right side seat support as- semblies.

  • Page 275: Reinstalling The Filler Hose Assembly

    Fuel System Fuel System Centaur Service Manual Centaur Service Manual Loosen the clamp and free the filler neck from the firewall. Pull the vent tube from the filler neck and slip the neck from the rubber filler hose. Loosen the lower gear clamp at the steel bent tube to replace that section of the rubber filler hose.
  • Page 276 Centaur Service Manual Fuel System Locate and disconnect the wiring at the plug. Photo FS-25 This wiring consists of a brown ground wire and a white wire /blue stripe sensor wire connected to the “water in fuel” indicator light on the dash. Remove the 2 M8 bolts and flat washers securing the pump to the upper frame cross brace assembly bracket.

  • Page 277: Changing The Fuel Filter(Gas Models

    Fuel System Centaur Service Manual To replace fuel filter element: Disconnect sensor wire. Remove drain plug and discard O-ring. Remove fuel filter with filter wrench. Screw new filter on by hand until gasket contacts housing. Then tighten 1/3 turn more. Install drain plug with new O-ring.
  • Page 278 Centaur Service Manual Fuel System SECTION FS Supplement Pages Fuel System Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 279 Fuel System Centaur Service Manual Notes: Ontario Drive & Gear Limited www.centaur8x8.ca FS-1(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 280 Centaur Service Manual Fuel System Fuel System From Serial # ..12281 FS-2(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 281 Fuel System Centaur Service Manual Fuel System From Serial # ..12281 Ref. Qty. Part # Description 112-97 HHCS M6x1x25mm Zn 108-08 Washer, .26x.62x.04 Zn 108-26 Washer .43x1.02x.09 Zn 117-60 Locknut, Nylon M10x1,5 Zn 112-20 HHCS M8x1,25x25mm Zn 108-24 Washer .34x.70x.06 Zn 117-77 Locknut, Nylon M8x1,25 Zn 808-126...
  • Page 282 Centaur Service Manual Vehicle Bodies SECTION VB Vehicle Bodies Table of Contents Upper Frame Illustration (Prior to S/N 0301191)........VB-2 Upper Frame Parts List (Prior to S/N 0301191)........VB-3 Upper Frame Illustration (From S/N 0301191)........Sup.VB-2(A) Upper Frame Parts List (From S/N 0301191)........Sup.VB-3(A) ROPS and Upper Body Illustration (Prior to S/N 0301191).......VB-4 ROPS and Upper Body Parts List (Prior to S/N 0301191)......VB-5 ROPS and Upper Body Illustration (From S/N 0301191)....Sup.VB-4(A)
  • Page 283 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual Installing the Mud Flaps................VB-17 Removing the Splash Panels................. VB-17 Removing the Tool Box................. VB-18 Removing the Seat Assembly................ VB-19 Removing the Dash..................VB-19 Ontario Drive & Gear Limited www.centaur8x8.ca VB-2 (519) 662-2840 FAX (519) 662-2421...
  • Page 284 Centaur Service Manual Vehicle Bodies From S/N: 0208146 TU V2001DT & Centaur steering lock from S/N: 0108067V2001DT 0210178 V2001G 0108063V2001D 0108064 V2001G (Refer to illustration & parts list on (Refer to illustration & parts list Page VB-2(A) & 3(A).) on page VB-2(A) & 3(A). ) Ontario Drive &...
  • Page 285 Vehicle Bodies Centaur Service Manual Centaur Service Manual Ref. Qty. Part # Description 127-88 Hinge 801-121 Decal, Centaur 950 (Gas) 801-122 Decal, Centaur 950D (Diesel) 801-113 Engine cover assembly 108-03 Lockwasher 1/4 Split Ring Zinc 112-98 HHCS M6x1x40mm Zn 806-175...
  • Page 286 Centaur Service Manual Vehicle Bodies Ontario Drive & Gear Limited www.centaur8x8.ca VB-5 (519) 662-2840 FAX (519) 662-2421...
  • Page 287 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual Ref. Qty. Part # Description Ref. Qty. Part # Description 801-138 Labels, Warning-Centaur 849-100 Cover, Soft Top and doors 801-137 Labels, Info-Centaur (incl. 2-4,12,32,42,45) 801-127 Insulation, Sound - 849-100R Roof Only -Centaur Soft Top Firewall 849-100DL Panel, Door Left...
  • Page 288 Centaur Service Manual Vehicle Bodies General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.
  • Page 289 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual Removing/Installing the Front And Rear Bent Floor Plates To remove the rear bent floor plate, undo all fasteners that are threaded to the upper and lower frame and remove the plate. Photo VB-1 The rear bent floor plate has (4) spacers between the frame and the plate.
  • Page 290 Centaur Service Manual Vehicle Bodies Removing The Front And Rear Floor Pans There are (3) fasteners securing the rear floor pan and (6) securing the front floor pan to the lower frame. Remove these and lift the pans from the vehicle to access the drive chains and drain plugs.
  • Page 291 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual VB-7 VB-8 Removing/Installing the Left & Right Transmission Cover These parts cover the steering lever assembly which is attached to the hydrostatic pump behind the drivers compartment. Remove both the left and right side transmission cov- ers by removing the fasteners that secure them to the tool box and upper frame cross brace assembly.
  • Page 292 Centaur Service Manual Vehicle Bodies If you choose to use a slot screw driver, you should modify it by rounding the edges to ensure that the windshield seal will not be damaged in any way. Using an unmodified screwdriver could pierce or puncture a hole in the rubber seal resulting in a windshield leak.
  • Page 293 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual VB-15 VB-16 VB-17 Installing the Windshield Place the windshield seal to the frame, starting at the bottom part of the frame and centering it with the CENTAUR name plate. Photo VB-18 Orientate the seal as shown in Photo VB-19 VB-18 VB-19...
  • Page 294 Centaur Service Manual Vehicle Bodies To secure the seal in place while installing the windshield, apply masking tape to the inside at the top, bottom and 4 corners. Photo VB-20 With the seal secured in place, Photo VB-21, begin by placing the windshield into the 2 bottom corners.
  • Page 295 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual VB-24 VB-25 With the windshield fitted to all corners it is time to seat the rubber around the glass. Place the installation tool or modified screwdriver into the secondary lip at the front of the seal, and while moving around the perimeter of the seal, push the lower lip beneath the upper lip, interlocking the two as you go along.
  • Page 296 Centaur Service Manual Vehicle Bodies Removing the Front Bumper Remove the silicon sealant along the front of the bumper and the bottom windshield panel. The silicon generally will just peel away. Photo VB-30 Remove all (4) headlamps from the front bumper. Refer to Replacing a Headlamp/ Bulb on page ES-13 to remove the headlamps.
  • Page 297 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual Locate and remove the fasteners all along the front of the bumper. Photo VB-35 At the top of the dash to the inside of the windshield, there are (4) fasteners that secure the bumper to the ROP frame.
  • Page 298 Centaur Service Manual Vehicle Bodies VB-40 VB-41 With the lower fasteners installed at the bottom, push the bumper in far enough at the top so that the (4) fasteners to the inside of the windshield, will secure it sufficiently in place when they are tightened down. Photo VB-42 Re-fasten the self tapping screw to each side of the bumper and re-rivet the convertible top “common sense fastener”...
  • Page 299 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual Removing the Mud Flaps Remove all of the fasteners along the underside of the body and pull the flaps free of the vehicle. Photo VB-44 The mud flaps are sandwiched between the front and rear upper frames and the lower body of the vehicle.
  • Page 300 Centaur Service Manual Vehicle Bodies VB-46 VB-47 VB-48 VB-49 Removing the Tool Box Remove the (2) bolts, (2) flat washers and (2) locknuts that secure the seat to the left and right side seat support as- semblies. Photo VB-49 Remove the seat from the vehicle. Photo VB-50 VB-50 Remove the front floor mat and floor...
  • Page 301 Vehicle Bodies Centaur Service Manual VB-53 VB-52 Remove the front (2) fasteners securing the tool box to the front fuel tank bracket as- sembly. Photo VB-54 Remove the tool box from the vehicle. Photo VB-55 VB-54 VB-55 Removing the Seat Assembly Refer to steps 1 and 2 of Removing The Tool Box on the previous page.
  • Page 302 Centaur Service Manual Vehicle Bodies SECTION VB Supplement Pages Vehicle Bodies Ontario Drive & Gear Limited www.centaur8x8.ca VB-1 (519) 662-2840 FAX (519) 662-2421...
  • Page 303 Vehicle Bodies Centaur Service Manual Notes: Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 304 Vehicle Bodies Centaur Service Manual Upper Frame From Serial # 0301191 Ontario Drive & Gear Limited www.centaur8x8.ca VB-2(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 305 Ref. Qty. Part # Description Ref. Qty. Part # Description 809-122 Bracket, Steering -Spring 127-88 Hinge 801-121 Decal, Centaur 950 (Gas) 108-12 Washer, .34x1.00x.06 Zn 801-143 Decal, Centaur 950DT (Turbo 806-153 Floor Plate, Front - Bent Diesel) 108-67 Lockwasher M10 Split Ring...
  • Page 306 Vehicle Bodies Centaur Service Manual ROPS From Serial # 0301191 Ontario Drive & Gear Limited VB-4(A) www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 307 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual ROPS From Serial # 0301191 Ref. Qty. Part # Description Ref. Qty. Part # Description 801-110 Dash 849-171 Door Asm, Centaur - Right 809-167RM Seal, Radiator (See pg. 37 for details) 801-138 Labels, Warning-Centaur 849-170...
  • Page 308 Vehicle Bodies Centaur Service Manual Upper Frame From Serial # T12318 VB-6(A) Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 309 Ref. Qty. Part # Description 108-12 Washer, .34x1.00x.06 Zn 127-88 Hinge 806-153 Floor Plate, Front - Bent 801-121 Decal, Centaur 950 (Gas) 108-67 Lockwasher M10 Split 801-143 Decal, Centaur 950DT (Turbo Ring Zn Diesel) 112-125 Screw, self drilling 12- 801-113 Engine cover assembly 14x1.5"...
  • Page 310 Vehicle Bodies Centaur Service Manual Upper Frame From Serial # T12433 Ontario Drive & Gear Limited www.centaur8x8.ca VB-8(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 311 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual Upper Frame From Serial # T12433 Ref. Qty. Part # Description Ref. Qty. Part # Description 112-125 Screw, self drilling 12- 112-136 Screw, Fast Lead-Knurled 14x1.5" Zn 127-120 Retainer, Fast Lead Screw 108-08 Washer .28x.62x.04 Zn 112-111...
  • Page 312 Vehicle Bodies Centaur Service Manual ROPS From Serial # T12433 Ontario Drive & Gear Limited www.centaur8x8.ca VB-10(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 313 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual ROPS From Serial # T12433 Ref. Qty. Part # Description Ref. Qty. Part # Description 849-171 Door Asm, Centaur - Right 108-08 Washer .28 x .62 x .07 Zn (See pg. 48 for details) 801-138 Labels, Warning-Centaur 849-170...
  • Page 314 Vehicle Bodies Centaur Service Manual Engine Cover & Firewall From Serial # T12433 Ontario Drive & Gear Limited www.centaur8x8.ca VB-12(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 315 From Serial # T12433 Ref. Qty. Part # Description 127-88L Hinge, Engine Cover - L 801-121 Decal, Centaur 950 (Gas) 801-143 Decal, Centaur 950DT (Turbo Diesel) 801-174L Engine Cover Ass'y Left (spec. colour) 108-03 Lockwasher 1/4 Split Ring Zn 112-176...
  • Page 316 Vehicle Bodies Centaur Service Manual Tubular Steel Frame Fabric Covered Doors (Centaurs manufactured from serial numbers 0207130) Door assemblies on Centaurs manufactured from the above serial number are constructed of a fabric skin with a zippered window fastened over a tubular steel frame. Removing the Door Assembly 1.
  • Page 317 Vehicle Bodies Vehicle Bodies Centaur Service Manual Centaur Service Manual 2. To remove the male hinge assembly, first remove the bracket to which it is fastened, at the ROPS. Remove the fasteners at the bracket. Photo VB-5 VB-4 VB-5 Assemblng the Female Hinge Assembly to the Door Frame 1.
  • Page 318 Vehicle Bodies Centaur Service Manual Assembling the Door Latch Assembly 1. Install the latch trim plate with the four studs on the outside of the door, pushing the studs through the fabric and the latch mounting plate. Photo VB-7 Install the door latch with the angled latching slide nearest the door frame and secure in place with the star-lockwasher/nut combinations.
  • Page 319 Centaur Service Manual Exhaust System SECTION EX Exhaust System Table of Contents Exhaust System Illustrations & Parts List ..........EX-2 Exhaust System Illustrations & Parts List-From Serial # T12271 ..EX-2(A) Exhaust System Illustrations & Parts List-From Serial # T12318 ..EX-3(A) General Information ................
  • Page 320 Exhaust System Exhaust System Centaur Service Manual Centaur Service Manual Exhaust System Gasoline, 26 Naturally Aspirated Diesel &TurboDiesel Gasoline and 26 N.A Diesel Exhaust System Turbo Diesel Exhaust System Ref. Qty. Part # Description 108-08 Washer .28x.62x.04 Zinc 707-35 Spring, Exhaust Connecting 117-77 Locknut, Nylon - M8x1,25MM Zinc 112-20...
  • Page 321 Centaur Service Manual Exhaust System General Instructions Detailed information on standard workshop and safety procedures, and general servicing operations is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.
  • Page 322 Exhaust System Exhaust System Centaur Service Manual Centaur Service Manual Removing The Muffler and Exhaust System Components Rermove the 2 fasteners that secure the muffler shield at the front of the muffler. Photo EX-1 Remove the 2 bolts, 4 flat washers and 2 locknuts that fasten the shield, as well as the muffler, to the brackets welded at the ROP.
  • Page 323 Centaur Service Manual Exhaust System Installing Exhaust System Components Be sure to install a new gasket at the manifold. Clean all old gasket material from the exhaust pipe flange or the manifold to ensure a good seal at the engine. When installing engine system components, ensure that all exhaust connections are tight and secure.

  • Page 324: Exhaust System

    Centaur Service Manual Exhaust System SECTION EX Supplement Pages Exhaust System EX-1 Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 325 Exhaust System Exhaust System Centaur Service Manual Centaur Service Manual Notes: Ontario Drive & Gear Limited www.centaur8x8.ca EX-1(A) (519) 662-2840 FAX (519) 662-2421...
  • Page 326 Centaur Service Manual Exhaust System Exhaust System - 950G From Serial # T12271 Exhaust System - 950DT From Serial # T12271 Ref. Qty. Part # Description Ref. Qty. Part # Description 108-82 Washer, Rubber - .94OD 807-124 Brace, Exhaust - Shield x.39ID x .56 Thk 807-121 Pipe, Tail - Asm...
  • Page 327 Exhaust System Centaur Service Manual Exhaust System - 950G From Serial # T12318 Exhaust System - 950DT From Serial # T12318 Ref. Qty. Part # Description 607-103 Spark Arrester 112-43 Screw, IHWH #8 x 3/8 807-131 Muffler, 950G & 954G -Side Exhaust 807-130 Muffler, 950 &...
  • Page 328 Centaur Service Manual Transmission SECTION TR Transmission Table of Contents Transmission and Hydrostatic Pump Illustration......... TR-3 Transmission and Hydrostatic Pump Parts List........... TR-4 Transmission Internal Illustration..............TR-5 Transmission Internal Parts List..............TR-6 Shift Box Illustration and Parts List............TR-7 General Instructions................
  • Page 329 Wheels, Axles & Chains Centaur Service Manual Ontario Drive & Gear ltd. (519) 662-2840 FAX (519) 662-2421...
  • Page 330 Centaur Service Manual Transmission Power Pack Transmission Includes *O-ring *NOTE: O.D.G does not stock these o-rings. If replacement is necessary, it may be ordered by standard industry code elsewhere. Prior to V2001D-0108064 Standard Industry Code is: “O-Ring, AS568-910 - .755” I.D. x .097” Thick Ontario Drive &...
  • Page 331 Transmission Centaur Service Manual Ref. Qty. Part # Description 112-20 HHCS M8x1,25x25mm Zinc 108-05 Lockwasher 5/16 Split-Ring Zinc 104-27 Pin, Clevis 5/16 x .75” Zinc 100-100 Pin, Cotter 1/8x3/4 Zinc 809-159 Bar, Shift - Cable End 809-149 Cable, Shift 103-29 HHCS 5/16-24x2.75 GR8 Zinc 103-16 HHCS 5/16-24x3.75 GR8 Zinc...
  • Page 332 Centaur Service Manual Transmission Transmission Centaur Parts Manual Ref. Qty. Part # Description CE-017 Shaft, Reverse CE-028 Fork, Shift -Reverse 111-08 Pin, Spring 0.125 Dia x 0.75 Long CE-016 Idler, Reverse -28T 101-77 Bushing, Oilite AA-1232-4 (1.00 x 2.25) 101-74 Bearing, Ball 6305Z Cl.N.
  • Page 333 Transmission Centaur Service Manual Centaur Parts Manual Transmission Ref. Qty. Part # Description 112-89 SHSS, M12 x 1,75 x 12 Cup Pt 486-05 Spring - 3/8 ID 479-03 Ball, Steel 3/8 Dia. 112-108 SHSS, M10 x 1,50 x 10 Plain CE-035 Dipstick w/ breather -190 mm 102-30...
  • Page 334 Centaur Service Manual Transmission Centaur Parts Manual Shift Box Ref. Qty. Part # Description 809-199 Shift Box Assembly - Slotted 809-197 Shift Block Assembly - 1 Cam 809-198 Shift Block Assembly - 2 Cams 809-177 Shift Yoke Assembly 809-200 Gate, Shift 809-182 Knuckle - Shift Lever 126-38...

  • Page 335: General Instructions

    Transmission Centaur Service Manual General Instructions Detailed information on standard workshop and safety procedures, and general servicing opera- tions is not included in this manual, which has been prepared to assist qualified service personnel. ODG assumes no responsibility or liability for PERSONAL INJURY or VEHICLE DAMAGE which results from any servicing procedure performed, including those instructions outlined in this manual.

  • Page 336: Transmission Description

    Centaur Service Manual Transmission Transmission Description The CENTAUR is equipped with a four position transmission. The gearshift lever is lo- cated to the left of the dash. * R (Reverse) - for backing up the vehicle * Neutral - for starting the engine or idling * L (Low) - for use when extra pulling power or very low speed is required in rough ter- rain.

  • Page 337: Transmission Oil

    Transmission Centaur Service Manual Transmission Oil Maintenance Schedule The transmission oil should be changed after the initial 25 hours of vehicle operation. After this, it should be changed every 150 operating hours. Proper transmission lubrication will reduce wear, and extend gearbox life. Please use the type, and quantity of transmission oil specified below.

  • Page 338: Oil Level Inspection

    Centaur Service Manual Transmission Oil Level Inspection Inspect the transmission oil on a daily basis Do not run the CENTAUR if the oil level in the transmission shows above or below the mark on the dipstick. Damage to transmission components could occur. Place the vehicle on a level surface.

  • Page 339: General Inspection Of The Transmission

    Transmission Centaur Service Manual Draw out a small quantity of gear oil from the transmission. iii. Remove the vacu-pump from the transmission iv. Repeat steps 1 to 5. 6 (b) Oil Level is Below The Groove Place a clean long spouted funnel into the oil fill/dipstick hole ii.

  • Page 340: Removing The Hydrostatic Belt

    Centaur Service Manual Transmission Changing The Hydrostatic Pump Oil Filter The hydrostatic transmission is equipped with a disposable, spin on oil filter. Replace this filter with a new one whenever transmission oil is changed. Refer to the maintenance sched- ule in the General Information section of this manual for correct time intervals. Remove the engine access cover.

  • Page 341: Removing The Hydrostatic Pump

    Transmission Centaur Service Manual Slip the poly chain belt on between the hydrostatic pump’s belt sprocket and the sprocket of the engine. Adjust the belt by prying the pump away from the engine and tightening down both bolts of the bridge blocks. Tension the belt so that 6lbs. of force causes a deflection of .21”...
  • Page 342 Centaur Service Manual Transmission 5. Remove the bridge blocks and mounting bolts completely from the hydrostatic pump and pull it free from the transmission. Photo TR-7 TR-7 TR-6 Be aware of the “O” ring installed between pump and housing ,and be sure to replace it with a new one when reassembling the pump to the transmission Removing The Belt Sprocket And Bushing from The Hydrostatic Pump 1.

  • Page 343: Sub-Assembling The New Pump

    Transmission Centaur Service Manual If a new pump is to be installed to the vehicle it may be necessary to modify the set up before it may be used for the CENTAUR.. Sub-Assembling The New Pump 1. Remove the top plug of the hydrostatic pump and discard the spring and plunger. TR-9 2.

  • Page 344: Reinstalling The Pump To The Vehicle

    Centaur Service Manual Transmission Installing The Hydrostatic Belt Sprocket To Pump 1. Thread the 2 set screws into the belt sprocket and bushing as in Photo TR-8 on page 14,or the 3 bolts and lockwashers as in Photo TR-8A 2. Apply some anti-sieze compound to the splined drive shaft of the pump and slip the belt sprocket on.

  • Page 345: Aligning The Hydrostatic Belt Sprocket

    Transmission Centaur Service Manual 6. Install the poly chain belt from the engine to the hydrostatic pump. Adjust the belt by prying the pump away from the engine and tightening down both bolts of the 2 bridge blocks. Torque to specifications. Tension the belt so that 6 lbs. of force causes a de- flection of .21”...
  • Page 346 Centaur Service Manual Transmission Remove The Transmission 1. Perform the servicing procedure, Remov- ing The Engine on page EN-21 of this service manual. 2. Loosen the 2 chain tensioners on the left and right side of the transmission. These tension the chains to the main drive sprockets on the transmission.
  • Page 347 Transmission Centaur Service Manual 6. Disconnect the steering linkage at the yoke directly behind the seat. Remove the cotter pin that secures the clevis pin and slide the clevis pin free of the linkage. Photo TR- 7. Remove the locknut from the shoulder screw of the steering lever assembly and slip the lever and spring from the shaft.
  • Page 348 Centaur Service Manual Transmission TR-26 TR-27 10. Screw 2 lift hooks into the transmission as shown in Photo TR-27 and attach an over- head hoist to raise the transmission out of the vehicle. 11. While raising the transmission, pull it towards the back of the vehicle. Photo TR-28 This will ensure that the hydrostatic pump does not catch near the drivers compartment.
  • Page 349 Transmission Centaur Service Manual TR-30 TR-31 16. Remove the bolt, lock washer and flat washer from the driven clutch and slide it off the input shaft. Take note of the 1/4” x 1/4” key in the shaft and make sure that it is reinstalled before the driven clutch assembly is assembled back on to the input shaft.
  • Page 350 Centaur Service Manual Transmission 20. If the hydrostatic pump was not removed prior to lifting it from the vehicle, remove it at this point. Un-thread the front and rear bolts of the 2 bridge blocks fastening the pump, and pull the pump from the transmission. Photo TR-35, 36 & 37 Be aware of the “O”...
  • Page 351 Transmission Centaur Service Manual TR-21 TR-39 TR-40 23. Remove the 2 sprocket assemblies on each output shaft of the transmission. Knock off each rubber sprocket seal to access the retaining ring that secure them to the output shafts. Photo TR-40 24.

  • Page 352: Transmission Assembly

    Centaur Service Manual Transmission Transmission Assembly To make assembly of the transmission a little easier, each gear sub-assembly will be done first, then each assembly will be refered to as Assy. A, B, C and so on while being installed into the housing during the final assembly. Find a clean and preferably spacious area to work in.
  • Page 354 Centaur Service Manual Transmission Building Assy. A 1. Locate 1 CE-006 Planet Gear Carrier and place it down into a hot oil bath. (Cooking Oil heated in a regular plug in style frying pan will do the job effectively). Heat the oil to approximately 275-300 degrees F and let sit for about 2-3 minutes.
  • Page 355 Transmission Centaur Service Manual TR-185 TR-184 5. Take the carrier assembly to the arbor press and install 2 101-68 needle bearings . The first bearing is pressed to a depth of 1-1/4”. Photo TR-185 & 186 If the bearing is installed too deep, it will come into contact with the planet gears below, preventing them from turning and causing them to lock up.
  • Page 356 Centaur Service Manual Transmission TR-188 TR-189 8. Mark each Planet Gear at the 2 teeth where the oil journal is located. Photo TR-190 There are 2 oil journals per pinion, positioned 172 degrees to each other Mark all 8 positions Photo TR-191 TR-190 TR-191 9.
  • Page 357 Transmission Centaur Service Manual 11. Take the CE-009 Drive Shaft Gear and align the magic marker lines on both sides, with those of the 2 opposing Pinions in the carrier assembly that have not been turned 90 degrees. The idea is to align the oil journals of the shaft with those in the planet gears. Photo TR-194 &...
  • Page 358 Centaur Service Manual Transmission 13. Install 2 101-68 needle bearings to the CE-004 Ring Gear. Press the first bearing into the gear to a depth of 1-1/4”. Photo TR-197 & 198 14. Press the second needle bearing on top of the first one and just below the oil journals on the face.
  • Page 359 Transmission Centaur Service Manual 16. Install the 106-14 Retaining Ring to the Drive Shaft. Photo TR-202 & 203 Make sure that the retaining ring has seated properly to the machined groove. Failure to observe this could result in serious damage to transmission compo- nents if the ring comes off unintentionally.
  • Page 360 Centaur Service Manual Transmission 20. Place a 101-71 Bearing on the end of the Drive Shaft over top of the High Input Pinion, and a 101-72 Bearing (shielded one side) to the other end of the drive shaft assembly with the shielded side facing out. Place the entire Assy A into the arbor press and press both bearings tightly to their shoulders.
  • Page 361 Transmission Centaur Service Manual TR-210 TR-211 3. Install the Steering Shaft to the Planet Gear Carrier, synchronizing the oil journals of the pinions, with those of the steering shaft. Accomplish this in the same manner as was done for Assy A. Refer to instructions 10 to 12 on page TR-24 if necessary. 4.
  • Page 362 Centaur Service Manual Transmission TR-214 TR-215 TR-216 TR-217 7. Place the CE-022 Steering Gear 71T, step side up, on to the spline of the Steering Shaft, above the pinion of the Ring Gear. You may have to seat it to the shoulder of the Steer- ing Shaft with a soft faced mallet.
  • Page 363 Transmission Centaur Service Manual TR-220 TR-221 9. Turn Assy. B around and place a CE-030 Thrust Carrier Washer over the Steering Shaft end. Photo 222 & 223 TR-222 TR-223 10. Install the 101-72 Ball Bearing to the end of the Steering Shaft with the shielded side up.
  • Page 364 Centaur Service Manual Transmission Building Assy. C 1. Locate the CE-015 Input Shaft and seat a 106-15 retaining ring to the keyed side of the shaft. Photo TR-226 & 227 2. Press a 101-73 ball bearing to the shaft and seat it to the previously installed retaining ring.
  • Page 365 Transmission Centaur Service Manual TR-231 TR-230 The next procedure, requires the use of a modified pair of vise grips to hold the shifting assembly’s balls and springs in place while installing the Input Pinion. Photo TR-231 4. Using the modified vise grips, install 4 109-02 Steel Balls and 2 CE-033 Compression Springs into the two holes machined through the Input Shaft.
  • Page 366 Centaur Service Manual Transmission TR-235 TR-234 7. Take the CE-013 Input Pinion 27T Low, and slip it on to the Input Shaft, orientating it as shown in Photo TR-236. Line up the spline of the Pinion with that of the Shaft. Slide it up to the modified vise grip.
  • Page 367 Transmission Centaur Service Manual TR-239 TR-240 10. Install a 106-15 Retaining Ring as shown in Photo TR-241 to the secure the pinion from sliding off the free end. 11. Remove the Input Pinion from the vise and stand it upright on the bench to install the 2 halves of the Synchronizer Cones.
  • Page 368 Centaur Service Manual Transmission 13. Slip the CE-018 Forward Shift Fork over top of the Synchronizer Cone, orientating it as shown in Photo TR-243, then secure the assembly in the aluminum jawed vise and tap the yoke gently and evenly around the perimeter until it is completely installed over the Cone.
  • Page 369 Transmission Centaur Service Manual TR-247 TR-248 IMPORTANT 18. Install the Retaining Ring so that the end gap of the ring, is opposed 180 degrees to the key way & Dowel Pin. Photo TR-250 TR-249 TR-250 Building Assy. D 1. Locate the CE-003 Output Shaft and press a 101-37 Ball Bearing to each end, seating them to the machined shoulders provided.
  • Page 370 Centaur Service Manual Transmission TR-253 TR-252 2. Assemble the CE-001 Output Gear 45T R to the shortest splined end of the Output Shaft. The oil journals are also machined to this end of the shaft. Photo TR-253 & 254 3. Secure the Output Gear with a 106-16 Retaining Ring. Photo TR-255 TR-254 TR-255 Building Assy.
  • Page 371 Transmission Centaur Service Manual 2. Remove from the bath and press to the CE-025 Steering Pinion 15T. You may start this press on a regular hand arbor press, Photo TR-257, but to seat this Adapter to the Pinion will require the use of a hydraulic press at approximately 20 tons. Photo TR- When Using a hydraulic press, be sure to always have a guard in place for protection against flying parts.
  • Page 372 Centaur Service Manual Transmission 2. Apply LOCTITE 242 (blue) to the threads of 2 112-108 Set Screws and install them flush into the Left Housing as in Photo TR-261 3. Apply LOCTITE 242 (blue) to the threads of 2 112-88 Set Screws and plug the 2 holes in the Left Housing as in Photo TR-262 4.
  • Page 373 Transmission Centaur Service Manual TR-265 TR-266 TR-267 TR-268 8. Use a soft faced mallet to seat the bearing to the race in the housing. Photo TR-269 9. Place a CE-031 Thrust Washer over the Idler Shaft and on top of the Idler Gear. Photo TR-270 TR-269 TR-270...
  • Page 374 Centaur Service Manual Transmission 10. Install and seat a 106-13 Retaining Ring to the groove above the Thrust Washer. Photo TR-271 11. Take the previously assembled Output Shaft, Assy. E, and install it to the housing. Place it into the output shaft opening of the housing with the oil journals facing up. Tap the assembly through the housing using a soft faced mallet until the first bearing passes through the inner race to the outer one, and the inner bearing has seated to the inside.
  • Page 375 Transmission Centaur Service Manual TR-275 TR-276 TR-277 TR-278 15. Install the CE-017 Reverse Shaft to the housing with a soft faced mallet, aligning the key way of the shaft with that of the previously installed Dowel Pin. Tap the shaft to firmly seat it into the housing. Photo TR-278 &...
  • Page 376 Centaur Service Manual Transmission TR-280 TR-281 17. Drop the entire assembly to the bottom of the housing and note how the rear of the Shift Fork’s machined hole lines up with that of the one in the housing. The example shown here shows the alignment to be a little out.
  • Page 377 Transmission Centaur Service Manual In rare cases you may need to remove some material from the shift fork in the same manner, to avoid having to take too much material off the housing. Photo TR- TR-284 TR-285 19. Locate the CE-021 Reverse Shift Shaft and install the CE-028 Shift Fork using 1 111- 07 roll pin.
  • Page 378 Centaur Service Manual Transmission TR-289 TR-288 22. Move the assembly up and down to confirm that it moves freely without any binding. Photo TR-289 23. Install the 479-03 Steel Ball and 486-05 Spring. Place the ball into the housing fol- lowed by the Spring.
  • Page 379 Transmission Centaur Service Manual 25. Check the shifting mechanism a few times. Use a “pry” type of bar under the Reverse Idler and pry up the shift shaft until it locks into the internal machined gate. Tap it back down again using a soft faced mallet. Photo TR-292 26.
  • Page 380 Centaur Service Manual Transmission TR-296 TR-297 29. Slip the CE-020 Forward Shift Shaft through the Shift Fork of Assy. C with the 1 ma- chined internal gate facing the Reverse Shift Shaft and the three on the opposite side facing to the outside. Photo 298 30.
  • Page 381 Transmission Centaur Service Manual TR-301 TR-302 33. With the help of a second set of hands, locate and place the CE-002 Output Gear 50T L, between the gears of the Drive Shaft and Steering Shaft. Photo TR-302 34. Lower all 3 assemblies together into the housing lining up the internal spline of the CE-002 Output Gear 50TL with the spline of the Output Shaft.
  • Page 382 Centaur Service Manual Transmission 36. Secure the CE-002 Output Gear to the Output Shaft with a 101-16 Retaining Ring. Photo TR-306 TR-306 37. Place a 104-23 Dowel Pin into the top of the Output Shaft, Photo TR-307, and slip a 101-75 Thrust Washer over the Dowel Pin.
  • Page 383 Transmission Centaur Service Manual 39. Install the CE-034 Spline Input Thrust Washer to the Input Shaft spline. Photo TR-311 & 312 40. Slip the CE-014 Hi Input Gear on to the Input Shaft lining up the smaller gear with the internal cut gear of the Input Pinion.
  • Page 384 Centaur Service Manual Transmission TR-316 TR-317 44. Install the another 473-03 Steel Ball and a 486-05 Compression Spring to the Forward Shift Shaft assembly. Photo TR-318 & 319 TR-318 TR-319 45. Secure the Ball and Spring using a 112-89 Set Screw. Apply 242 (blue) LOCTITE to the threads and thread it in flush to the housing.
  • Page 385 Transmission Centaur Service Manual 47. Degrease and wipe down the sealing edges of both the Left and Right hand side Hous- ings. Photo TR-322 48. Apply LOCTITE Instant Gasket around the tiny threaded hole in the CE-024 Right Hand Housing, Photo TR-323, and install the CE-029 Magnet using a 112-105 Screw. Photo TR- 324 49.
  • Page 386 Centaur Service Manual Transmission TR-326 TR-327 TR-328 TR-329 53. Apply LOCTITE instant gasket around the entire perimeter of the CE-023 Left Hand Side Housing and smooth the entire surface with your finger. Photo TR-330 54. Assemble the Right Hand Housing Cover to the Left Hand Side Cover. Photo TR- TR-330 TR-331 Ontario Drive &...
  • Page 387 Transmission Centaur Service Manual 55. Tap the housing with a rubber mallet until it drops over the first Output Bearing to the second one. Photo TR-332 & 333 56. Ensuring that the locator pins in the lower housing are aligned properly, continue tap- ping evenly around the perimeter of the upper housing, until both sealing surfaces are tightly together.
  • Page 388 Centaur Service Manual Transmission TR-336 TR-337 IMPORTANT Check to make sure that the rubber “O” ring is on the adapter. Do not tighten the swivel nut to secure the adapter until the hydrostatic pump has been installed, and the correct angle has been adjusted for the hose between pump and transmission. 61.
  • Page 389 Transmission Centaur Service Manual TR-340 TR-341 64. Install the 102-30 Oil Seal to the Drive Shaft with a seal installing tool. Photo TR-341 & 342 65. Prepare a 101-29 Oil Seal by spraying LOCTITE primer Part # 21348 around the outer edge, and then applying 609 green LOCTITE around the outer edge as well.
  • Page 390 Centaur Service Manual Transmission TR-345 TR-346 68. Install 2 112-101 Long Bolts(45mm) and flat washers through the housing at the hy- drostatic opening. Photo TR-347 69. Place a flat washer and 117-77 Locknut to the other side of the bolt and tighten down securely.
  • Page 391 Transmission Centaur Service Manual 72. Install a 102-30 oil seal to the second Input Shaft. Photo TR-351 73. Prepare another 102-29 Oil Seal as before and install it to the other Output Shaft. 74. Place the 127-86RM 9” Hydrostatic Hose into the hot oil bath for approximately 3 minutes and press the hose on to the 127-99 hose fitting.
  • Page 392 Centaur Service Manual Transmission Transmission Sub-Assembly Before Installing Into Vehicle 1. Apply some anti-seize compound to the splined drive shaft of the transmission and install the brake disc hub. Secure with a new retaining Ring. Photo TR-354 IMPORTANT New cotter pins and retaining rings should always be used in reassembly. This will avoid the possibility of using a damaged and ineffective one that may come off with potentially dangerous results.
  • Page 393 Transmission Centaur Service Manual 5. Install the rubber oil seal to the output sprocket using a soft faced hammer and install- ing tool. Photo TR-358 TR-357 TR-358 Be careful not to damage the rubber oil seal in any way. Any deformity to it could af- fect the sealing edge, the result being a possible oil leak.
  • Page 394 Centaur Service Manual Transmission TR-361 TR-362 8. Secure the hydrostatic pump to the transmission. Fasten it at the front and rear using the specified bolts, lock washers and bridge blocks . Photo TR-362 & 363 Snug the fasteners of the hydrostatic pump at this time. Do not completely tighten the bridge blocks until the hydrostatic drive belt has been installed between the pump and engine.
  • Page 395 Transmission Centaur Service Manual TR-365 TR-366 Installing The Transmission Into The CENTAUR 1. Install two eye hooks to the transmission and, using an overhead hoist, carefully lower the transmission back into the vehi- cle lining up the front mount as well as the two in the rear.
  • Page 396 Centaur Service Manual Transmission TR-368 TR-369 2. Insert each cable through the holes on the transmission casting. Tighten the cables so that there are an equal amount of threads on each side of the transmission bosses. Photo TR-368 This is usually the correct placement at the rear. However, there may be a slight adjustment required in some cases.
  • Page 397 Transmission Centaur Service Manual TR-371 TR-372 IMPORTANT Be sure that the steering lever bracket that is attached to the Upper Frame Cross Brace Assembly, does not come into contact with the lever and spring assembly. Be sure to set a gap of 1/8” between the two. Steering can become impaired if these grate against each other.
  • Page 398 Centaur Service Manual Transmission TR-376 TR-375 10. Perform the servicing procedure, Brake Caliper Installation (Mechanical) on page BR-11 of this service manual. 11. Perform the servicing procedure, Reinstalling The Engine To The Vehicle on page EN-35 12. Perform the servicing procedure, Adjusting The Emergency Brake Caliper on page BR-17 13.
  • Page 399 Transmission Centaur Service Manual TR-378 TR-379 4. Remove the shift gate on the shift box and check to make sure that the shift blocks are aligned with the shift yoke assembly when in the neutral position. Photo TR- 5. Install the shift gate temporarily and shift the gear lever into low gear.
  • Page 400 Centaur Service Manual Transmission TR-381 TR-382 6. Adjust the high/low shift cable at the threaded yoke and reconnect to the shift block. Photo TR-383 Place the shifter into low to obtain the 3/8” setting as shown in Photo TR-380 on the previous page.
  • Page 401 Transmission Centaur Service Manual TR-386 TR-385 3. Continue slipping the bolt through the shifter box assembly, through another nylon washer and the shift lever knuckle. Photo TR-386 4. Slip on a third nylon washer and a second shift block assembly (2 Cams), then a fourth nylon washer between the double cam block and the inside wall of the shift box assembly’s right side.
  • Page 402 Centaur Service Manual Transmission TR-391 TR-390 6. Mount the 3 micro switches to the shift TR-392 box assembly using the specified hard- ware. Two are mounted to the right and 1 is mounted to the left. Connect the green jumper cable between the two sides to link the switches for the neutral safety feature.
  • Page 403 Transmission Centaur Service Manual TR-394 TR-395 8. Thread the shift cable yoke to the shift cable and adjust so that when connected to the shift block assembly, the shift block’s arm is 90 degrees to the base of the shift box. Photo TR-395 9.
  • Page 404 Centaur Service Manual Transmission TR-398 TR-399 Ontario Drive & Gear Limited www.centaur8x8.ca TR-77 (519) 662-2840 FAX (519) 662-2421...
  • Page 405 Centaur Service Manual SECTION TR Supplement Pages Transmission Ontario Drive & Gear Limited www.centaur8x8.ca (519) 662-2840 FAX (519) 662-2421...
  • Page 406 Transmission Transmission Centaur Service Manual Centaur Service Manual From Serial Number 0301191 Includes *O-ring *NOTE: O.D.G does not stock these o-rings. If replacement is necessary, it may be ordered by standard industry code elsewhere. Standard Industry Code is: “O-Ring, AS568-910 - .755” I.D. x .097” Thick Ontario Drive &...
  • Page 407 Centaur Service Manual Transmission Ref. Qty. Part # Description Ref. Qty. Part # Description 112-20 HHCS M8x1,25x25mm Zn 610-103 Bushing, Gates QD - SH w/21T Spline 108-05 Lockwasher 5/16 Split-Ring Zn 112-91 HHCS M10x1,5x150MM Zn 104-27 Pin, Clevis 5/16 x .75" Zn 610-114 Filter, Oil Hydrostat 100-100...
  • Page 408 Centaur Service Manual Transmission From Serial Number 0301191 Ref. Qty. Part # Description CE-017 Shaft, Reverse CE-028 Fork, Shift -Reverse 111-08 Pin, Spring 0.125 Dia x 0.75 Long CE-016 Idler, Reverse -28T 101-77 Bushing, Oilite AA-1232-4 (1.00 x 2.25) 101-74 Bearing, Ball 6305Z Cl.N.
  • Page 409 Transmission Centaur Service Manual Ref. Qty. Part # Description 109-02 Ball, Steel 1/4 Chromesteel 101-73 Bearing, Ball 6307 CL. N. 112-89 SHSS, M12 x 1,75 x 12 Cup Pt 486-05 Spring - 3/8 ID 479-03 Ball, Steel 3/8 Dia. 112-108 SHSS, M10 x 1,50 x 10 Plain 102-30 Seal, Oil CR#13946 35x50x8...
  • Page 410 Transmission Transmission Centaur Service Manual Centaur Service Manual Transmission Disassembly IMPORTANT The following instruction is a bare bones procedure illustrating the order and technique used in removing the main components from the CENTAUR transmission housing. For complete disassembly of each component, you may refer to the Transmission Assembly section which details step by step, the assembling of each gear assembly.
  • Page 411 Centaur Service Manual Transmission Remove the retaining ring from the output gear. Photo TR-2 IMPORTANT The next step requires the removal of the output shaft gear, steering shaft differential and drive shaft differential. These (3) components must be removed together and may require the assistance from a second pair of hands.
  • Page 412 Transmission Centaur Service Manual TR-5 TR-6 Removing the Pinions from the Gear Cage When each of the differentials has been disassembled, you will need to remove each of the planet shafts that secure the planet gears within the carrier assembly. Thread the specialized planet shaft puller (available from O.D.G), to the planet gear shaft and remove one at time from the gear carrier.
  • Page 414 Sauer-Danfoss Date: 4 February 2002 Service Parts List 90-1278 Item Part Number Description Usage 3103345 Housing 9004800-2506 9001310-0001 Ball bearing 3102029 Swashplate 3102020 Thrust plate 3101045 Trunnion shaft 3101703 Trunnion shaft 9009625-6904 Washer 9006320-0069 Retaining ring 9004690-1910 Spring pin 3103521 Valve plate 9004800-1508 9001355-0005...
  • Page 416 saue Series 70 / 15 Series Axial Piston Pumps, Motors, and Transmissions Technical Information...
  • Page 417 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Series 70 Transmissions and Pumps 2 Transmission Frame Sizes: 10 and 21 Variable Pump Version of 10 Frame Size Available Cost Effective, Compact Design Low Noise High Efficiency Worldwide Sales and Service 15 Series Pumps, Motors, and Transmissions Proven Reliability and Performance...
  • Page 418 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Series 70 Transmissions and Pumps A Complete Transmission Family to Meet Advanced Technology the Needs of the Lawn and Turf Equipment Compact, Lightweight Design Market Designed for Economical Manufacturing Two (2) Different Sizes - Design Provides for Reduced Operating .61 in...
  • Page 419 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Contents Description Page General Description ................................. 2 Technical Features ................................3 Product Configurations ..............................5 Technical Specifications - Series 70 Products ......................6 Technical Specifications - 15 Series Products ......................7 Type Designation and Order Code ..........................
  • Page 420 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Series 70 / 15 Series - Configuration Series 70 Units 15 Series Units Series 70 units are of axial piston design, utilizing 15 Series units are of axial piston design, utilizing spherical nosed pistons.

  • Page 421: Technical Specifications - Series 70 Products

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Technical Specifications - Series 70 Products Product Type “U” Style Transmissions Variable Pump BDU-10S BDU-10L BDU-21L BDP-10L Displacement Variable Pump (Maximum) /Rev 0.61 0.61 1.28 0.61 cc/Rev Fixed Motor /Rev 0.61 0.61...

  • Page 422: Technical Specifications - 15 Series Products

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Technical Specifications - 15 Series Products Product Type Transmissions Variable Pump Tandem Pump Fixed Motor 15 “U” 15 In-line 15 PV 15 PT 15 MF Displacement Variable Pump (Maximum) /Rev 0.913 0.913...
  • Page 423 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Series 70 Type Designation and Order Code BDU Transmissions and BDP Pumps PRODUCT OR SERIES BD = Bantam Duty Transmission or Variable Pump CONFIGURATION U = Transmission P = Pump - Variable (10 cc/Rev., Charge Pump Std.) DISPLACEMENT 10 = 10 cc/Rev (0.61 in /Rev.)
  • Page 424 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series 15 Series Typical Models Incorporating Standard Options 15 PV Model Pump Pump Control Number Shaft Side Comments 15-2125 Straight, Sq Key (E) 15-2133 17T Spline, Tapped (J) 15-2158 Straight, Wdrf Key (A) 7/8-14 Inlet 15 MF...

  • Page 425: Description Of Operation For Series 70 And 15 Series Products

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Description of Operation for Series 70 and 15 Series Products Basic Pump/Motor Circuit Variable Displacement Pump A typical hydrostatic transmission consists of a vari- The variable displacement pump (PV) is an axial able displacement axial piston pump connected in piston design.
  • Page 426 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Description of Operation for Series 70 and 15 Series Products (Continued) Charge Pump CASE Axial piston pumps and motors use a small amount of DRAIN COOLING ORIFICE fluid for internal lubrication. This results in fluid being CHARGE lost from the closed circuit that must be replenished.

  • Page 427: Implement Circuit

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Description of Operation for Series 70 and 15 Series Products (Continued) Implement Pump CASE Implement (auxiliary) flow capability is offered on the DRAIN Series 70 21 cc transmission and on 15 Series units. Charge (implement) pump sizes available are .18 in CHARGE Rev.

  • Page 428: Easy-Ride Valves

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Description of Operation for Series 70 and 15 Series Products (Continued) Easy-Ride Valves The Series 70 BDU-21L transmissions are available CHARGE CHECK with optional Easy-Ride valves to reduce the rate of VALVES change in acceleration (“jerkiness”) in vehicle propel applications.
  • Page 429 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Notes...
  • Page 430 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series General Technical Specifications Speed Ratings Fluids Maximum speed is the highest operating speed Ratings and data for Sauer-Sundstrand products are recommended and cannot be exceeded without re- based on operating with premium hydraulic fluids duction in the life of the product or risking premature containing oxidation, rust, and foam inhibitors.

  • Page 431: Loads

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series General Technical Specifications (Continued) Temperature and Cooling Allowable Pump Input Shaft Side Loads The operating temperature of the transmission should The following graphs assume that a self tensioning not exceed 180°...
  • Page 432 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series General Technical Specifications (Continued) Direct Displacement Control (DDC) Implement Pump Performance The Direct Displacement Control can be located on The following graphs provide typical implement pump either side of the Series 70 and 15 Series transmis- performance information for the Series 70-BDU-21L sion or pump (except the BDP-10L).

  • Page 433: Efficiency And Performance Of Series 70 Units

    d n su Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Efficiency and Performance of Series 70 Units The following graphs provide typical efficiency and performance information for Series 70 units. BDU-10L Overall Efficiency BDU-10L Performance (@ 3000 RPM Pump Input Speed) (@ 3000 RPM Pump Input Speed) 3000 Full Displacement...

  • Page 434: Efficiency And Performance Of 15 Series Units

    d n su Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Efficiency and Performance of 15 Series Units The following graphs provide typical efficiency and performance information for 15 Series units. 15 PV OutputFlow 15 MF Output Speed (@ Full Displacement) 5000 4500...
  • Page 435 d n su Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Definitions of Typical Lawn and Garden and Turf Maintenance Vehicles Lawn Tractor – Vehicle with an 8 to 16 horsepower (6 Front Mount Mower – Vehicle used primarily for to 12 kW) gasoline engine that is used primarily for mowing, where the mowing attachment is located in mowing with limited drawbar capability and some...
  • Page 436 d n su Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Component Selection (Continued) Because there are no system pressure relief valves in Series 70 / 15 Series Transmission System Series 70 units and many 15 Series transmissions, Operating Pressure Limits (and the maximum hydrostatic motor torque should occur Corresponding Motor Output Torques) for...
  • Page 437 d n su Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • Series 70 BDU-10S and BDU-10L Transmission inches [mm] Input Shaft Rotation Control Shaft Rotation Output Shaft Rotation 7/16—20 SAE STR THD O-RING BOSS CHARGE PUMP INLET 2 (FOR UNITS WITH 9/16—18 SAE STR CHARGE PUMP ONLY)
  • Page 438 d n su Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • Series 70 BDP-10L Pump inches [mm] Input Shaft Rotation Control Shaft Rotation Port A Flow Port B Flow 1.25 [31.70] 0.020 R [0.508] (2) PLACES 0.39 [10.00] 4.02 0.591DIA [15.000]...
  • Page 439 d n su Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • Series 70 BDU-21L Transmission inches [mm] Input Shaft Rotation Control Shaft Rotation Output Shaft Rotation 2.05 [52.07] MOUNTING SURFACE .625 DIA [15.88] (REF) 5.24 [133.1] PITCH DIA .5938 [15.08] 30 PRESSURE ANGLE 19 TEETH 32/64 PITCH...

  • Page 440: Dimensions • 15 Series Variable Displacement Pump • 15 Pv

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • 15 Series Variable Displacement Pump • 15 PV Input Shaft Rotation [in.] Control Trunnion Rotation Port A Flow Port B Flow 134.1 9/16 — 18 SAE STR [5.28] THD O-RING BOSS FROM IMPLEMENT...
  • Page 441 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • 15 Series Variable Displacement Pump • 15 PV Input Shaft Rotation [in.] Control Trunnion Rotation Port A Flow Port B Flow 134.1 9/16 — 18 SAE STR [5.28] THD O-RING BOSS FROM IMPLEMENT...
  • Page 442 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • 15 Series Variable Displacement Pump • 15 PV (Continued) [in.] MOUNTING FLANGE (REF) 57.15 [2.250] 4.7625 [0.1875] SQ KEY 25.4 [1.00] LONG 3.6 [0.14] MAX 1.17 [0.046] MAX 21.13 [0.832] 19.02 DIA [0.749]...

  • Page 443: Dimensions • 15 Series Variable Displacement Tandem Pump (15 Pt)

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • 15 Series Variable Displacement Tandem Pump (15 PT)

  • Page 444: Dimensions • 15 Series Fixed Displacement Motor • 15 Mf

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • 15 Series Fixed Displacement Motor • 15 MF Dimensions in inches Flow Direction Output Shaft Rotation Port A Port B Clockwise (CW) Counter-clockwise (CCW) 1.35 3/4 — 16 UNF-2B SAE STRT THD 3/4 —...

  • Page 445: Dimensions • 15 Series In-Line Transmission

    saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • 15 Series In-line Transmission Pickup Drawing from old book...
  • Page 446 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Dimensions • 15 Series “U” Style Transmission...
  • Page 447 saue Axial Piston Pumps, Motors, and Transmissions Series 70 / 15 Series Notes...
  • Page 448 saue Hydraulic Power Systems SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide SAUER-SUNDSTRAND is a world leader in the design and SAUER-SUNDSTRAND specializes in integrating a full manufacture of Hydraulic Power Systems. Research and range of system components to provide vehicle designers development resources in both North America and Europe with the most advanced total-design system.
  • Page 450 Centaur Products Manufactured by: Ontario Drive & Gear Limited 220 Bergey Court New Hamburg, Ontario CANADA N3A 2J5 www.centaur8x8.ca Dedicated to quality and performance.

This manual is also suitable for:

Centaur 950dtCentaur 950d2001 9502001 950d2001 950dt

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