TEREX Equipment Limited Maintenance Manual

TA27 - TA30
MAINTENANCE MANUAL

15503430
SM889/892/
894/897/908 CLICK HERE FOR TABLE OF CONTENTS
THIS PAGE IS INTENTIONALLY BLANK
 TEREX Equipment Limited Maintenance Manual Re-order

Issued by;
Customer Support Department
Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
TA27 - TA30

Scotland
MAINTENANCE MANUAL

Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210

www.terex.com

Technical Assistance:
http://constructionsupport.terex.com

SM889/892/894/897/908

Re-order Part Number

15503430

Revision: April 2010

15503430
SM889/892/894/
897/908
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 TEREX Equipment Limited Maintenance Manual - Introduction

For further information on the subject matter detailed within this Maintenance Manual,
please refer to Terex Equipment Limited Operator Handbooks and Product Parts
Books.

Alternatively, please contact;

Customer Support Department

TA27 - TA30

Terex Equipment Limited

Newhouse Industrial Estate
Motherwell, ML1 5RY
MAINTENANCE MANUAL

Tel; +44 (0) 1698 732121

Fax; +44 (0) 1698 503210

The illustrations, technical information, data and descriptive text in this manual, to the
best of our knowledge, were correct at the time of print. The right to change
specifications, equipment and maintenance instructions at any time without notice, is
reserved as part of the Terex Equipment Limited policy of continuous development
and improvement of the product.

No part of this publication may be reproduced, transmitted in any form - electronic,

mechanical, photocopying, recording, translating or by any other means without prior
permission of Customer Support Department - Terex Equipment Limited.

Please refer to TEREX Specification Sheets or consult Factory Representatives to

ensure that information is current.

15503430
SM889/892/
894/897/908
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 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all motor vehicles. The service
procedures recommended and described in this publication, are effective methods for performing service
operations. Some of these service operations require the use of tools specially designed for the purpose.
The special tools should be used when, and as recommended.

It is important to note that this publication contains various WARNINGS and NOTES which should be
carefully read in order to minimize the risk of personal injury to personnel, or the possibility that improper
service methods will be followed which may damage the vehicle or render it unsafe. It is also important to
understand these WARNINGS and NOTES are not exhaustive. It is not possible to know, evaluate and
advise the service trade of ALL conceivable ways in which service might be carried out, or, of the possible
hazardous consequences of each way. Consequently, no such broad evaluation has been undertaken.
Accordingly, anyone who uses a service procedure, or tool, which is not recommended, must first satisfy
themselves thoroughly that neither their safety, nor vehicle safety, will be jeopardized by the service
method he/she selects.

Safety Alert Symbol

The safety alert symbol is used to alert you to a potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.

Hazard Classification
A multi-tier hazard classification system is used to communicate potential personal injury hazards. The following
signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard. Signal
words used without the safety alert symbol relate to property damage and protection only. All are used as
attention getting devices throughout this manual as well as on deals and labels fixed to the machinery to assist in
potential hazard recognition and prevention.

DANGER indicates an imminently hazardous situation which, if not avoided, will

DANGER result in death or serious injury.

WARNING indicates an potentially hazardous situation which, if not a

voided, could
WARNING result in death or serious injury.

CAUTION indicates an potentially hazardous situation which, if not avoided, may

CAUTION result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous
CAUTION
situation which, if not avoided, may result in property damage.

WARNING
Never use parts which are altered, modified, or weakened in operation. This can seriously jeopardise
the integrity of the machine and could result in property damage or serious personal injury.

SM 2495 03-07
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 TABLE OF CONTENTS

Section No. Description SM No.

000 GENERAL INFORMATION
0000 Technical Data - TA27 2474 Rev 4
0000 Technical Data - TA30 2462 Rev 4
0010 Welding Procedure 2172
100 CHASSIS
0010 Frames 2170
0020 Articulation and Oscillation Pivot 2273
0040 Hood and Mounting 2173
110 ENGINE
0030 Engine and Mounting 2324 Rev 3
0040 Cooling Fan 2175
0050 Air Cleaner 2176
120 TRANSMISSION
0010 Transmission and Mounting 2177 Rev 5
130 DRIVELINES
0010 Front and Rear Drivelines 2178
140 FRONT AXLE GROUP
0020 Axle Group (Hub) 2494 Rev 1
0040 Wheel Rim and Tyre (Refer to Section 160-0050) -
0060 Differential Drive Head (Refer to Section 160-0020) -
0100 Differential Lock Controls 2473 Rev 1

150 CENTRE AXLE

0020 Differential Drive Head 2469 Rev 1
160 REAR AXLE GROUP
0020 Differential Drive Head 2463 Rev 2
0030 Axle Group (Hub) 2363 Rev 3
0050 Wheel Rim and Tyre 2449
165 BRAKE ASSEMBLY
0010 Oil Immersed Disc Brakes (Refer to Section 160-0030) -

170 PARKING BRAKE

0010 Parking Brake and Mounting 2409 Rev 2
180 SUSPENSION SYSTEM
0020 Front Suspension (Later Style) 2560
0020 Front Suspension (IFS) 2365 Rev 1
0040 Rear Suspension 2183 Rev 2

190 ELECTRICAL SYSTEM

0000 Circuit Diagrams 2466 Rev 4
0085 Hydraulic System ECU 2200 Rev 2
0270 Switches and Sensors 2465 Rev 1

SM 2496 Rev 18 04-10 1

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2 SM 2496 Rev 18 04-10

 TABLE OF CONTENTS

Section No. Description SM No.

200 FUEL SYSTEM
0040 Fuel System 2186
0051 Electronic Foot Pedal 2472
210 COOLING SYSTEM
0000 Cooling System 2455 Rev 1
0040 Radiator and Mounting 2325
0060 Transmission Oil Cooler 2190 Rev 1
0100 Hydraulic Oil Cooler 2191
215 MAIN HYDRAULIC VALVE
0050 Main Hydraulic Valve Assembly 2192 Rev 3
220 STEERING SYSTEM
0000 Steering System Schematic 2197 Rev 1
0090 Steering Valve 2193
0120 Steering Cylinder 2195
230 BODY SYSTEM
0000 Body System Schematic 2199 Rev 4
0040 Hydraulic Tank 2350
0050 Main Hydraulic Pump 2196 Rev 1
0081 Body Control Lever 2202 Rev 1
0130 Body Cylinder 2207
250 BRAKING SYSTEM
0000 Braking System Schematic 2485 Rev 3
0060 Accumulators 2326 Rev 2
0070 Treadle Valve 2486 Rev 4
260 OPERATOR'S COMPARTMENT
0010 Cab and Mounting 2493
0090 Driver Seat and Mounting 2210
0110 Instructor Seat and Mounting 2572
0130 Air Conditioning 2211 Rev 1
270 BODY
0010 Body and Mounting 2212 Rev 1
300 MISCELLANEOUS
0020 Lubrication System 2360 Rev 11
0070 Service Tools 2468
0080 Axle Bolt and Nut Torque Specifications 1521
0080 Standard Bolt and Nut Torque Specifications 1238 Rev 1
0090 Unit Storage 2629

* * * *

SM 2496 Rev 18 04-10 3

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4 SM 2496 Rev 18 04-10

 General Information - Technical Data TA27
Section 000-0000
SM - 3319

2 685
Max. (8-10)
Body 1 240
Depth (4-1) 2 895
(9-6)

45˚

6 015
65˚ (19-9)
SAE Turning Radius 8 470mm (27-9)
Clearing Radius 8 950mm (29-4)

5 000
(16-5)
4 930
(16-2)
3 450
(11-3) GENERATION

3 420
(11-2)
3 120 2 740
(10-3) (8-11)

2 175
(7-0)
405 725
(1-6) (2-3)
1 580
(5-3)
2 200 2 400 1 310 2 945 1 690 1 410
(7-2) (7-9) (4-4) (9-8) (5-6) (4-9)
2 895 9 755
(9-6) (32-0)

Fig. 1 - Machine Dimensions

ENGINE
overspeed. Blocked filter indicator and filter bypass system
Make/Model .............................................. Cummins QSM11 provide valve block with additional protection from unfiltered
Type ............. Four cycle diesel, turbocharged with air-to-air oil.
charge cooling, water-cooled. Electronic management.
Pressures:
Gross power at 1800 rev/min .................... 272 kW (365 hp) Main ........................................ 16 + 2 bar (232 + 30 lbf/in²)
Net power at 2100 rev/min ........................ 238 kW (319 hp) Lockup (Wk) ........................... 14 ± 1 bar (190 ± 15 lbf/in²)
Converter 'IN' .......... 10.5 bar (152 lbf/in²) at 2300 rev/min
Note: Gross power rated to SAE J1995 Jun 90. Engine
Converter 'OUT' ........... 4.8 bar (70 lbf/in²) at 2300 rev/min
emission meets USA EPA/CARB Tier III and EU NRMM
Converter Relief Valve ........................ 8.5 bar (123 lbf/in²)
(non-road mobile machinery) Tier III directive.
Retarder ................................................ 5.5 bar (80 lbf/in²)
Maximum Torque ...... 1673 Nm (1234 lbf ft) at 1400 rev/min Temperatures:
Number of cylinders/configuration .......................... 6, in line Normal ................................... 80° - 110° C (176° - 230° F)
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in) Maximum (Retarder Mode) ....................... 145° C (293° F)
Piston Displacement .............................. 10.8 litres (661 in³) Stall Speed .............................................. 1718 ± 50 rev/min
Air cleaner .................................... Dry type, double element Ratios:
Starting ..................................................................... Electric Torque Converter .................................................... 1.84:1
Maximum Speed (No load) ............................. 2350 rev/min Transmission ..................................... Refer to table below
Maximum Speed (Full load) ............................ 2100 rev/min
Idle Speed ......................................................... 750 rev/min
Forward
Gear 1 2 3 4 5 6
TRANSMISSION
km/h 5.6 8.7 13.6 21.1 31.0 51.0
Make/Model .................................... ZF 6WG 260 Automatic
with manual override. The transmission assembly consists
mile/h 3.5 5.4 8.5 13.1 19.3 31.7
of a torque converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. Automatic Reverse
shifting throughout the range, with kickdown feature. Lockup
action in all forward gears. A torque proportioning output
Gear 1 2 3
differential transmits drive permanently to front and rear km/h 5.6 13.6 31.0
axles. This differential may be locked by the driver for use in mile/h 3.5 8.5 19.3
difficult traction conditions. Optional integral hydraulic
retarder which automatically operates should the engine
SM 2474 Rev 4 10-08 1
General Information - Technical Data TA27
Section 000-0000
AXLES HYDRAULIC SYSTEM
Three axles in permanent all-wheel drive with differential Braking, steering and body hoist systems are controlled by
coupling between each axle to prevent driveline wind-up. a main hydraulic valve mounted on frame. Systems are
Heavy duty axles with fully-floating axle shafts and outboard supplied with oil from a common tank by the main hydraulic
planetary reduction gearing. pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
Transverse differential locks are activated by a request from line.
the foot operated switch.
Pump:
Type ......................................................................... Piston
Ratios: Capacity at 2100 rev/min ........... 4.9 l/s (77.4 US gal/min)

Differential ............................................................. 3.875:1 Brakes

Planetary ................................................................. 5.71:1 Full hydraulic braking system with enclosed, oil-immersed
Total Reduction ..................................................... 22.12:1 multiple discs on each wheel. Independent circuits for front
and rear brake systems. Warning lights and audible alarm
SUSPENSION indicate low brake system pressure. Brake system
Front: Axle is carried on the leading arms of a sub-frame conforms to ISO 3450, SAE J1473.
which pivots on the main frame. Suspension is by rubber
elements with four heavy duty hydraulic dampers. Actuating Pressure ................ 60 ± 5.2 bar (870 ± 75 lbf/in²)
Rear: Each axle is coupled to the frame by three rubber-
bushed links with lateral restraint by a transverse link. Braking surface (tractor) ............ 22000 mm2 (34.1 in 2)/brake
Pivoting inter-axle balance beams equalise load on each Braking surface (trailer) ............. 22000 mm2 (34.1 in 2)/brake
axle. Suspension movement is cushioned by rubber/metal
laminated compression units between each axle and Parking: Spring-applied, hydraulic-released disc on
underside of balance beam ends. Pivot points on rear rear driveline.
suspension linkages are rubber-bushed and maintenance-
free. Emergency: Automatic application of driveline brake
should pressure fall in main brake hydraulic
system. Service brakes may also be applied
WHEELS AND TYRES using the parking-emergency brake control.
Wheels: ............ 5-piece earthmover rims with 12 stud fixing
Size: Retardation: Hydraulic retarder integral with transmission.
Standard ....................... 25 x 19.50 in for 23.5 R25** tyres
Optional .................... 25 x 22.00 in for 750/65 R25** tyres
Tyres: Steering
Standard ........................................................... 23.5 R25** Hydrostatic power steering by two single-stage, double-
Optional ........................................................ 750/65 R25** acting, cushioned steering cylinders. Emergency steering
pressure is provided by a ground driven pump mounted on
Inflation Pressures (Bridgestone): the rear of the transmission. An audible alarm and warning
Front Rear light indicates should the emergency system activate.
23.5 R25** ...... 4.35 bar (63 lbf/in²) 4.35 bar (63 lbf/in²) Conforms to ISO 5010, SAE J53.
750/65 R25** ....... 3 bar (44 lbf/in²) 3 bar (44 lbf/in²)
System Pressure ................................ 241 bar (3500 lbf/in²)
Inflation Pressures (Michelin): Steering Angle to either side .......................................... 45°
Front Rear Lock to Lock Turns, steering wheel .................................... 4
23.5 R25** ........ 3.5 bar (51 lbf/in²) 3.5 bar (51 lbf/in²)
750/65 R25** .. 2.75 bar (40 lbf/in²) 2.75 bar (40 lbf/in²) Body Hoist
Two single-stage, double-acting hoist rams, cushioned at
Inflation Pressures (Pirelli): both ends of stroke. Electro servo assisted hoist control.
Front Rear
23.5 R25** ........ 4.3 bar (62 lbf/in²) 4.3 bar (62 lbf/in²) System Pressure ................................. 220 bar (3 200 lbf/in²)
Control Valve ....................... Pilot Operated, Closed Centre
Inflation Pressures (Continental): Body Raise Time (loaded) .......................................... 12 sec
Front Rear Body Lower Time (power down) ................................ 7.5 sec
23.5 R25** ...... 4.25 bar (62 lbf/in²) 4.25 bar (62 lbf/in²)
ELECTRICAL SYSTEM
Type .............................................. 24 volt, Negative Ground
Battery ............................................. Two, 12 V, 143 Ah each
Note: Tyre pressures should be regarded as nominal only. It Accessories ................................................................... 24 V
is recommended that for tyres both listed and unlisted, the Alternator .................................................................. 70 Amp
user should consult the tyre manufacturer and evaluate all
job conditions in order to make the proper selection.

2 SM 2474 Rev 4 10-08

 General Information - Technical Data TA27
Section 000-0000

BODY vibrations.
The single whole-body emission value listed above is
Of all welded construction, fabricated from high hardness determined under particular operating and terrain
(min. 360 BHN) 1000 MPa (145000 lbf/in²) yield strength
conditions. In accordance with EN474 it is not intended to
steel. 25° tail chute angle provides good load retention be used to determine the whole-body vibration exposure to
without tailgate. the operator using this machine.
Plate Thicknesses: Note 2: It is recognized that the appropriate design of
Floor and Tailchute ................................... 14 mm (0.55 in) operator’s seat is the most effective construction measure
Sides ......................................................... 12 mm (0.47 in) to minimize the whole-body vibration emission of a
Front ........................................................... 8 mm (0.31 in) particular machine family.
Volume: This machine is equipped with an operator’s seat which
Struck (SAE) .......................................... 12.5 m³ (16.4 yd³) meets the criteria of EN ISO 7096 representing vertical
Heaped 2:1 (SAE) ................................. 15.5 m³ (20.3 yd³) vibration under severe operating conditions.

SERVICE CAPACITIES The seat in this machine has been tested with input
Fuel tank .................................................. 390 l (103 US gal) spectral class EM1 and has a seat transmissibility factor
Hydraulic System .................................... 202 l (53.4 US gal) SEAT >1.1.
Engine Crankcase and filters ..................... 34 l (9.0 US gal)
Cooling System ........................................ 55 l (14.5 US gal)
Transmission (including cooler) ............... 63 l (16.6 US gal)
Differentials - Front & Rear (each) ............. 28 l (7.4 US gal)
Differential - Centre .................................... 31 l (8.2 US gal)
Planetaries - Front ...................................... 11 l (3.0 US gal)
Vehicle Weights 23.5 R25 Tyres
Planetaries - Centre & Rear (each) ........... 7.5 l (2.0 US gal) Standard Vehicle kg lb
Hand Pump Tank ........................................ 1 l (0.26 US gal) Net Distribution
Air Conditioning Compressor ............ 0.125 l (0.033 US gal)
Front Axle 11724 25793
Centre Axle 5205 11451
VIBRATION AND SOUND INFORMATION Rear Axle 5276 11709
Operator Ear (ISO 6394) ........................................... 78 dbA Vehicle, Net 22205 48953
*Exterior Sound Rating (ISO 6395) .......................... 108 dbA Payload 25000 55115
* - The above result is for the mode giving the highest Gross Distribution
exterior sound level when measured and operated as per Front Axle 15880 34936
the prescribed procedures of the standard. Results shown Centre Axle 15592 34302
are for the vehicle in base configuration. Rear Axle 15733 34830
Vehicle, Gross 47205 104068
Note: Noise Level Exposure to the operator and bystander
personnel may be higher depending upon proximity to Bare Chassis 17335 38213
buildings, rock piles, machinery etc.. The actual job site Body 4100 9040
Noise Level Exposure must be measured and applicable Body Hoists (Pair) 530 1 170
regulations complied with in respect to Employee Hearing
Protection.

Hand and Arm Vibration Ground Pressures

The weighted root mean square acceleration to which the
At 15% sinkage of unloaded radius and specified weights
hand and arms of the operator are exposed is less than 2.5
m/s² under normal operating conditions. 23,5 R25 Net Loaded
Front 118 kPa (17.1 psi) 161 kPa (23.3 psi)
Whole Body Vibration Rear 53 kPa (7.6 psi) 158 kPa (22.9 psi)
Under simulated field duty cycle, the weighted root mean
square acceleration emission of the machine to which the 750/65 R25 Net Loaded
body is subjected is less than 0.5 m/s². Front 87 kPa (12.6 psi) 119 kPa (17.3 psi)
Rear 40 kPa (5.8psi) 119 kPa (17.3 psi)
Note 1: Whole body vibrations on construction machines
are influenced by many factors independent of machine
design, for example ground conditions, working methods,
correct seat adjustment, operator input to vehicle speed.
It is therefore not possible to state one single value which is
representative of operator’s exposure to whole body

* * * *

SM 2474 Rev 4 10-08 3

General Information - Technical Data TA27
Section 000-0000

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4 SM 2474 Rev 4 10-08

 General Information - Technical Data TA30
Section 000-0000
SM - 3286

2 685
Max. (8-10)
Body 1 445
Depth (4-9) 2 895
(9-6)

45˚

6 110
65˚ (20-0)
SAE Turning Radius 8 470mm (27-9)
Clearing Radius 8 950mm (29-4)

5 010
(16-5)
4 920
(16-2)
3 450
(11-3) G E N E R AT I O N

3 420
(11-2)
3 325 2 895
(10-10) (9-6)

2 175
(7-0)
405 725
(1-6) (2-3)
1 580
(5-3)
2 200 2 400 1 310 2 945 1 690 1 410
(7-2) (7-9) (4-4) (9-8) (5-6) (4-9)
2 895 9 755
(9-6) (32-0)

Fig. 1 - Machine Dimensions

ENGINE
overspeed. Blocked filter indicator and filter bypass system
Make/Model .............................................. Cummins QSM11 provide valve block with additional protection from unfiltered
Type ............. Four cycle diesel, turbocharged with air-to-air oil.
charge cooling, water-cooled. Electronic management.
Pressures:
Gross power at 1800 rev/min .................... 287 kW (385 hp) Main ........................................ 16 + 2 bar (232 + 30 lbf/in²)
Net power at 2100 rev/min ........................ 248 kW (333 hp) Lockup (Wk) ........................... 12 ± 2 bar (174 ± 30 lbf/in²)
Converter 'IN' .......... 10.5 bar (152 lbf/in²) at 2300 rev/min
Note: Gross power rated to SAE J1995 Jun 90. Engine
Converter 'OUT' ........... 4.8 bar (70 lbf/in²) at 2300 rev/min
emission meets USA EPA/CARB Tier III and EU NRMM
Converter Relief Valve ........................ 8.5 bar (123 lbf/in²)
(non-road mobile machinery) Tier III directive.
Retarder ................................................ 5.5 bar (80 lbf/in²)
Maximum Torque ...... 1775 Nm (1309 lbf ft) at 1400 rev/min Temperatures:
Number of cylinders/configuration .......................... 6, in line Normal ............................ 80 °C - 110 °C (176 °F - 230 °F)
Bore x Stroke ........................ 125 x 147 mm (4.92 x 5.79 in) Maximum (Retarder Mode) ...................... 145 °C (293 °F)
Piston Displacement ..................................... 10.8 l (661 in³) Stall Speed .............................................. 1805 ± 50 rev/min
Air cleaner .................................... Dry type, double element Ratios:
Starting ..................................................................... Electric Torque Converter .................................................... 1.84:1
Maximum Speed (No load) ............................. 2350 rev/min Transmission ..................................... Refer to table below
Maximum Speed (Full load) ............................ 2100 rev/min
Idle Speed ......................................................... 750 rev/min
Forward
Gear 1 2 3 4 5 6
TRANSMISSION
km/h 5.6 8.7 13.6 21.1 31.0 51.0
Make/Model ............................ ZF 6WG 310 RPC Automatic
with manual override. The transmission assembly consists
mile/h 3.5 5.4 8.5 13.1 19.3 31.7
of a torque converter close-coupled to a countershaft-type
gearbox with integral output transfer gearing. Automatic Reverse
shifting throughout the range, with kickdown feature. Lockup
action in all forward gears. A torque proportioning output
Gear 1 2 3
differential transmits drive permanently to front and rear km/h 5.6 13.6 31.0
axles. This differential may be locked by the driver for use in mile/h 3.5 8.5 19.3
difficult traction conditions. Standard integral hydraulic
retarder which automatically operates should the engine
SM 2462 Rev 4 10-08 1
General Information - Technical Data TA30
Section 000-0000
AXLES HYDRAULIC SYSTEM
Three axles in permanent all-wheel drive with differential Braking, steering and body hoist systems are controlled by
coupling between each axle to prevent driveline wind-up. a main hydraulic valve mounted on frame. Systems are
Heavy duty axles with fully-floating axle shafts and outboard supplied with oil from a common tank by the main hydraulic
planetary reduction gearing. pump, driven from power takeoff on transmission. System
components are protected by full flow filtration on the return
Transverse differential locks are activated by a request from line.
the foot operated switch. Locking of transverse differential
locks is actuated simultaneously with the transmission Pump:
output differential lock. Type ......................................................................... Piston
Capacity at 2 100 rev/min .......... 4.9 l/s (77.4 US gal/min)
Ratios:
Differential ............................................................. 3.875:1 Brakes
Planetary ................................................................. 5.71:1
Total Reduction ..................................................... 22.12:1 Full hydraulic braking system with enclosed, oil-immersed
multiple discs on each wheel. Independent circuits for front
and rear brake systems. Warning lights and audible alarm
SUSPENSION indicate low brake system pressure. Brake system
Front: Axle is carried on the leading arms of a sub-frame conforms to ISO 3450, SAE J1473.
which pivots on the main frame. Suspension is by rubber
elements with four heavy duty hydraulic dampers. Actuating Pressure ................ 60 ± 5.2 bar (870 ± 75 lbf/in²)
Rear: Each axle is coupled to the frame by three rubber-
bushed links with lateral restraint by a transverse link.
Braking surface (tractor) ............ 22000 mm2 (34.1 in 2)/brake
Pivoting inter-axle balance beams equalise load on each
Braking surface (trailer) ............. 22000 mm2 (34.1 in 2)/brake
axle. Suspension movement is cushioned by rubber/metal
laminated compression units between each axle and
Parking: Spring-applied, hydraulic-released disc on
underside of balance beam ends. Pivot points on rear
rear driveline.
suspension linkages are rubber-bushed and maintenance-
free.
Emergency: Automatic application of driveline brake
WHEELS AND TYRES should pressure fall in main brake hydraulic
system. Service brakes may also be applied
Wheels: ............ 5-piece earthmover rims with 12 stud fixing using the parking-emergency brake control.
Size:
Standard ....................... 25 x 19.50 in for 23.5 R25** tyres Retardation: Hydraulic retarder integral with transmission.
Optional .................... 25 x 22.00 in for 750/65 R25** tyres
Tyres: Steering
Standard ........................................................... 23.5 R25**
Optional ........................................................ 750/65 R25** Hydrostatic power steering by two single-stage, double-
acting, cushioned steering cylinders. Emergency steering
Inflation Pressures (Bridgestone): pressure is provided by a ground driven pump mounted on
Front Rear the rear of the transmission. An audible alarm and warning
23.5 R25** ...... 4.75 bar (69 lbf/in²) 4.75 bar (69 lbf/in²) light indicates should the emergency system activate.
750/65 R25** .. 3.25 bar (47 lbf/in²) 3.25 bar (47 lbf/in²) Conforms to ISO 5010, SAE J53.

Inflation Pressures (Michelin): System Pressure ................................ 241 bar (3 500 lbf/in²)
Front Rear Steering Angle to either side ............................................ 45°
23.5 R25** ........ 4.0 bar (58 lbf/in²) 4.0 bar (58 lbf/in²) Lock to Lock Turns, steering wheel .................................... 4
750/65 R25** .... 3.0 bar (44 lbf/in²) 3.0 bar (44 lbf/in²)
Body Hoist
Inflation Pressures (Pirelli): Two single-stage, double-acting hoist rams, cushioned at
Front Rear both ends of stroke. Electro servo assisted hoist control.
23.5 R25** ........ 4.8 bar (70 lbf/in²) 4.8 bar (70 lbf/in²)
System Pressure ................................ 220 bar (3200 lbf/in²)
Inflation Pressures (Continental): Control Valve ....................... Pilot Operated, Closed Centre
Front Rear Body Raise Time (loaded) ......................................... 12 sec
23.5 R25** ........ 5.0 bar (73 lbf/in²) 5.0 bar (73 lbf/in²) Body Lower Time (power down) ............................... 7.5 sec

Inflation Pressures (Marangoni): ELECTRICAL SYSTEM

Front Rear Type ................................................. 24 V, Negative Ground
750/65 R25** .... 3.0 bar (43 lbf/in²) 3.0 bar (43 lbf/in²) Battery ............................................. Two, 12 V, 143 Ah each
Accessories ................................................................... 24 V
Note: Tyre pressures should be regarded as nominal only. It Alternator .................................................................. 70 Amp
is recommended that for tyres both listed and unlisted, the
user should consult the tyre manufacturer and evaluate all
job conditions in order to make the proper selection.

2 SM 2462 Rev 4 10-08

 General Information - Technical Data TA30
Section 000-0000
BODY vibrations.
Of all welded construction, fabricated from high hardness The single whole-body emission value listed above is
(min. 360 BHN) 1000 MPa (145000 lbf/in²) yield strength determined under particular operating and terrain
steel. 25° tail chute angle provides good load retention conditions. In accordance with EN474 it is not intended to
without tailgate. be used to determine the whole-body vibration exposure to
the operator using this machine.
Plate Thicknesses:
Floor and Tailchute ................................... 14 mm (0.55 in) Note 2: It is recognized that the appropriate design of
Sides ......................................................... 12 mm (0.47 in) operator’s seat is the most effective construction measure
Front ........................................................... 8 mm (0.31 in) to minimize the whole-body vibration emission of a
particular machine family.
Volume:
Struck (SAE) .......................................... 13.8 m³ (18.0 yd³) This machine is equipped with an operator’s seat which
Heaped 2:1 (SAE) ................................. 17.5 m³ (22.9 yd³) meets the criteria of EN ISO 7096 representing vertical
vibration under severe operating conditions.
SERVICE CAPACITIES
The seat in this machine has been tested with input
Fuel tank .................................................. 398 l (103 US gal)
spectral class EM1 and has a seat transmissibility factor
Hydraulic System .................................... 202 l (53.4 US gal)
SEAT >1.1.
Engine Crankcase and filters ..................... 34 l (9.0 US gal)
Cooling System ........................................ 55 l (14.5 US gal)
Transmission (including cooler) ............... 63 l (16.6 US gal)
Differentials - Front & Rear (each) ............. 28 l (7.4 US gal)
Differential - Centre .................................... 31 l (8.2 US gal)
Planetaries - Front ...................................... 11 l (3.0 US gal) Vehicle Weights 23.5 R25 Tyres
Planetaries - Centre & Rear (each) ........... 7.5 l (2.0 US gal) Standard Vehicle kg lb
Hand Pump Tank ........................................ 1 l (0.26 US gal)
Net Distribution
Air Conditioning Compressor ............ 0.125 l (0.033 US gal)
Front Axle 11753 25913
Centre Axle 5315 11718
VIBRATION AND SOUND INFORMATION Rear Axle 5417 11942
Operator Ear (ISO 6394) ........................................... 78 dbA Vehicle, Net 22485 49573
*Exterior Sound Rating (ISO 6395) .......................... 109 dbA Payload 28000 61730
* - The above result is for the mode giving the highest Gross Distribution
exterior sound level when measured and operated as per Front Axle 16821 37086
the prescribed procedures of the standard. Results shown Centre Axle 16740 36904
are for the vehicle in base configuration. Rear Axle 16924 37313
Vehicle, Gross 50485 111303
Note: Noise Level Exposure to the operator and bystander
personnel may be higher depending upon proximity to Bare Chassis 17555 38703
buildings, rock piles, machinery etc.. The actual job site Body 4400 9700
Noise Level Exposure must be measured and applicable Body Hoists (Pair) 530 1170
regulations complied with in respect to Employee Hearing
Protection.
Ground Pressures
Hand and Arm Vibration
The weighted root mean square acceleration to which At 15% sinkage of unloaded radius and specified weights
hand and arms of the operator are exposed is less than 23,5 R25 Net Loaded
2.5m/s² under normal operating conditions? Front 119 kPa (17.2 psi) 170 kPa (24.6 psi)
Rear 54 kPa (7.8 psi) 170 kPa (24.6 psi)
Whole Body Vibration
Under simulated field duty cycle, the weighted root mean 750/65 R25 Net Loaded
square acceleration emission of the machine to which the Front 90 kPa (13.1 psi) 128 kPa (18.6 psi)
body is subjected is less than 0.5 m/s². Rear 41 kPa (5.9 psi) 111 kPa (18.6 psi)
Note 1: Whole body vibrations on construction machines
are influenced by many factors independent of machine
design e.g ground conditions, working methods, correct
seat adjustment, operator input to vehicle speed.

It is therefore not possible to state one single value which is

representative of operator’s exposure to whole body

* * * *

SM 2462 Rev 4 10-08 3

General Information - Technical Data TA30
Section 000-0000

THIS PAGE IS INTENTIONALL Y BLANK

4 SM 2462 Rev 4 10-08

 General Information - Welding Procedure
Section 000-0010

Welding
WARNING
Welding and flame cutting cadmium plated
WARNINGS metals produce odourless fumes which are
Before any welding is done on a machine toxic. Recommended industrial hygiene
equipped with any electronic systems, practice for protection of the welding operator
disconnect the following (if applicable) in this from the cadmium fumes and metallic oxides
order: Battery earth cable, battery supply requires enclosure ventilation specifically
cable, alternator earth cables, alternator supply designed for the welding process. A
cables and electrical connections at the engine respiratory protective device such as the
ECM, transmission ECU, body control lever, M.S.A. 'Gasfoe' respirator with G.M.A. cartridge
hydraulics ECU and cab bulkhead to avoid will provide protection against cadmium,
damage to electrical components. Turn off fumes and metallic oxides. The 'Gasfoe'
battery master switch to isolate the batteries respirator has been approved by the U.S.
before disconnecting any components. Bureau of Mines: Approval number 23B-10,
After welding connect all of the above in the and is designed to protect against gases,
reverse order. vapours, and/or metal fumes.

Note: The current from the welding rod always follows

the path of least resistance. If, for example, the ground
Before any welding is done ensure all paint has clamp is attached to the rear frame when welding is
been removed from the area to be welded. performed on the front frame, the current must pass a
Failure to do so may result in hazardous fumes frame connection to return to the welding machine.
being given off from the paint. Since the pivot coupling offers the least resistance but
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
Note: Always fasten the welding machines ground cause welding blotches on their wearing surfaces and
cable to the piece/frame being welded if possible. increase the wear rate of these components.

Electric arc welding is recommended for all welded

frame repairs. Since the nature and extent of damage General Welding Procedure
to the frame cannot be predetermined, no definite The following general procedure should be used for
repair procedure can be established. As a general rule the repair of defects outwith the vicinity of alloy steel
however, if parts are twisted, bent or pulled apart, or a castings.
frame is bent or out of alignment, no welding should be
done until the parts are straightened or realigned. 1. Completely ARC-AIR gouge or grind out the crack
until sound metal is reached. If ARC-AIR method is
Successfully welded repairs will depend to a great employed, pre-heat area to 100° C (212° F), measure
extent upon the use of the proper equipment, materials 3 - 4" either side of repair prior to gouging. On
and the ability of the welder. The Customer Support completion of gouging grind to remove thin carbon
Department can be consulted regarding the feasibility layer.
of welding repairs.
2. Apply dye-penetrant check to ensure crack has
been completely removed.

SM 2172 10-02 1
General Information - Welding Procedure
Section 000-0010
3. Pre-heat area to 100° C (212° F), measured 3 - 4" 3 - 4" either side of repair prior to gouging. On
either side of repair. Avoid local overheating. completion of gouging grind to remove thin carbon
layer.
4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from 2. Apply dye-penetrant check to ensure crack has
moisture pick-ups at all times. been completely removed.

5. Allow repair weld to cool slowly. 3. Pre-heat area to 200° C (392° F), measured 3 - 4"
either side of repair. Avoid local overheating.
6. Grind and blend repair to original contour. Paint
heat damaged areas. 4. Weld completely using E-7016 electrodes. Care
must be taken to ensure electrodes are protected from
moisture pick-ups at all times.
The following general procedure should be used for
the repair of defects in alloy steel castings and in the 5. On completion of welding, post-heat repair area to
welds joining steel castings. 400° C (752° F), measure 3 - 4" either side of repair.

1. Completely ARC-AIR gouge or grind out the crack 6. If welding has to be interrupted for any reason, e.g.
until sound metal is reached. If ARC-AIR method is overnight, post-heat immediately as in Step 5.
employed, pre-heat area to 200° C (392° F), measure

* * * *

2 SM 2172 10-02
 Chassis - Frames
Section 100-0010

SM - 2783

Fig. 1 - General Arrangement of Frame Assemblies

DESCRIPTION thrust faces of the bushes is compensated by

The chassis consists of two separate frame tightening this thrust nut.
assemblies which provide the articulation of the unit.
The front and rear frames are constructed of all
welded high-grade steel fabrications with rectangular INSPECTION AND MAINTENANCE
box section beams forming main, side and cross
members. Inspection
Inspect the frames and attached parts at intervals not
The front frame is fabricated to form a rigid structure exceeding 250 hours for cracked or broken welds and
which carries the cab, power train and suspension bending of the frame. Any defects found should be
system. repaired before they progress into major failures.

The rear frame is fabricated to form a rigid structure

which carries the body, body hydraulics, suspension Straightening
and rear drive axles. Hydraulic straightening or aligning equipment should
be used to straighten bent or twisted frames whenever
Steering is by frame articulation to 45° either side by possible. However, if heat must be applied, never heat
two widely spaced vertical pivot pins in taper roller the metal beyond a dull, cherry red colour, as too
bearings. Oscillation between the front and rear frames much heat will weaken the metal. When it is necessary
is provided by a large diameter cylindrical coupling to heat the metal, apply heat uniformly over the area to
carried on nylon bushes located in the rear frame. be straightened and protect the heated surface from
Longitudinal shocks are absorbed by the thrust faces sudden cooling. Frame parts that cannot be
of the nylon bushes. A large thrust nut, which is straightened should be renewed.
threaded to the end of the coupling and locked to the
frame, secures the coupling in position. Wear on the

SM 2170 9-02 1
Chassis - Frames
Section 100-0010

Welding
WARNING
Welding and flame cutting cadmium plated
metals produce odourless fumes which are
WARNINGS
toxic. Recommended industrial hygiene
Before any welding is done on a machine
practice for protection of the welding operator
equipped with the Quantum Electronic Fuel
from the cadmium fumes and metallic oxides
System, disconnect the following in this order:
requires enclosure ventilation specifically
Battery earth cable, battery supply cable,
designed for the welding process. A respiratory
alternator earth cables, alternator supply
protective device such as the M.S.A. 'Gasfoe'
cables, body hydraulics joystick and electrical
respirator with G.M.A. cartridge will provide
connections at the engine ECM, transmission
protection against cadmium, fumes and
ECU and hydraulics ECU to avoid damage to
metallic oxides. The 'Gasfoe' respirator has
electrical components. Turn off battery master
been approved by the U.S. Bureau of Mines:
switch to isolate the batteries before
Approval number 23B-10, and is designed to
disconnecting any components.
protect against gases, vapours, and/or metal
After welding connect all of the above in the
fumes.
reverse order.
Note: The current from the welding rod always follows
the path of least resistance. If, for example, the ground
clamp is attached to the rear frame when welding is
Before any welding is done ensure all paint has
performed on the front frame, the current must pass a
been removed from the area to be welded.
frame connection to return to the welding machine.
Failure to do so may result in hazardous fumes
Since the pivot coupling offers the least resistance but
being given off from the paint.
not a sound electrical connection, small electric arcs
may be set up across the moving parts which may
cause welding blotches on their wearing surfaces and
Note: Always fasten the welding machines ground
increase the wear rate of these components.
cable to the piece/frame being welded if possible.

Electric arc welding is recommended for all welded Reinforcement

frame repairs. Since the nature and extent of damage
Frame reinforcement can be made with channel or
to the frame cannot be predetermined, no definite repair
angle or flat structural stock. Whenever possible, the
procedure can be established. As a general rule
reinforcement should extend well beyond the bent,
however, if parts are twisted, bent or pulled apart, or a
broken or cracked area. The reinforcement stock
frame is bent or out of alignment, no welding should be
thickness should not exceed that of the frame stock
done until the parts are straightened or realigned.
and the material should be of the same tensile
strength.
Successfully welded repairs will depend to a great
extent upon the use of the proper equipment, materials
and the ability of the welder. The Customer Support Painting
Department can be consulted regarding the feasibility
A check of the condition of the paint should be made
of welding repairs.
approximately twice a year and chassis repainted if
necessary.

2 SM 2170 9-02
 Chassis - Frames
Section 100-0010
To keep rust and corrosion to a minimum, periodic
WARNING painting of abrasions and other exposed metal areas
Welding, burning, heating or dressing surfaces on the frames is highly recommended.
previously painted using polyurethane paint
produces fumes which are toxic. Surfaces must If painting of a frame is required, thoroughly clean the
be prepared using paint stripper prior to area areas to be painted. Apply a primer coat of
being reworked. Recommended Industrial polyurethane red oxide and then a finish coat of
Hygiene and Safety Rules should be followed polyurethane enamel.
for protection of the welding operator from the
fumes.

* * * *

SM 2170 9-02 3
Chassis - Frames
Section 100-0010

THIS PAGE IS INTENTIONALLY BLANK

4 SM 2170 9-02
 Chassis - Articulation and Oscillation Pivot
Section 100-0020

SM - 3933

25 52 56
50 51 29 56
16 64-69 5,6 55
19 7
20
27 53 54
14 8,9 56
17
DETAIL A 25
42
41 39
45,46,49 36,49
45,47,49
1
32
26,56 26,53
30
52,55 54,55 10,26
23
56
38 11
2,3,4 2,3,4
33 60
57,58,59
49,61,62 36,49 40 28
A 51 18
13
15 8,9
51
31 63
17
50 16
19
64-69
44,48,49 43 19
37,49
16 29
31
35 14 24 8,9
29 15
38
30,23 21,22

34 12
25
10,26
45,46,49 37,49 45,47,49

1 - Pivot Assembly 16 - Lockplate 27 - Lube Fitting 41 - Washer 55 - Lube Fitting

2 - Nylon Bush 17 - Front Yoke 28 - Plug 42 - Nut 56 - Elbow
3 - Loctite 648 18 - Brake Yoke 29 - 'O' Ring 43 - Lower Pin 57 - Adaptor
4 - Loc Quick Primer 19 - Bolt 30 - Bearing Assembly 44 - Hardened Washer 58 - Connector
5 - Gasket 20 - Washer 31 - Retaining Ring 45 - Washer 59 - Elbow
6 - Cover Plate 21 - Lockwasher 32 - Seal Housing 46 - Bolt 60 - Pipe Assembly
7 - Bolt 22 - Bolt 33 - Seal Housing 47 - Bolt 61 - Washer
8 - Bearing Assy - Cup 23 - Extreme Pressure 34 - Seal Housing 48 - Bolt 62 - Bolt
9 - Bearing Assy - Cone Lithium No.2 Grease 35 - Seal Housing 49 - Loctite 243 63 - Thrust collar-Rear
10 - 'V' Ring Seal 24 - SAE 80W-90 EP 36 - Seal 50 - Thrustcollar-Front 64 - Shim
11 - Thrust Nut Gear Oil 37 - Seal 51 - 'O' Ring 65 - Shim
12 - Locking Plate 25 - Plug 38 - Shim 52 - Hose Assembly 66 - Shim
13 - Antiseize Comp 26 - Extreme Pressure 39 - Spacer 53 - Hose Assembly 67 - Shim
14 - Driveshaft Multipurpose Grease 40 - Upper Pin 54 - Connector 68 - Shim
15 - Seal 69 - Shim

Fig. 1 - Articulation and Oscillation Pivot

DESCRIPTION AND OPERATION connecting the drive between the front and rear frames.
The articulation and oscillation pivot allows the front
and rear frames to rotate horizontally (articulation) and Articulation bearings, oscillation bushes, pivot
tilt laterally (oscillation) with respect to each other. It is driveshaft bearing and associated parts can be
also the main load bearing coupling between the two removed, inspected and replaced or renewed by
frames. The pivot assembly houses the driveshaft following the procedures outlined in this section.

SM 2273 03-04 1
Chassis - Articulation and Oscillation Pivot
Section 100-0020

9. Disconnect mounting hardware securing protective

guard (if fitted), from beneath the parking brake disc, to
THRU-DRIVE DRIVESHAFT
the rear frame.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified. 10. Release the parking brake by turning the hex-head
on the parking brake actuator fully anticlockwise.
Note: The following procedures assume that only
thru-drive components require repair.
WARNING
Note: Tighten all fasteners without special torques Tensioned spring on adjuster.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE 11. Remove mounting hardware securing parking
SPECIFICATIONS. brake assembly to mounting bracket on frame, then
secure parking brake assembly clear of brake disc.

WARNINGS 12. Identify the relationship of the driveline caps to

To prevent personal injury and property brake yoke (18). Remove capscrews, disconnect
damage, be sure wheel blocks are properly driveline and secure clear of brake yoke.
secured and of adequate capacity to do the job
safely. 13. Withdraw driveshaft assembly (14) from housing
by pulling rearwards on parking brake disc/brake
When necessary to drive out or drive on yoke assembly (18). If necessary, tap front end of
components during disassembly/assembly, be driveshaft (14) to ease removal, take care to avoid
sure to use a soft drift to prevent property damaging threads. Place driveshaft (14) assembly on
damage and personal injury. work bench for further disassembly.

14. Prise out and discard seal (15) from front of the
Removal and Disassembly
housing.
1. Position the vehicle on a level work area and apply
parking brake. 15. Lift out front bearing assembly cup (8) from front
of the housing.
2. Raise body and install body safety prop to secure
body in partially raised position. 16. If bearing replacement is required, use a suitable
puller to remove front and rear bearing assembly
3. Shut down engine and block all wheels securely. cups (8) from the housing.

4. Identify the relationship of the driveline caps to the Note: If either bearing assembly cup or cone (8 or 9)
transmission yoke and front yoke (17). Remove need replacing, they must be replaced as a set.
capscrews and remove driveline from vehicle.
17. If retaining rings (31) need replacing, use a
Note: Take extra care when handling drivelines as suitable drift or puller to remove them from the housing.
any deformity on a rotating mass creates vibration
and excessive wear during any operation. 18.Temporarily install front yoke (17) fully onto front of
driveshaft (14) and suitably restrain to resist rotation.
5. Remove wheel blocks, start engine and steer
vehicle into a full left-hand lock. Shut down engine 19. Remove mounting hardware securing parking
and block all wheels securely. brake disc to brake yoke (18) and remove brake disc.

6. Remove Lockplate (16) , 2 0ff Front bolts (19) & 20. Remove Lockplate (16) , 2 off Rear bolts (19) ,
Front thrust collar (50). Rear Thrust collar (63) & Brake yoke (18) from
driveshaft (14). Identify front and rear ends of
7. Remove and discard 'O' rings (29 & 51) from Thrust driveshaft (14).
collar (50).
21. Remove and discard 'O' rings (29 & 51) from Rear
8. Place a suitable container under the front of the Thrust collar (63).
pivot and pull front yoke (17) from driveshaft (14).

2 SM 2273 03-04
 Chassis - Articulation and Oscillation Pivot
Section 100-0020

9 SM - 3143
14
22. Remove and discard seal (15) from driveshaft (14).

23. If bearing replacement is required, use a suitable

puller or drift to remove rear bearing assembly cone (9)
from driveshaft (14).

Inspection

1. Clean all parts with a suitable solvent and let dry.

DO NOT spin bearings with compressed air. Place 55mm
bearings on a clean surface, cover with a lint free
cloth and allow to dry.
Fig. 2 - Pre assembly of bearing
2. Check bearing assemblies cups and cones (8 & 9) 6. Refer to Fig. 2, Maintain end face of cone approximately
for wear or damage. Renew as necessary. 55mm from end of spline face.

Note: If either bearing assembly cup or cone (8 or 9) 7. Insert driveshaft (14) into truck end of pivot casing
need replacing, they must be replaced as a set. until bearing assembly cone (9) seats firmly in the
bearing asembly cup (8).
3. Inspect splines of driveshaft (14) and yokes
(17 & 18) for nicks, burrs or excessive wear. Replace 8. Apply loctite (3) to new seal (15) and fit over the
if wear is excessive or splines are nicked. Burrs may driveshaft (14) with seal 'Lip' to bearing side.Press seal
be removed with a fine file or medium India stone. home using a mandrel.

4. Check yokes (17 & 18) for damage in region 9. Apply grease to splines of Front yoke (17) and slide
polished by oil seal lip; even slight damage in this onto the drive shaft (14).
area can cause leakage. Very slight marks may be
polished out with fine emery cloth but it is essential 10. Fit new 'O'-rings ( 29 & 51) to Front thrust collar
that polishing marks are parallel to the seal lip. (50) and fit collar over stub end of driveshaft (14) (align
mating holes). Fit 2 off front bolts (19).
5. Replace all seals and 'O' rings with new parts.
11. Tighten Front bolts (19) ; alternately 1/4 - 1/2 turns,
drawing driveshaft (14) hard against the inner face of
Assembly and Installation Front thrust collar (50). Shaft will be visible through
1. If removed, use a suitable driver and install retaining inspection hole on the collar.
rings (31) into housing, ensuring that they butt hard
against abutment shoulders. 12. Lock Front yoke (17) from rotation by a suitable
method / bar acting on the ground. Torque front bolts
2. Using a suitable driver, install front bearing cup (8) (19) to 54Nm/39 Ibf ft.
into tractor end of pivot casing. Ensure it is firmly
seated & that a 0.05mm (0.002") feeler gauge cannot 13. Using special mandrel (15270104) home locking
be inserted between cup and mating face. plate (16) onto Bolts (19). Remove the clamping bar.

3. Check rear bearing cup (8) is firmly seated in the 14. Slide Rear bearing asembly cone (9) onto rear end
body end of the pivot casing, again ensuring 0.05mm of drive shaft (14) until it seats in bearing assembly
(0.002") feeler gauge cannot be inserted between cup cup (8).
and mating face.
15. Position clamping bar assembly and screw central
4. Lightly oil both bearing assembly cones (9) with SAE bolt hard against bolts (19) of front thrust collar (50),
80W - 90 E. P. gear oil (24). enabling body end bearing to be fully seated home.

5. Support driveshaft (14) in a suitable fixture & tap one 16. Using mandrel and heavy hammer, drive Rear
Bearing assembly cone (9) onto driveshaft (14) using a bearing assembly cone, fully into cup. Now remove
tubular mandrel. clamp bar assembly from front end.

SM 2273 03-04 3
Chassis - Articulation and Oscillation Pivot
Section 100-0020

MOT00048
'A' 'D'
'C' DEPTH
MICROMETER SHAFT - FRONT

SHIM
AREA
'B' 'E' (D - C)

Fig. 3 - Measurements / various

17. Take remaining seal (15), apply loctite (3) and fit
over drive shaft with seal 'Lip' to bearing side. Press 22. The actual free air space 'E' to be shimmed
seal home using a mandrel. between end of drive shaft (14) and compression face
of Thrust collar (63) equals:
18. Apply grease to splines of brake yoke (18) and
slide onto drive shaft (14). Ensure milled slots of E='D' - 'C'.
driving flanges are aligned with those of brake yoke.
23. Now add 0.6mm (0.024") to dimension 'E' to allow
Note : For Measurment letters- refer to fig. 3, unless for oversize shims. This value is dimension 'F'
otherwise stated. (End float will be determined by subtraction).

19. Before fitting of Rear Thrust collar (63) record 24. Remove Rear bolts (19) and Rear thrust collar (63)
Measurements as stated: from pivot body end and chap drive shaft (14) to free
bearing.
i) Measure total width 'A' of Rear thrust collar (63)
25. Calculate the nominal combination of minimum
ii) Using Depth micrometer, measure inner bore depth number if shims (64) to achieve the size nearest to
'B' of collar (63) and record value. dimension 'F'. Record the appropriate part numbers and
total nominal thickness value.
iii) Subtract 'B' from 'A' to determine recess dimension
'C'. 26. Select the shims (64) and measure the total actual
thickness of the combination. Record this value.
20. Fit Rear thrust collar (63) without 'O'-rings onto
Drive shaft (14) and tighten Rear bolts (19) to a nominal 27. Place the shim pack (64) in the rear thrust collar
torque of 15Nm/11Ibf ft. (63) , lock off the Brake yoke (18) from rotation by
suitable method / bar on ground. Torque bolts (19) to
Note : a gap should be visible between end of shaft full torque.
and inner face of collar.
28. Remove the clamp and spin the yoke (18) to
21. Using a Depth micrometer, measure distance 'D' ensure driveshaft (14) free rotation.
from collar (63) outer face to end face of drive shaft
(14) via the hole in the collar and record the value. 29. Take a magnetic clock gauge located on the flange
of pivot casing, needle acting on rear thrust collar (63)

4 SM 2273 03-04
 Chassis - Articulation and Oscillation Pivot
Section 100-0020
end face. Check Brake yoke (18) float movement.
43. Remove plug (25) from underside of oscillation hub
30. Take reading obtained and subtract a figure to drain the cavity between the oscillation hub and
sufficient to give an end float in the range 0.05mm - pivot assembly (1) of any oil that entered while filling
0.15mm (0.002" - 0.006"), reduce shim pack (64) the driveshaft bearing housing.
accordingly.
44. Install plug (25) into filler/level hole on pivot
31. Remove Rear thrust collar (63) and shims (64) and assembly (1). Install gasket (5) and cover plate (6) on
re-assemble with the apporpriate shims. Ensure 'O'- side of oscillation hub, secure with bolts (7) and
rings (29 & 51) are now fitted. washers (20).

32. Lock Brake yoke (18) flange as before ,applying 45. Install plug (25) into cavity drain port on underside
alternate 1/4 -1/2 turns on bolts (19). Torque to 54 Nm of oscillation hub.
(39 Ibf ft).
46. Install parking brake disc protective guard (if fitted)
33. Remove the locking bar and confirm that the and secure with bolts, washers and nuts. Tighten nuts
driveshaft (14) end float is in the range 0.05mm - to a torque of 73 Nm (54 lbf ft).
0.15mm (0.002" - 0.006") by moving the brake yoke
(18) for and aft against the clock gauge. 47. Start engine, raise body, lower body safety prop
and lower body.
34. Adjust and refit the shim pack (63) as necessary.
48. Remove wheel blocks.
35. Float set correctly; Drive home locking plate (16)
using a mandrel (15270104) . Re-check the end float.
ARTICULATION COMPONENTS
36. Install parking brake disc on brake yoke (18) and Numbers in parentheses refer to Fig. 1, unless
secure with bolts and washers. Tighten bolts to a otherwise specified.
torque of 73 Nm (54 lbf ft).
Note: The following procedures assume that only
37. Install parking brake assembly to mounting components associated with articulation require repair.
brackets and secure with bolts, washers and nuts.
Refer to Section 170-0010, PARKING BRAKE AND Note: It is essential that the grease used for articulation
MOUNTING. components is Extreme Pressure Lithium Complex No. 2
(23), as specified in Section 300-0020, LUBRICATION
38. Apply parking brake by turning the hex-head on the SYSTEM.
parking brake actuator fully clockwise.
Note: Tighten all fasteners without special torques
39. Apply Loctite 638 to the threads of capscrews used specified to torques listed in Section 300-0080,
to mount driveline to brake yoke (18). Align match STANDARD BOLT AND NUT TORQUE
marks and install driveline. Tighten capscrews to a SPECIFICATIONS.
torque of 153 Nm (113 lbf ft).

40. Apply Loctite 638 to the threads of capscrews used WARNINGS

to mount driveline between transmission yoke and front To prevent personal injury and property
yoke (17). Align match marks and install driveline. damage, be sure wheel blocks, blocking
Tighten capscrews to a torque of 153 Nm (113 lbf ft). materials and lifting equipment are properly
secured and of adequate capacity to do the job
41. Remove bolts (7), washers (20), gasket (5) and safely.
cover plate (6) from side of oscillation hub to gain
access to filler/level hole plug (25) on pivot assembly When necessary to drive out or drive on
(1). Remove filler/level plug (25). components during disassembly/assembly, be
sure to use a soft drift to prevent property
42. Add SAE 80W - 90 E. P. gear oil (24) through filler/ damage and personal injury.
level hole in pivot assembly (1) until the oil is level with
the bottom of filler/level hole.

SM 2273 03-04 5
Chassis - Articulation and Oscillation Pivot
Section 100-0020

SM - 008
9. Remove bolt (62), washer (61), large nut (42) and
washer (41) securing upper pin (40).

10. Remove upper pin (40). If necessary tap upper pin

(40) to ease removal taking care to avoid damaging the
threads.

Note: It may be necessary to relieve binding between

the pin and pin bores by raising or lowering the pivot/
rear frame assembly.

11. Remove bolt (48) and hardened washer (44)

securing lower pin (43).
Fig. 4 - Determining Shim Thickness
12. Remove lower pin (43). If necessary tap lower pin
Disconnecting Front and Rear Frames (43) to ease removal taking care to avoid damaging the
Note: The front and rear frames can be separated pin.
sufficiently to permit disassembly/assembly of the
articulation components without disconnecting Note: Only separate the frames sufficiently to permit
hydraulic lines or electrical wiring. removal of the articulation bearings or damage to
hydraulic and electrical connections could result.
1. Position the vehicle on a level work area and apply
parking brake. 13. Remove blocks from rear wheels and use lifting
equipment to pull pivot/rear frame assembly clear of
2. Raise body and install body safety prop to secure the front frame. After moving, block pivot/rear frame
body in partially raised position. assembly and block the wheels.

3. Shut down engine and block all wheels securely. 14. Remove spacer (39) noting orientation to ensure
correct installation.
4. Identify the relationship of the driveline caps to the
transmission yoke and front yoke (17). Remove
capscrews and remove driveline from vehicle. Disassembly
1. Identify seal housings (32, 33, 34 & 35) to ensure
5. Support tractor frame at front and rear with suitably correct location on assembly/installation.
placed stands or timbers so the frame will remain level
during and after pin removal. Note: Seal housings (32, 33, 34 & 35) are not
interchangeable.
6. Remove bolts, washers and pins securing steering
cylinders to pivot. Secure steering cylinders clear of 2. Remove bolts (46 & 47), washers (45), seal housings
pivot. (32, 33, 34 & 35) and upper and lower shims (38).

7. Release the parking brake by turning the hex-head 3. Prise out and discard seals (36 & 37) from the
on the parking brake actuator fully anticlockwise. housings.

4. Remove and tag all bearing assemblies (30) with

WARNING spacers to ensure correct assembly/installation.
Tensioned spring on adjuster.
Note: Bearing assemblies (30) and spacers are a
8. Attach suitable lifting equipment to pivot/rear frame matched set, never interchange cups, cones or
assembly. Lifting equipment must prevent pivot from spacers between sets.
oscillating after separation, and, be capable of pulling
pivot/rear frame assembly clear of front frame. Raise Inspection
lifting equipment to support pivot/rear frame assembly. 1. Clean all parts with a suitable solvent and let dry.
DO NOT spin bearings with compressed air. Place
bearings on a clean surface, cover with a lint free cloth

6 SM 2273 03-04
 Chassis - Articulation and Oscillation Pivot
Section 100-0020
and allow to dry. Connecting Front and Rear Frames
1. Install spacer (39) in upper outer seal housing (32),
2. Check bearing assemblies (30) and spacers, and as noted on removal.
pins (40 & 43) for wear or damage. Renew as
necessary. 2. Smear bearing and pin bores with Extreme Pressure
Lithium Complex No. 2 grease (23).
Note: Bearing assemblies (30) and spacers must be
renewed as a matched set. 3. Attach suitable lifting equipment to pivot/rear frame
assembly. Lifting equipment must prevent pivot from
3. Replace all seals with new parts. oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame
Assembly pin bores. Raise lifting equipment to support pivot/rear
frame assembly.
1. Apply Loctite 243 (49) sparingly to bore of seal
housings (32, 33, 34 & 35). 4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull
2. Using a suitable driver, install seals (36 & 37) into pivot/rear frame assembly to align pivot bearing bores
seal housings (32, 33, 34 & 35) ensuring that the metal and front frame pin bores. Block wheels and block
ring on inside of the seals are not disturbed, and, that pivot/rear frame assembly to remain level and
they are located towards the inside of seal housing. stationary.
3. Apply Loctite 243 (49) to threads of outer seal 5. Freeze upper and lower pins (40 & 43) to ease
housing bolts (46). installation.
4. Place outer seal housings (32 & 34) in position 6. Smear lower pin (43) with Extreme Pressure Lithium
ensuring that grease relief hole in seal housings are Complex No. 2 grease (23) and install through front
directly opposite bearing grease port on pivot. Secure frame and bearing bores.
with bolts (46) and washers (45). Tighten bolts (46) to a
torque of 94 Nm (68 lbf ft). Note: It may be necessary to relieve binding between
the pin and pin bores by raising or lowering pivot/rear
Note: Bearing assemblies (30) and spacers are a frame assembly.
matched set, never interchange cups, cones or
spacers between sets. 7. Apply Loctite 243 (49) to threads of bolt (48) and
secure lower pin (43) with bolt (48) and hardened
5. Using Extreme Pressure Lithium Complex No. 2 washer (44). Tighten bolt (48) to a torque of 73 Nm
grease (23), pack bearing assemblies (30), including (54 lbf ft).
end faces, and install bearings.
8. Smear upper pin (40) with Extreme Pressure Lithium
6. Place inner seal housings (33 & 35) temporarily in Complex No. 2 grease (23) and install through front
position and secure with bolts (47) and washers (45). frame and bearing bores.
Tighten bolts (47) to a torque of 16 Nm (12 lbf ft).
9. Apply Loctite 243 (49) to threads of bolt (62). Secure
7. Using feeler gauges, as shown in Fig. 4, measure upper pin (40) with bolt (62), washer (61), large nut (42)
the dimension between the inner pivot faces and seal and washer (41). Tighten nut (42) to a torque of 1 425
housings (33 & 35). Measure at 3 positions equally Nm (1 050 lbf ft).
spaced around seal housings and determine average
dimension, this is the size of shims (38) required.
Final Assembly
8. Remove bolts (47), washers (45) and inner seal 1. Apply parking brake by turning the hex-head on the
housings (33 & 35). parking brake actuator fully clockwise.
9. Install shims (38) as calculated at Step 7, reinstall 2. Remove lifting equipment from pivot/rear frame
inner seal housings (33 & 35) and secure with bolts assembly.
(47) and washers (45). Tighten bolts (47) to a torque of
94 Nm (68 lbf ft). 3. Remove stands or timbers from front frame.

SM 2273 03-04 7
Chassis - Articulation and Oscillation Pivot
Section 100-0020

SM - 038
4. Apply Loctite 270 to the threads of capscrews used
to mount driveline between transmission yoke and front
yoke (17). Align match marks and install driveline.
Tighten capscrews to a torque of 153 Nm (113 lbf ft).

5. Align steering cylinder bores and mounting pin bores

on pivot, install pins and secure with bolts and
washers. Tighten bolts to a torque of 73 Nm (54 lbf ft).

6. Remove plugs (28) from articulation bearing, grease

ports and replace with lube fittings (27).

Note: Lube fittings (27) are stored on pad on side of

pivot assembly (1). Fig. 5 - Preventing Pivot Assembly From Oscillating

7. Fill bearing housings with Extreme Pressure Lithium

lifting equipment are properly secured and of
Complex No. 2 grease (23), through lube fittings (27),
adequate capacity to do the job safely.
until excess grease starts to escape from seal
housings (32 & 34).
When necessary to drive out or drive on
components during disassembly/assembly, be
8. Remove lube fittings (27) and reinstall plugs (28).
sure to use a soft drift to prevent property
Store lube fittings (27) on pad on side of pivot
damage and personal injury.
assembly (1).
Hydraulic fluid pressure will remain
9. Start engine, raise body, lower body safety prop and
within the braking system after engine shut
lower body.
down. Operate the treadle pedal continuously
until the pressure has dissipated before
10. Remove wheel blocks.
carrying out any work on the braking system
or serious injury could result.

OSCILLATION COMPONENTS
Disconnecting Front and Rear Frames
Numbers in parentheses refer to Fig. 1.
1. Position the vehicle on a level work area and apply
Note: The following procedure assumes that only parking brake.
components associated with oscillation require repair.
2. Raise body and install body safety prop to secure
Note: It is necessary to disconnect the front and rear body in partially raised position.
frames at the articulation point to service the
oscillation components. 3. Shut down engine and block all wheels securely.

Note: It is essential that the grease used for 4. Depress and release brake pedal continuously to
oscillation components is Extreme Pressure relieve the pressure in the braking system.
Multipurpose Grease (26), as specified in Section 300-
0020, LUBRICATION SYSTEM. 5. Carefully loosen brake lines at base of both
accumulators to check that the pressure has
Note: Tighten all fasteners without special torques released. Re-tighten brake lines.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE 6. Tag all hydraulic lines and electrical wiring between
SPECIFICATIONS. front and rear frames to ensure correct assembly/
installation. Disconnect all hydraulic lines and plug
openings to prevent ingress of dirt. Disconnect
WARNINGS electrical wiring and any other attachments which could
To prevent personal injury and property damage, be damaged on separation of front and rear frames.
be sure wheel blocks, blocking materials and

8 SM 2273 03-04
 Chassis - Articulation and Oscillation Pivot
Section 100-0020
7. Identify the relationship of the driveline caps to the securing guard to the rear frame. Refer to
transmission yoke and front yoke (17). Remove Section 170-0010, PARKING BRAKE AND
capscrews and remove driveline from the vehicle. MOUNTING.

8. Support tractor frame at front and rear with suitably 2. Remove mounting hardware securing parking brake
placed stands or timbers to keep the frame level during assembly to mounting bracket on frame. Remove and
and after pin removal. secure parking brake assembly clear of brake disc.

9. Remove bolts, washers and pins securing steering 3. Identify the relationship of the driveline caps to
cylinders to pivot. Secure steering cylinders clear of brake yoke (18). Remove capscrews, disconnect
pivot. driveline and secure clear of brake yoke (18).

10. Release the parking brake by turning the hex- 4. Remove mounting hardware securing parking brake
head on the parking brake actuator fully anticlockwise. disc to brake yoke (18) and remove brake disc.

5. Place a suitable container under rear brake yoke (18)

WARNING to catch oil released when pulling brake yoke (18) from
Tensioned spring on adjuster. driveshaft (14).

11. Attach suitable lifting equipment to pivot/rear frame 6. Remove Rear bolts (19), Lockplate (16) & Rear
assembly. Lifting equipment must prevent pivot from thrust collar (63). Pull brake yoke (18) from driveshaft
oscillating after separation, and, be capable of pulling (14) .
pivot/rear assembly clear of front frame. Raise lifting
equipment to support pivot/rear frame assembly. 7. Remove adaptor (57), connector (58), elbow (59)
and pipe assembly (60) from oscillation hub.
12. Remove bolt, washer, large nut (42) and washer
(41) securing upper pin (40). 8. Remove bolts (22) and washers (21) securing
locking plate (12). Remove locking plate (12).
13. Remove upper pin (40). If necessary tap upper pin
(40) to ease removal taking care to avoid damaging 9. Restrain pivot assembly (1) to prevent it oscillating,
the threads. by placing a heavy bar between the steering cylinder
mountings. Lock the bar in position using suitable
Note: It may be necessary to relieve binding between trestles or stands. See Fig. 5.
the pin and pin bores by raising or lowering the pivot/
rear frame assembly. 10. Using a suitable tool, remove thrust nut (11). If
wear area of thrust nut (11) is damaged, replace thrust
14. Remove bolt (48) and hardened washer (44) nut (11).
securing lower pin (43). 11. Insert an M20 eyebolt into tapped pad provided on
top of pivot assembly (1) and attach suitable lifting
15. Remove lower pin (43). If necessary tap lower pin equipment.
(43) to ease removal taking care to avoid damaging the 12. Remove pivot restraining bar.
pin.
13. Using lifting equipment, carefully pull pivot
16. Remove blocks from rear wheels and use lifting assembly (1) clear of oscillation hub. Place pivot
equipment to pull pivot/rear frame assembly clear of assembly (1) in a suitable work area for further
the front frame. After moving, block pivot/rear frame disassembly.
assembly and block the wheels.
14. Note position of front 'V' ring (10) to aid in
17. Remove spacer (39) noting orientation to ensure 'Installation'. Remove and discard 'V' ring (10).
correct installation. Cover articulation bearings to
prevent ingress of dirt. 15. Inspect nylon oscillation bushes (2) as described in
'Inspection'. If bushes are to be renewed, proceed with
step 16.
Disassembly
1. Remove protective guard (if fitted) from beneath 16. Remove nylon oscillation bushes (2) with hammer
parking brake disc by removing mounting hardware and chisel.

SM 2273 03-04 9
Chassis - Articulation and Oscillation Pivot
Section 100-0020

SM - 011 3. Install plug (25) in filler/level hole on pivot assembly

(1). Install gasket (5) and cover plate (6) on side of
PAINT DOT oscillation hub and secure with bolts (7) and washers
(20).

4. Install plug (25) in cavity drain port on underside of

oscillation hub.

5. Install plugs (28) into oscillation bearing grease

ports.

6. Lightly coat 'V' ring (10) and machined surfaces of

pivot with Extreme Pressure Multipurpose Grease (26)
and, install 'V' ring (10), with lip towards rear, on front of
Fig. 6 - Installing Oscillation Bushes
oscillation hub.

Note: The suggested method is to make an axial cut 7. Using suitable lifting equipment, and taking care to
along the bush then to lever the bush in order to prevent damaging bushes (2) or pivot threads, install
collapse it upon itself. pivot assembly (1) into rear frame.

Inspection 8. Lightly coat 'V' ring (10) and machined surfaces of

pivot with Extreme Pressure Multipurpose Grease (26)
1. Clean nylon oscillation bushes with a suitable and, install 'V' ring (10), with lip towards front, on rear of
solvent and allow to dry. oscillation hub.

2. Inspect nylon oscillation bushes for wear, scoring, 9 . a) Restrain pivot assembly (1) to prevent it
erosion and 'out of round'. Pay particular attention to oscillating, by placing a heavy bar between the steering
the thrust faces of the bushes which should also be cylinder mountings. Lock the bar in position using
inspected for cracking/splitting. Renew if required. suitable trestles or stands. See Fig. 5.

3. Replace all seals with new parts. b) Secure a suitable tool to pivot thrust nut (11) and
tighten thrust nut (11) until there is no end float/
Assembly clearance at thrust face of either bush. Slacken thrust
nut (11) until pin of the locking plate (12) can be
Numbers in parentheses refer to Fig. 1. inserted in the first available hole in the thrust nut (11).

Note: Tighten all fasteners without special torques c) Secure locking plate (12) with bolts (22) and
specified to torques listed in Section 300-0080, lockwashers (21). Torque tighten bolts (22) to 94 Nm
STANDARD BOLT AND NUT TORQUE (69 lbf ft).
SPECIFICATIONS.
10. Install adaptor (57), connector (58), elbow (59) and
pipe assembly (60) to oscillation hub.
WARNING
To prevent personal injury and property 11. Install brake yoke (18) on driveshaft (14) until it
damage, be sure wheel blocks are properly butts against bearing assembly cup and cone (8 & 9).
secured and of adequate capacity to do the job
safely. 12. Install parking brake disc on brake yoke (18) and
secure with bolts, washers and nuts. Tighten bolts to a
1. Wipe bush housing clean using a suitable solvent torque of 73 Nm (54 lbf ft).
and allow to dry.
13. Install rear of driveshaft (14).
2. Apply Loctite 648 (3) and Loc Quick Primer (4) and
align new bushes (2) to housing with grease holes 14. install Brake yoke (18) , Rear thrust collar (63)
aligned vertically and identification 'PAINT DOT' at Top ensuring 'O'-rings (29& 51) are in place , shim pack (64)
Dead Centre. Refer to Fig. 6. Drift bushes (2) into and bolts (19).
housing using hammer with soft packing for protection.

10 SM 2273 03-04
 Chassis - Articulation and Oscillation Pivot
Section 100-0020

15. Lock off Brake yoke flange as before (18) with 8. Smear upper pin (40) with Extreme Pressure Lithium
suitable clamping method. Torque bolts (19) to 73 Nm Complex No. 2 grease (23) and install through front
(Ibf ft) frame and bearing bores.

9. Apply Loctite 243 (49) to threads of bolt (62). Secure

16. Take a magnetic clock gauge located on the flange upper pin (40) with bolt (62), washer (61), washer (41)
of pivot casing , needle acting on Rear thrust collar (63) and large nut (42). Tighten nut (42) to a torque of 1 425
end face. Check Brake yoke (18) float movement. Nm (1 050 lbf ft).
Ensure still within range 0.05mm - 0.15mm (0.002" -
0.006").
17. If float is incorrect, alter arrangement of shim pack Final Assembly
(64) to bring within size. 1. Install parking brake assembly to mounting
brackets and secure with bolts, washers and nuts.
18. Using special mandrel (15270104) home locking Refer to Section 170-0010, PARKING BRAKE AND
plate (16) onto bolts (19). Remove clamping bar. MOUNTING.

2. Apply parking brake by turning the hex-head on the

parking brake actuator fully clockwise.
Connecting Front and Rear Frames
1. Install spacer (39) in upper bearing assembly (30) as
noted on removal. WARNING
Tensioned spring on adjuster.
2. Smear bearing assembly (30) and pin bores with
Extreme Pressure Lithium Complex No. 2 grease (23). 3. Remove lifting equipment from pivot/rear frame
assembly.
3. Attach suitable lifting equipment to pivot/rear frame
assembly. Lifting equipment must prevent pivot from 4. Remove stands or timbers from front frame.
oscillating and be capable of pulling pivot/rear frame
assembly to align pivot bearing bores and front frame 5. Apply Loctite 270 to threads of capscrews used to
pin bores. Raise lifting equipment to support pivot/rear mount driveline between transmission yoke and front
frame assembly. yoke (17). Align match marks and install driveline.
Tighten capscrews to a torque of 153 Nm (113 lbf ft).
4. Remove blocks from rear wheels and blocking from
pivot/rear frame assembly. Using lifting equipment, pull 6. Align match marks and reconnect driveline to brake
pivot/rear frame assembly to align pivot bearing bores yoke (18). Tighten capscrews to a torque of
and front frame pin bores. Block wheels and block 153 Nm (113 lbf ft).
pivot/rear frame assembly to remain level and
stationary. Note: Take extra care when handling drivelines as
chips, dents, burrs or deformity on any rotating mass
5. Freeze upper and lower pins (40 & 43) to ease creates vibration and excessive wear during any
installation. operation.

Note: It may be necessary to relieve binding between 7. Align steering cylinder bores and mounting pin bores
the pin and pin bores by raising or lowering pivot/rear on pivot. Install pins and secure with bolts and washers.
frame assembly. Tighten bolts to a torque of 73 Nm (54 lbf ft).

6. Smear lower pin (43) with Extreme Pressure Lithium 8. Connect hydraulic lines and electrical wiring as
Complex No. 2 grease (23) and install through front noted on disassembly.
frame and bearing bores.
9. Remove bolts (7), washers (20), gasket (5) and
7. Apply Loctite 243 (49) to threads of bolt (48). Secure cover plate (6) from side of oscillation hub to gain
lower pin (43) with bolt (48) and hardened washer (44). access to filler/level plug (25) on pivot assembly (1).
Tighten bolt (48) to a torque of 73 Nm Remove filler/level plug (25).
(54 lbf ft).

SM 2273 03-04 11
Chassis - Articulation and Oscillation Pivot
Section 100-0020
(26) to oscillation bushing lube fittings (55) on top of
10. Add SAE 80W - 90 E. P. gear oil (24) through filler/ oscillation hub. Lube until excess grease in seen.
level hole in pivot assembly (1) until the oil is level with
the bottom of filler/level hole.
WARNING
11. Remove plug (25) from underside of oscillation hub To prevent personal injury and property
to drain the cavity between the oscillation hub and damage, be sure wheel blocks are properly
pivot assembly (1) of any oil that entered while filling secured and of adequate capacity to do the job
the driveshaft bearing housing. safely.

12. Install plug (25) in filler/level hole on pivot Every 250 hours, check the end float/clearance at the
assembly (1). Install gasket (5) and cover plate (6) on thrust face of the oscillation bushes. Any clearance
side of oscillation hub, secure with bolts (7) and found must be removed by adjustment of the thrust
washers (20). nut, as described in step 9 of 'Assembly' procedure.

13. Install plug (25) in cavity drain port on underside of Note: A practical method of establishing the effective
oscillation hub. adjustment of the thrust nut is to use movement of the
machines body in the raised position. Move the body
14. Remove plugs (28) from articulation bearing grease from fully raised to almost fully raised while watching
ports and replace with lube fittings (27). the effect of this action on the frame and pivot
arrangement. Any slackness between the thrust nut
Note: Lube fittings (27) are stored on pad on side of and thrust faces will be clearly visible movement of the
pivot assembly (1). frame.

15. Fill bearing housings with Extreme Pressure Every 1 000 hours (6 months), follow the procedure
Lithium Complex No. 2 grease (23) through lube fittings given below to check the oil level in the driveshaft
(27) until excess grease starts to escape from seal bearing housing, and, lubricate the articulation and
housings (32 & 34). oscillation bearings.

16. Remove lube fittings (27) and reinstall plugs (28). Note: It is essential that the grease used for
Store grease fittings (27) on pad on side of pivot articulation components is Extreme Pressure Lithium
assembly (1). Complex No. 2 grease (23), as specified in Section
300-0020, LUBRICATION SYSTEM.
17. Add Extreme Pressure Multipurpose grease (26) to
oscillation bushing lube fittings (55) on top of oscillation 1. Position the vehicle on a level work area and apply
hub. Lube until excess grease in seen. parking brake.

18. Install parking brake disc protective guard (if fitted) 2. Raise body and install body safety prop to secure
and secure with bolts, washers and nuts. Tighten nuts body in partially raised position.
to a torque of 73 Nm (54 lbf ft).
3. Shut down engine and block all wheels securely.
19. Start engine to charge hydraulic systems, raise
body, lower body safety prop and lower the body. 4. Remove protective guard (if fitted) from beneath
parking brake disc by removing nuts, washers and
20. Bleed the braking system as described in Section bolts securing guard to rear frame.
165-0010, BRAKE PARTS.
5. Remove bolts (7), washers (20), gasket (5) and
21. Remove wheel blocks. cover plate (6) from side of oscillation hub to gain
access to filler/level plug (25) on pivot assembly (1).
Remove filler/level plug (25).
MAINTENANCE
Numbers in parentheses refer to Fig. 1. 6. Add SAE 80W - 90 E. P. gear oil (24) through filler/
level hole in pivot assembly (1) until the oil is level with
Every 250 hours, oscillation bushes must be the bottom of filler/level hole.
lubricated. Add Extreme Pressure Multipurpose grease

12 SM 2273 03-04
 Chassis - Articulation and Oscillation Pivot
Section 100-0020

7. Remove plug (25) from underside of oscillation hub

to drain the cavity between the oscillation hub and
pivot assembly (1) of any oil that entered while filling
the driveshaft bearing housing.

8. Install plug (25) into filler/level hole on pivot

assembly (1). Install gasket (5) and cover plate (6) on
side of oscillation hub, secure with bolts (7) and
washers (20).

9. Install plug (25) into cavity drain port on underside of

oscillation hub.

10. Remove plugs (28) from articulation bearing grease

ports and replace with lube fittings (27).

Note: Lube fittings (27) are stored on pad on side of

pivot assembly (1).

11. Fill bearing housings with Extreme Pressure

Lithium Complex No. 2 grease (23) through lube fittings
(27) until excess grease starts to escape from seal
housings (32 & 34).

12. Remove lube fittings (27) and reinstall plugs (28).

Store grease fittings (27) on pad on side of pivot
assembly (1).

13. Add Extreme Pressure Multipurpose grease (26) to

oscillation bushing lube fittings (55) on top of oscillation
hub. Lube until excess grease in seen.

14. Install parking brake disc protective guard (if fitted)

and secure with bolts, washers and nuts. Torque
tighten nuts to 73 Nm (54 lbf ft).

15. Start engine, raise body, lower body safety prop

and lower body.

16. Remove wheel blocks.

SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the thrust nut tool and general service tools
and adhesives required for procedures outlined in this
section. These tools and adhesives are available from
your dealer.

SM 2273 03-04 13
Chassis - Articulation and Oscillation Pivot
Section 100-0020

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. No. ITEM No. ITEM NAME Nm lbf ft
1 19 Nut (to seat bearing only) 250 180
1 22 Bolt 94 69
1 42 Nut 1 425 1 050
1 46 & 47 Bolt 94 68
1 48 Bolt 73 54
- - Parking Brake Disc Bolts 73 54
- - Parking Brake Brkt Mounting Nuts 680 490
- - Driveline Mounting Capscrews 153 113
- - Protective Guard Mounting Nuts 73 54
- - Steering Cylinder Pin Bolts 73 54

* * * *

14 SM 2273 03-04
 Chassis - Hood and Mounting
Section 100-0040

SM - 2785

33 19
31,32 (PART OF HOOD)
9,10,11
20
34
21
35
30 22

29 38,39,40
18
28 36
HOOD CATCH ASSEMBLY 23
9
24

1 9
10 25
26
16
11

12 41 IN BATTERY BOX

27 12 15

37
7 14
8 13
6 17
7
4
5
2 3

1 - Hood Assembly 15 - Gas Strut 28 - Locknut

2 - Hinge Assembly 16 - Hood Catch Cable 29 - Washer
3 - Bolt 17 - Nut 30 - Bolt
4 - Nut 18 - Goalpost Assembly 31 - Bolt
5 - Washer 19 - Bolt 32 - Washer
6 - Adjustment Rod 20 - Hood Stop 33 - Striker Bolt
7 - Nut 21 - Spring 34 - Hood Catch
8 - Hardened Washer 22 - Locknut 35 - Bracket Assembly
9 - Hood Handle 23 - Bolt 36 - Bracket Hood-catch
10 - Bolt 24 - Hardened Washer 37 - Bolt
11 - Washer 25 - Washer 38 - Insulation quilt LHS
12 - Seal 26 - Locknut 39 - Insulation quilt RHS
13 - Washer 27 - Grille 40 - Insulation quilt Top
14 - Hood Retaining Strap 41 - Lip Seal

Fig 1 - Hood and Mounting

HOOD 2. Block all road wheels and place the battery master
switch in the 'Off' position.
Removal
Numbers in parentheses refer to Fig. 1. 3. Remove bolts, washers, lockwashers and nuts
securing grille (27) to grille subframe. Secure grille
(27) clear of hood (1).
WARNING
To prevent personal injury and property 4. Pull cable assembly (16), handle inside battery box,
damage, be sure blocking materials and lifting to release hood catch and lift up hood (1). Secure
equipment are properly secured and of hood (1) in raised position using suitable lifting
adequate capacity to do the job safely. equipment.

1. Position the machine on a level surface, apply the 5. Carefully remove bolts, washers and nuts securing
parking brake and switch off the engine. hood retaining straps (14) and gas struts (15).

SM 2173 Rev1 04-05 1

Chassis - Hood and Mounting
Section 100-0040
Remove fasteners, hood retaining straps (14) and gas GOALPOST SUPPORT ASSEMBLY
struts (15) from hood (1).
Removal
6. Remove bolts (37), washers (13) and nuts (17) Numbers in parentheses refer to Fig. 1.
securing hinge assemblies (2) to frame. Carefully lift
hood (1) assembly from the machine.
WARNING
7. If required, remove mounting hardware securing To prevent personal injury and property
grille subframe to hood (1). Secure grille subframe damage, be sure blocking materials and lifting
clear of hood (1). equipment are properly secured and of
adequate capacity to do the job safely.
8. If required, remove bolts (10) and washers (11)
securing handles (9) to hood (1). Secure handles (9) 1. Position the machine on a level surface, apply the
clear of hood (1). parking brake and switch off the engine.

Installation 2. Block all road wheels and place the battery master
switch in the off position.
Numbers in parentheses refer to Fig. 1.
3. Pull cable assembly (16), handle inside battery box,
Note: Tighten all fasteners to torques listed in to release hood catch and lift up hood (1). Secure
Section 300-0080, STANDARD BOLT AND NUT hood (1) in raised position.
TORQUE SPECIFICATIONS.
4. Remove mounting hardware securing washer bottle
to mounting bracket on the left hand side of goalpost
WARNING support assembly (18). Secure washer bottle clear of
To prevent personal injury and property goalpost support assembly (18).
damage, be sure blocking materials and lifting
equipment are properly secured and of 5. Remove plate and mounting hardware securing
adequate capacity to do the job safely. transmission oil cooler to goalpost support assembly
(18). If required, disconnect transmission oil cooler
1. If removed, secure handles (9) to hood (1) using hoses.
bolts (10) and washers (11).
6. Remove mounting hardware securing air cleaner
2. If removed, secure grille subframe to hood (1) using intake tube to goalpost support assembly (18).
mounting hardware as removed at 'Removal'.
7. With a suitable container available to catch leakage,
3. Using suitable lifting equipment, lift and position remove drain plug from radiator header tank and drain
hood (1) on the machine and align holes in hinge coolant. Apply Loctite 225 to drain plug and reinstall in
assemblies (2) with mounting holes on frame. Secure header tank.
hood (1) using bolts (37), washers (13) and nuts (17).
8. Ensure all cooling lines connected to header tank
4. Carefully install hood straps (14) and gas struts (15) are identified for ease of installation and with suitable
using mounting hardware as removed at 'Removal'. containers available to catch leakage, disconnect
cooling lines. Fit blanking caps to all open lines.
5. With lifting equipment still in place, lower hood (1) to
match with goalpost support assembly (18). Remove 9. Disconnect electrical harness from coolant level
lifting equipment. sensor in header tank. Note routing of all hoses and
harnesses attached to and through goalpost support
6. If required, adjust fitment of hood (1) to frame at assembly (18) and disconnect.
hinge assemblies (2) and adjustment rod (6).
10. Disconnect hood cable (16) ball joint from cam
7. Install grille (27) to hood (1) and secure using bolts, plate assembly (33) and secure cable (16) clear of
washers, lockwashers and nuts. hood catch mechanism.
8. Remove wheel blocks. 11. Check to make certain that all necessary line and

2 SM 2173 Rev1 04-05

 Chassis - Hood and Mounting
Section 100-0040
cable disconnections have been made, before lifting 6. Fit plate and mounting hardware securing
goalpost support assembly (18). transmission oil cooler to goalpost support assembly
(18) as removed during 'Removal'. If necessary,
12. Attach suitable lifting equipment to goalpost reconnect transmission oil cooler hoses. Ensure
support assembly (18). Remove bolts (23), washers transmission oil cooler contains sufficient oil. Refer to
(24 & 25) and locknuts (26) securing goalpost support Section 210-0060, TRANSMISSION OIL COOLER.
assembly (18) to its mounting. Lift goalpost support
assembly (18) from the machine. 7. Install washer bottle to mounting bracket on the left
hand side of goalpost support assembly (18) and
13. If required, remove locknuts (22), bolts (19), hood secure using mounting hardware as removed during
stops (20) and springs (21) from goalpost support 'Removal'.
assembly (18).
8. Secure air cleaner intake tube to goalpost support
14. If required, remove bolts (30), washers (29) and assembly (18) using mounting hardware as removed
nuts (28) securing hood catch mechanism (31 - 36) to during 'Removal'.
goalpost support assembly (18). Remove hood catch
mechanism (31 - 36). 9. Remove blanking caps from all cooling lines and
connect cooling lines to radiator header tank as tagged
at 'Removal'.
Installation
Numbers in parentheses refer to Fig. 1. 10. Connect electrical harness to coolant level sensor
in header tank. Secure all hoses and harnesses to and
Note: Tighten all fasteners to torques listed in through goalpost support assembly (18) following
Section 300-0080, STANDARD BOLT AND NUT routing as noted at 'Removal'.
TORQUE SPECIFICATIONS.
11. Fill radiator header tank with coolant as specified
in Section 210-0000, COOLING SYSTEM.
WARNING
To prevent personal injury and property 12. Lubricate hood catch mechanism. Use grease as
damage, be sure blocking materials and lifting specified in Section 300-0020, LUBRICATION
equipment are properly secured and of SYSTEM.
adequate capacity to do the job safely.
13. Lower hood assembly and check for correct
1. If removed, secure hood catch mechanism (28 - 38) alignment between hood (1) and goalpost support
to goalpost support assembly (18) with mounting assembly (18) and for operation of hood catch
hardware as removed at 'Removal'. mechanism.

2. If removed, secure hood stops (20) and springs (21) 14. Remove wheel blocks.
to goalpost support assembly (18) with bolts (19) and
locknuts (22).
MAINTENANCE
3. Using suitable lifting equipment, lift and position Periodically check bolts (39), washers (13) and
goalpost support assembly (18) on the machine. locknuts (17) and tighten when necessary.
Secure goalpost support assembly (18) to its mounting
with bolts (23), washers (24 & 25) and locknuts (26). Periodically check condition of hood catch mechanism
and adjust and lubricate when necessary.
4. Remove lifting equipment.

5. Connect hood cable (16) ball joint to cam plate SPECIAL TOOLS
assembly (33) and secure cable (16) using clips There are no special tools required for procedures
removed during 'Removal'. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
adhesives are available from your dealer.

* * * *

SM 2173 Rev1 04-05 3

Chassis - Hood and Mounting
Section 100-0040

THIS PAGE IS INTENTIONALLY BLANK

4 SM 2173 Rev1 04-05

 Engine - Engine and Mounting
Section 110-0030

SM - 3273
52 53
45 51
50
46 48 49 54
1 31
47 79,80
81,82 43
42
20 41

23 38 30 29
77
18
19

21 19 28 27

78
16 10
9 6
12
2 13 16

15
22
24
40
14 44
39 25 14
40
8 15
7 12
17 11 17

INSIDE BATTERY BOX 26

57
59 36,37
OUT IN 58 68
33
34 69
ENGINE LEFT HAND SIDE LUBE LINES- S.W.E.
FUEL WATER
OIL
76
70,71 5
72
3 73,74,75
4
35 56 MOUNTED TO AIR COND BRACKET -ENGINE LHS
55

60
32
61
62 63,64,65,66,67

1 - Engine 22 - Bracket 42 - Lockwasher 62 - Bolt

2 - Alternator Belt 23 - Engine Coupling 43 - Washer 63 - Bolt
3 - Oil Filter 24 - Bolt 44 - Earth Cable 64 - Nut-Stacking
4 - Fuel Filter 25 - Nut 45 - P.Clip 65 - Bushing Split
5 - Coolant Filter 26 - Bracket Assembly 46 - Nut 66 - Bushing Split
6 - Fan Belt 27 - Fan Clutch 47 - 'L' Bracket 67 - Clamp
7 - Rear Mount 28 - Fan 48 - Bolt 68 - Reducer
8 - Front Mounting Bracket 29 - Nut 49 - Nut 69 - Elbow
9 - Bolt 30 - Washer 50 - Lockwasher 70 - Bolt
10 - Lockwasher 31 - Bracket 51 - Washer 71 - Locknut
11 - Bolt 32 - Hose Assembly 52 - P.Clip 72 - Clip
12 - Washer 33 - Elbow 53 - Bolt 73 - Bolt
13 - Bolt 34 - Elbow 54 - Bracket 74 - Locknut
14 - Isolation Mount 35 - Hose Assembly 55 - Clip - Rubber 75 - Clip
15 - Snubbing Washer 36 - Bolt 56 - Clip - Rubber 76 - Elbow
16 - Bolt 37 - Lockwasher 57 - Washer 77 - Plug
17 - Locknut 38 - Snubbing Washer 58 - Lockwasher 78 - Connector Kit
18 - Bolt 39 - P.Clip 59 - Bolt 79 - Washer
19 - Lockwasher 40 - Washer 60 - Brackey Assembly 80 - Clamp
20 - Flywheel Guard 41 - Bolt 61 - Lockwasher 81 - Bolt
21 - Bolt 82 - Nut
Fig. 1 - Engine and Mounting

SM 2324 Rev3 02-07 1

Engine - Engine and Mounting
Section 110-0030

DESCRIPTION correct fuel output and timing for optimum power, fuel
economy and emissions.
Numbers in parentheses refer to Figure 1.
The Quantum Electronic Fuel System also takes
For engine make, model and specification, refer to
action to prevent damage to the engine and, provides
Section 000-0000, General Information. For engine
the serviceman with diagnostic capabilities so that
servicing and repair data refer to the engine
problems can be corrected quickly and easily.
manufacturers service manual.
1. Electronic Control Module (ECM) - Receives
The engine is mounted to the tractor frame at three
electronic inputs from the driver as well as from
points by a mounting bracket at the front of engine (8)
mounted sensors that provide information
and two rear mounts (7). Rubber isolation mounts (14)
electronically, such as oil pressure and temperature
through engine mounts provide sufficient flexibility to
and intake manifold pressure. This information is used
absorb varying engine vibration and torsional loads.
to control both the quantity of fuel injected and injection
timing.
Lube oil filter (3) and fuel filter (4) are remote mounted
in the battery box on the left hand side of machine. The
2. Programmable Read Only Memory (PROM) -
filters are of the throw away, spin-on type. Oil supplied
Located in the ECM and encoded with the operating
by the engine oil pump passes through oil filter (3)
software. Additional information is programmed into the
before reaching the various moving parts of engine (1).
EEPROM. This information controls the horsepower
Fuel drawn from the fuel tank passes through fuel filter
rating, torque curve, maximum engine speed and
(4) before reaching the fuel pump.
engine protection devices. The ECM processes this
information and sends electronic signals to the
Engine coolant filter (5) is a replaceable spin-on type
Electronic Fuel System Injectors where the precise
element mounted on the left hand side of engine (1).
amount of fuel is injected into the engine.
Refer to Section 210-0000, Cooling System.
3. Electronic Fuel System Injectors - The injector is
QUANTUM ELECTRONIC FUEL SYSTEM a lightweight, compact unit that injects diesel fuel
directly into the combustion chamber. The amount of
Description fuel injected and the beginning of injection timing is
Refer to Figure 2. determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.
WARNING
The injector performs four functions:
Before any welding is done on a machine
equipped with the Quantum Electronic Fuel
a - Creates the high fuel pressure required for efficient
System, disconnect the following in this order:
injection.
Battery earth cable, battery supply cable,
b - Meters and injects the exact amount of fuel required
alternator earth cables, alternator supply cables
to handle the load.
and electrical connections at the engine ECM,
c - Atomizes the fuel for mixing with the air in the
transmission ECU, body control lever,
combustion chamber.
hydraulics ECU and cab bulkhead to avoid
d - Permits continuous fuel flow for component cooling.
damage to electrical components. Turn off
battery master switch to isolate the batteries
Electronic fuel system injectors are self compensating
before disconnecting any components.
and virtually eliminate engine tune-ups.
After welding connect all of the above in the
Note: Never apply 12 V directly to terminals on the
reverse order.
injector as it will burn out. Before removing injectors,
the fuel passages must be blown out to prevent fuel
The engine is equipped with Quantum Electronic Fuel
flow from entering the cylinder head.
System which controls the timing and amount of fuel
injection by the electronic fuel system injectors. The
4. Batteries - Two 12 volt maintenance free batteries
system also monitors several engine functions using
supply the machine with electrical power to operate all
electrical sensors which send electrical signals to the
electrical components.
electronic control module (ECM). The ECM then
computes the incoming data and determines the

2 SM 2324 Rev3 02-07

 Engine - Engine and Mounting
Section 110-0030

SM - 3734

6 7
3

2 STOP P
1

9
8

10 11
1,2
4

LO

HI

1 - Electronic Control Module (ECM) 7 - Check Engine Light

2 - Programmable Read Only Memory (PROM) 8 - Diagnostic Test Point
3 - Electronic Fuel System Injectors 9 - Maintenance Light
4 - Batteries 10 - Engine Diagnostic Switch
5 - Electronic Foot Pedal 11 - Engine Diagnostic Search Switch
6 - Stop Engine Light
Fig. 2 - Quantum Electronic Fuel System Components

5. Electronic Foot Pedal - The electronic foot pedal 8. Diagnostic Test Point - Plug in connector for
provides an electrical signal to the engine's fuel control diagnostic data reader (DDR).
system in proportion to the degree of pedal actuation.
9. Maintenance Light - The maintenance light will
Note: The engine MUST be started with foot 'OFF' the illuminate when it is time to change the engine oil. The
electronic foot pedal. maintenance monitor continuously monitors the time
the engine has been operating and the amount of fuel
Do not place engine under full load at full speed burned to determine when it is time to change oil.
immediately after starting. Always allow the engine to
fully circulate lubricant and warm up gradually before Note: Whenever an electrical fault has occurred, the
operating at full speed and full load. Operate engine at maintenance monitor data can be inaccurate.
top rated speed when maximum power is needed for
the load. 10. Engine Diagnostic Switch - To check for active
codes:
6. Stop Engine Light - When the 'Stop Engine' light
comes on, the computer has detected a major a - turn the ignition key switch to the 'OFF' ('0') position.
malfunction in the engine that requires immediate
b - press the diagnostic switch to the 'ON' position.
attention. It is the operators responsibility to shut down
the engine to avoid serious damage. c - turn the ignition key switch to position '1'.

7. Check Engine Light - When the 'Check Engine' light If no active codes are recorded, both the 'Stop' and
comes on, the computer has detected a fault in the 'Check' lights will illuminate and stay on.
engine. The fault should be diagnosed and corrected at
the earliest opportunity. If active codes are recorded the 'Stop' and 'Check'

SM 2324 Rev3 02-07 3

Engine - Engine and Mounting
Section 110-0030
lights will illuminate momentarily. The amber 'Check' A special diagnostic data reader (INSITE) is available
and red 'Stop' lights will begin to flash the code of the that can be plugged into the engine computer memory
recorded fault. via the diagnostic test point (8). The reader is used to
extract information related to the cause of the problem.
11. Engine Diagnostic Search Switch - When the Once the malfunction has been corrected, the
engine is in diagnostic mode this switch is used to Electronic Fuel System will return the engine to normal
search through a list of fault codes, ie. pressing the top operation. The data reader can now distinguish
of the switch momentarily will advance to the next between active codes and those stored in the historic
active fault code, pressing the bottom of the will go code memory (inactive codes). Inactive codes can only
back to the previous code. If only one code is active, be viewed using the data reader. The fault code
the system will continuously display the same fault recorded in the ECM memory will remain until it is
code. erased by a technician.

Operation WARNING
Numbers in parentheses refer to Fig. 2. The operator of a Quantum-equipped vehicle
must not attempt to use or read a data reader of
When the 'Stop' light on the dash panel illuminates, the any kind while the vehicle is operating. Doing
ECM (1) has detected a major malfunction in the so can result in loss of control, which may
engine that requires immediate attention. It is the cause vehicle damage and may result in
operators responsibility to shut down the engine to personal injury.
avoid serious damage.
The operator can check for active faults by turning the
The machine is equipped with an engine protection ignition key switch to the 'OFF' position, switching the
derate system, which records fault codes and diagnostic switch (10) 'ON' and then turning the ignition
illuminates appropriate warning lights when an out-of- key switch to position '1'.
range condition associated with any of the following
sensors is found: If no active fault codes are recorded, both 'Stop' (7) and
• Coolant temperature 'Check' (6) lights will come on and stay on. If active
codes are recorded, both lights will come on
• Coolant level
momentarily. The amber 'Check' (6) and red 'Stop' (7)
• Intake manifold temperature lights will begin to flash the code of the recorded fault.
• Oil pressure The fault codes flash in the following sequence: the
• Oil temperature amber light flashes once, then there is a pause where
The engine power and speed will be gradually reduced both lights are off. Then the numbers of the recorded
depending on the level of severity of the out-of-range fault code flash in red. There is a pause between each
condition. The operator MUST shut down the engine to number. When the number is done, the amber light
avoid serious damage. flashes again. e.g. amber flashes once - pause - red
flashes twice - pause - red flashes three times - pause
- red flashes five times - pause - amber flashes once,
The engine should not be restarted after it has been
indicates fault code 235. The number will repeat in the
shut down after activation of the engine protection
same sequence until the the system is advanced to
derate system unless the problem has been diagnosed
the next active fault code by diagnostic request switch
and corrected.
(11), or the diagnostic switch (10) is switched to the
'OFF' position. Refer to 'Electronic Fuel System
Whenever the 'Stop' (7) or 'Check' (6) light comes on,
Diagnostic Codes' table for fault code descriptions.
the Electronic Fuel System computer will determine
where the problem is and will store this information in
1 FLASH 2 FLASHES 3 FLASHES 5 FLASHES 1 FLASH
its memory. If the malfunction is intermittent, the lights
will come on and go off as the computer senses the
changing engine condition. AMBER RED RED RED AMBER
(CEL) (SEL) (SEL) (SEL) (CEL)

PAUSE PAUSE PAUSE PAUSE

CODE 235
SM - 3735

4 SM 2324 Rev3 02-07

 Engine - Engine and Mounting
Section 110-0030

ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES

Error Code Description Fault Lamp
111 ECM Hardware Internal Failure - Mission disabling Red
115 Engine Speed Sensor - Both signals lost Red
121 Engine Speed Sensor - One signal lost Amber
122 Boost Pressure Sensor - Component shorted high Amber
123 Boost Pressure Sensor - Component shorted low Amber
131 Throttle Position Sensor - Component shorted high Red
132 Throttle Position Sensor - Component shorted low Red
133 Remote Accelerator Pedal Position Sensor- Circuit shorted high Red
134 Remote Accelerator Pedal Position Sensor- Circuit shorted low Red
135 Oil Pressure Sensor - Component shorted high Amber
141 Oil Pressure Sensor - Component shorted low Amber
143 Oil Pressure Sensor - Data below normal range Amber
144 Engine Coolant Temperature Sensor - Component shorted high Amber
145 Engine Coolant Temperature Sensor - Component shorted low Amber
147 Throttle Position Sensor - Circuit low frequency Red
148 Throttle Position Sensor - Circuit high frequency Red
151 Engine Coolant Temperature Sensor - Data above normal range Amber
153 Intake Manifold Temperature Sensor - Component shorted high Amber
154 Intake Manifold Temperature Sensor - Component shorted low Amber
155 Intake Manifold Temperature Sensor - Data above normal range Amber
187 Sensor Supply Voltage #2 - Circuit shorted low Amber
211 Additional OEM/Vehicle Diagnostic Codes have been logged None
212 Oil Temperature Sensor - Component shorted high Amber
213 Oil Temperature Sensor - Component shorted low Amber
214 Oil Temperature - Data above normal range Red
219 Low Oil Level in Make up tank Maint.
221 Ambient Air Pressure Sensor - Component shorted high Amber
222 Ambient Air Pressure Sensor - Component shorted low Amber
223 Engine Oil Burn Valve Solenoid - Circuit shorted low Amber
227 Sensor Supply Voltage #2 - Circuit shorted high Amber
234 Engine Speed - Data above normal range Red
235 Engine Coolant Level - Data below normal range Amber
237 External Speed Input (Multiple Unit Sychronization) - Data incorrect Amber
241 Vehicle Speed Sensor Circuit - Data incorrect Amber
242 Vehicle Speed Sensor Circuit - Tampering has been detected Amber
245 Fan Clutch - Circuit shorted low Amber
254 Fuel Shutoff Value - Component shorted low Red
255 Fuel Shutoff Value - Component shorted high Amber
285 SAE J1939 Multiplexing PGN timeout error Amber
286 SAE J1939 Multiplexing configuration error Amber
287 SAE J1939 Multiplexing accelerator pedal sensor system error Red
288 SAE J1939 Multipexing Remote throttle data error Red
293 Auxiliary Temperature Sensor Input #1 - Circuit shorted high Amber
294 Auxiliary Temperature Sensor Input #1 - Circuit shorted low Amber
295 Ambient Air Pressure Sensor - Circuit data incorrect Amber
297 Auxiliary Pressure Sensor Input #2 - Circuit shorted high Amber
298 Auxiliary Pressure Sensor Input #2 - Circuit shorted low Amber
299 Engine Shutdown - Commanded by J1939 Amber
311 Injector Solenoid Valve Cylinder #1 Circuit - Grounded circuit Amber
312 Injector Solenoid Valve Cylinder #5 Circuit - Grounded circuit Amber
313 Injector Solenoid Valve Cylinder #3 Circuit - Grounded circuit Amber
314 Injector Solenoid Valve Cylinder #6 Circuit - Grounded circuit Amber
315 Injector Solenoid Valve Cylinder #2 Circuit - Grounded circuit Amber

SM 2324 Rev3 02-07 5

Engine - Engine and Mounting
Section 110-0030

ELECTRONIC FUEL SYSTEM DIAGNOSTIC CODES

Error Code Description Fault Lamp
319 Real Time Clock - Power interrupt Maint
321 Injector Solenoid Valve Cylinder #4 Circuit - Grounded circuit Amber
322 Injector Solenoid Valve Cylinder #1 Circuit - Open circuit Amber
323 Injector Solenoid Valve Cylinder #5 Circuit - Open circuit Amber
324 Injector Solenoid Valve Cylinder #3 Circuit - Open circuit Amber
325 Injector Solenoid Valve Cylinder #6 Circuit - Open circuit Amber
331 Injector Solenoid Valve Cylinder #2 Circuit - Open circuit Amber
332 Injector Solenoid Valve Cylinder #4 Circuit - Open circuit Amber
341 ECM - Data lost Amber
343 ECM - Warning internal hardware failure Amber
346 ECM - Warning software error Amber
349 Transmission Output Shaft Speed High - Warning Amber
352 Sensor Supply Voltage #1 - Circuit shorted low Amber
381 Error detected in intake air heater relay circuit Amber
386 Sensor Supply Voltage #1 - Circuit shorted high Amber
387 Accelerator Pedal Position Sensor Supply Voltage - Circuit shorted high Amber
388 Less than 6 VDC detected at engine brake circuit 1 Amber
392 Less than 6 VDC detected at engine brake circuit 2 Amber
412 Data transmission error on J1587/J1922 datalink None
414 Data transmission error on J1587/J1922 datalink None
415 Oil Pressure Sensor - Data indicates very low oil pressure Red
418 Water in Fuel Indicator High Maint
419 Error in intake manifold pressure sensor signal detected by ECM Amber
422 Engine Coolant Level Sensor Signals - Data invalid Amber
426 SAE J1939 datalink - cannot transmit None
427 Data transmission on J1939 datalink not occuring at an acceptable rate None
428 Water in Fuel Sensor - Circuit shorted high Amber
429 Water in Fuel Sensor - Circuit shorted low Amber
431 Accelerator Pedal Idle Validation Circuit - Data incorrect Amber
432 Accelerator Pedal Idle Validation Circuit - Out of calibration Red
433 Intake Manifold Pressure Sensor - Circuit data incorrect Amber
434 Power Lost without ignition off Amber
435 Engine Oil Pressure Sensor - Circuit data incorrect Amber
441 Battery Voltage Low - Warning Amber
442 Battery Voltage High - Warning Amber
443 Accelerator Pedal Position Sensor Supply Voltage - Circuit shorted low Amber
465 High voltage detected at wastegate actuator No. 1 circuit Amber
466 Less than 6 VDC detected at wastegate actuator No. 1 circuit Amber
489 Transmission Output Shaft Speed Low - Warning Amber
491 High voltage detected at wastegate actuator No. 2 circuit Amber
492 Less than 6 VDC detected at actuator No. 2 circuit Amber
497 Error detected in multiple unit synch control sw. input pins 34 & 32 of OEM harness Amber
527 Auxiliary Input/Output #2 - Circuit shorted high Amber
528 OEM Alternate Torque Validation Switch - Data incorrect Amber
529 Auxiliary Input/Output #3 - Circuit shorted high Amber
551 Accelerator Pedal Idle Validation - Circuit shorted low Amber
581 Fuel Supply Pump Inlet Pressure Sensor - Circuit shorted high Amber
582 Fuel Supply Pump Inlet Pressure Sensor - Circuit shorted low Amber
583 Fuel Supply Pump Inlet Pressure Low - Warning level Amber
596 Electrical Charging System Voltage High - Warning level Amber
597 Electrical Charging System Voltage Low - Warning level Amber
598 Electrical Charging System Voltage Low - Critical level Red
611 Engine Hot Shutdown None
951 Cylinder Power Imbalance between cylinders None
6 SM 2324 Rev3 02-07
 Engine - Engine and Mounting
Section 110-0030

Maintenance Monitor 3. Press engine diagnostic switch on for a minimum of

The maintenance monitor uses data received from the 3 seconds, then switch off.
ECM to determine the amount of fuel burned and the
time the engine has been operating to determine when 4. Press engine diagnostic switch on/off quickly, twice
it is time to change the oil. The operator must still be (less than 1 second per cycle).
alert for any indications that the engine needs other
service. 5. Press engine diagnostic switch on for a minimum of
3 seconds, then switch off.
Note: Maintenance monitor is designed to alert the
operator of the need for a routine maintenance stop. 6. The maintenance light will flash three times. This
Maintenance records must still be maintained for means the maintenance monitor is reset.
historical purposes.
Note: If the maintenance light does not flash as
Note: Whenever an electrical fault has occurred, the described, the reset sequence must be performed
maintenance monitor data can be inaccurate. again.

'Severe' oil drain interval duty cycle is the default 7. Turn key to position '0'.
setting for the maintenance monitor, however this can
be adjusted by using diagnostic tools, to suit duty 8. Remove blocks from road wheels.
cycle and oil type used. Engine oil drain intervals are
dependant on working environment and oil type used. Alternative method of resetting maintenance monitor is
Refer to 'Engine oil drain intervals by duty cycle as follows:
(Hours)' table below. Refer to Section 300-0020,
Lubrication System for recommended oil type. 1. Park machine on level ground, block road wheels,
apply parking brake and switch off engine.
The maintenance monitor will alert the operator of the
need to change oil by flashing the maintenance light for 2. Turn keyswitch to position '1'.
approximately 12 seconds after key-on. The flashing
sequence will be three quick flashes, followed by a 3. Press engine diagnostic switch on.
pause. This flash sequence will go through five cycles
in the 12 second period. This sequence will occur at 4. Press and hold throttle pedal at 100% for 3 seconds,
every key-on until the maintenance monitor has been then release.
reset.
5. Press throttle pedal 100% on then off quickly, twice.
Note: The diagnostic switch must be OFF for the
flashing sequence to occur. 6. Press and hold throttle pedal at 100% for 3 seconds,
then release.
Resetting the Maintenance Monitor - There are two
ways to reset the maintenance monitor, depending on 7. The maintenance light will flash three times.
the engine ECU calibration.
Note: If the maintenance light does not flash as
1. Park machine on level ground, block road wheels, described, the reset sequence must be performed
apply parking brake and switch off engine. again.

2. Turn key to position '1'. 8. Press engine diagnostic switch off.

ENGINE OIL DRAIN INTERVALS BY DUTY CYCLE (HOURS)

Severe Heavy Medium Light
Fuel Consumption > 13 gal/hr 10 to 13 gal/hr 8.5 to 10 gal/hr < 8.5 gal/hr
API CF-4 150 200 250 300
API CG-4 250 300 400 500
API CH-4 or ACEA E5 300 350 500 600
CES20076 or CES20077 350 400 550 700

SM 2324 Rev3 02-07 7

Engine - Engine and Mounting
Section 110-0030
9. Turn key to position '0'. to Section 100-0040, Hood and Mounting.

10. Remove blocks from road wheels. Note: Radiator header tank will be removed as part of
the goalpost assembly.
REMOVAL
Numbers in parentheses refer to Figure 1. 9. With a suitable container in position, remove drain
valve on the cooler and drain the oil. Remove
Note: Tag all cables, harnesses, lines and pipes transmission oil cooler from the vehicle. Refer to
disconnected during removal to aid in installation. Section 210-0060, Transmission Oil Cooler.

10. Support engine sump guard with suitable blocking

WARNINGS and remove mounting hardware securing sump guard to
To prevent personal injury and property the frame. Remove sump guard from the frame.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 11. Support guard plate under the engine (1) at the front
secured and of adequate capacity to do the job of the frame with suitable blocking and remove
safely. mounting hardware securing guard plate to the frame.
Remove guard plate from the frame.
High electrical current can cause sparks
and personal injury from burns. Turn battery 12. Place a suitable container under the engine drain
master switch to the 'Off' position before port, remove drain plug and drain the oil. After draining,
removing any components. Remove battery reinstall drain plug in engine sump and tighten
ground cable first, and reconnect last, to avoid securely.
damaging electrical components.

1. Position the vehicle in a level work area, ensure the WARNING

body is fully lowered, apply the parking brake and Before disconnecting any air conditioner lines,
switch off the engine. Turn steering wheel several refer to Section 260-0130, Air Conditioning.
times to relieve any pressure in the steering circuit. Refrigerant will rapidly freeze all objects with
which it comes into contact. It can cause
2. Block all road wheels and place the battery master serious and permanent damage to the eyes and
switch in the 'Off' position. skin.

3. Disconnect battery cables from terminal posts (earth 13. Evacuate air conditioning system and disconnect
cable first). air conditioner lines at the engine compressor. Refer to
Section 260-0130, Air Conditioning.
4. Pull on handle, inside battery box, to release hood
catch and lift up hood. 14. Remove the radiator assembly from the vehicle.
Refer to Section 210-0040, Radiator and Mounting.
5. Using hydraulic hand pump inside battery box, tilt
cab and secure. Refer to Section 260-0010, Cab and 15. Remove charge air cooler pipes from engine
Mounnting. turbocharger and engine inlet manifold.

6. Remove mounting hardware securing air cleaner 16. Disconnect exhaust piping from the engine
intake tube to goalpost assembly. Remove mounting turbocharger.
hardware securing air cleaner to battery box. Slacken
mounting clamp at air cleaner intake tube and draw air 17. Disconnect air cleaner intake pipe from engine
cleaner away from intake pipe. Cover open ends to turbocharger and remove from the engine (1).
prevent entry of dirt.
18. Identify heater lines for ease of installation and with a
7. Carefully remove filler cap from header tank. With a suitable container in position, disconnect heater lines
suitable container in position, remove plug and open from the engine (1). Cap open line ends and fittings.
shut-off valve on the radiator assembly and drain the
coolant. 19. Identify fuel lines for ease of installation and with a
suitable container in position, disconnect fuel lines
8. Remove hood and goalpost from the vehicle. Refer from the engine (1). Cap open line ends and fittings.

8 SM 2324 Rev3 02-07

 Engine - Engine and Mounting
Section 110-0030
3. If required, remove rubber isolation mounts (14) from
20. Identify all electrical harnesses and cables for ease
rear mounts (7) and front mounting bracket (8).
of installation and disconnect from the engine (1).
4. Loosen air conditioner compressor drive belt and
21. Disconnect clips securing items to the engine (1)
remove compressor from engine (1). Refer to Section
that cannot be removed with the engine.
260-0130, Air Conditioning.
22. Remove guard from flywheel housing and
5. Loosen alternator adjusting screw locknut (1, Fig. 3).
disconnect driveline from the engine coupling and
secure clear of the engine (1). Refer to Section
6. Loosen the adjustment link locking capscrew (2,
130-0010, Front Drivelines.
Fig.3).
23. Attach suitable lifting equipment to the lifting
7. Loosen the alternator mounting capscrew (3, Fig. 3).
brackets on the engine and raise lifting equipment to
take up the slack.
8. Turn the adjusting screw (4, Fig. 3) anticlockwise to
release tension. Remove alternator belt (2).
24. Remove locknuts (17), snubbing washers (15 ) and
bolts (16) securing engine (1) to the frame through front
9. Remove alternator mounting capscrew (3, Fig. 3)
mounting bracket (8) and rear mounting brackets (7).
and adjustment link locking capscrew (2, Fig. 3).
Remove alternator.
25. Check to make certain that all necessary line and
electrical disconnections have been made before lifting
engine (1). 10. Disconnect the electrical connector (78) harness to
fan clutch (27).
26. Carefully lift engine (1) clear of the frame, remove
to a suitable work area and mount securely on a work 11. Remove nut (29), washers (30) and studs (38)
stand. securing fan (28) and clutch (27) to engine (1) fan hub.

12. Remove both fan (28) and clutch (27) together from
DISASSEMBLY the engine (1).
Numbers in parentheses refer to Figure 1.
13. Loosen fan idler pulley shaft locknut. Loosen the
1. Remove bolts (11 & 13) and washers (12) securing adjusting link to slacken the fan belt (6). Remove fan
front mounting bracket (8) to engine (1). Remove front belt (6).
mounting bracket (8).
14. Remove bracket supporting hoses from top of
2. Remove bolts (9) and washers (10) securing rear flywheel housing.
mounts to engine (1). Remove mounts (7).
15. Remove bolts (21) and washers (19) securing
flywheel guard (20) to flywheel housing, then remove
SM - 2786
flywheel guard (20) from engine (1).

16. Remove bolts (18) and washers (19) securing

engine coupling (23) at rear of engine (1) then remove
engine coupling (23).

17. Remove and discard filters (3, 4 & 5) from engine

(1), as described in 'Maintenance'. Cover engine inlet
ports to prevent entry of dirt.

18. Refer to 'Engine Manufacturers Service Manual' if

engine service or repair is required.

1 - Locknut 3 - Capscrew INSPECTION

2 - Capscrew 4 - Adjusting Screw
Numbers in parentheses refer to Figure 1.
Fig. 3 - Alternator Mounting

SM 2324 Rev3 02-07 9

Engine - Engine and Mounting
Section 110-0030
accessory drive pulley. Turn adjusting screw (4, Fig. 3)
1. Inspect rubber isolation mounts (14) for damage and
clockwise to increase belt tension; anticlockwise to
replace if required.
decrease belt tension. Refer to Engine Operation and
Maintenance Manual for correct alternator belt (2)
2. Check mounting brackets (7 & 8) and mounting
tension.
brackets on the front frame for cracks and/or damage.
Repair or replace as necessary.
11. Tighten the adjusting screw locknut (1, Fig. 3)
against the retainer. Tighten the adjustment link locking
3. Inspect engine coupling (23) for damage and repair
capscrew (2, Fig. 3) to 59 lbf ft (80 Nm).
or replace as required.
12. Tighten the alternator mounting capscrew (3, Fig. 3)
ASSEMBLY to 35 lbf ft (47 Nm).
Numbers in parentheses refer to Figure 1.
13. Install air conditioning compressor and compressor
drive belt on engine (1). Refer to Section 260-0130, Air
Note: Tighten all fasteners without special torques
Conditioning.
specified to standard torques listed in Section
300-0080, Standard Bolt and Nut Torque
14. If removed, install rubber isolation mounts (14) to
Specifications.
rear mounts (7) and front mounting bracket (8).
1. Remove covers from engine filter ports and install
15. Install rear mounts (7) to engine (1) and secure with
new filters (3, 4 & 5) on engine (1), as described in
bolts (9) and washers (10).
'Maintenance'.
16. Install front mounting bracket (8) to engine (1) and
2. Install engine coupling (23) to rear of engine (1) and
secure with bolts (11 & 13) and washers (12).
secure with bolts (18) and washers (19). Tighten bolts
(18) to a torque of 31 Nm (23 lbf ft).
INSTALLATION
3. Install flywheel guard (20) to flywheel housing and
Numbers in parentheses refer to Figure 1.
secure with bolts (21) and washers (19).
Note: Tighten all fasteners without special torques
4. Install bracket supporting hoses to top of flywheel
specified to standard torques listed in Section
housing.
300-0080, Standard Bolt and Nut Torque
Specifications.
5. Fit fan belt (6) and tighten adjusting link to tighten
fan belt (6). Refer to Engine Operation and
Maintenance Manual for the correct fan belt (6)
WARNING
tension.
To prevent personal injury and property
damage, be sure lifting device is properly
6. Tighten the fan idler pulley shaft locknut to 140 lbf ft
secured and of adequate capacity to do the job
(190 Nm). Check the belt tension again after the
safely.
locknut is tightened.
1. Attach suitable lifting equipment to engine (1) lifting
7. Install fan (28) and clutch (27) to fan hub and secure
brackets and carefully position engine (1) assembly in
with studs (38), nuts (29) and washers (30). Tighten nut
the tractor frame.
(29) to a torque of 31 Nm (23 lbf ft).
2. Secure engine (1) assembly to frame mounting
8. Connect electrical connector (78) harness to fan
brackets with bolts (16), snubbing washers (15) bolt (9)
clutch (27).
and locknuts (10) as shown in Fig. 1. Tighten bolts (16)
to a torque of 298 Nm (220 lbf ft).
9. Install alternator on engine (1) and secure with
adjustment link locking capscrew (2, Fig. 3) and
3. Connect driveline to the engine coupling (23). Install
alternator mounting capscrew (3, Fig. 3).
guard to flywheel housing. Refer to Section 130-0010,
Front Drivelines.
10. Fit alternator belt (2) between alternator pulley and
4. Install radiator assembly on the vehicle. Refer to

10 SM 2324 Rev3 02-07

 Engine - Engine and Mounting
Section 110-0030
Section 210-0040, Radiator and Mounting. against areas where heat will be evident.

5. Install air cooler pipes from engine turbocharger and 18. Ensure shut-off valve at the bottom of the radiator
engine inlet manifold to charge air cooler mounted on assembly and any drain cocks on engine (1) water
the radiator assembly. Refer to Section 210-0040, jacket are securely closed. Ensure shut off cocks at
Radiator and Mounting. coolant filter (5) are open to allow flow through the filter.

6. Install air cleaner intake pipe and exhaust piping to 19. Fill the cooling system with coolant. Refer to
engine turbocharger. Section 210-0000, Cooling System.

7. Remove caps from heater lines and fittings and 20. Fill the engine with lubricant through oil filler to the
connect heater lines to engine (1) as identified at top mark on dipstick. Refer to Section 300-0020,
removal. Lubrication System for oil specification.

8. Remove caps from fuel lines and fittings and 21. Fill transmission oil cooler with oil. Refer to Section
connect fuel lines to engine (1) as identified at removal. 210-0060, Transmission Oil Cooler.

9. Connect all electrical harnesses and cables to 22. Check all line and pipe connections for leaks prior
engine (1) (with the exception of battery connections) to starting the vehicle. Tighten as required.
as identified at removal.
23. Install hood assembly on the vehicle. Refer to
10. Connect air conditioner lines at the compressor as Section 100-0040, Hood And Mounting.
identified at removal. On completion of engine
installation the air conditioning system will require to 24. Using hydraulic hand pump inside battery box,
be charged. Refer to Section 260-0130, Air lower cab and secure. Refer to Section 260-0010, Cab
Conditioning. and Mounting.

11. Install the goalpost and radiator header tank 25. Switch the battery master switch to the 'On'
assembly on the vehicle. Refer to Section 100-0040, position, start up the engine and check for leaks.
Hood and Mounting. Tighten lines, pipes and fittings and top up all systems
as required.
12. Ensure all cooling lines to radiator assembly,
engine (1) and radiator header tank are correctly 26. Using suitable lifting equipment position front guard
connected. Refer to Section 210-0040, Radiator and plate under the engine and secure to the frame with
Mounting. mounting hardware removed during removal.

13. Remove covers from air cleaner intake pipe and 27. Using suitable lifting equipment position engine
rubber hose on the air cleaner inlet then slide air sump guard under the engine and secure to the frame
cleaner assembly towards the cab locating the rubber with mounting hardware removed during removal.
hose to the inlet pipe.
28. Remove wheel blocks from all road wheels.
14. Secure air cleaner assembly to the battery box,
rubber hose to the inlet pipe and intake tube to
goalpost assembly with mounting hardware removed MAINTENANCE
during removal. Numbers in parentheses refer to Figure 1.

15. Install transmission oil cooler on the vehicle. Refer Note: Carry out the following maintenance procedures
to Section 210-0060, Transmission Oil Cooler. in conjunction with additional procedures listed in
Section 300-0020, Lubrication System.
16. Connect battery positive connections to battery
terminals. Connect battery earth connections to battery
terminals. Every 10 Hours (Daily)
Engine (1) - Visually check engine for damage, loose
17. Ensure all lines, harnesses and cables are secured or frayed belts and listen for any unusual noises.
with clips and clamps as removed during removal. Check coolant level and air cleaner restriction. Check
Ensure no lines are chaffing on sharp edges or resting charge air piping for damage.

SM 2324 Rev3 02-07 11

Engine - Engine and Mounting
Section 110-0030
Engine (1) Oil Level Check - Position the vehicle on a
level work area, apply the parking brake, shut off the WARNING
engine and wait at least five minutes (to allow oil to Avoid direct contact of hot oil with your skin.
drain to the oil pan) before checking the oil level. The Hot oil can cause serious personal injury.
oil level should be between the low (L) and high (H)
marks on the dipstick. Add oil if low. Refer to Section Operate the engine until the water temperature reaches
300-0020, Lubrication System for the oil specification. 60° C (140° F). Position the vehicle on a level work
area, apply the parking brake and switch off the engine.
Note: Never operate the engine with oil level below the Position a suitable container under the engine oil drain
low (L) or above the high (H) mark on the dipstick. plug and drain the oil immediately to make sure all the
oil and suspended contaminants are removed from the
Fuel Filter/Water Separator (4) - Drain the water and engine.
sediment from the separator daily. Position the vehicle
on a level work area, apply the parking brake, shut off Clean the area around the lube oil filter head and, using
the engine and, with a suitable container below the strap type filter wrench, remove lube oil filter (3).
drain valve to catch spillage, open the drain valve by Discard lube oil filter (3) if it is not required for a failure
hand. Turn the valve anticlockwise approximately analysis. Clean the gasket sealing surface of the filter
1.5 - 2 turns until draining occurs. Drain the filter sump head.
until clear fuel is visible. Turn the valve clockwise to
close the drain valve. Note: The 'O' ring can stick on the filter head. Make
sure the 'O' ring is removed and discarded.
Note: Do not overtighten the drain valve as
overtightening can damage the threads. Note: Fill the filter with clean lubricating oil prior to
installation. The lack of lubrication during the delay
Cooling Fan (28) - Visually inspect the fan for cracks until the filter is pumped full of oil is harmful to the
or damaged blades. Check the fan to make sure that engine.
mounting bolts (29) are secure. Tighten bolts as
required. Replace any fan that is damaged. Apply a light film of clean lubricating oil to the gasket
surface of the new filter and install the filter on the filter
head. Turn the filter until the gasket contacts the filter
WARNING head surface. Tighten the filter an additional 1/2 to 3/4
Personal injury can result from a fan blade of a turn, or as specified by the filter manufacturer.
failure. Never pull or pry on the fan as this can
damage the blades and lead to fan failure. Note: Mechanical tightening of the filter is not
recommended and may result in seal and/or cartridge
Drive Belts - Visually inspect all drive belts daily. damage. Tighten filter by hand only.
Replace belts that are cracked or frayed and adjust
belts that have a glazed or shiny surface which Check and clean the engine oil drain plug threads and
indicates belt slippage. Correctly installed and the seal surface. Replace plug if damaged. Install and
tensioned belts will show even pulley and belt wear. tighten the drain plug to a torque of 88 Nm (65 lbf ft).
Fill the engine with clean lubricating oil specified in
Engine (1) Crankcase Breather - Check and clean the Section 300-0020, Lubrication System. The oil level
crankcase breather hose. Remove the breather hose should be between the low (L) and high (H) marks on
and check internally for obstructions or sludge buildup. the dipstick.
Clean or replace breather hose as necessary, to
prevent excess crankcase pressure buildup. Engine oil pressure must be indicated on the gauge
within 15 seconds after starting engine. If oil pressure
is not reached within 15 seconds, shut off the engine
Every 500 Hours
immediately to avoid engine damage. Confirm the
Engine Oil and Lube Oil Filter (3) - Replace the correct oil level in the oil pan.
lubricating oil and oil filter (3).
Start the engine and operate at idle speed to inspect
for leaks at the filter and oil drain plug. Shut off the
engine, wait approximately ten minutes to let the oil
drain back to the sump and check the oil level again.

12 SM 2324 Rev3 02-07

 Engine - Engine and Mounting
Section 110-0030
Add oil as necessary to bring the level to the high (H)
mark on the dipstick. Do not overfill the engine with oil. WARNING
A small amount of coolant can leak when
servicing the coolant filter with the shut off
Every 1000 Hours valves in the closed position. To avoid personal
injury, avoid contact with hot coolant.
Fuel Filter (4) - Clean the area around the fuel filter
head and replace the fuel filter. 3. Clean the filter adaptor with a clean, lint free cloth.

Position the vehicle on a level work area, apply the 4. Lightly coat new coolant filter (5) seal with clean
parking brake and switch off the engine. Using a strap engine oil as specified in Section 300-0020, Lubrication
type filter wrench, remove fuel filter (4) and discard the System.
thread adaptor sealing ring. Clean the gasket surface of
the filter head. 5. Start coolant filter (5) on the filter adaptor and tighten
it by hand until the seal touches the adaptor filter head.
Install the new thread adaptor sealing ring (supplied Tighten an additional 1/2 to 3/4 of a turn after contact,
with new filter) and apply a film of clean engine oil to or as specified by the filter manufacturer.
lubricate the filter seal. Fill the new filter with clean fuel
specified in Section 300-0020, Lubrication System. Note: Mechanical tightening of coolant filter (5) is not
necessary and will distort or crack the adaptor. Tighten
Install new fuel filter (6) on the filter head and tighten coolant filter by hand only.
by hand until the gasket contacts the filter head
surface. Tighten fuel filter (6) per filter manufacturer's 6. Open shut off valves at coolant filter (5) inlet and
instructions. outlet lines, and install pressure cap on header tank.

Note: Mechanical tightening of the filter is not 7. Start the engine and check for leaks. If any leaks are
recommended and may result in seal and/or cartridge noted, have them corrected. Add coolant as required.
damage. Tighten filter by hand only. Refer to Section 210-0000, Cooling System.

Coolant Filter (5) - Replace coolant filter (5) as

follows: Every 2000 Hours
Engine Mounting Bolts (16) - Check torque on engine
Note: There is a shut off valve at the coolant inlet and mounting bolts (16). If required, tighten to 298 Nm (220
outlet lines of coolant filter (5). Closing these valves lbf ft).
will enable coolant filter (5) to be replaced without an
excessive loss of coolant. Engine (1) - Steam clean.

Engine (1) Overhead Set - Adjust the valves and

WARNING injectors. Refer to Engine Operation and Maintenance
Do not remove the pressure cap from a hot Manual for details.
engine. Wait until the coolant temperature is
below 50° C (120° F) before removing the Engine (1) Water Pump - Inspect water pump weep
pressure cap. Heated coolant spray or steam hole and ensure it is not blocked.
can cause personal injury.
Engine (1) Turbocharger Mounting Nuts - Tighten
1. Remove the cooling system pressure cap from nuts to 65 Nm (50 lbf ft).
header tank.

2. Close shut off valves at coolant filter (5) inlet and SPECIAL TOOLS
outlet lines and, using filter wrench, remove and Refer to Section 300-0070, Service Tools, for part
discard coolant filter (5) from engine (1). numbers of service tools which should be used in
conjunction with procedures outlined in the engine
manufacturers service manual, and, general service
tools required. These tools are available from your
dealer.

SM 2324 Rev3 02-07 13

Engine - Engine and Mounting
Section 110-0030

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
3 2 Capscrew 80 59
3 3 Capscrew 47 35
1 16 Bolt 298 220
- - Engine Drain Plug 88 65
1 18 Bolt 31 23
1 29 Nut 31 23

* * * *

14 SM 2324 Rev3 02-07

 Engine - Cooling Fan
Section 110-0040

SM - 2790

2,3

1
5

ECM ON ENGINE LHS

7
6
SWE

1 - Bolt 5 - EST Fan Drive

2 - Lockwasher 6 - Electronic Control Module (ECM)
3 - Nut 7 - Harness
4 - Fan

Fig. 1 - Typical Layout View of Cooling Fan and Electronic Clutch

DESCRIPTION AND OPERATION further rises in coolant/air intake temperature results in

increased fan speed. The fan speed increases
Numbers in parentheses refer to Fig. 1.
proportionally with the increase in temperature until the
fan is fully engaged.
Note: The rate of fan (4) speed change and maximum
fan speed is preset to the cooling needs of the engine.
Note: The fan is fully engaged when the air
conditioning is switched on.
The electronic sensing technology (EST) fan (5) drive
system uses a pulse width modulated signal from the
When the temperature drops, so the fan speed reduces
engine electronic control module (6) to provide the
proportionally until the idle speed is reached.
appropriate fan speed necessary to satisfy any cooling
demand.
The EST fan drive (5) has a failsafe feature, ie. if the
electrical current to the fan drops to zero, the fan will
At a pre-determined engine coolant temperature or
be automatically engaged.
engine air intake temperature, variable current signals
from the ECM (6) give an increased fan speed. Any

SM 2175 10-02 1
Engine - Cooling Fan
Section 110-0040

REMOVAL
Numbers in parentheses refer to Fig. 1. WARNING
To prevent personal injury and property
damage, make sure blocking or lifting
WARNINGS equipment is properly secured and of adequate
To prevent personal injury and property capacity to do the job safely.
damage, make sure blocking or lifting
equipment is properly secured and of adequate 1. Install EST fan drive (5) on fan (4) mounting surface
capacity to do the job safely. of housing and secure in place with lockwashers (2)
and nuts (3).

Personal injury can result from a fan blade 2. Using suitable lifting equipment, position fan (4)
failure. Never pull or pry on the fan as this can assembly on the machine and secure to engine with
damage the blades and lead to fan failure. bolts (1). Torque tighten bolts (1) to 31 Nm (23 lbf ft).

1. Position the machine on a level work area, ensure Note: Ensure there is even clearance, all the way
the body is fully lowered, apply the parking brake and round, between fan (4) and the fan shroud.
switch off the engine. Operate the steering several
times to discharge the steering system. 3. Connect harness (7) at the connector on the fan
drive (5) braided cable.
2. Block all road wheels and place the battery master
switch in the off position. 4. If removed, install radiator on machine. Refer to
Section 210-0040, RADIATOR, HEADER TANK AND
3. If required, remove mounting hardware securing MOUNTING. Install fan guards to the fan shroud and
hood assembly to the machine and, using suitable secure with mounting hardware, as removed at
lifting equipment, remove hood assembly. Refer to 'Removal'.
Section 100-0040, HOOD AND MOUNTING.
5. If removed, position the hood assembly on the
4. Remove mounting hardware securing fan guards to machine using a suitable lifting device. Secure hood
the fan shroud. Remove fan guards from the machine. assembly on the machine with mounting hardware, as
If required remove radiator from the machine. Refer to removed at 'Removal'. Refer to Section 100-0040,
Section 210-0040, RADIATOR, HEADER TANK AND HOOD AND MOUNTING.
MOUNTING.
6. Start the engine and check for correct operation of
5. Disconnect harness (7) at the connector on the fan the fan. Refer to 'Testing' procedures contained in this
drive (5) braided cable. section.

6. Support fan (4) assembly with suitable lifting 7. Remove wheel blocks.
equipment and remove bolts (1) securing fan (4)
assembly to the engine. Remove fan (4) assembly
from the machine. TESTING

7. Remove nuts (3) and lockwashers (2) securing EST Static Test
fan drive (5) to fan (4) mounting surface of housing. Note: This test will only determine if the fan drive has
Remove EST fan drive (5) from housing. seized or is very close to seizure.

With the engine stopped, the fan should turn smoothly

INSTALLATION
with resistance (viscous) without scraping, scratching
Numbers in parentheses refer to Fig. 1. or grating noise.

Note: Tighten all fasteners without special torques Note: Rotation without resistance indicates a fault.
specified, to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. Basic Dynamic Test - Cut In/Cut Out
Note: This test is carried out with the machine static
and secured at rest.

2 SM 2175 10-02
 Engine - Cooling Fan
Section 110-0040
After the machine has stood for approximately 30 2. Maintain engine speed at 2 100 rev/min and
minutes with the engine stopped, start the engine and disconnect harness at the connector on the fan drive
increase engine speed to 2 100 rev/min. braided cable. Fan should automatically engage to full
flow speed.
Initially the fan noise should be loud (cut in), but before
a further minute has elapsed, the fan noise should
significantly reduce (cut out). MAINTENANCE
Every 10 Hours/Daily
Basic Dynamic Test - Fan Drive Operation Check the fan for cracks or damaged blades. Clean or
Note: This test is carried out with the machine static replace as required.
and secured at rest.
Note: This DST fan is a non-serviceable component.
1. Place a cardboard, or alternative material, sheet However, the following instructions must be strictly
over the radiator front with an approximate 100 mm adhered to:
(4 in) diameter hole in the sheet, in line with the centre
of the fan drive. 1. DO NOT clean around fan drive with steam or high
pressure jet.
2. Start the engine and increase engine speed to
2 100 rev/min. 2. DO NOT tamper with modulation control mechanism
for ANY reason.
3. Fan noise should initially be loud and reduce
significantly before 1 minute has elapsed. 3. DO NOT add any fluids or lubricants to the drive.

4. Maintain engine speed at 2 100 rev/min. Fan drive 4. DO NOT restrict fan rotation during engine operation
should 'cut in' (engage) before coolant temperature for ANY reason.
gauge indicates excessive coolant temperature.
5. DO NOT operate a machine with a damaged fan
5. Return engine speed to idle, quickly remove the assembly. Replace a damaged fan as soon as the fault
sheet in front of the radiator and bring engine speed is noted.
back up to 2 100 rev/min. Fan speed should 'cut out'
(disengage) within 1 minute. 6. DO NOT disassemble ANY fan assembly or
associated parts that are still within the warranty
coverage period.
Failsafe Check
Note: This test is carried out with the machine static 7. IMMEDIATELY investigate and correct ANY
and secured at rest. Hood should be raised and operator complaint involving drive or cooling system
secured. performance.

1. Start the engine and increase engine speed to

2 100 rev/min.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 1 Bolt 31 23

* * * *

SM 2175 10-02 3
Engine - Cooling Fan
Section 110-0040

THIS PAGE IS INTENTIONALLY BLANK

4 SM 2175 10-02
 ENGINE - Air Cleaner
Section 110-0050

SM - 2791

5
1

4 3

1 - Air Cleaner Body

2 - Primary Element
3 - Safety Element
4 - Vacuator Valve
5 - Mounting Band
6 - Cover Assembly
Fig. 1 - Exploded View of Typical Air Cleaner

DESCRIPTION AND OPERATION A mechanical air restriction gauge (2, Fig. 2) is

Numbers in parentheses refer to Fig. 1. mounted on the air cleaner body and shows when the
system air flow is being restricted. A red band
The dual dry element air cleaner is remote mounted gradually rises in the gauge window as air restriction
horizontally on the left hand side of the machine. The increases. The red band is locked when maximum
air cleaner prolongs engine life by removing grit, dust allowable restriction is reached. When the red band
and water from the air as it enters the engine. Grit and locks at the top of the gauge window, primary filter
dust, combined with engine oil, forms a highly abrasive element (2) should be serviced. Air restriction gauge (2,
compound which can destroy the engine in a Fig. 2) should be reset by pushing the button on the
comparatively short period of time. gauge, holding it for several seconds and then
releasing it.
A rubber vacuator valve (4) attached to end cover (6) in
a downward position, ejects grit, dust and water while While air restriction gauge (2, Fig. 2) indicates the need
the engine is running. Vacuator valve (4) minimizes the for servicing, it does not give as precise a
need for daily servicing. Even though vacuator valve measurement as a water manometer or vacuum
(4) is normally under a slight vacuum when the engine gauge. Refer to 'Measuring Air Restriction'.
is running, pulsing of the vacuum opens and closes the
rubber valve, expelling dust and water as they collect. Secondary (safety) element (3) is installed in air
When the engine is stopped, vacuator valve (4) opens cleaner body (1) inside of primary element (2). This
and expels any accumulated grit, dust or water. element increases the reliability of the air cleaner’s

SM 2176 11-02 1
Engine - Air Cleaner
Section 110-0050

SM - 2792

19 18 1716
24

9 2513 10
15 16
11
14

1 13
12

2
20 8

23

3
4

22 21
18
17 5
19 6

1 - Air Intake Tube 8 - Band Clamp 14 - Retaining Bracket 20 - Clamp

2 - Air Restriction Gauge 9 - Air Intake Tube 15 - Seal 21 - Air Cleaner Bracket
3 - Bolt 10 - Bracket 16 - Bolt 22 - Bolt
4 - Washer 11 - Clamp 17 - Lockwasher 23 - Clamp
5 - Lockwasher 12 - Bolt 18 - Washer 24 - Air Intake Coupling
6 - Nut 13 - Washer 19 - Locknut 25 - Nut
7 - Elbow
Fig. 2 - Exploded View of Typical Air Cleaner Mounting

protection of the engine from airborne dirt. It protects the 'Off' position.
the engine from dirt admitted by a damaged primary
element (2), or dirt that might be dropped into air 3. Pull on handle to release hood catch and lift up the
cleaner assembly while changing primary element (2). hood.

4. Remove bolts (16), washers (13) and nuts (25)

AIR CLEANER securing coupling (24) to air intake tube (1).
Removal 5. Slacken clamps (8 & 23) securing elbow (7).
Numbers in parentheses refer to Fig. 2.
6. Remove bolts (3), washers (4), lockwashers (5) and
1. Position the vehicle in a level work area, apply the nuts (6) securing air cleaner to bracket (21). Using
parking brake and switch off the engine. suitable lifting equipment, support the air cleaner
assembly and draw air cleaner assembly away from
2. Block all road wheels, place the steering lock bar in elbow (7).
the 'Locked' position and the battery master switch in

2 SM 2176 11-02
 Engine - Air Cleaner
Section 110-0050
7. Blank off all open ends with tape or cardboard to b. Check that air cleaner mounting bracket (21) is
prevent entry of dirt. secure and that air cleaner is mounted securely.

8. If required, remove bolts (22), lockwashers (17),

washers (18) and nuts (19) securing bracket (21) to the MAINTENANCE
battery box. Remove bracket (21). Numbers in parentheses refer to Fig. 1, unless
otherwise specified.

Disassembly
Numbers in parentheses refer to Fig. 1, unless WARNING
otherwise specified. Always shutdown the engine before servicing
air cleaner.
Note: Air cleaner body (1) should be thoroughly
cleaned twice a year. Do not apply heat in any form to Check air restriction gauge (2, Fig. 2) daily (every 10
air cleaner body (1). hours). The air cleaner elements should be serviced
only when the maximum allowable restriction has been
1. Release latches on cover assembly (6) and remove reached, as indicated by air cleaner restriction gauge
cover assembly from air cleaner body (1). (2, Fig. 2). The elements should not be serviced on the
basis of visual observation as this would lead to over
2. Remove primary element (2) and safety element (3) service. When restriction readings finally indicate a
from air cleaner body (1). change, remove primary element (2) carefully and
clean/replace as required. Refer to 'Primary Element'.
3. Open mounting bands (5) and remove from air
cleaner body (1). Never attempt to clean safety element (3). Change
safety element (3) after every third primary element (2)
4. Slacken clamp (20, Fig. 2) and remove air intake service.
tube (1, Fig. 2), complete with retaining bracket (14,
Fig. 2) and seal (15, Fig. 2), from air cleaner body (1). Make sure vacuator valve (4) is not damaged or
plugged and that the joint with cover assembly (6) is
5. Blank off air cleaner body (1) outlets with tape or not broken. If vacuator valve (4) is lost or damaged,
cardboard. Reach inside body with a compressed air replace it to maintain pre-cleaner efficiency and normal
nozzle or brush and remove dust from the body. filter element service life.

6. Remove all loose dust from air cleaner body (1) and Check condition of clamps (8 & 23, Fig. 2), elbow
remove tape or cardboard from body outlets. (7, Fig. 2) and air intake tubes (1 & 9, Fig. 2). Tighten/
replace as necessary.
Assembly/Installation
Numbers in parentheses refer to Fig. 2, unless Primary Element
otherwise specified. Numbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners to standard torques listed Although a paper primary element (2) is used, it is
in Section 300-0080, STANDARD BOLT AND NUT possible to remove excess dirt by tapping element.
TORQUE SPECIFICATIONS.
1. Release latches on cover assembly (6) and remove
Assembly and installation of the air cleaner assembly cover assembly from air cleaner body (1).
is the reverse of disassembly and removal. Reset air
restriction gauge (2). 2. Remove primary element (2) from air cleaner body (1)
and clean/replace. It is advised to replace the element
Following installation, but before starting the engine, rather than attempt to clean thoroughly.
the following system checks should be carried out:
3. Using a damp cloth and a suitable solvent, wipe out
a. Check air intake tube (9) for defects and that clamps all excess dust from air cleaner body (1) and allow to
(8 & 23) (and those supplied with the engine) are dry.
securely tightened to ensure that there are no leaks in
the system. 4. Install primary element (2) in air cleaner body (1).

SM 2176 11-02 3
Engine - Air Cleaner
Section 110-0050
5. Install cover assembly (6) on air cleaner body (1) (air cleaner outlet) increases. This vacuum is generally
and secure with latches. measured as 'restriction in mm (inches) of water'.

The recommended maximum allowable intake

Secondary Element restrictions at rated speed and load are as follows:
Numbers in parentheses refer to Fig. 1.
a. 380 mm-H2O (15 in-H2O) with clean filter elements.
Since safety element (3) is protected from b. 635 mm-H2O (25 in-H2O) with dirty filter elements.
contamination by primary element (2), it needs no
periodic cleaning and should be replaced only after While the air restriction gauge sends a signal to
every third primary element (2) service. indicate the need for servicing, it does not give as
precise a measurement as a water manometer or
1. With primary element (2) removed from air cleaner vacuum gauge.
body (1), remove safety element (3).
Water Manometer
2. Remove any dust dislodged into air cleaner body (1) a. Remove air restriction gauge (2) from port in air
outlet and, using a damp cloth and a suitable solvent, cleaner assembly.
wipe out all excess dust from air cleaner body (1) and
allow to dry. b. Hold water manometer vertically and fill both legs
approximately half full of water. Connect one of the
3. Install new safety element (3) followed by primary upper ends to port by means of a flexible hose.
element (2) in air cleaner body (1).
c. With the manometer held vertically and the engine
4. Install cover assembly (6) on air cleaner body (1) drawing maximum air, the difference in height of the
and secure with latches. water columns in the two legs is measured as the air
cleaner restriction.
Recommendations d. If the restriction exceeds the levels indicated, engine
Numbers in parentheses refer to Fig. 2. performance will be affected. Primary filter element
should be cleaned or replaced.
1. Under no condition should the vehicle be operated
without both filter elements in each air cleaner Vacuum Gauge
assembly. a. Remove air restriction gauge (2) from port in air
cleaner assembly.
2. It is very important that elbow (7) and air intake tube
(9) from the air cleaner assembly to the engine be b. Connect the hose from the vacuum gauge to
airtight or the purpose of the air cleaner will be port and, with the engine drawing maximum air, take a
completely defeated. All clamps (8 & 23) (and those note of the reading on the gauge.
supplied with the engine) should be checked frequently
and tightened to prevent leaks. c. If the restriction exceeds the levels indicated, engine
performance will be affected. Primary filter element
3. Keep new or cleaned filter elements on hand for should be cleaned or replaced.
replacement to prevent unnecessary downtime of the
vehicle.
SERVICE TOOLS
Refer to Section 300-0070, SERVICE TOOLS for part
MEASURING AIR RESTRICTION numbers of service tools referenced in this section and
Numbers in parentheses refer to Fig. 2. general service tools required. These tools are
available from your dealer.
As a dry air cleaner element becomes loaded with
dust, the vacuum on the engine side of the air cleaner

* * * *

4 SM 2176 11-02
 Transmission - Transmission and Mounting
Section 120-0010

SM - 3364

11

17

16
2 15
14

5 12 LH
3 13 RH
4
16

22

10
10
CROSSMEMBER ON FRONT FRAME
1 6 8
23
8 9 24
7 25

26
27
21 19
20 28
18

1 - Sleeve 8 - Washer 15 - Lockwasher 22 - Hardened Washer

2 - Front Bracket 9 - Bolt 16 - Isolation Mount 23 - Nut
3 - Lockwasher 10 - Nut 17 - Snubbing Washer 24 - Lockwasher
4 - Bolt 11 - Bolt 18 - Dipstick Tube 25 - Washer
5 - Front Plate 12 - LH Bracket 19 - Gasket 26 - Plate-cover
6 - Centre Bonded Mount 13 - RH Bracket 20 - Bolt 27 - Washer
7 - Bolt 14 - Bolt 21 - Lockwasher 28 - Bolt

Fig. 1 - Exploded View of Transmission and Mounting

DESCRIPTION integral output transfer gearing. Automatic shifting in

Numbers in parentheses refer to Figure 1. gear ranges 1 to 6, with kickdown feature. Lockup in all
forward gears. An optional, wear-resistant
For transmission make, model and specification, refer hydrodynamic retarder integral to the transmission is
to Section 000-0000, General Information. For available.
transmission servicing and repair data refer to
transmission manufacturer's service manual. An engine dependent power takeoff at the rear of the
transmission provides the drive for the main hydraulic
The transmission is supported by front plate (5), LH pump which supplies the braking, steering and body
bracket (12) and RH bracket (13) which are bolted to hoist systems. A ground driven emergency steering
the transmission and attached to front frame mounting pump is attached at the lower rear left hand side of the
brackets through centre bonded mount (6) and isolation transmission.
mounts (16). Mounts (6 and 16) provide sufficient
flexibility to absorb varying transmission vibration and Mounted off bracket assembly on top of transmission
torsional loads. is the diff-lock/retarder valve which houses the retarder
solenoid, axle differential lock solenoid and pressure
The transmission assembly consists of a torque reducing valve (refer to Figures 4 and 5).
converter close-coupled to a 6 speed gearbox with

SM 2177 Rev 5 04-10 1

Transmission - Transmission and Mounting
Section 120-0010

SM - 2794
1

2
10 4

11

RHS
8
1 - Oil Temperature Sender (Gauge)
2 - Main Control Valve 7
3 - Transmission Difflock Solenoid
4 - Lockup Solenoid
5 - Engine Speed Sensor
6 - Output Speed Sensor
7 - Central Gear Train Sensor
8 - Turbine Speed Sensor
9 - Trans. Cooler Fan Drive Temp. Sensor
10 - Breather
11 - Retarder Oil Temperature Sensor 3

Fig. 2 - Location of Transmission Switches, Sensors and Solenoids

SWITCHES AND SENSORS The transmission oil temperature is also monitored by

temperature sensors in the main control valve, which
Numbers in parentheses refer to Figure 2, unless
sends a signal to illuminate the transmission STOP
otherwise specified.
warning light. The light will illuminate to indicate any of
Transmission Oil Temperature the following conditions:
Oil temperature sender (1) sends a signal to indicate
High retarder temperature
transmission oil temperature on the transmission oil
High transmission sump temperature
temperature gauge in the cab. The gauge should read
between 80° C (176° F) and 120° C (248° F) during Engine overspeed
normal operation and may reach 145° C (293° F) during
retarder operation. If the needle remains at high If the light illuminates during normal operation, a fault
temperatures for extended periods, the machine should code will also register on the display unit (See EST-37
be brought to a stop, transmission shifted to neutral Trouble Shooting tables). Bring the machine to a stop
and engine speed increased to 1 200 - 1 500 rev/min. and investigate the cause.
Under this condition, oil temperature should drop to
normal values in about 2 - 3 minutes. If oil temperature Temperature sensor (9) sends a signal to the hydraulic
does not drop, the cause should be investigated. ECU to operate the transmission cooler fan drive at a
speed proportional to transmission oil temperature.

2 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

SM - 1826

VALVE BLOCK

COVER

Y3 Y4

Y2 Y5 6

Y1 Y6

2 1
HOUSING
SYSTEM PRESSURE FROM
CONTROL UNIT BREATHER

1 - Main Pressure Valve 16+2 bar 5 - Follow-on Slide

2 - Pressure Reduction Valve 9 bar 6 - Proportional Valve (P1 to P6)
3 - Lockup Solenoid 7 - Vibration Damper
4 - Lockup Reduction & Shift Valve 8 - Harness Connection Y1 to Y6 - Pressure Regulators

Fig. 3 - Sectional View of Typical Control Unit with Lockup Clutch (Wk)

Lockup Clutch (Wk) clutches. These clutches are controlled via the six
The transmission lockup clutch is automatically proportional valves (6, Fig. 3). Each proportional valve
engaged. Engine speed is picked up by turbine speed (6, Fig. 3) is composed of a pressure regulator (Y1 to
sensor (8) which sends a signal to energise lockup Y6, Fig.3), follow-on slide (5, Fig. 3) and vibration
solenoid (3, Fig. 3) when turbine speed reaches a damper (7, Fig. 3).
predetermined level. Energising lockup solenoid
(3, Fig. 3) will move lockup valve (4, Fig. 3) across, The control pressure of 9 bar for the actuation of the
allowing oil to flow through the valve to engage lockup. follow-on slides (5, Fig. 3) is created by the pressure
reduction valve (2, Fig. 3). The pressure oil (16+2
bar) is directed via the follow-on slide (5, Fig. 3) to
Gear Selection the respective clutch.
The transmission can be engaged and disengaged
under load by means of hydraulically controlled multi- Due to the direct proportional control with separate
disc clutches. All gears run in antifriction bearings and pressure modulation for each clutch, the pressures to
are constantly meshed. The gears, bearings and the clutches, which are taking place in the gear
clutches are lubricated with cooled oil. change, are controlled. In this way, a hydraulic
intersection of the clutches to be engaged and
The transmission is equipped with six multi-disc disengaged becomes possible. This creates fast

SM 2177 Rev 5 04-10 3

Transmission - Transmission and Mounting
Section 120-0010
shiftings without traction force interruption. move when the vehicle speed is below 20 km/hr. A
Warning light will illuminate when the differential lock is
selected (NOT attained).
Speedometer Sensor
Speedometer sensor, within the ECU, sends a signal to Note: Before driving in soft or slippery conditions, stop
the speedometer, via the speedometer frequency and engage the differential locks. Spinning wheels can
divider, to indicate travel speed in kilometres per result in damage to the transmission and axle
hour and miles per hour. differentials.

Note: Disengage differential locks when driving on firm

Differential Pressure Switch ground.
The differential pressure switch is located in the
transmission filter head. The switch will close and The procedure for checking the differential lock
record a fault code when the filters become blocked, pressure is detailed in Section 140-0020, Differential
indicating a filter change is required. Lock Controls.

Note: The differential pressure switch is not operational Note: Differential lock (pilot) pressure can only be
when oil temperature is below 50°C (122°F) or when tested with the differential lock NOT actuated.
transmission output speed is greater than 2000 rev/
min.
Retarder Control
The hydro dynamic retarder is arranged between the
Differential Locks engine and torque converter so that a good braking
Note: The transmission differential lock requires effect is obtained in all speeds. The retarder is a
hydraulic pressure to hold it 'Off', whereas, the centre wear resistant hydrodynamic brake with speed
axle differential lock requires pressure to hold it 'On'. dependent action.

When the engine is started, hydraulic pressure is Retarder solenoid (4, Figs. 4 & 5) is energised on
applied to the transmission differential lock to ensure application of the retarder switch, located on the left
the differential lock is released. On activation of the hand switch bank, provided that the lockup clutch is
differential lock switch, the transmission differential engaged and the transmission 'Stop' warning light is
lock solenoid is de-energized and hydraulic pressure is OUT. Energizing the retarder solenoid will shift retarder
released at the transmission differential lock and solenoid valve and allow oil to flow through the valve to
applied at the centre axle differential lock. In this engage the retarder. The pressure reducing valve (2,
condition, the differential locks are engaged. Figures 4 and 5) reduces the inlet pressure from 16 bar
(232 lbf/in2) to 5.5 bar (80 lbf/in2).
Note: The differential locks can be preselected when the
machine is moving however, they will only engage on the Pressing the retarder switch OFF will de-energize
SM - 3348 SM - 2857

5 6
A1 B1 A2 B2
3 CT1 CT2
1
INLET
1
CT3 T2
2
2
CT4 TRANS
SUMP
4
3
4
7
TO 'TS' PORT ON
MAIN HYDRAULIC
VALVE
TRANSMISSION
PILOT PRESSURE

1 - Valve 4 - Retarder Solenoid 1 - Valve 4 - Retarder Solenoid

2 - Pressure Reducing Valve 5 - Bolt 2 - Pressure Reducing Valve 6 - Diff-lock
3 - Axle Diff-lock Solenoid 3 - Axle Diff-lock Solenoid 7 - Retarder
Fig. 4 - Diff-lock/Retarder Valve Fig. 5 - Diff-lock/Retarder Valve Schematic

4 SM 2177 Rev 5 04-10

 2nd POWER TAKE-OFF
SCHEDULE OF MEASURING POINTS
CONVERTER
Measurements to be carried out with oil at normal operating 14
RETARDER WK
temperature of 80° C and operating at full speed.
KV K1

MEASURING POINTS FOR PRESSURE OIL AND TEMPERATURE: 1st POWER TAKE-OFF

51 = Before the Convertor - Opening Pressure 8.5 bar

SM 2177 Rev 5 04-10

52 = Behind the Convertor - Opening Pressure 5 bar INPUT
53 = Clutch forward 16+2 bar KV
55 = Clutch reverse 16+2 bar KR KR K2
56 = Clutch 16+2 bar K1 PUMP
57 = Clutch 16+2 bar K2
58 = Clutch 16+2 bar K3
6 31
60 = Clutch 16+2 bar K4 K4 K3
63 = Temperature 100° C behind the retarder (short time 150° C)
65 = System pressure 16+2
66 = Temperature 100° C behind the converter (short time 120° C)
67 = WK-Control pressure 13±1 bar 39
OUTPUT OUTPUT

58
56 ENGAGEMENT AND DISENGAGEMENT DIFFERENTIAL
53
DIFFERENTIAL LOCK
60 D C
INDUCTIVE TRANSMITTERS AND SPEED SENSORS
E B 6 = Inductive Transmitter n Turbine
55 14 = Inductive Transmitter n Engine
F A
31 = Speed Sensor n Output and Speedometer
G
39 = Inductive Transmitter n Central Gear Train
J H K
57

66 • PRESS REG. UNDER VOLTAGE

51
52 SPEED Y1 Y2 Y3 Y4 Y5 Y6
F1 • •
F2 • •
F3 • •

Fig. 6 - Typical Schedule of Measuring Points and Gear Pattern

F4 • •
F5 • •
F6 • •
63 R1 • •
67 65 R2 • •
R3 • •
N
CLUTCH KR K4 K1 K3 KV K2
POS. VALVE F E D C B A
POINTS 55 60 56 58 53 57
SM - 1824
Transmission - Transmission and Mounting
Section 120-0010

5
6
KR K4 K1 K3 KV K2

SM - 2570
F 55 E 60 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D
Section 120-0010

Y1 NFS Y2 NFS Y3 NFS Y4 NFS Y5 NFS Y6 NFS

RV-9
TEMP

No. Denomination of the Position Port

K 65
NOT SCOPE OF SUPPLY ZF
15 To the heat exchanger
WK-M HDV
HYDRAULIC PRESSURE 16 From the heat exchanger
WK-V 28 To the ZF-filter
29 From the ZF-filter
32 Behind the Convertor to heat exchanger
PRESSURE REDUCTION VALVE
33 Before the Convertor to heat exchanger
5.5 bar 34 From heat exchanger to lubrication into Transmission
CONVERTER
67 WK 51 Before the Convertor - Opening Pressure 8.5 bar H
51
52 Behind the Convertor - Opening Pressure 5 bar
53 Clutch forward 16+2 bar KV B
55 Clutch reverse 16+2 bar KR F
H 56 Clutch 16+2 bar K1 D
TO THE RETARDER VALVE WSV 57 Clutch 16+2 bar K2 A
5.5 bar 66 52 58 Clutch 16+2 bar K3 C
Transmission - Transmission and Mounting

60 Clutch 16+2 bar K4 E

29 63 Temp. 100° C behind the retarder (short time 150° C)
WGV 65 System pressure 16+2 K
66 Temp. 100° C behind the converter (short time 120° C)
BYPASS VALVE 67 WK-Control pressure 13±1 bar
ZF-FINE FILTER
32
WT (SCOPE OF SUPPLY CUSTOMER) 28

16 15

WITH RETARDER
RT-V
LEGEND:
FILLING POSITON IN THE CABIN TRANSMISSION PUMP = MAIN PRESSURE
63 = CONTROLLED MAIN PRESSURE
= PILOT PRESSURE
= CONVERTER INLET PRESSURE
WITHOUT RETARDER = CONVERTER EXIT PRESSURE

Fig. 7 - Oil Circulation Diagram for Typical Transmission with Lockup Clutch and Retarder
= LUBRICATION
= RETURN TO SUMP
COARSE FILTER
LUBRICATION

33 34

RT OIL SUMP

SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010
retarder solenoid and retarder solenoid valve will shift
back to disengage the retarder. Note: When in manual mode, if the engine rev/min
drops below 'lock up disengaging rev/min', the
Note: Irrespective of speed, the retarder will transmission will automatically downshift to the next
automatically disengage when the transmission oil lowest gear. A manual upshift will only be accepted if
temperature reaches 150° C (302° F). the transmission is in lock up.

Note: To perform a stall test, manual upshifts can be

OPERATION
selected without lock up being engaged by special
activation of the auto/manual button on the gearshift
EST-37 Automatic Shift Control
controller. The procedure is as follows:
The EST-37 transmission is equipped with an 1. Press the function button from neutral and move the
electronic control unit (ECU) which continually monitors gear lever forward to select automatic mode.
the transmission and shift system electrical
components and warns the operator when a problem 2. Press function button five times within four seconds.
develops. It also takes action to prevent damage to the 3. Manually select the gear by pushing the lever to the
transmission, and provides the serviceman with right.
diagnostic capabilities so that problems can be WARNING
corrected quickly and easily.
Before any welding is done on a machine
When a fault occurs, a two digit error code will be equipped with an EST-37 shift system,
displayed on the LCD display to the right hand side of disconnect the following in this order: battery
the gearshifter. The error code is also recorded in the earth cable, battery supply cable, alternator
transmission ECU, and can be accessed by the earth cables, alternator supply cables and
serviceman by plugging in a data reader to extract electrical connections at the engine ECM,
information relating to the fault. The error code transmission ECU, body control lever,
recorded in the ECU memory will remain until it is hydraulics ECU and cab bulkhead to avoid
erased by a technician. damage to electrical components. Turn off the
battery master switch to isolate the batteries
If a major fault is detected, it is the operator's before disconnecting any components.
responsibility to shut down the machine as soon as it After welding connect all of the above in the
is safe to do so. The machine should not be restarted reverse order.
until the fault has been diagnosed and corrected.
VTS-3 Shift Controller - Operation: The shift
Refer to 'EST-37 Trouble Shooting' table for a list of controller has 3 positions the lever can rest in,
fault codes and checks. Forward, Neutral and Reverse. Within each of these
positions, the gear can be changed by pushing the
The EST-37 transmission control has been designed to lever to the right (+) to upshift or to the left (-) to
provide the driver with maximum operational flexibility downshift. In the Neutral position, this can be used to
by allowing the choice of automatic or manual gear preselect the starting gear (the default being 2nd gear).
selection to optimize vehicle performance under all
operating conditions. The shift controller has a 'Function' button on the top of
the lever which is used to switch between automatic
The rotational pressure-compensated (RPC) system and manual modes. Press the function button from
gives improved shift quality due to more accurate 'NEUTRAL' and move the lever forward to select
clutch filling, in addition to reduced clutch filling time. automatic mode, when driving normal upshifting and
downshifting will occur. If required, a gear can be held
The transmission provides six forward gears, three in manual mode by pressing the function button once.
reverse gears and a neutral position. The gear To resume full automatic mode, the function button
positions are indicated on the VDU screen and on the should be pressed again. Manual gears can also be
LCD display located to the right of the operator, on selected by pushing the lever to the left for lower gears
the dash panel beside the gearshift controller . When or to the right for higher gears, again by pressing the
the lever is in the automatic range, shifts will occur function button once automatic mode will be resumed.
automatically between 1st and 6th gear, depending on
operating requirements. The reverse gears 1st through Note: The transmission will only allow gear shifting
3rd are manual mode only. when the predetermined values have been reached.

SM 2177 Rev 5 04-10 7

Transmission - Transmission and Mounting
Section 120-0010

SM - 2798 SM - 2335

S
T
O
P

1 2 3

1 - Bars show gear ranges and full display (as

IDLE
shown) indicates driving in automatic mode.

FULL LOAD/THROTTLE
2 - Display shows actual driving direction.
KICK/HOLD DOWN 3 - Display shows actual gear in use.

Fig. 8 - Accelerator Load Ranges and Kickdown Position Fig. 9 - Dashboard Display
vehicle speed is within the range allowable. That is, the
Note: There is no shift inhibitor in the gear shift control, vehicle is not travelling at a speed that would result in
therefore, no resistance would be felt while moving the engine overspeeding in the lower gear. When
through the gear ranges. driving with kickdown, the transmission will give earlier
downshifts and later upshifts. To disengage the
The gear lever housing sends a signal to the electronic transmission kickdown, release the throttle pedal and
control unit, which in turn will only allow the engine to allow it to return to a light throttle position.
be started when the gear lever is in the 'NEUTRAL'
position. The gear shift lever must always be placed in When operating in automatic range with the display
'NEUTRAL' and the parking brake applied when starting indicating that the transmission has downshifted to 2nd
the engine, or whenever the machine is left unattended. gear, there are two options for providing a further
downshift as conditions indicate.
When shifting from 'NEUTRAL' to start from a
standstill, or to reverse direction, decelerate the engine 1. 1st gear can be manually selected by pushing the
to idle speed before selecting the proper gear. When shift lever to the left.
'REVERSE' is selected, the 'Reverse Alarm' sounds 2. Kickdown can be selected from 2nd automatic, when
and the 'Reverse Light' illuminates to warn personnel to the transmission will downshift to 1st gear, depending
the rear of the machine that reverse gear has been upon the vehicle speed.
selected.
When the kickdown is released, the transmission will
When the gear is selected the park brake is upshift to 2nd automatic, provided that the forward
automatically released.When Neutral is selected and speed has increased sufficiently to allow this to
the transmission output speed is less than happen, and that the shift lever is in the automatic
60RPM~1MPH, the paking brake applies automatically. mode.

During reversing operations it is recommended to A dashboard display is provided which indicates gear
reduce engine speed, use only 1st or 2nd gear and never selected and driving direction as follows (See Figure 9):
exceed 10 km/h (6.2 mile/h).
Manual Mode - When driving with shift selector in
The electronic control system distinguishes between manual range, the bars only are shown in position 1,
the throttle position (or load ranges) depending on the and, driving direction and gear selected are indicated
governor position (injection pump). On a light throttle in positions 2 and 3.
opening, the transmission will give earlier upshifts and
later downshifts than when operating at full throttle. Automatic Mode - When driving with shift selector in
automatic range, a full display of bars and arrows are
A kickdown facility (See Figure 8), which can be used shown in position 1, and, driving direction and gear
when automatic mode is selected, allows for the selected are indicated in positions 2 and 3.
possibility of selecting a lower gear by pressing down
fully on the throttle pedal and holding. This can be used Under certain conditions the transmission may start
to provide a downshift on demand provided that the to 'hunt' between gears when in automatic mode. The

8 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010
transmission changes up and down between two gears Note: In cold weather, the transmission oil should be
at short intervals because there is not sufficient power warmed up by running the engine at idle speed with the
to sustain driving in the higher gear, but is sufficient for gear selector in neutral, since the system will not
upshifting from the lower gear. By using the shift operate satisfactorily if the oil is too cold.
display, it can be established which gears are involved
and in these circumstances the lower gear should be When temporarily stopped, such as for yielding the
selected using the shift control lever. Automatic mode right-of-way to a loaded machine, the transmission can
should be reselected at the earliest opportunity. be left in gear and the machine held stationary with the
service brakes.
During machine operation, watch for wide deviations
from normal readings on the transmission oil When stopped for a more extended period with the
temperature gauge. If the gauge shows the oil engine left running, shift to 'NEUTRAL' to avoid
temperature rising above 120°C (248°F) during normal unnecessary heat buildup, and apply the parking brake
operation, or above 145°C (293°F) during retarder switch.
operation, the machine must be stopped and inspected
for external oil leakage. If no leaks are found, shift to Note: The Parking brake is automatically applied in
'NEUTRAL' and operate the engine at 1200-1500 rev/ these operating conditions
min. If the transmission oil temperature does not
decrease into the normal zone within 2 or 3 minutes,
the cause of the overheating should be corrected
before the machine is operated further.

Display during operation

Symbol Meaning Remarks
1F, 1R Actual gear and direction. Left digit shows
2F, 2R actual gear, right digit shows actual
3F, 3R direction
4F
5F
6F
LF, LR Limp home gear
F or R, no gear Clutch Cutoff
F or R flashing Direction F or R selected while turbine CAUTION gear will
speed is too high, engage if turbine speed drops

NN Not neutral, waiting for neutral after To engage a gear, first move shift
power up or a severe fault selector to neutral position and again
to F or R position
** Oil temperature too low, no gear available Warm up engine / transmission
*N Oil temperature low, only one gear available Warm up engine / transmission
1 bar (special symbol) Manual mode 1st gear
2 bars Manual mode 2nd gear
3 bars Manual mode 3rd gear
4 bars Manual mode 4th gear, 5th gear, 6th gear (6WG)
4 bars and 2 arrows Automatic mode
bars flashing 6 WG: converter lockup clutch open Difference of engine and turbine speed
above a certain limit and lockup clutch
not activated
spanner At least one fault active Select neutral to get fault code displayed
fault code See faultcode list

SM 2177 Rev 5 04-10 9

Transmission - Transmission and Mounting
Section 120-0010

Display During Operation - Continued

Symbol Meaning Remarks
WS Warning sump temperature Changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WR Warning retarder temperature Changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WT Warning torque converter temperature Changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WE Warning high engine speed Changes between actual gear/direction
while driving, in neutral only displayed
if no fault is detected (spanner)
WV Warning high output speed (velocity) Changes between actual gear/direction
while driving, in neutral only displayed if
no fault is detected (spanner)
WL Warning high transmission input torque Changes between actual gear/direction
(load) while driving, in neutral only displayed if
no fault is detected (spanner)
WO Warning high transmission output torque Changes between actual gear/direction
(load) while driving, in neutral only displayed if
no fault is detected (spanner)
F or R flashing Direction F or R selected while turbine CAUTION, gear will
speed is to high. engage if turbine speed drops
EE flashing No communication with display Checked wiring from TCU to display
The AEB-Starter is a tool to start the AEB (automatic filling parameter adjustment) of ergopower transmissions
with ease. Connect AEB-Starter to plug X25 located below dash adjacent to TCU.

Display during AEB-Mode

Symbol Meaning Remarks
PL AEB - Starter is plugged at the diagnostic
plug
ST AEB-Starter-button is pressed
K1..K4,KV,KR Calibrating clutch K1..K4,KV,KR
_ and Kx Wait for start, initialization of clutch Kx,
x: 1, 2, 3, 4, V, R
º and Kx Fast fill time determination of clutch Kx
= and Kx Compensating pressure determination of
clutch Kx
OK Calibration for all clutches finished Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
after removing AEB-Starter
STOP AEB cancelled (activation stopped) Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx can’t be calibrated Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
Spanner and Kx Kx couldn’t be calibrated, AEB finished Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
E engine speed too low, -> raise engine
speed

10 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

Display during AEB-Mode - Continued

Symbol Meaning Remarks
E Engine speed too high, -> lower engine
speed
T Transmission oil temperature too low,
-> heat up transmission
T Transmission oil temperature too high
-> cool down transmission
FT Transmission temperature not in defined Transmission stays in neutral, you
range during calibration have to restart the TCU (ignition off/on)
FB Operating mode not NORMAL or Transmission stays in neutral, you
transmission temperature sensor defective have to restart the TCU (ignition off/on)
or storing of Calibrated values to
EEPROM-has failed.
FO Outputspeed_not_zero Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
FN Shift lever not in Neutral position Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
FP Parkbrake_not_applied Transmission stays in neutral, you
have to restart the TCU (ignition off/on)
STOP AEB - Starter was used incorrect or is Transmission stays in neutral, you
defective. Wrong device or wrong cable used have to restart the TCU (ignition off/on)

Table Of Fault Codes

Fault MEANING OF THE FAULT CODE Reaction of the TCU Possible steps to repair Remarks
Code Possible reason for fault detection
(hex)

11 LOGICAL ERROR AT GEAR RANGE SIGNAL TCU shifts transmission to • check the cables from TCU to shift failure cannot be detected in
TCU detected a wrong signal combination for the gear neutral lever systems with DW2/DW3
range OP-Mode: transmission • check signal combinations of shift shift lever
• cable from shift lever to TCU is broken shutdown lever positions for gear range fault is taken back if TCU
• cable is defective and is contacted to battery voltage detects a valid signal for the
or vehicle ground position
• shift lever is defective
12 LOGICAL ERROR AT DIRECTION SELECT SIGNAL TCU shifts transmission to • check the cables from TCU to shift fault is taken back if TCU
TCU detected a wrong signal combination for the neutral lever detects a valid signal for the
direction OP-Mode: transmission • check signal combinations of shift direction at the shift lever
• cable from shift lever to TCU is broken shutdown lever positions F-N-R
• cable is defective and is contacted to battery voltage
or vehicle ground
• shift lever is defective
13 LOGICAL ERROR AT ENGINE DERATING DEVICE after selecting neutral, TCU • check engine derating device This fault is reset after
TCU detected no reaction of engine while derating changes to OP-Mode limp power up of TCU
device activ home
14 LOGICAL ERROR AT PARKBRAKE STATUS TCU shifts transmission to • check the cables from electronic
Parkbrake-status-signal measured by TCU DCO-State boxes to status switches
and parkbrake-status-signal send by CAN don't fit OP-Mode: normal • check signals of the status switches
• one of the cables from status-switch to electronic box
is broken
• one of the status-switches is defective
15 LOGICAL ERROR AT DIRECTION SELECT SIGNAL 2. SHIFT TCU shifts transmission to • check the cables from TCU to shift fault is taken back if TCU
LEVER neutral if selector activ lever 2 detects a valid neutral signal
TCU detected a wrong signal combination for the OP-Mode: transmission • check signal combinations of shift for the direction at the shift
direction shutdown if selector activ lever positions F-N-R lever
• cable from shift lever 2 to TCU is broken
• cable is defective and is contacted to battery voltage
or vehicle ground
• shift lever is defective

SM 2177 Rev 5 04-10 11

Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction

Reactionofofthe
theTCU
TCU Pos
Possible steps
sible to repair
steps to repair Remarks
Remarks
Code Possible reason for fault detection
(hex)
16 LOGICAL ERROR AT AXLE CONNECTION OP-Mode: normal • check the cables from TCU to
feedback axle connection measured by feedback axle connection switch
TCU and output signal axle connection don't fit • check signals of the feedback axle
• axle can’t be connected or disconnected due to connection switch
mechanical problem
• one of the cables from feedback axle connection -
switch to TCU is broken
17 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 1 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 1
looks like a s.c. to vehicle ground device
• cable is defective and is contacted to vehicle ground • check the connectors from customer
• customer specific function no. 1 device has an specific function no. 1 to TCU
internal defect • check the resistance of customer
• connector pin is contacted to vehicle ground specific function no. 1 device
18 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to
1)
see &IGURE
FUNCTION NO. 1 customer specific function no. 1
TCU detected a wrong voltage at the output pin, that device
looks like a s.c. to battery voltage • check the connectors from customer
• cable is defective and is contacted to battery voltage specific function no. 1 to TCU
• customer specific function no. 1 device has an • check the resistance of customer
internal defect specific function no. 1 device
• connector pin is contacted to battery voltage
19 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 1 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 1
looks like a o.c. for this output pin device
• cable is defective and has no connection to TCU • check the connectors from customer
• customer specific function no. 1 device has an specific function no. 1 device to TCU
internal defect • check the resistance of customer
• connector has no connection to TCU specific function no. 1 device
1A S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 2 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 2
looks like a s.c. to vehicle ground device
• cable is defective and is contacted to vehicle ground • check the connectors from customer
• customer specific function no. 2 device has an specific function no. 2 device to TCU
internal defect • check the resistance of customer
• connector pin is contacted to vehicle ground specific function no. 2 device
1B S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to
FUNCTION NO. 2 customer specific function no. 2
TCU detected a wrong voltage at the output pin, that device
looks like a s.c. to battery voltage • check the connectors from customer
• cable is defective and is contacted to battery voltage specific function no. 2 device to TCU
• customer specific function no. 2 device has an • check the resistance of customer
internal defect specific function no. 2 device
• connector pin is contacted to battery voltage
1C O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 2 customer specific • check the cable from TCU to
TCU detected a wrong voltage at the output pin, that customer specific function no. 2
looks like a o.c. for this output pin device
• cable is defective and has no connection to TCU • check the connectors from customer
• customer specific function no. 2 device has an specific function no. 2 device to TCU
internal defect • check the resistance of customer
• connector has no connection to TCU specific function no. 2 device
1D S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 3 customer specific • check the cable from TCU to
TCU detected a wrong voltage at the output pin, that customer specific function no. 3
looks like a s.c. to vehicle ground device
• cable is defective and is contacted to vehicle ground • check the connectors from customer
• customer specific function no. 3 device has an specific function no. 3 device to TCU
internal defect • check the resistance of customer
• connector pin is contacted to vehicle ground specific function no. 3 device
1E S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to
FUNCTION NO. 3 customer specific customer specific
TCU detected a wrong voltage at the output pin, that function no. 3 device
looks like a s.c. to battery voltage • check the connectors from customer
• cable is defective and is contacted to battery voltage specific function no. 3 device to TCU
• customer specific function no. 3 device has an • check the resistance of customer
internal defect specific function no. 3 device
• connector pin is contacted to battery voltage

12 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reactionofofthe

Reaction theTCU
TCU Pos
Possible steps
sible steps to to repair
repair Remarks
Remarks
Code Possible reason for fault detection
(hex)

1F O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 3 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 3
looks like a o.c. for this output pin device
• cable is defective and has no connection to TCU • check the connectors from customer
• customer specific function no. 3 device has an specific function no. 3 device to TCU
internal defect • check the resistance of customer
• connector has no connection to TCU specific function no. 3 device
21 S.C. TO BATTERY VOLTAGE AT CLUTCH CUTOFF INPUT clutch cutoff function is • check the cable from TCU to the
the measured voltage is too high: disabled sensor
• cable is defective and is contacted to battery voltage OP-Mode: normal • check the connectors
• clutch cut off sensor has an internal defect • check the clutch cutoff sensor
• connector pin is contacted to battery voltage
22 S.C. TO GROUND OR O.C. AT CLUTCH CUTOFF INPUT clutch cutoff function is • check the cable from TCU to the
the measured voltage is too low: disabled sensor
• cable is defective and is contacted to vehicle ground OP-Mode: normal • check the connectors
• cable has no connection to TCU • check the clutch cutoff sensor
• clutch cut off sensor has an internal defect
• connector pin is contacted to vehicle ground or is
broken
23 S.C. TO BATTERY VOLTAGE AT LOAD SENSOR INPUT retarder function is affected • check the cable from TCU to the availability of retarder
the measured voltage is too high: TCU uses default load sensor depends on default load
• cable is defective and is contacted to battery voltage OP-Mode: normal • check the connectors
• load sensor has an internal defect • check the load sensor sensor
• connector pin is contacted to battery voltage • check the assembly tolerances of load
sensor
24 S.C. TO GROUND OR O.C. AT LOAD SENSOR INPUT retarder function is affected • check the cable from TCU to the availability of retarder
the measured voltage is too low: TCU uses default load sensor depends on default load
• cable is defective and is contacted to vehicle ground OP-Mode: normal • check the connectors
• cable has no connection to TCU • check the load sensor sensor
• load sensor has an internal defect • check the assembly tolerances of load
• connector pin is contacted to vehicle ground or is sensor
broken

25 S.C. TO BATTERY VOLTAGE OR O.C. AT TRANSMISSION no reaction, • check the cable from TCU to the
SUMP TEMPERATURE SENSOR INPUT TCU uses default sensor
the measured voltage is too high: temperature • check the connectors
• cable is defective and is contacted to battery voltage OP-Mode: normal • check the temperature sensor
• cable has no connection to TCU
• temperature sensor has an internal defect
• connector pin is contacted to battery voltage or is
broken
26 S.C. TO GROUND AT TRANSMISSION SUMP TEMPERATURE no reaction, • check the cable from TCU to the
SENSOR INPUT TCU uses default sensor
the measured voltage is too low: temperature • check the connectors
• cable is defective and is contacted to vehicle ground OP-Mode: normal • check the temperature sensor
• temperature sensor has an internal defect
• connector pin is contacted to vehicle ground
27 S.C. TO BATTERY VOLTAGE OR O.C. AT RETARDER / no reaction, • check the cable from TCU to the
TORQUECONVERTER TEMPERATURE SENSOR INPUT TCU uses default sensor
the measured voltage is too high: temperature • check the connectors
• cable is defective and is contacted to battery voltage OP-Mode: normal • check the temperature sensor
• cable has no connection to TCU
• temperature sensor has an internal defect
• connector pin is contacted to battery voltage or is
broken
28 S.C. TO GROUND AT RETARDER / TORQUECONVERTER no reaction, • check the cable from TCU to the
TEMPERATURE SENSOR INPUT TCU uses default sensor
the measured voltage is too low: temperature • check the connectors
• cable is defective and is contacted to vehicle ground OP-Mode: normal • check the temperature sensor
• temperature sensor has an internal defect
• connector pin is contacted to vehicle ground
29 S.C. TO BATTERY VOLTAGE OR O.C. AT PARKING BRAKE TCU uses default value • check the cable from TCU to the
SENSOR INPUT OP-Mode: normal sensor
the measured voltage is too high: • check the connectors
• cable is defective and is contacted to battery voltage • check the parking brake sensor
• cable has no connection to TCU
• sensor has an internal defect
• connector pin is contacted to battery voltage or is
broken

SM 2177 Rev 5 04-10 13

Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction of the TCU Possible steps
sibleto repair
steps to repair Remarks
Remarks
Code Possible reason for fault detection
(hex)

2A S.C. TO GROUND PARKING BRAKE SENSOR INPUT TCU uses default value • check the cable from TCU to the
the measured voltage is too low: OP-Mode: normal sensor
• cable is defective and is contacted to vehicle ground • check the connectors
• sensor has an internal defect • check the parking brake sensor
• connector pin is contacted to vehicle ground
2B INCHSENSOR-SIGNAL MISMATCH During inching mode: TCU • check the cable from TCU to the
the measured voltage from CCO and CCO2 signal don’t shifts to neutral sensor
match: While not inching: no • check the connectors
• cable is defective change • check sensor
• sensor has an internal defect OP-Mode: normal
2C S.C. TO BATTERY VOLTAGE OR O.C. AT DLM TRACTION TCU uses default value • check the cable from TCU to the
ADJUST DASHBOARD DEVICE INPUT OP-Mode: normal sensor
the measured voltage is too high: • check the connectors
• cable is defective and is contacted to battery voltage • check the DLM Traction Adjust
• cable has no connection to TCU dashboard device
• sensor has an internal defect
• connector pin is contacted to battery voltage or is
broken
2D S.C. TO GROUND DLM TRACTION ADJUST DASHBOARD TCU uses default value • check the cable from TCU to the
DEVICE INPUT OP-Mode: normal sensor
the measured voltage is too low: • check the connectors
• cable is defective and is contacted to vehicle ground • check the DLM Traction Adjust
• sensor has an internal defect dashboard device
• connector pin is contacted to vehicle ground
2E S.C. TO BATTERY VOLTAGE OR O.C. AT DLM STEERING TCU uses default value • check the cable from TCU to the
ANGLE SENSOR INPUT OP-Mode: normal sensor
the measured voltage is too high: • check the connectors
• cable is defective and is contacted to battery voltage • check the DLM STEERING ANGLE
• cable has no connection to TCU SENSOR
• sensor has an internal defect
• connector pin is contacted to battery voltage or is
broken
2F S.C. TO GROUND DLM STEERING ANGLE SENSOR INPUT TCU uses default value • check the cable from TCU to the
the measured voltage is too low: OP-Mode: normal sensor
• cable is defective and is contacted to vehicle ground • check the connectors
• sensor has an internal defect • check the DLM STEERING ANGLE
• connector pin is contacted to vehicle ground SENSOR
31 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the
ENGINE SPEED INPUT control sensor
TCU measures a voltage higher than 7.00 V at speed • check the connectors
input pin • check the speed sensor
• cable is defective and is contacted to battery voltage
• cable has no connection to TCU
• speed sensor has an internal defect
• connector pin is contacted to battery voltage or has
no contact
32 S.C. TO GROUND AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin • check the connectors
• cable / connector is defective and is contacted to • check the speed sensor
vehicle ground
• speed sensor has an internal defect
33 LOGICAL ERROR AT ENGINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the This fault is reset after
TCU measures a engine speed over a threshold and the control sensor power up of TCU
next moment the measured speed is zero • check the connectors
• cable / connector is defective and has bad contact • check the speed sensor
• speed sensor has an internal defect • check the sensor gap
• sensor gap has the wrong size
34 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the
TURBINE SPEED INPUT control sensor
TCU measures a voltage higher than 7.00 V at speed if a failure is existing at • check the connectors
input pin output speed, • check the speed sensor
• cable is defective and is contacted to battery voltage TCU shifts to neutral
• cable has no connection to TCU OP-Mode: limp home
• speed sensor has an internal defect
• connector pin is contacted to battery voltage or has
no contact

14 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

Reaction
Reaction of the
of the TCU TCU Pos Possible steps to repair Remarks
Fault MEANING OF THE FAULT CODE sible steps to repair Remarks
Code Possible reason for fault detection
(hex)

35 S.C. TO GROUND AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin if a failure is existing at • check the connectors
• cable / connector is defective and is contacted to output speed, • check the speed sensor
vehicle ground TCU shifts to neutral
• speed sensor has an internal defect OP-Mode: limp home
36 LOGICAL ERROR AT TURBINE SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the This fault is reset after
TCU measures a turbine speed over a threshold and at control sensor power up of TCU
the next moment the measured speed is zero if a failure is existing at • check the connectors
• cable / connector is defective and has bad contact output speed, • check the speed sensor
• speed sensor has an internal defect TCU shifts to neutral • check the sensor gap
• sensor gap has the wrong size OP-Mode: limp home
37 S.C. TO BATTERY VOLTAGE OR O.C. AT OP-Mode: substitute clutch • check the cable from TCU to the
INTERNAL SPEED INPUT control sensor
TCU measures a voltage higher than 7.00 V at speed • check the connectors
input pin • check the speed sensor
• cable is defective and is contacted to battery voltage
• cable has no connection to TCU
• speed sensor has an internal defect
• connector pin is contacted to battery voltage or has
no contact
38 S.C. TO GROUND AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin • check the connectors
• cable / connector is defective and is contacted to • check the speed sensor
vehicle ground
• speed sensor has an internal defect

39 LOGICAL ERROR AT INTERNAL SPEED INPUT OP-Mode: substitute clutch • check the cable from TCU to the This fault is reset after
TCU measures a internal speed over a threshold and at control sensor power up of TCU
the next moment the measured speed is zero • check the connectors
• cable / connector is defective and has bad contact • check the speed sensor
• speed sensor has an internal defect • check the sensor gap
• sensor gap has the wrong size
3A S.C. TO BATTERY VOLTAGE OR O.C. AT special mode for gear • check the cable from TCU to the
OUTPUT SPEED INPUT selection sensor
TCU measures a voltage higher than 12.5 V at speed OP-Mode: substitute clutch • check the connectors
input pin control • check the speed sensor
• cable is defective and is contacted to battery voltage if a failure is existing at
• cable has no connection to TCU turbine speed,
• speed sensor has an internal defect TCU shifts to neutral
• connector pin is contacted to battery voltage or has OP-Mode: limp home
no contact
3B S.C. TO GROUND AT OUTPUT SPEED INPUT special mode for gear • check the cable from TCU to the
TCU measures a voltage less than 1.00V selection sensor
at speed input pin OP-Mode: substitute clutch • check the connectors
• cable / connector is defective and is contacted to control • check the speed sensor
vehicle ground if a failure is existing at
• speed sensor has an internal defect turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3C LOGICAL ERROR AT OUTPUT SPEED INPUT special mode for gear • check the cable from TCU to the This fault is reset after
TCU measures a output speed over a threshold and at the selection sensor power up of TCU
next moment the measured speed is zero OP-Mode: substitute clutch • check the connectors
• cable / connector is defective and has bad contact control • check the speed sensor
• speed sensor has an internal defect if a failure is existing at • check the sensor gap
• sensor gap has the wrong size turbine speed,
TCU shifts to neutral
OP-Mode: limp home
3D TURBINE SPEED ZERO DOESN’T FIT TO OTHER SPEED - - not used
SIGNALS

3E OUTPUT SPEED ZERO DOESN’T FIT TO OTHER special mode for gear • check the sensor signal of output This fault is reset after
SPEED SIGNALS selection speed sensor power up of TCU
if transmission is not neutral and the shifting has OP-Mode: substitute clutch • check the sensor gap of output speed
finished, control sensor
TCU measures outputspeed zero and turbine speed or if a failure is existing at • check the cable from TCU to the
internal speed not equal to zero. turbine speed, sensor
• speed sensor has an internal defect TCU shifts to neutral
• sensor gap has the wrong size OP-Mode: limp home

SM 2177 Rev 5 04-10 15

Transmission - Transmission and Mounting
Section 120-0010
Fault Reaction
Code
MEANING OF THE FAULT CODE Reactionofofthe
theTCU
TCU Pos
Possible steps to repair
sible steps to repair Remarks
Remarks
Possible reason for fault detection
(hex)

40 GEAR RANGE RESTRICTION SIGNAL no gear range restriction • check cluster controller
CAN signal for gear range restriction is defective • check wire of CAN-Bus
• cluster controller is defective • check cable to cluster controller
• interference on CAN-Bus
40 FCAN MESSAGE ‘GEAR RANGE SELECT gear range set from 1st to 5th • check FWD controller
(ZF_3_IDENT)’ contains invalid data • check wire of CAN-Bus
41 DECLUTCH MODULATION SELECTION SIGNAL - - not used
41 TCU RECEIVES MESSAGES ‘GEAR RANGE SELECT ignore FWD commands • reconfigure with
(ZF_3_IDENT)’ AND ‘FRONT WHEEL DRIVE STATUS’ TCU Configuration Command
(V_IDENT_FWD) ALTHOUGH CONFIGURATION STATES (ID PC)
THAT FWD CONTROLLER IS NOT INSTALLED
50 FMR1 TIMEOUT TCU operates like jake brake • check engine controller
Timeout of CAN-message FMR1 from engine controller is off and exhaut brake is • check wire of CAN-Bus
• interference on CAN-Bus off. • check cable to engine controller
• CAN wire/connector is broken OP-Mode: normal
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
• engine controller is defective
51 FMR2 TIMEOUT OP-Mode: substitute clutch • check engine controller
Timeout of CAN-message FMR2 from engine controller control • check wire of CAN-Bus
• interference on CAN-Bus • check cable to engine controller
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
• engine controller is defective
52 EAMODUL1 TIMEOUT TCU shifts to neutral and • check I/O controller
Timeout of CAN-message EAM1 from I/O - controller uses substitute gear selector • check wire of CAN-Bus
• interference on CAN-Bus OP-Mode: normal • check cable to I/O controller
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
53 ABS TIMEOUT no reaction • check ABS controller
Timeout of CAN-message ABS from ABS - controller • check wire of CAN-Bus
• interference on CAN-Bus • check cable to ABS controller
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
54 MDU1 TIMEOUT TCU keeps old auto • check cluster controller
Timeout of CAN-message MDU1 from cluster controller downshift information and • check wire of CAN-Bus
• interference on CAN-Bus old manual downshift • check cable to cluster controller
• CAN wire/connector is broken information
• CAN wire/connector is defective and has contact to OP-Mode: normal
vehicle ground or battery voltage
54 DCT1 TIMEOUT OP-Mode: normal • check display computer
Timeout of CAN-message DCT1 from display computer • check wire of CAN-Bus
• interference on CAN-Bus • check cable to display computer
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage

54 GEAR RANGE SELECT TIMEOUT gear range set from 1st to 5th • check wire of CAN-Bus
Timeout of CAN-message ‘Gear Range Select • check FWD controller
(ZF_3_IDENT)’
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
• FWD Controller is defective
55 DNS1 TIMEOUT TCU shifts to neutral • check OMRON-master
Timeout of CAN-message DNS1 from OMRON-master OP-Mode: normal • check wire of CAN-Bus
• interference on CAN-Bus • check cable to OMRON-master
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage

16 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010
Fault MEANING OF THE FAULT CODE Reaction
Reactionofofthe
theTCU
TCU Pos
Possible steps to
to repair
repair Remarks
Code
sible steps Remarks
Possible reason for fault detection
(hex)

55 SCT1 TIMEOUT OP-Mode: normal • check steering computer

Timeout of CAN-message SCT1 from steering computer • check wire of CAN-Bus
• interference on CAN-Bus • check cable to steering computer
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
55 FLC1 TIMEOUT TCU keeps old auto/man • check cluster controller
Timeout of CAN-message FCL1 from cluster controller selection, old Clutch cutoff • check wire of CAN-Bus
• interference on CAN-Bus selection and old Clutch • check cable to cluster controller
• CAN wire/connector is broken Cuttoff Setting
• CAN wire/connector is defective and has contact to OP-Mode: normal
vehicle ground or battery voltage
55 FRONT WHEEL DRIVE STATUS TIMEOUT TCU shifts to neutral • check wire of CAN-Bus
Timeout of CAN-message • check FWD controller
‘Front Wheel Drive Status (V_IDENT_FWD)’
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
• FWD Controller is defective
56 ENGINE CONF TIMEOUT OP-Mode: substitute clutch • check engine controller
Timeout of CAN-message ENGINE CONF from engine control • check wire of CAN-Bus
controller • check cable to engine controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
57 EEC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller
Timeout of CAN-message EEC1 from EEC controller control • check wire of CAN-Bus
• interference on CAN-Bus • check cable to EEC controller
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage

58 EEC3 TIMEOUT OP-Mode: substitute clutch • check EEC controller

Timeout of CAN-message EEC3 from EEC controller control • check wire of CAN-Bus
• interference on CAN-Bus • check cable to EEC controller
• CAN wire/connector is broken
• CAN wire/connector is defective an has contact to
vehicle ground or battery voltage
59 TEST MODE SIGNAL Testmode is aborted, if activ • check cluster controller
CAN signal for test mode status is defective • check wire of CAN-Bus
• cluster controller is defective • check cable to cluster controller
• interference on CAN-Bus
5A PARKBRAKE STATUS SIGNAL no reaction ???? • check cluster controller
CAN signal for parkbrake status is defective • check wire of CAN-Bus
• cluster controller is defective • check cable to cluster controller
• interference on CAN-Bus
5B SHIFT QUALITY SEL SIGNAL • check cluster controller Not used
CAN signal for shift qualtiy selection is defective • check wire of CAN-Bus
• cluster controller is defective • check cable to cluster controller
• interference on CAN-Bus
5C AUTO DOWNSHIFT SIGNAL last selection is kept • check cluster controller
CAN signal for automatic downshift is defective • check wire of CAN-Bus
• cluster controller is defective • check cable to cluster controller
• interference on CAN-Bus
5D MANUAL DOWNSHIFT SIGNAL last selection is kept • check cluster controller
CAN signal for manual downshift is defective • check wire of CAN-Bus
• cluster controller is defective • check cable to ???? controller
• interference on CAN-Bus

5E CCO REQUEST SIGNAL last selection is kept • check cluster controller

CAN signal for CCO request is defective • check wire of CAN-Bus
• cluster controller is defective • check cable to ???? controller
• interference on CAN-Bus
5F SHIFT LEVER SIGNAL TCU shifts to neutral and • check I/O controller
CAN signal for shift lever is defective uses informations from • check wire of CAN-Bus
• I/O controller is defective substitute shift lever • check cable to I/O controller
• interference on CAN-Bus OP-Mode: normal

SM 2177 Rev 5 04-10 17

Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction

Reactionofofthe
theTCU
TCU Pos
Possible
Code sible steps
steps to
to repair
repair Remarks
Remarks
Possible reason for fault detection
(hex)

5F TRANSMISSION NEUTRAL REQUEST SIGNAL OP-Mode: normal • check steering computer

CAN signal for transmission Neutral Request is • check wire of CAN-Bus
defective • check cable to steering computer
• steering computer is defective
• interference on CAN-Bus
5F CAN MESSAGE ‘ FRONT WHEEL DRIVE STATUS TCU shifts to neutral • check FWD controller
(V_IDENT_FWD)’ CONTAINS INVALID DATA
60 ADDITIONAL BRAKE STATUS SIGNAL no reaction • check I/O controller
CAN signal for additional park brake status is defective OP-Mode: normal • check wire of CAN-Bus
• I/O controller is defective • check cable to I/O controller
• interference on CAN-Bus
61 AEB REQUEST SIGNAL no reaction • check I/O controller
CAN signal for AEB request is defective OP-Mode: normal • check wire of CAN-Bus
• I/O controller is defective Last selection is kept • check cable to I/O controller
• interference on CAN-Bus
62 PTO TORQUE SIGNAL no reaction, • check I/O controller
CAN signal for PTO torque is defective TCU uses default PTO • check wire of CAN-Bus
• I/O controller is defective torque signal • check cable to I/O controller
• interference on CAN-Bus OP-Mode: normal
63 DRIVING MODE SIGNAL no reaction, • check I/O controller
CAN signal for driving mode is defective TCU uses default driving • check wire of CAN-Bus
• I/O controller is defective mode signal • check cable to I/O controller
• interference on CAN-Bus OP-Mode: normal
64 STARTING GEAR SIGNAL no reaction, • check I/O controller
CAN signal for starting gear is defective TCU uses default starting • check wire of CAN-Bus
• I/O controller is defective gear • check cable to I/O controller
(illegal starting gear) OP-Mode: normal
• interference on CAN-Bus
65 ENGINGE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for engine torque is defective control • check wire of CAN-Bus
• engine controller is defective • check cable to engine controller
• interference on CAN-Bus
69 REFERENCE ENGINE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for reference of engine torque is defective control • check wire of CAN-Bus
• engine controller is defective • check cable to engine controller
• interference on CAN-Bus
6A ACTUAL ENGINE TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for actual engine torque is defective control • check wire of CAN-Bus
• engine controller is defective • check cable to engine controller
• interference on CAN-Bus
6B NOM FRICTION TORQUE SIGNAL OP-Mode:substitute clutch • check engine controller
CAN signal for nominal friction torque is defective control • check wire of CAN-Bus
• engine controller is defective • check cable to engine controller
• interference on CAN-Bus
6E EEC2 TIMEOUT no reaction, • check EEC controller
Timeout of CAN-message EEC2 from EEC controller TCU uses default signal • check wire of CAN-Bus
• interference on CAN-Bus accelerator pedal in idle • check cable to EEC controller
• CAN wire/connector is broken position
• CAN wire/connector is defective and has contact to OP-Mode: normal
vehicle ground or battery voltage
71 S.C. TO BATTERY VOLTAGE AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K1 valve is too high. if failure at another clutch is • check the connectors from TCU to
• cable / connector is defective and has contact to pending the gearbox
battery voltage TCU shifts to neutral • check the regulator resistance 1)
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
72 S.C. TO GROUND AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K1 valve is too low. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
vehicle ground TCU shifts to neutral • check the regulator resistance 1)
• cable / connector is defective and has contact to OP-Mode: TCU shutdown • check internal wire harness of the
another regulator output of the TCU gearbox
• regulator has an internal defect

18 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction

Reactionof of
thethe
TCUTCU PosPossible steps to to
repair Remarks
Code
sible steps repair Remarks
Possible reason for fault detection
(hex)

73 O.C. AT CLUTCH K1 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit. OP-Mode: limp home gearbox
• cable / connector is defective and has no contact to if failure at another clutch is • check the connectors from gearbox to
TCU pending TCU
• regulator has an internal defect TCU shifts to neutral • check the regulator resistance 1)
OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
74 S.C. TO BATTERY VOLTAGE AT CLUTCH K2 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K2 valve is too high. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
battery voltage TCU shifts to neutral • check the regulator resistance 1)
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
75 S.C. TO GROUND AT CLUTCH K2 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K2 valve is too low. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
vehicle ground TCU shifts to neutral • check the regulator resistance 1)
• cable / connector is defective and has contact to OP-Mode: TCU shutdown • check internal wire harness of the
another regulator output of the TCU gearbox
• regulator has an internal defect
76 O.C. AT CLUTCH K2 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit. OP-Mode: limp home gearbox
• cable / connector is defective and has no contact to if failure at another clutch is • check the connectors from gearbox to
TCU pending TCU
• regulator has an internal defect TCU shifts to neutral • check the regulator resistance 1)
OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
77 S.C. TO BATTERY VOLTAGE AT CLUTCH K3 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K3 valve is too high. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
battery voltage TCU shifts to neutral • check the regulator resistance 1)
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire harness of the
• gearbox
78 S.C. TO GROUND AT CLUTCH K3 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K3 valve is too low. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
vehicle ground TCU shifts to neutral • check the regulator resistance 1)
• cable / connector is defective and has contact to OP-Mode: TCU shutdown • check internal wire harness of the
another regulator output of the TCU gearbox
• regulator has an internal defect
79 O.C. AT CLUTCH K3 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit. OP-Mode: limp home gearbox
• cable / connector is defective and has no contact to if failure at another clutch is • check the connectors from gearbox to
TCU pending TCU
• regulator has an internal defect TCU shifts to neutral • check the regulator resistance 1)
OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
7A S.C. TO BATTERY VOLTAGE AT CONVERTER CLUTCH no reaction • check the cable from TCU to the
OP-Mode: normal valve
• check the regulator resistance 1)
7B S.C. TO GROUND AT CONVERTER CLUTCH no reaction • check the cable from TCU to the
OP-Mode: normal valve
• check the regulator resistance 1)
7C O.C. AT CONVERTER CLUTCH no reaction • check the cable from TCU to the
OP-Mode: normal valve
• check the regulator resistance 1)

SM 2177 Rev 5 04-10 19

Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction

Reactionof of
thethe
TCUTCU PosPossible
Code siblesteps
stepstotorepair
repair Remarks
Remarks
Possible reason for fault detection
(hex)

7D S.C. TO GROUND AT engine derating will be on • check the cable from TCU to the
1)
see &IGURE
ENGINE DERATING DEVICE until TCU power down even engine derating device
• cable is defective and is contacted to vehicle ground if fault vanishes (loose • check the connectors from engine
• engine derating device has an internal defect connection) derating device to TCU
• connector pin is contacted to vehicle ground OP-Mode: normal • check the resistance 1) of engine
derating device
7E S.C. TO BATTERY VOLTAGE AT no reaction • check the cable from TCU to the
ENGINE DERATING DEVICE OP-Mode: normal engine derating device
• cable / connector is defective and is contacted to • check the connectors from backup
battery voltage alarm device to TCU
• engine derating device has an internal defect • check the resistance 1) of backup
alarm device
7F O.C. AT ENGINE DERATING DEVICE no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-Mode: normal engine derating device
looks like a o.c. for this output pin • check the connectors from engine
• cable is defective and has no connection to TCU derating device to TCU
• engine derating device has an internal defect • check the resistance 1) of engine
• connector has no connection to TCU derating device
1)
81 S.C. TO BATTERY VOLTAGE AT CLUTCH K4 TCU shifts to neutral • check the cable from TCU to the see&IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K4 valve is too high. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
battery voltage TCU shifts to neutral • check the regulator resistance 1)
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
82 S.C. TO GROUND AT CLUTCH K4 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at K4 valve is too low. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
vehicle ground TCU shifts to neutral • check the regulator resistance 1)
• cable / connector is defective and has contact to OP-Mode: TCU shutdown • check internal wire harness of the
another regulator output of the TCU gearbox
• regulator has an internal defect
83 O.C. AT CLUTCH K4 TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit. OP-Mode: limp home gearbox
• cable / connector is defective and has no contact to if failure at another clutch is • check the connectors from gearbox to
TCU pending TCU
• regulator has an internal defect TCU shifts to neutral • check the regulator resistance 1)
OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
84 S.C. TO BATTERY VOLTAGE AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at KV valve is too high. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
battery voltage TCU shifts to neutral • check the regulator resistance 1)
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
85 S.C. TO GROUND AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at KV valve is too low. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
vehicle ground TCU shifts to neutral • check the regulator resistance 1)
• cable / connector is defective and has contact to OP-Mode: TCU shutdown • check internal wire harness of the
another regulator output of the TCU gearbox
• regulator has an internal defect
86 O.C. AT CLUTCH KV TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit. OP-Mode: limp home gearbox
• cable / connector is defective and has no contact to if failure at another clutch is • check the connectors from gearbox to
TCU pending TCU
• regulator has an internal defect TCU shifts to neutral • check the regulator resistance 1)
OP-Mode: TCU shutdown • check internal wire harness of the
gearbox

20 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction of the

Reaction TCU
of the TCU Pos Possible
Code
siblesteps
stepstotorepair
repair Remarks
Remarks
Possible reason for fault detection
(hex)

87 S.C. TO BATTERY VOLTAGE AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at KR valve is too high. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
battery voltage TCU shifts to neutral • check the regulator resistance 1)
• regulator has an internal defect OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
88 S.C. TO GROUND AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit, OP-Mode: limp home gearbox
the voltage at KR valve is too low. if failure at another clutch is • check the connectors from gearbox to
• cable / connector is defective and has contact to pending TCU
vehicle ground TCU shifts to neutral • check the regulator resistance 1)
• cable / connector is defective and has contact to OP-Mode: TCU shutdown • check internal wire harness of the
another regulator output of the TCU gearbox
• regulator has an internal defect
89 O.C. AT CLUTCH KR TCU shifts to neutral • check the cable from TCU to the
1)
see &IGURE
the measured resistance value of the valve is out of limit. OP-Mode: limp home gearbox
• cable / connector is defective and has no contact to if failure at another clutch is • check the connectors from gearbox to
TCU pending TCU
• regulator has an internal defect TCU shifts to neutral • check the regulator resistance 1)
OP-Mode: TCU shutdown • check internal wire harness of the
gearbox
8A S.C. TO GROUND AT DLM TRANSVERSAL OUTPUT output will be on until TCU • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that power down even if fault valve
looks like a s.c. to vehicle ground vanishes (loose connection) • check the connectors
• cable is defective and is contacted to vehicle ground OP-Mode: normal • check the resistance of valve
• device has an internal defect
• connector pin is contacted to vehicle ground
8B S.C. TO BATTERY VOLTAGE AT DLM TRANSVERSAL no reaction • check the cable from TCU to the
1)
see &IGURE
OUTPUT OP-Mode: normal valve
TCU detected a wrong voltage at the output pin, that • check the connectors
looks like a s.c. to battery voltage • check the resistance of valve
• cable is defective and is contacted to battery voltage
• device has an internal defect
• connector pin is contacted to battery voltage
1)
8C O.C. AT DLM TRANSVERSAL OUTPUT no reaction • check the cable from TCU to the see&IGURE
TCU detected a wrong voltage at the output pin, that OP-Mode: normal valve
looks like a o.c. for this output pin • check the connectors
• cable is defective and has no connection to TCU • check the resistance of valve
• device has an internal defect
• connector has no connection to TCU
8D S.C. TO GROUND AT DLM INDICATOR LAMP OUTPUT output will be on until TCU • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that power down even if fault device
looks like a s.c. to vehicle ground vanishes (loose connection) • check the connectors
• cable is defective and is contacted to vehicle ground OP-Mode: normal • check the resistance of device
• device has an internal defect
• connector pin is contacted to vehicle ground
8E S.C. TO BATTERY VOLTAGE AT DLM INDICATOR LAMP no reaction • check the cable from TCU to the
1)
see &IGURE
OUTPUT OP-Mode: normal device
TCU detected a wrong voltage at the output pin, that • check the connectors
looks like a s.c. to battery voltage • check the resistance of device
• cable is defective and is contacted to battery voltage
• device has an internal defect
• connector pin is contacted to battery voltage
8F O.C. DLM INDICATOR LAMP OUTPUT no reaction • check the cable from TCU to the
1)
see &IGURE
OP-Mode: normal device
TCU detected a wrong voltage at the output pin, that • check the connectors
looks like a o.c. for this output pin • check the resistance of device
• cable is defective and has no connection to TCU
• device has an internal defect
• connector has no connection to TCU
91 S.C. TO GROUND AT RELAY REVERSE WARNING ALARM backup alarm will be on • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that until TCU power down even backup alarm device
looks like a s.c. to vehicle ground if fault vanishes (loose • check the connectors from backup
• cable is defective and is contacted to vehicle ground connection) alarm device to TCU
• backup alarm device has an internal defect OP-Mode: normal • check the resistance 1) of backup
• connector pin is contacted to vehicle ground alarm device
&IGURE

SM 2177 Rev 5 04-10 21

 &IGURE

Transmission - Transmission and Mounting

Section 120-0010

&IGURE
Fault MEANING OF THE FAULT CODE Reaction
Reactionofofthe TCU
the TCU PosPossible
Code
siblesteps
stepstotorepair
repair Remarks
Remarks
Possible reason for fault detection
(hex)
connector pin is contacted to vehicle ground
92 S.C. TO BATTERY VOLTAGE AT RELAY REVERSE WARNING no reaction • check the cable from TCU to the
1)
see &IGURE
ALARM OP-Mode: normal backup alarm device
TCU detected a wrong voltage at the output pin, that • check the connectors from backup
looks like a s.c. to battery voltage alarm device to TCU
• cable is defective and is contacted to battery voltage • check the resistance 1) of backup
• backup alarm device has an internal defect alarm device
• connector pin is contacted to battery voltage
93 O.C. AT RELAY REVERSE WARNING ALARM no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-Mode: normal backup alarm device
looks like a o.c. for this output pin • check the connectors from backup
• cable is defective and has no connection to TCU alarm device to TCU
• backup alarm device has an internal defect • check the resistance 1) of backup
• connector has no connection to TCU alarm device
94 S.C. TO GROUND AT RELAY STARTER INTERLOCK no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-Mode: normal starter interlock relay
looks like a s.c. to vehicle ground • check the connectors from starter
• cable is defective and is contacted to vehicle ground interlock relay to TCU
• starter interlock relay has an internal defect • check the resistance 1) of starter
• connector pin is contacted to vehicle ground interlock relay
95 S.C. TO BATTERY VOLTAGE AT RELAY STARTER no reaction • check the cable from TCU to the
1)
see &IGURE
INTERLOCK OP-Mode: normal starter interlock relay
TCU detected a wrong voltage at the output pin, that • check the connectors from starter
looks like a s.c. to battery voltage interlock relay to TCU
• cable is defective and is contacted to battery voltage • check the resistance 1) of starter
• starter interlock relay has an internal defect interlock relay
• connector pin is contacted to battery voltage
96 O.C. AT RELAY STARTER INTERLOCK no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-Mode: normal starter interlock relay
looks like a o.c. for this output pin • check the connectors from starter
• cable is defective and has no connection to TCU interlock relay to TCU
• starter interlock relay has an internal defect • check the resistance 1) of starter
• connector has no connection to TCU interlock relay
97 S.C. TO GROUND AT PARK BRAKE SOLENOID no reaction • check the cable from TCU to the park
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-Mode: normal brake solenoid
looks like a s.c. to vehicle ground • check the connectors from park brake
• cable is defective and is contacted to vehicle ground solenoid to TCU
• park brake solenoid has an internal defect • check the resistance 1) of park brake
• connector pin is contacted to vehicle ground solenoid
98 S.C. TO BATTERY VOLTAGE AT PARK BRAKE SOLENOID no reaction • check the cable from TCU to the park
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that optional: (some customers) brake solenoid
looks like a s.c. to battery voltage TCU shifts to neutral caused • check the connectors from park brake
• cable is defective and is contacted to battery voltage by park brake feed back solenoid to TCU
• park brake solenoid has an internal defect OP-Mode: normal • check the resistance 1) of park brake
• connector pin is contacted to battery voltag solenoid
99 O.C. AT PARK BRAKE SOLENOID no reaction • check the cable from TCU to the park
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that optional: (some customers) brake solenoid
looks like a o.c. for this output pin TCU shifts to neutral caused • check the connectors from park brake
• cable is defective and has no connection to TCU by park brake feed back solenoid to TCU
• park brake solenoid has an internal defect OP-Mode: normal • check the resistance 1) of park brake
• connector has no connection to TCU solenoid
9A S.C. TO GROUND AT CONVERTER LOCK UP CLUTCH no reaction • check the cable from TCU to the
1)
see &IGURE
SOLENOID OP-mode: normal converter clutch solenoid
TCU detected a wrong voltage at the output pin, that • check the connectors from converter
looks like a s.c. to vehicle ground clutch solenoid to TCU
• cable is defective and is contacted to vehicle ground • check the resistance 1) of converter
• converter clutch solenoid has an internal defect clutch solenoid
• connector pin is contacted to vehicle ground
9B O.C. AT CONVERTER LOCK UP CLUTCH SOLENOID converter clutch always • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that open, retarder not available converter clutch solenoid
looks like a o.c. for this output pin OP-mode: normal • check the connectors from converter
• cable is defective and has no connection to TCU clutch solenoid to TCU
• converter clutch solenoid has an internal defect • check the resistance 1) of converter
• connector has no connection to TCU clutch solenoid
&IGURE

22 SM 2177 Rev 5 04-10

&IGURE
 &IGURE

Transmission - Transmission and Mounting

Section 120-0010

&IGURE
Fault MEANING OF THE FAULT CODE Reaction
Reactionof of
thethe
TCUTCU PosPossible
sible steps
steps toto repair
repair Remarks
Remarks
Code Possible reason for fault detection
(hex)

connector has no connection to TCU

9C S.C. TO BATTERY VOLTAGE AT CONVERTER LOCK UP no reaction • check the cable from TCU to the
1)
see &IGURE
CLUTCH SOLENOID OP-mode: normal converter clutch solenoid
TCU detected a wrong voltage at the output pin, that • check the connectors from converter
looks like a s.c. to battery voltage clutch solenoid to TCU
• cable is defective and is contacted to battery voltage • check the resistance 1) of converter
• converter clutch solenoid has an internal defect clutch solenoid
• connector pin is contacted to battery voltage
9D S.C. TO GROUND AT RETARDER SOLENOID no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal retarder solenoid
looks like a s.c. to vehicle ground • check the connectors from retarder
• cable is defective and is contacted to vehicle ground solenoid to TCU
• retarder solenoid has an internal defect • check the resistance 1) of retarder
• connector pin is contacted to vehicle ground solenoid
9E O.C. AT RETARDER SOLENOID no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal retarder solenoid
looks like a o.c. for this output pin • check the connectors from retarder
• cable is defective and has no connection to TCU solenoid to TCU
• retarder solenoid has an internal defect • check the resistance 1) of retarder
• connector has no connection to TCU solenoid
9F S.C. TO BATTERY VOLTAGE AT RETARDER SOLENOID no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal retarder solenoid
looks like a s.c. to battery voltage • check the connectors from retarder
• cable is defective and is contacted to battery voltage solenoid to TCU
• retarder solenoid has an internal defect • check the resistance 1) of retarder
• connector pin is contacted to battery voltage solenoid
A1 S.C. TO GROUND AT DIFFLOCK OR AXLE CONNECTION no reaction • check the cable from TCU to the
1)
see &IGURE
SOLENOID OP-mode: normal difflock solenoid
TCU detected a wrong voltage at the output pin, that • check the connectors from difflock
looks like a s.c. to vehicle ground solenoid to TCU
• cable is defective and is contacted to vehicle ground • check the resistance 1) of difflock
• difflock solenoid has an internal defect solenoid
• connector pin is contacted to vehicle ground
A2 S.C. TO BATTERY VOLTAGE AT DIFFLOCK OR AXLE no reaction • check the cable from TCU to the
1)
see &IGURE
CONNECTION SOLENOID OP-mode: normal difflock solenoid
TCU detected a wrong voltage at the output pin, that • check the connectors from difflock
looks like a s.c. to battery voltage solenoid to TCU
• cable is defective and is contacted to battery voltage • check the resistance 1) of difflock
• difflock solenoid has an internal defect solenoid
• connector pin is contacted to battery voltage
A3 O.C. AT DIFFLOCK OR AXLE CONNECTION SOLENOID no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal difflock solenoid
looks like a o.c. for this output pin • check the connectors from difflock
• cable is defective and has no connection to TCU solenoid to TCU
• difflock solenoid has an internal defect • check the resistance 1) of difflock
• connector has no connection to TCU solenoid
A4 S.C. TO GROUND AT WARNING SIGNAL OUTPUT no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal warning device
looks like a s.c. to vehicle ground • check the connectors from warning
• cable is defective and is contacted to vehicle ground device to TCU
• warning device has an internal defect • check the resistance 1) of warning
• connector pin is contacted to vehicle ground device
A5 O.C. AT WARNING SIGNAL OUTPUT no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal warning device
looks like a o.c. for this output pin • check the connectors from warning
• cable is defective and has no connection to TCU device to TCU
• warning device has an internal defect • check the resistance 1) of warning
• connector has no connection to TCU device
A6 S.C. TO BATTERY VOLTAGE AT WARNING SIGNAL OUTPUT no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal warning device
looks like a s.c. to battery voltage • check the connectors from warning
• cable is defective and is contacted to battery voltage device to TCU
• warning device has an internal defect • check the resistance 1) of warning
• connector pin is contacted to battery voltage device
1)
&IGURE

SM 2177 Rev 5 04-10 23

&IGURE
 &IGURE

Transmission - Transmission and Mounting

Section 120-0010
&IGURE
Fault MEANING OF THE FAULT CODE
Reaction of the TCU
Reaction of the TCU PosPossible
siblesteps
stepstotorepair
repair Remarks
Remarks
Code Possible reason for fault detection
(hex)

A7 S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 4 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 4
looks like a s.c. to vehicle ground device
• cable is defective and is contacted to vehicle ground • check the connectors from customer
• customer specific function no. 4 device has an specific function no. 4 device to
internal defect TCU
• connector pin is contacted to vehicle ground • check the resistance of customer
specific function no. 4 device
A8 S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to
1)
see &IGURE
FUNCTION NO. 4 customer specific function no. 4
TCU detected a wrong voltage at the output pin, that device
looks like a s.c. to battery voltage • check the connectors from customer
• cable is defective and is contacted to battery voltage specific function no. 4 device to TCU
• customer specific function no. 4 device has an • check the resistance of customer
internal defect specific function no. 4 device
• connector pin is contacted to battery voltage

A9 O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 4 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 4
looks like a o.c. for this output pin device
• cable is defective and has no connection to TCU • check the connectors from customer
• customer specific function no. 4 device has an specific function no. 4 device to TCU
internal defect • check the resistance of customer
• connector has no connection to TCU specific function no. 4 device
AA S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 5 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 5
looks like a s.c. to vehicle ground device
• cable is defective and is contacted to vehicle ground • check the connectors from customer
• customer specific function no. 5 device has an specific function no. 5 device to
internal defect TCU
• connector pin is contacted to vehicle ground • check the resistance of customer
specific function no. 5 device
AB S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to
1)
see &IGURE
FUNCTION NO. 5 customer specific function no. 5
TCU detected a wrong voltage at the output pin, that device
looks like a s.c. to battery voltage • check the connectors from customer
• cable is defective and is contacted to battery voltage specific function no. 5 device to TCU
• customer specific function no. 5 device has an • check the resistance of customer
internal defect specific function no. 5 device
• connector pin is contacted to battery voltage
AC O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 5 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 5
looks like a o.c. for this output pin device
• cable is defective and has no connection to TCU • check the connectors from customer
• customer specific function no. 5 device has an specific function no. 5 device to TCU
internal defect • check the resistance of customer
• connector has no connection to TCU specific function no. 5 device
AD S.C. TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO. 6 customer specific • check the cable from TCU to function
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that 6 device
looks like a s.c. to vehicle ground • check the connectors from customer
• cable is defective and is contacted to vehicle ground specific function no. 6 device to
TCU
• customer specific function no. 6 device has an • check the resistance of function 6
internal defect device
• connector pin is contacted to vehicle ground

&IGURE

&IGURE

24 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction

Reaction ofTCU
of the the TCUPos Possible steps to repair Remarks
sible steps to repair Remarks
Code Possible reason for fault detection
(hex)

AE S.C. TO BATTERY VOLTAGE AT CUSTOMER SPECIFIC customer specific • check the cable from TCU to
1)
see &IGURE
FUNCTION NO. 6 customer specific function no. 6
TCU detected a wrong voltage at the output pin, that device
looks like a s.c. to battery voltage • check the connectors from customer
• cable is defective and is contacted to battery voltage specific function no. 6 device to TCU
• customer specific function no. 6 device has an • check the resistance of customer
internal defect specific function no. 6 device
• connector pin is contacted to battery voltage
AF O.C. AT CUSTOMER SPECIFIC FUNCTION NO. 6 customer specific • check the cable from TCU to
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that customer specific function no. 6
looks like a o.c. for this output pin device
• cable is defective and has no connection to TCU • check the connectors from customer
• customer specific function no. 6 device has an specific function no. 6 device to TCU
internal defect • check the resistance of customer
• connector has no connection to TCU specific function no. 6 device
B1 SLIPPAGE AT CLUTCH K1 TCU shifts to neutral • check pressure at clutch K1
TCU calculates a differential speed at closed clutch K1. OP-Mode: limp home • check main pressure in the system
If this calculated value is out of range, TCU interprets if failure at another clutch is • check sensor gap at internal speed
this as slipping clutch. pending sensor
• low pressure at clutch K1 TCU shifts to neutral • check sensor gap at output speed
• low main pressure OP-Mode: TCU shutdown sensor
• wrong signal at internal speed sensor • check signal at internal speed sensor
• wrong signal at output speed sensor • check signal at output speed sensor
• wrong size of the sensor gap • replace clutch
• clutch is defective

B2 SLIPPAGE AT CLUTCH K2 TCU shifts to neutral • check pressure at clutch K2

TCU calculates a differential speed at closed clutch K2. OP-Mode: limp home • check main pressure in the system
If this calculated value is out of range, TCU interprets if failure at another clutch is • check sensor gap at internal speed
this as slipping clutch. pending sensor
• low pressure at clutch K2 TCU shifts to neutral • check sensor gap at output speed
• low main pressure OP-Mode: TCU shutdown sensor
• wrong signal at internal speed sensor • check signal at internal speed sensor
• wrong signal at output speed sensor • check signal at output speed sensor
• wrong size of the sensor gap • replace clutch
• clutch is defective
B3 SLIPPAGE AT CLUTCH K3 TCU shifts to neutral • check pressure at clutch K3
TCU calculates a differential speed at closed clutch K3. OP-Mode: limp home • check main pressure in the system
If this calculated value is out of range, TCU interprets if failure at another clutch is • check sensor gap at internal speed
this as slipping clutch. pending sensor
• low pressure at clutch K3 TCU shifts to neutral • check sensor gap at output speed
• low main pressure OP-Mode: TCU shutdown sensor
• wrong signal at internal speed sensor • check signal at internal speed sensor
• wrong signal at output speed sensor • check signal at output speed sensor
• wrong size of the sensor gap • replace clutch
• clutch is defective

B4 SLIPPAGE AT CLUTCH K4 TCU shifts to neutral • check pressure at clutch K4

TCU calculated a difference speed at TCU calculates a OP-Mode: limp home • check main pressure in the system
differential speed at closed clutch K4. If this calculated if failure at another clutch is • check sensor gap at internal speed
value is out of range, TCU interprets this as slipping pending sensor
clutch. TCU shifts to neutral • check sensor gap at turbine speed
• low pressure at clutch K4 OP-Mode: TCU shutdown sensor
• low main pressure • check signal at internal speed sensor
• wrong signal at internal speed sensor • check signal at turbine speed sensor
• wrong signal at turbine speed sensor • replace clutch
• wrong size of the sensor gap
• clutch is defective

SM 2177 Rev 5 04-10 25

Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction

Reactionof of
thethe
TCUTCU PosPossible steps to to
repair Remarks
sible steps repair Remarks
Code Possible reason for fault detection
(hex)

B5 SLIPPAGE AT CLUTCH KV TCU shifts to neutral • check pressure at clutch KV

TCU calculates a differential speed at closed clutch KV. OP-Mode: limp home • check main pressure in the system
If this calculated value is out of range, TCU interprets if failure at another clutch is • check sensor gap at internal speed
this as slipping clutch. pending sensor
• low pressure at clutch KV TCU shifts to neutral • check sensor gap at turbine speed
• low main pressure OP-Mode: TCU shutdown sensor
• wrong signal at internal speed sensor • check signal at internal speed sensor
• wrong signal at turbine speed sensor • check signal at turbine speed sensor
• wrong size of the sensor gap • replace clutch
• clutch is defective
B6 SLIPPAGE AT CLUTCH KR TCU shifts to neutral • check pressure at clutch KR
TCU calculates a differential speed at closed clutch KR. OP-Mode: limp home • check main pressure in the system
If this calculated value is out of range, TCU interprets if failure at another clutch is • check sensor gap at internal speed
this as slipping clutch. pending sensor
• low pressure at clutch KR TCU shifts to neutral • check sensor gap at turbine speed
• low main pressure OP-Mode: TCU shutdown sensor
• wrong signal at internal speed sensor • check signal at internal speed sensor
• wrong signal at turbine speed sensor • check signal at turbine speed sensor
• wrong size of the sensor gap • replace clutch
• clutch is defective

B7 OVERTEMP SUMP no reaction • cool down machine

TCU measured a temperature in the oil sump that is over OP-Mode: normal • check oil level
the allowed threshold. • check temperature sensor

B8 OVERTEMP RETARDER TCU disables retarder • cool down machine

TCU measured a temperature in the retarder oil that is OP-Mode: normal • check oil level
over the allowed threshold. • check temperature sensor

B9 OVERSPEED ENGINE retarder applies if configured -

OP-Mode: normal
BA DIFFERENTIAL PRESSURE OIL FILTER no reaction • check oil filter
TCU measured a voltage at differential pressure switch OP-Mode: normal • check wiring from TCU to
out of the allowed range differential pressure switch
• oil filter is polluted • check differential pressure switch
• cable/connector is broken or (measure resitance)
cable/connector is contacted to battery voltage or
vehicle ground
• differential pressure switch is defective
BB SLIPPAGE AT CONVERTER LOCKUP CLUTCH • check pressure at converter lockup
TCU calculates a differential speed at closed converter clutch
lockup clutch. If this calculated value is out of range, • check main pressure in the system
TCU interprets this as slipping clutch. • check sensor gap at engine speed
• low pressure at converter lockup clutch sensor
• low main pressure • check sensor gap at turbine speed
• wrong signal at engine speed sensor sensor
• wrong signal at turbine speed sensor • check signal at engine speed sensor
• wrong size of the sensor gap • check signal at turbine speed sensor
• clutch is defective • replace clutch

BC OVERSPEED OUTPUT No reaction

TCU messures an transmission output speed above the OP-Mode: normal
defined threshold
&IGURE

&IGURE

26 &IGURE
SM 2177 Rev 5 04-10
 Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction of of

thethe
TCU
Reaction TCU PosPossible steps
sible to repair
steps to repair Remarks
Remarks
Code Possible reason for fault detection
(hex)

BD S.C. TO GROUND AT ENGINE BRKAE SOLENOID no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal engine brake solenoid
looks like a s.c. to vehicle ground • check the connectors from engine
• cable is defective and is contacted to vehicle ground brake solenoid to TCU
• engine brake solenoid has an internal defect • check the resistance 1) of engine
• connector pin is contacted to vehicle ground brake solenoid

BE S.C. TO BATTERY VOLTAGE AT ENGINE BRAKE no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal engine brake solenoid
looks like a s.c. to battery voltage • check the connectors from engine
• cable is defective and is contacted to battery voltage brake solenoid to TCU
• engine brake solenoid has an internal defect • check the resistance 1) of engine
• connector pin is contacted to battery voltage brake solenoid

BF O.C. AT ENGINE BRAKE no reaction • check the cable from TCU to the
1)
see &IGURE
TCU detected a wrong voltage at the output pin, that OP-mode: normal engine brake solenoid
looks like a o.c. for this output pin • check the connectors from engine
• cable is defective and has no connection to TCU brake solenoid to TCU
• engine brake solenoid has an internal defect • check the resistance 1) of engine
• connector has no connection to TCU brake solenoid

C0 ENGINE TORQUE OR ENGINE POWER OVERLOAD OP-Mode: normal

TCU calculates an engine torque or engine power above
the defined thresholds
C1 TRANSMISSION OUTPUT TORQUE OVERLOAD OP-Mode: normal
TCU calculates an transmission output torque above the
defined threshold
C2 TRANSMISSION INPUT TORQUE OVERLOAD programmable :No reaction
TCU calculates an transmission input torque above the or shift to neutral
defined threshold OP-Mode: normal
C3 OVERTEMP CONVERTER OUTPUT no reaction • cool down machine
TCU measured a oil temperature at the converter ouput OP-Mode: normal • check oil level
that is over the allowed threshold. • check temperature sensor
C4 S.C. TO GROUND AT JOYSTICK STATUS INDICATOR no reaction • check the cable from TCU to joystick
TCU detected a wrong voltage at the output pin, that OP-Mode: normal status indicator
looks like a s.c. to vehicle ground • check the connectors from joystick
• cable is defective and is contacted to vehicle ground status indicator to TCU
• joystick status indicator has an internal defect • check the resistance 1) of joystick
• connector pin is contacted to vehicle ground status indicator
C5 S.C. TO BATTERY VOLTAGE AT JOYSTICK no reaction • check the cable from TCU to joystick
STATUS INDICATOR OP-Mode: normal status indicator
TCU detected a wrong voltage at the output pin, that • check the connectors from joystick
looks like a s.c. to battery voltage status indicator to TCU
• cable is defective and is contacted to battery voltage • check the resistance 1) of joystick
• joystick status indicator has an internal defect status indicator
• connector pin is contacted to battery voltage
C6 O.C. AT JOYSTICK STATUS INDICATOR no reaction • check the cable from TCU to joystick
TCU detected a wrong voltage at the output pin, that OP-Mode: normal status indicator
looks like a o.c. for this output pin • check the connectors from joystick
• cable is defective and has no connection to TCU status indicator to TCU
• joystick status indicator has an internal defect • check the resistance 1) of joystick
• connector has no connection to TCU status indicator
C7 S.C. TO GROUND AT OVERTEMP NEUTRAL no reaction • check the cable from TCU to
INDICATOR OP-Mode: normal OVERTEMP NEUTRAL INDICATOR
TCU detected a wrong voltage at the output pin, that • check the connectors from
looks like a s.c. to vehicle ground OVERTEMP NEUTRAL INDICATOR to
• cable is defective and is contacted to vehicle ground TCU
• overtemp status indicator has an internal defect • check the resistance 1) of
• connector pin is contacted to vehicle ground OVERTEMP NEUTRAL INDICATOR

SM 2177 Rev 5 04-10 27

Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction

Reactionof
ofthe
theTCU
TCU Pos
Possible
siblesteps
stepstotorepair
repair Remarks
Remarks
Code Possible reason for fault detection
(hex)
connector pin is contacted to vehicle ground
C8 S.C. TO BATTERY VOLTAGE AT OVERTEMP NEUTRAL no reaction • check the cable from TCU to
INDICATOR OP-Mode: normal OVERTEMP NEUTRAL INDICATOR
TCU detected a wrong voltage at the output pin, that
looks like a s.c. to battery voltage
• cable is defective and is contacted to battery voltage • check the connectors from
• overtemp status indicator has an internal defect OVERTEMP NEUTRAL INDICATOR to
• connector pin is contacted to battery voltage TCU
• check the resistance 1) of
OVERTEMP NEUTRAL INDICATOR
C9 O.C. AT OVERTEMP NEUTRAL INDICATOR no reaction • check the cable from TCU to
TCU detected a wrong voltage at the output pin, that OP-Mode: normal OVERTEMP NEUTRAL INDICATOR
looks like a o.c. for this output pin • check the connectors from
• cable is defective and has no connection to TCU OVERTEMP NEUTRAL INDICATOR to
• OVETEMP status indicator has an internal defect TCU
• connector has no connection to TCU • check the resistance 1) of
OVERTEMP NEUTRAL INDICATOR
CA ENGINE_RETARDER CONFIG_TIMEOUT OP-Mode: substitute clutch • check EEC controller
Timeout of CAN-message ENGINE_RETARDER CONFIG control • check wire of CAN-Bus
from EEC controller • check cable to EEC controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective an has contact to
vehicle ground or battery voltage
CB ERC1 TIMEOUT OP-Mode: substitute clutch • check EEC controller fault codes no. 21 to no. 2C
Timeout of CAN-message ERC1 from EEC controller control • check wire of CAN-Bus may be a reaction of this
• interference on CAN-Bus • check cable to EEC controller fault
• CAN wire/connector is broken
• CAN wire/connector is defective an has contact to
vehicle ground or battery voltage
D1 S.C. TO BATTERY VOLTAGE AT POWER SUPPLY FOR see fault codes no. 21 to 2C • check cables and connectors to
SENSORS sensors, which are supplied from
TCU measures more than 6V at the pin AU1 (5V sensor AU1
supply) • check the power supply at the pin
AU1
(should be appx. 5V)
D2 S.C. TO GROUND AT POWER SUPPLY FOR SENSORS see fault codes no. 21 to 2C • check cables and connectors to
TCU measures less than 4V at the pin AU1 (5V sensor sensors, which are supplied from
supply) AU1
• check the power supply at the pin
AU1 (should be appx. 5V)

D3 LOW VOLTAGE AT BATTERY shift to neutral • check power supply battery

measured voltage at power supply is lower than 10 V OP-Mode: TCU shutdown • check cables from batteries to TCU
(12V device) • check connectors from batteries to
lower than 18 V (24V device) TCU
D4 HIGH VOLTAGE AT BATTERY shift to neutral • check power supply battery
measured voltage at power supply is higher than 18 V OP-Mode: TCU shutdown • check cables from batteries to TCU
(12V device) • check connectors from batteries to
higher than 32.5 V (24V device) TCU
D5 ERROR AT VALVE POWER SUPPLY VPS1 shift to neutral • check fuse
TCU switched on VPS1 and measured VPS1 is off or OP-Mode: TCU shutdown • check cables from gearbox to TCU
TCU switched off VPS1 and measured VPS1 is still on • check connectors from gearbox to
• cable or connectors are defect and are contacted to TCU
battery voltage • replace TCU
• cable or connectors are defect and are contacted to
vehicle ground
• permanent power supply KL30 missing
• TCU has an internal defect
D6 ERROR VALVE POWER SUPPLY VPS2 shift to neutral • check fuse
TCU switched on VPS2 and measured VPS2 is off or OP-Mode: TCU shutdown • check cables from gearbox to TCU
TCU switched off VPS2 and measured VPS2 is still on • check connectors from gearbox to
• cable or connectors are defect and are contacted to TCU
battery voltage • replace TCU
• cable or connectors are defect and are contacted to
vehicle ground
• permanent power supply KL30 missing
• TCU has an internal defect
D7 S.C. TO GROUND AT DLM LONGITUDINAL OUTPUT output will be on until TCU • check the cable from TCU to the
TCU detected a wrong voltage at the output pin, that power down even if fault valve
looks like a s.c. to vehicle ground vanishes (loose connection) • check the connectors
• cable is defective and is contacted to vehicle ground OP-Mode: normal • check the resistance of valve
• device has an internal defect
• connector pin is contacted to vehicle ground

28 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE Reaction of the

Reaction TCU
of the TCU Pos Possible
sible steps
steps to to repair
repair Remarks
Remarks
Code Possible reason for fault detection
(hex)

connector pin is contacted to vehicle ground

D8 S.C. TO BATTERY VOLTAGE AT DLM no reaction • check the cable from TCU to the
LONGITUDINAL OUTPUT OP-Mode: normal valve
TCU detected a wrong voltage at the output pin, that • check the connectors
looks like a s.c. to battery voltage
• cable is defective and is contacted to battery voltage • check the resistance of valve
• device has an internal defect
• connector pin is contacted to battery voltage
D9 O.C. AT DLM LONGITUDINAL OUTPUT no reaction • check the cable from TCU to the
TCU detected a wrong voltage at the output pin, that OP-Mode: normal valve
looks like a o.c. for this output pin • check the connectors
• cable is defective and has no connection to TCU • check the resistance of valve
• device has an internal defect
• connector has no connection to TCU
E1 OPEN CIRCUIT AT DIRECTION SELECT TCU shifts transmission to • check the cables from TCU to shift
SIGNALS neutral lever
TCU detected a o.c signals for the direction OP-Mode: transmission
• cable from shift lever to TCU is broken shutdown
• cable is defective and is contacted to vehicle ground
• shift lever is defective
E2 OPEN CIRCUIT AT DIRECTION SELECT TCU shifts transmission to • check the cables from TCU to shift
SIGNALS OF SHIFTER 2 neutral lever
TCU detected a o.c signals for the direction OP-Mode: transmission
• cable from shift lever to TCU is broken shutdown
• cable is defective and is contacted to vehicle ground
• shift lever is defective
E3 S.C. TO BATTERY VOLTAGE AT DISPLAY OUTPUT no reaction • check the cable from TCU to the
TCU sends data to the display and measures allways a OP-Mode: normal display
high voltage level on the connector • check the connectors at the display
• cable or connectors are defective and are contacted • change display
to battery voltage
• display has an internal defect
E4 S.C. TO GROUND AT DISPLAY OUTPUT no reaction • check the cable from TCU to the
TCU sends data to the display and measures allways a OP-Mode: normal display
high voltage level on the connector • check the connectors at the display
• cable or connectors are defective and are contacted • change display
to vehicle ground
• display has an internal defect
E5 DISPID1_TIMEOUT TCU select parameter set • check display controller
Timeout of CAN-message DISPID1 from display with ID0 • check wire of CAN-Bus
controller OP-Mode: Limp Home • check cable to display controller
• interference on CAN-Bus
• CAN wire/connector is broken
• CAN wire/connector is defective and has contact to
vehicle ground or battery voltage
E5 CL1 TIMEOUT TCU keeps old information • check cluster controller
Timeout of CAN-message CL1 from cluster controller for: • check wire of CAN-Bus
• interference on CAN-Bus status test mode • check cable to cluster controller
• CAN wire/connector is broken status plock
• CAN wire/connector is defective and has contact to shift quality selection
vehicle ground or battery voltage gear range restriction
OP-Mode: normal
E6 ILLEGAL ID REQUEST VIA CAN transmission stay neutral
OP-Mode: TCU shutdown

F1 GENERAL EEPROM FAULT no reaction • replace TCU

TCU can't read non volantile memoy OP-Mode: normal
• TCU is defective

F2 CONFIGURATION LOST transmission stay neutral • Reprogramm the correct

TCU has lost the correct configuration and can't control OP-Mode: TCU shutdown configuration for the vehicle (e.g.
the transmission. with cluster controller,...)
• interference during saving data on non volatile
memory
• TCU is brand new or from another vehicle

SM 2177 Rev 5 04-10 29

Transmission - Transmission and Mounting
Section 120-0010

Fault MEANING OF THE FAULT CODE

Code Possible reason for fault detection Reactionofofthe
Reaction theTCU
TCU Possible
Pos steps to
sible steps to repair
repair Remarks
Remarks
(hex)

F2 FWD CONFIGURATION LOST gear range set from 1st to 4th • reconfigure with
TCU has lost the FWD configuration. TCU Configuration Command
• interference during saving data on non volatile (ID PC)
memory
• TCU is brand new or from another vehicle

F3 APPLICATION ERROR transmission stay neutral • replace TCU !! This fault occurs only if an
something of this application is wrong OP-Mode: TCU shutdown test engineer did something
wrong in the application of
the vehicle
F4 LIMP HOME REQUEST shift to neutral • The external controller has to cancel
no fault! indicates that another computer requested limp OP-Mode: limp home the request
home via CAN
F5 CLUTCH FAILURE transmission stay neutral • check clutch TCU shows also the affected
AEB was not able to adjust clutch filling parameters OP-Mode: TCU shutdown clutch on the Display
• One of the AEB-Values is out of limit
F6 CLUTCH ADJUSTMENT DATA LOST OR INCHPEDAL default values = 0 for AEB • execute AEB
CALIBRATION DATA LOST offsets used
TCU was not able to read correct clutch adjustment OP-Mode: normal
parameters no Inchmode available
• interference during saving data on non volatile
memory
• TCU is brand new

8.1 Actuator:
1

2
G

open circuit: R12 ≈ R1G ≈ R2G ≈ ∞

short cut to ground: R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 (for s.c. to ground, G is connected to
vehicle ground)
short cut to battery: R12 ≈ R; R1G ≈ 0, R2G ≈ R or R1G ≈ R, R2G ≈ 0 (for s.c. to battery, G is connected to
battery voltage)

8.2 Cable: UBat

P (power supply)
TCU

1 2 Actuator / Sensor

C (chassis)

Gnd

open circuit: R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞

short cut to ground: R12 ≈ 0; R1C ≈ R2C ≈ 0, R1P ≈ R2P ≈ ∞
short cut to battery: R12 ≈ 0, R1C ≈ R2C ≈ ∞, R1P ≈ R2P ≈ 0

Fig. 10 - Measuring Resistance at Actuator/Sensors and Cable

30 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

upshifted to the next highest gear. If the rate of

WARNING descent is too fast, the service brakes should be
applied and the transmission shifted into a lower gear
Always select the correct drive direction and
which will allow a safe descent and efficient retarder
gear before releasing the parking brake.
operation.

WARNINGS Frequent use of the retarder will result in higher

Never allow the machine to coast with the transmission oil temperatures. Therefore, the oil
transmission in 'NEUTRAL'. temperature gauge should be checked frequently.
During normal operation the gauge should read between
When running down a gradient the engine
80°C (176°F) and 120°C (248° F). However, during
speed should not be allowed to drop below
retarder operation the gauge may reach 145°C (293°F).
1200 rev/min, at which point, lockup would
Provided the vehicle is not in an overspeed condition,
disengage preventing retarder operation.
the transmission 'Stop' warning light will illuminate
In the event of a loss of electric power to the when the transmission oil temperature reaches 140°C
gear shift control, the transmission will (284°F). The retarder will automatically disengage when
automatically shift to 'NEUTRAL'. If this occurs, the oil temperature reaches 150°C (302°F) irrespective
stop the machine using the service brakes.The of the engine speed. The speed must be reduced by
parking brake will be applied automatically using the service brakes so that the oil is cooled down.
when the speed reduces to below 1m/h. Do not Reduce the downgrade travel speed to avoid the oil
operate until the fault has been repaired. overheating and possible damage to the transmission.
Always select 'NEUTRAL' and apply the parking
If the vehicle is approaching an overspeed condition,
brake before leaving the operator's seat.
the transmission upshifts automatically through the
gears (to 6th) to decrease the engine speed, whether in
manual or automatic mode. The service brakes should
be applied to reduce travel speed. With the accelerator
Retarder pedal released, the retarder will automatically engage
The retarder is engaged when the bottom of the switch when the engine speed reaches 2000 rev/min and it will
is pressed and provided that the transmission 'Stop' disengage at 1850 rev/min to prevent the engine from
warning light is OUT and the transmission is in 'lock overspeeding.
up'. To disengage the retarder, press the top of the
switch. The retarder will be disengaged when any of the With the accelerator pedal depressed, the retarder is
conditions are out of range. automatically engaged at 2600 rev/min to decrease the
engine speed. The retarder is disengaged at 2450 rev/
The retarder is used to apply a continuous braking min. A fault code will be displayed and recorded by the
force to hold the truck to a safe steady speed when
descending grades, to reduce the need for service
brake applications, thus reducing service brake wear
and preventing overheating. The retarder may be used
anytime to slow down. If additional braking is required
apply the service brakes. The retarder is not meant for
bringing the vehicle to a halt, or for sudden deceleration
- the service brakes should be employed for this
purpose.

Before the vehicle starts down the grade, release the

accelerator, slow the vehicle with the service brakes,
select the required gear, and apply the retarder. For
maximum retardation, oil circulation and cooling, the
vehicle downgrade speed (retarder applied) in the gear
selected should be high enough to keep the engine
operating at governed speed. Generally the gear used
to ascend a grade is also correct for its descent. If the
rate of descent is too slow, the transmission should be

SM 2177 Rev 5 04-10 31

Transmission - Transmission and Mounting
Section 120-0010
drain port, remove the drain plug and drain the oil. After
ECU. If the oil temperature reaches 150°C (302°F) the
draining, reinstall the drain plug and tighten it securely.
retarder is disengaged and a fault code will be
displayed and recorded by the ECU.
5. Remove the blanking cap from the remote drain line
at the bottom of the hydraulic tank. Install a length of
REMOVAL hose on the remote drain fitting, open the drain cock
and drain the hydraulic oil into a suitable container.
Numbers in parentheses refer to Figure 1.
Close the drain cock, remove the hose and reinstall the
blanking cap.
Note: Tag all lines, cables and linkages disconnected
during removal to aid in installation.
6. Remove the cab from the machine. Refer to Section
260-0010, Cab and Mounting. Ensure that all
connections and lines connected to the cab are
WARNINGS
disconnected.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
7. Disconnect all drivelines connected to the
materials and lifting equipment are properly
transmission and secure them clear of the
secured and of adequate capacity to perform
transmission. Refer to Section 130-0010, Drivelines.
the task safely.
8. Identify and tag the oil filter hose assemblies (5, 6
Hydraulic oil pressure will remain within
and 7, Figure 11) to aid installation. Disconnect the
the braking system after engine shutdown.
hose assemblies (5, 6 and 7, Figure 11) and cap the
Operate the treadle valve continuously until the
open ends and the adapter (8, Figure 11) and elbows
pressure has dissipated before removing any
(9, 10 and 11, Figure 11) to prevent the entry of dirt.
brake lines or serious injury could result.
9. Remove the filter bracket (1, Figure 11) from the
High electrical current can cause sparks
exhaust cradle. Remove all exhaust tubes, the
and personal injury from burns. Turn battery
silencer, the exhaust stack and the exhaust cradle.
master switch to the 'Off' position before
Remove the engine air intake tube if required.
disconnecting any components.
10. Disconnect all electrical harnesses and
1. Position the vehicle in a level work area, ensure the
connections not previously disconnected on removal of
body is fully lowered, apply the parking brake and
the cab assembly.
switch off the engine. Operate the steering right and
left several times to relieve any pressure in the
11. Identify and tag all hydraulic lines at the hydraulic
steering system.
pump. Disconnect hydraulic lines and cap lines and
ports to prevent the ingress of contaminants.
2. Operate the treadle valve continuously to discharge
the accumulators, block all road wheels, place the
Note: The transmission can be removed from the
steering lock bar in the 'Locked' position and the
vehicle without removing the hydraulic pump.
battery master switch in the 'Off' position.
12. Identify, tag and disconnect the hydraulic lines at
3. Disconnect the following cables and connectors in
the main hydraulic valve. Cap lines and ports to
the order given, to prevent serious damage to the
prevent the ingress of contaminants.
vehicles electrical components.
13. Identify, tag and disconnect the transmission oil
a- Battery earth cables
cooler lines from the transmission. Cap lines and ports
b- Battery supply cables
to prevent the ingress of contaminants.
c- Alternator earth cables
d- Alternator supply cables
14. Identify, tag and disconnect hydraulic lines (6, 7, 8,
e- Transmission ECU (Est-37) connector
9 and 10, Figure 12) at the diff-lock/retarder valve. Cap
f- Engine ECM connectors
lines and ports to prevent the ingress of contaminants.
g- Body control lever
h- Hydraulics ECU
15. Identify, tag and disconnect the hydraulic lines at
the hydraulic tank. Cap lines and ports to prevent the
4. Place a suitable container under the transmission
ingress of contaminants.

32 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

SM 2795

8
12
13
14
5

7 10 2
3
1 4

11 8

1 - Filter Bracket 6 - Hose Assembly 11 - Elbow

2 - Bolt 7 - Hose Assembly 12 - Bolt
3 - Washer 8 - Adapter 13 - Lockwasher
4 - Locknut 9 - Elbow 14 - Washer
5 - Hose Assembly 10 - Elbow

Fig. 11 - Transmission Oil Filter Lines

21. Remove the locknuts (10), washers (8) and bolts

16. Identify and tag the diagnostic hose assemblies (22 (9) securing the front bracket assembly to the frame
and 23, Figure 12) to aid in installation. Disconnect the mounts.
hose assemblies (22 and 23, Figure 12) and cap the
open ends and tee (21, Figure 12) and adapter (26, 22. Check to make certain that all necessary line and
Figure 12) to prevent entry of dirt. cable disconnections have been made before lifting the
transmission.
17. Identify, tag and disconnect all remaining lines and
fixtures necessary to allow removal of the transmission 23. Carefully raise the transmission ensuring that no
from the vehicle. lines, cables or components foul during removal. The
transmission may have to be pushed forward to allow
18. Attach suitable lifting equipment to the lifting points the output yoke to clear the rear of the frame. When
on transmission and raise lifting equipment to take up the transmission is clear of the frame assembly, move
the slack. it to a suitable work area and mount it securely on a
work stand.
19. Remove locknut (10), hardened washer (22), bolt
(11) and snubbing washer (17) securing the LH bracket
(12) to the frame mounts. DISASSEMBLY
Numbers in parentheses refer to Figure 1, unless
20. Remove lock-nut (10), hardened washer (22), bolt otherwise specified.
(11) and snubbing washer (17) securing the RH bracket
(13) to the frame mounts. 1. Remove the bracket assembly (20, Figure 12)

SM 2177 Rev 5 04-10 33

Transmission - Transmission and Mounting
Section 120-0010

SM - 2796

21 13
5
12
23
11 6
1
11
7
17 2
1

22 26
18 10
3,4
8 25
19 20

TO DIAGNOSTIC
MANIFOLD PLATE

TO 'TS' PORT
ON HYD. VALVE
9 TO AXLE DIFF-LOCK
24
27
15 16
MANIFOLD
(REAR OF FRONT FRAME)

MANIFOLD
14 (REAR FRAME)

1 - Differential Lock/Retarder Valve 10 - Hose Assembly 19 - Adapter

2 - Pressure Reducing Valve 11 - Adapter 20 - Bracket Assy
3 - Cartridge 12 - Elbow 21 - Tee
4 - Coil 13 - Plug 22 - Diagnostic Hose
5 - Bolt 14 - Elbow 23 - Diagnostic Hose
6 - Hose Assembly 15 - Adapter 24 - Hose Assembly
7 - Hose Assembly 16 - Manifold Plate 25 - Elbow
8 - Hose Assembly 17 - Tee 26 - Adapter
9 - Hose Assembly 18 - Adapter 27 - Adapter

Fig. 12 - Transmission Retarder And Diff-Lock Lines

complete with the diff lock/retarder valve (1, Figure 12). 5. Remove the bolts (4) and lock washers (3) securing
Remove the bolts (5, Figure 12) securing the diff lock/ the front bracket (2) and front plate (5) to the
retarder valve to the bracket assembly and remove the transmission.
valve.
6. Remove the mounting hardware securing the front
2. If required, the pressure reducing valve (2, Figure plate (5) to the front bracket (2). Press out the centre
12), solenoid cartridges (3, Figure12) and coils (4, bonded mount (6) from the front plate (5) and remove
Figure 12) can be removed from the diff lock/retarder the sleeve (1).
valve.
7. Remove the mounting hardware securing the
3. Remove the bolts (14), lock washers (15) and LH hydraulic pump to the transmission power take off.
bracket (12) from the transmission. Remove the Refer to Section 230-0050, Hydraulic Pump.
isolation mount (16) from the LH bracket (12) and
replace it if required. 8. If required, identify and tag the electrical
connections to the engine speed sensor, output speed
4. Remove the bolts (14), lock washers (15) and RH sensor, central gear train sensor and turbine speed
bracket (13) from the transmission. Remove the isolation sensor (5, 6, 7 and 8, Figure 2) and remove the
mount (16) from the RH bracket (13) and replace it if sensors from the transmission.
required.

34 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

9. If required, identify and tag the electrical

connections to the oil temperature sender (gauge) (1, 3. If removed, install the engine speed sensor, output
Figure 2), transmission oil cooler fan drive temperature speed sensor, central gear train sensor and turbine
switch (9, Figure 2) and retarder oil temperature sender speed sensor (5, 6, 7 and 8, Figure 2) in the
(11, Figure 2), and remove them from the top of the transmission as shown in Figure 2. Tighten the
transmission. electrical connections securely.

10. Remove the fasteners securing the dipstick tube 4. Install the hydraulic pump to the transmission power
(18) support bracket. Remove bolts (20), lock washers take off and secure it using the mounting hardware
(21), dipstick tube (18) assembly and gasket (19) from removed at Disassembly. Refer to Section 230-0050,
the transmission. Main Hydraulic Pump.

11. Refer to the transmission manufacturer's service 5. Install the centre bonded mount (6) and sleeve (1) to
manual if transmission service or repair is required. the front plate (5). Secure the front plate assembly to
the front bracket (2) with the bolt (7), washer (8) and
nut. Tighten the bolt (7) to 920 Nm (679 lbf ft).
INSPECTION
Numbers in parentheses refer to Figure 1. Note: Clean, prime and seal the joint using Loctite
7063 cleaner, Loctite T primer and Loctite 648 retaining
1. Check front bracket assembly (1, 2, 5 - 8), the LH compound.
bracket (12), the RH bracket (13) and the frame
mounting brackets for cracks and damage. Repair or 6. Secure the front bracket assembly to the
renew as required. transmission using the bolts (4) and lock washers (3).
Tighten the bolts (4) to 225 Nm (166 lbf ft).
2. Check the general condition of the transmission
assembly for wear and damage. Check for worn or 7. Secure the LH bracket (12) and RH bracket (13) to
damaged driveline flanges and excessive wear on the transmission with bolts (14) and lock washers (15).
mounting holes and isolation mounts (16). Tighten the bolts (14) to 410 Nm (302 lbf ft).

3. Check the condition of all electrical harnesses and Note: Clean, prime and seal the joint using Loctite
connections and repair/renew as required. Check the 7063 cleaner, Loctite T primer and Loctite 648 retaining
condition of all hydraulic lines on the transmission and compound.
renew if damaged.
8. Secure the diff-lock/retarder valve (1, Figure 12) to
the bracket assembly (20, Figure 12) with mounting
ASSEMBLY hardware removed during Disassembly.
Numbers in parentheses refer to Figure 1, unless
otherwise specified. 9. Mount the bracket assembly (20, Figure 12) and diff-

Note: Tighten all fasteners without special torques

specified to standard torques listed in Section 300-
0080, Stadard Bolt and Nut Torque Specifications.

1. Install a new gasket (19) on the dipstick tube (18)

assembly and secure the assembly to the transmission
with bolts (20) and lock washers (21). Secure the
dipstick tube (18) to the support bracket with the
fasteners previously removed.

2. If removed, install the oil temperature sender (gauge)

(1, Figure 2), transmission oil cooler fan drive
temperature switch (9, Figure 2) and retarder oil
temperature sender (11, Figure 2) on the top of the
transmission. Tighten the electrical connections
securely.

SM 2177 Rev 5 04-10 35

Transmission - Transmission and Mounting
Section 120-0010
lock/retarder valve (1, Figure 12) to the transmission
with the fasteners removed during Disassembly. 7. Remove the blanking caps from the hydraulic tank
hose assemblies and ports, and connect the hose
assemblies to the hydraulic tank.
INSTALLATION
Numbers in parentheses refer to Figure 1, unless 8. Remove the blanking caps from the hose
otherwise specified. assemblies (6, 7, 8, 9 and 10, Figure 12) and ports at
diff-lock/retarder valve. Connect the hose assemblies
Note: Tighten all fasteners without special torques to the diff-lock/retarder valve.
specified to standard torques listed in Section
300-0080, Standard Bolt and Nut Torque 9. Remove the blanking caps from the transmission oil
Specifications. cooler lines and retarder ports, and connect the oil
cooler lines. Refer to Section 210-0060,Transmission
Note: Tighten all hydraulic lines fitted with ORFS Oil Cooler.
connections, as described in Section 250-0000,
Braking System Schematic. Renew all O-rings where 10. Remove the blanking caps and connect the lines to
used. the main hydraulic valve, as identified at removal.

11. Remove the blanking caps and connect the

WARNING hydraulic lines to the hydraulic pump, as identified at
To prevent personal injury and property removal.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 12. Connect all electrical cables, harnesses and
secured and of adequate capacity to perform connections to the transmission, as identified at
the task safely. removal.

1. Lubricate the isolation mounts (16) with water or a 13. Install the air intake tube (if removed), exhaust
suitable rubber lubricant and install them in the front tubes, exhaust cradle, exhaust silencer and exhaust
frame mounts, with the spigots to the underside of the stack. Install the filter bracket (1, Figure 11) to the
mounts. cradle.

2. Attach suitable lifting equipment to transmission 14. Connect all drivelines to the transmission and
lifting points and carefully position the transmission secure them with the mounting hardware removed
assembly in the frame. Take care to avoid snagging during removal. Refer to Section 130-0010, Drivelines.
any lines, harnesses or components attached to the
transmission. 15. Prior to installing the cab, ensure that all connections
to the transmission, other than cab connections, are
3. Secure rear mounting brackets (12 and 13) to the connected securely and properly clipped.
frame mounts with the bolts (11), snubbing washers
(17), hardened washers (22) and lock-nuts (10), as 16. Install the cab assembly on the front frame. Refer
shown in Figure 1. Tighten the bolts (11) to a torque of to Section 260-0010, Cab and Mounting.
920 Nm (679 lbf ft).
17. Connect all harnesses and electrical connections at
4. Secure the front bracket assembly to the frame front of the cab.
mounts with bolts (9), washers (8) and lock-nuts (10).
Tighten the bolts (9) to a torque of 920 Nm (679 lbf ft). 18. Fill the hydraulic tank with hydraulic oil specified in
Section 300-0020, Lubrication System. Refer to
5. Remove the lifting equipment from the lifting points Section 230-0040, Hydraulic Tank for the fill level and
on the transmission. procedure.

6. Remove the blanking caps from the hose 19. Fill the transmission with engine oil specified in
assemblies (22 and 23, Figure 12), tee (21, Figure 12) Section 300-0020, Lubrication System. Check the oil
and adapter (26, Figure 12) and connect the hose level as described under 'Oil Level Check'.
assemby (22, Figure 12) to the adapter (26, Figure 12),
and the hose assembly (23, Figure 12) to the tee (21, Note: The transmission oil cooler should be primed
Figure12).

36 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010
when refilling the transmission. Refer to Section 210- SM2797
0060, Transmission Oil Cooler. HOT COLD FILL
LEVEL LEVEL
COLD FILL LEVEL BAND - MINIMUM -
20. Connect the following cables and connectors in the MINIMUM -
ENGINE OFF
ENGINE ENGINE
RUNNING RUNNING
order given to prevent serious damage to the engine's
electrical components. MAX MIN

152mm (6") Min

a- Hydraulics ECU
b- Body control lever
c- Engine ECM connectors
Fig. 13 - Transmission Dipstick Markings
d- Transmission ECU (Est-37) connector
e- Alternator supply cables
f- Alternator earth cables Check the transmission oil level and replenish if low,
g- Battery supply cables every 10 hours/daily. Use only oil specified in
h- Battery earth cables Section 300-0020, Lubrication System.

21. Turn the battery master switch to the 'On' position, Because the transmission oil cools, lubricates and
start the engine and make an operational check of all transmits hydraulic power it is important that the proper
lines and electrical connections disconnected during oil level be maintained at all times. If the oil level is too
removal. Check for leaks and tighten lines and fittings low, the converter and clutches will not receive an
as required. Allow the transmission to warm up and adequate supply of oil. If the oil level is too high, the oil
recheck all connections for leaks. will aerate and the transmission will overheat. It is
absolutely necessary that the oil put into the
22. Ensure that the parking brake is applied, transmission is clean.
disconnect the steering lock bar and secure it in the
'Stowed' position. Remove the wheel blocks from all Cold Oil Level Check - Engine Off
road wheels. This check is made only to determine if the transmission
contains sufficient oil for safe starting. Oil level should
23. Check for correct operation of the transmission, show at least 6" (152 mm) above the hot oil maximum
shift selector and warning lights. (MAX 80°C) mark on the dipstick. Add oil if low.

Cold Oil Level Check - Engine Running

MAINTENANCE This cold check is valid only when transmission oil
temperature is below 40 °C (104 °F).
Periodic Inspections
For easier inspection, the transmission should be kept 1. Position the vehicle on a level work area, apply the
clean. Make periodic checks for loose mounting bolts parking brake and block all road wheels securely.
and leaking oil lines. Check the condition of electrical
harnesses and connections regularly. 2. With the parking brake applied, te gear selector in
neutral and the engine idling, check the oil level on the
The transmission breather (10, Figure 2) should be dipstick. Oil level should be up to the 'COLD MIN' mark
checked on a regular basis (every 250 hours), and as on the dipstick. Add oil if low.
frequently as necessary, depending on operating
conditions. A badly corroded or plugged breather Hot Oil Level Check - Engine Running
restricts proper breathing and causes a buildup of This hot check is valid for normal operating oil
condensation and subsequent oil deterioration. temperature of 80 °C (176 °F).

1. Position the vehicle on a level work area, apply the

Oil Level Check parking brake and block all road wheels securely.

2. With the transmission in neutral and the engine

WARNING running, allow the machine to idle until normal operating
When checking the oil level, be sure that the temperature of 80 °C (176 °F) is achieved.
parking brake is applied and all road wheels are
securely blocked. 3. With parking brake applied, foot on service brake,

SM 2177 Rev 5 04-10 37

Transmission - Transmission and Mounting
Section 120-0010
engine idling and transmission operating at normal The transmission oil and filter cartridges should be
temperature, select each gear position in turn. Allow changed every 1000 hours, or sooner, depending on
the transmission to remain in each gear for 5 - 10 operating conditions. Clean the oil filter head when
seconds. changing the filter cartridges. Also, the oil must be
changed whenever there are traces of dirt or evidence
4. Return gear selector to neutral and, with the engine of high temperature indicated by discoloration or strong
idling, check the oil level on dipstick. Oil level should odour.
be between the 'MAX 80°C' upper mark and the 'MIN
80°C' lower mark on the dipstick. Add oil if low. The internal filter and finger magnet at the lower front
left hand of the sump should be removed and cleaned
with mineral spirits at each oil and filter change. Metal
Topping Up Oil
particles in the oil (except for the minute particles
If the transmission oil level has to be topped up, normally trapped in the oil filters) indicate damage has
according to dipstick, oil should be added through the occurred in the transmission. When these particles are
filler on the transmission oil cooler. The bleed plug on found in the filters, the cause must be established and
the top of the transmission oil cooler should be opened rectified immediately to prevent damage to the
while adding oil. Allow the oil to drain into the system transmission.
then recheck the level.
At each oil change, examine the used oil for evidence
of dirt or water. A normal amount of condensation will
Oil and Filter Change
emulsify in the oil during transmission operation.
However, if there is evidence of water or engine coolant
WARNING in the oil, the cause must be established and rectified
immediately to prevent damage to the transmission. Oil
When changing filter cartridges, it is imperative should be added to transmission as described in
that new filter cartridges are the same part 'Topping Up Oil'.
number and colour as the original cartridges.

AEB Starter Procedure

ACTION DISPLAY MESSAGE REMARK
1 warm up transmission normal operating messages
2 turn off ignition nothing
3 plug in AEB - Starter
4 • move shift lever to N position
• engage parkbrake
5 start engine ‘PL’ TCU must recognise PL for at
least 2 seconds before you
can press the button
6 set engine speed to idle ‘PL’ if start conditions are OK
7 press button of the AEB-Starter ‘ST’ if start conditions are OK The button must not be
released before TCU has
started the AEB or quit with
an error code (see display
table)
8 hold button until AEB has started ‘K1’ (Information about the AEB TCU has started the AEB,
state) and goes on adjusting K1, K2,
…, KR. (Button may be
released)
9 wait until AEB has finished ‘OK’ (AEB has been successful)
10 turn off ignition and unplug nothing
AEB-Starter

38 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

AEB Starter Engine speed sensor (5) and turbine speed sensor (8) -
The AEB Starter is an electronic tool used to calibrate gap should be 0.5 - 0.8 mm.
the transmission to ensure optimum shift comfort. It is
recommended to run the AEB Starter after the first 500 Central gear train speed sensor (7) - gap should be 0.3
hours of transmission operation. The AEB Starter ± 0.1 mm.
should also be run if shift quality deteriorates, or
whenever the transmission, electronic control unit Output speed sensor (6) - gap should be 1.0 - 1.5 mm.
(ECU) or shift lever are replaced. The procedure for
running the AEB Starter is detailed in the table on Lock-Up Solenoid
previous page. Refer to table on page 10 for typical
codes displayed during AEB mode. The solenoid can be checked at plug X9, pins 7 & 8
(located below the right hand dash panel).
Note: Connect the AEB Starter to plug X25 located Resistance: 60 - 80 ohms
below the instructor seat, adjacent to the ECU. Current: 0.25 - 0.35 A
Voltage: 24 V
Pressure can also be checked (see Fig. 6).
TROUBLESHOOTING
Numbers in parentheses refer to Figure 2, unless
otherwise specified. Temperature Sensors
The sump temperature sensor, located in the main
Transmission Sensor Checks control valve (2) can be checked at plug X8, pins 14
and 15. Resistance should be 1000 - 1500 ohms.
The engine (5), turbine (8), central gear train (7) and
output (6) speed sensors can be checked by The retarder temperature sensor (11) can be checked
measuring their resistance at plug X8 (located below at plug X9, pins 15 and 16. Resistance should be 800 -
the right hand dash panel). 1500 ohms.

1. Engine speed sensor (5). Check across pins 1 and The transmission oil cooler fan drive temperature
2. Resistance should be 945 - 1 155 ohm at a sensor (9) can be checked by measuring resistance
temperature of 20°C (68°F). across terminals:
At 20°C (68°F), resistance should be 1020 - 1280
2. Turbine speed sensor (8). Check across pins 3 and ohms.
4. Resistance should be 945 - 1155 ohms at a At 60°C (140°F), resistance should be 219 - 261 ohms.
temperature of 20°C (68°F). At 90°C (194°F), resistance should be 82 - 96 ohms.
At 120° C (248° F), resistance should be 36.3 - 40.7
3. Central gear train speed sensor (7). Check across ohms.
pins 5 and 6. Resistance should be 945 - 1155 ohms at
a temperature of 20°C (68°F).
Shift Controller
4. Output speed sensor (6). Check across pins 21 and To troubleshoot the shift controller, continuity checks
22. Resistance should be 5 mega ohms. can be easily done by removing plug X2, selecting
position and measuring across following pins:
The installation of the speed sensors can also be
checked by measuring the gap between the sensor and
the gear tooth:

Measuring CAN-Bus Resistance At Plug X4 (Ignition OFF)

Measurement between Specified Value (ohms) Actual Value (ohms) Possible Cause
CAN H (X4 pin 1) 120 0.1 Short circuit from CAN H to CAN L
and 120 - -
CAN L (X4 pin 2)
120 Infinity End resistor damaged or cut off

SM 2177 Rev 5 04-10 39

Transmission - Transmission and Mounting
Section 120-0010

Measuring CAN-Bus Voltage At Plug X4 (Ignition ON)

Measurement between Specified Value (Volts) Actual Value (volts) Possible Cause
CAN H (X4 pin 1) 24 Short circuit from CAN H to battery
and 2.4 - 2.9 0 Short circuit from CAN H to ground
Ground 0 - 2.3 Intermittent short circuit from
3.0 - 24 CAN H to another component
CAN L (X4 pin 2) 24 Short circuit from CAN L to battery
and 2.2 - 2.7 0 Short circuit from CAN L to ground
Ground 0 - 2.1 Intermittent short circuit from
2.8 - 24 CAN L to another component

Neutral - Pins 2 and 5 connected to the switch, resistance should be 500

ohms.
Forward - Pins 2 and 4
Reverse - Pins 2 and 6
Up - Pins 2 and 7 Pressure Checks
Down - Pins 2 and 8 Refer to Figure 6 for measurement points and
pressures. The system pressure, convertor pressure
Button - Pins 2 and 10
and retarder pressure can be measured at the
diagnostic test points in the battery box. If other
pressures are to be measured, then diagnostic
Transmission To Engine CAN-Bus
connectors on main control valve (2) should be moved
The communication link between the transmission and to required point, so pressure can be read from
the engine can be electrically checked by measuring diagnostic test point.
resistance and voltage. Refer to tables.

SERVICE TOOLS
Refer to Section 300-0070, Service Tools, for part
number of AEB Starter and other service tools which
Solenoid Coil Ratings
should be used in conjunction with procedures outlined
The following data should be referenced when in the transmission manufacturers service manual,
checking solenoids: and, general service tools required. These tools are
1. Centre axle diff-lock solenoid (3, Figures 4 and 5) (at available from your dealer.
the valve on top of the transmission)
Resistance: 41 ohms
Current: 0.6 A
2. Transmission diff-lock solenoid (at transmission
output to front axle)
Resistance: 30 ohms
Current: 0.8 A
3. Retarder solenoid (4, Figures 4 and 5) (at the valve
on top of the transmission). The solenoid can be
checked at plug X9, pins 9 and 10.
Resistance: 41 ohms
Current: 0.6 A

Differential Pressure Switch

When oil is at operating temperature, the switch can be
checked at plug X9, pins 17 and 18. With the harness

40 SM 2177 Rev 5 04-10

 Transmission - Transmission and Mounting
Section 120-0010

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 4 Bolt 225 166
1 7 Bolt 920 679
1 9 Bolt 920 679
1 11 Bolt 920 679
1 14 Bolt 410 302

* * * *

SM 2177 Rev 5 04-10 41

Transmission - Transmission and Mounting
Section 120-0010

THIS PAGE IS INTENTIONALLY BLANK

42 SM 2177 Rev 5 04-10

 Drivelines - Front and Rear Drivelines
Section 130-0010

SM - 2799

15

13 14
12

15 2 3
ENGINE

TRANSMISSION

10
1
10

5 9 8
6
TO
TRAILER

FRONT AXLE

11 11 10 10
4 7
1 - Driveline Assembly 6 - Screw 11 - Capscrew
2 - Universal Joint 7 - Driveline Assembly 12 - Anti-flail Guard
3 - Screw 8 - Universal Joint 13 - Bolt
4 - Driveline Assembly 9 - Screw 14 - Washer
5 - Universal Joint 10 - Capscrew 15 - Bracket

Fig. 1 - Front Drivelines and Mounting

DESCRIPTION generated during operation, preventing tension or

Numbers in parentheses refer to Fig. 1, unless compression loads from causing serious damage to the
otherwise specified. components.

The function of the driveline is to transmit rotating Note: Extra care should be taken when handling the
power from one point to another in a smooth and drivelines since chips, dents, burrs or deformity on any
continuous action while allowing a degree of rotating mass creates vibration and excessive wear
movement or misalignment of the components it during any operation.
connects.
There are three driveline assemblies installed between
The drivelines must operate through constantly various components in the tractor frame as follows:
changing relative angles between the components
they are mounted to and must also be capable of Driveline assembly (1) is connected between the
changing length while transmitting torque. engine drive and transmission input drive.

A typical driveline consists of universal joints which Driveline assembly (4) is connected between the front
allow some misalignment and permit the driveline to axle drive flange and transmission final drive.
pivot in any direction, and, a light rigid hollow slip yoke
and splined shaft assembly forming a slip joint. Driveline assembly (7) connects the rear final drive of
the transmission to the articulation and oscillation
The slip joint accommodates length variations pivot.

SM 2178 11-02 1
Drivelines - Front and Rear Drivelines
Section 130-0010

SM - 2800

CENTRE AXLE REAR AXLE

2,3 5,6
2,3 5,6

1 4
7 8
7 8
OSCILLATION
PIVOT

1 - Driveline Assembly 4 - Driveline Assembly 7 - Capscrew

2 - Universal Joint 5 - Universal Joint 8 - Capscrew
3 - Screw 6 - Screw

Fig. 2 - Rear Drivelines and Mounting

There are two driveline assemblies connecting the 1. Position the vehicle in a level work area, apply the
centre and rear axles to the drive supplied from the parking brake and switch off the engine.
transmission, through the pivot drive arrangement, as
follows: 2. Block all road wheels and place the battery master
switch in the 'Off' position.
Driveline assembly (1, Fig. 2) is connected between
the oscillation pivot drive arrangement and the centre Note: Access to remove driveline assembly (1) can be
axle. obtained by tilting the cab. Refer to Section 260-0010,
CAB AND MOUNTING.
Driveline assembly (4, Fig. 2) is connected between
the centre axle and the rear axle. 3. Remove bolts (13) and washers (14) securing anti-
flail guard (12) to bracket (15). Remove anti-flail guard
(12).
REMOVAL
Numbers in parentheses refer to Fig. 1, unless 4. Remove bracket (15) over driveline assembly (1)
otherwise specified. from engine flywheel housing.

Note: Extra care should be taken when handling 5. Match mark universal joint (2) and their mating
drivelines since carelessness can result in premature surfaces to ensure correct mating alignment when
failure of the components. Chips, dents, burrs, or any installing driveline assembly (1).
other deformity of universal joints will prevent accurate
mating. This will cause misalignment which is 6. Support driveline (1) with suitable lifting equipment
accompanied by vibration and excessive wear. and remove capscrews (10) securing universal joints
(2) to their mating components. Remove driveline
assembly (1). If necessary tap driveline assembly (1)
WARNINGS from its mating components with a soft faced hammer.
To prevent personal injury and property
damage, be sure wheel blocks, blocking Note: Access to driveline assemblies (4 & 7) can be
materials and lifting equipment are properly obtained from underneath the vehicle.
secured and of adequate capacity to do the job
safely. 7. Match mark universal joints (5 & 8) and their mating
surfaces to ensure correct mating alignment when
installing driveline assemblies (4 & 7).
To prevent serious injury or death, DO NOT go
under the vehicle when the engine is running. 8. Remove capscrews (11) securing universal joints (5)
Rotating shafts can be dangerous. You can to their mating components and remove driveline
snag clothes, skin, hair, hands, etc.. assembly (4). If necessary tap driveline assembly (4)

2 SM 2178 11-02
 Drivelines - Front and Rear Drivelines
Section 130-0010
from its mating components with a soft faced hammer. SM - 088

9. Remove capscrews (10) securing universal joints APPLY PRESSURE MAXIMUM PERMISSIBLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
(8) to their mating components and remove driveline
assembly (7). If necessary tap driveline assembly (7)
from its mating components with a soft faced hammer.
STRAIGHT EDGE
Note: Access to driveline assemblies (1 & 4, Fig. 2)
can be obtained from underneath the vehicle.

10. Match mark universal joints (2 & 5, Fig. 2) and their

mating surfaces to ensure correct mating alignment
REMOVE ALL
when installing driveline assemblies (1 & 4, Fig. 2).
BURRS AND
PAINT FROM
11. Remove capscrews (7, Fig. 2) securing universal THESE SURFACES
joints (2, Fig. 2) to their mating components and
remove driveline assembly (1, Fig. 2). If necessary tap
driveline assembly (1, Fig. 2) from its mating
components with a soft faced hammer.
Fig. 3 - Checking Parallelism
12. Remove capscrews (8, Fig. 2) securing universal
joints (5, Fig. 2) to their mating components and splines are nicked. Burrs may be removed with a fine
remove driveline assembly (4, Fig. 2). If necessary tap file or medium India stone.
driveline assembly (4, Fig. 2) from its mating
components with a soft faced hammer. 3. Check the surfaces of the components that universal
joints mate against for parallelism. Refer to Fig. 3.

DISASSEMBLY 4. Check condition of mounting capscrews and replace

if required.
Universal Joint
Numbers in parentheses refer to Fig. 1.
ASSEMBLY
1. Place the yoke end of driveline assembly (1) in a
soft jawed vice, clamping on the tube of shaft. Universal Joint
Numbers in parentheses refer to Fig. 1.
Note: Do not distort the tube with excessive grip.
1. Place the yoke end of driveline assembly (1) in a
2. Remove screws (3) and universal joints (2) from soft jawed vice, clamping on the tube of shaft.
driveline assembly (1).
Note: Do not distort the tube with excessive grip.
3. Place the shaft end of driveline assembly (1) in a
soft jawed vice. 2. Install universal joint (2) to yoke end of driveline
assembly (1) and secure with screws (3).
4. Remove screws (3) and universal joints (2) from
driveline assembly (1). 3. Place the shaft end of driveline assembly (1) in a
soft jawed vice.
5. Repeat steps 1 to 4 for drivelines (4 & 7) and
(1 & 4, Fig. 2) 4. Install universal joint (2) to shaft end of driveline
assembly (1) and secure with screws (3).

INSPECTION 5. Repeat steps 1 to 4 for drivelines (4 & 7) and

1. Clean all metal parts in a suitable solvent, and dry (1 & 4, Fig. 2)
all parts with compressed air.

2. Inspect splines of shaft and yoke for nicks, burrs INSTALLATION

and excessive wear. Replace if wear is excessive or Numbers in parentheses refer to Fig. 1, unless

SM 2178 11-02 3
Drivelines - Front and Rear Drivelines
Section 130-0010
otherwise specified. 8. Secure anti-flail guard (12) to bracket (15) with bolts
(13) and washers (14).
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section 9. Position driveline assembly (1, Fig. 2) on the vehicle
300-0080, STANDARD BOLT AND NUT TORQUE as shown and align match marks on universal joints (2,
SPECIFICATIONS. Fig. 2) with those on its mating surfaces.

Note: Extra care should be taken when handling 10. Apply Loctite 648 to the threads of capscrews
drivelines since carelessness can result in premature (7, Fig. 2) and secure universal joints (2, Fig. 2) to its
failure of the components. Chips, dents, burrs, or any mating surfaces with capscrews (7, Fig. 2). Tighten
other deformity of wing bearings will prevent accurate capscrews (7, Fig. 2) to a torque of 153 Nm
mating. This will cause misalignment which is (113 lbf ft).
accompanied by vibration and excessive wear.
11. Position driveline assembly (4, Fig. 2) on the
vehicle as shown and align match marks on universal
WARNINGS joints (5, Fig. 2) with those on its mating surfaces.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 12. Apply Loctite 648 to the threads of capscrews
materials and lifting equipment are properly (8, Fig. 2) and secure universal joints (5, Fig. 2) to its
secured and of adequate capacity to do the job mating surfaces with capscrews (8, Fig. 2). Tighten
safely. capscrews (8, Fig. 2) to a torque of 153 Nm
(113 lbf ft).
To prevent serious injury or death, DO
NOT go under the vehicle when the engine is 13. Lower the cab, place the battery master switch in
running. Rotating shafts can be dangerous. the 'On' position, ensure the parking brake is applied
You can snag clothes, skin, hair, hands, etc.. and start the engine. Remove wheel blocks from all
road wheels.
1. Position driveline assembly (7) on the vehicle as
shown in Fig. 1 and align match marks on universal
joints (8) with those on its mating surfaces. MAINTENANCE
Every 500 hours, check the universal joints for wear
2. Apply Loctite 648 to the threads of capscrews (10) and replace if required.
and secure universal joints (8) to its mating surfaces
with capscrews (10). Tighten capscrews (10) to a Every 2 000 hours, check drivelines for leaks and
torque of 153 Nm (113 lbf ft). damage, and replace if required.

3. Position driveline assembly (4) on the vehicle as

shown in Fig. 1 and align match marks on universal Periodic Inspection
joints (5) with those on its mating surfaces. Use a small pry bar to check the companion flange
yokes for looseness. If loose, drop one end of the
4. Apply Loctite 648 to the threads of capscrews (11) driveline and twist the yoke to check the backlash
and secure universal joints (5) to its mating surfaces between the splines and yokes. Replace any yoke that
with capscrews (11). Tighten capscrews (11) to a does not fit snugly.
torque of 153 Nm (113 lbf ft).
With the pry bar, check the universal joints for play. If
5. Position driveline assembly (1) on the vehicle as loose, replace the universal joints. Check the splines at
shown in Fig. 1 and align match marks on universal the slip joint and replace the yoke if excessively worn.
joints (2) with those on its mating surfaces.

6. Apply Loctite 648 to the threads of capscrews (10) SERVICE TOOLS

and secure universal joints (2) to its mating surfaces There are no special tools required for the procedures
with capscrews (10). Tighten capscrews (10) to a outlined in this section. Refer to Section 300-0070,
torque of 153 Nm (113 lbf ft). SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools and
7. Secure bracket (15) over driveline assembly (1) with adhesives are available from your dealer.
mounting hardware previously removed.

4 SM 2178 11-02
 Drivelines - Front and Rear Drivelines
Section 130-0010

DRIVELINE DIAGNOSIS CHART

CONDITION REASON REMEDY
Vibration or noise Driveline bent or out of balance Clean driveline in a suitable solvent. Inspect for
contact with adjacent parts. If driveline is
distorted or sprung, replace. If driveline does not
run smoothly, and vibration is felt, remove
driveline and dynamically balance the assembly.
Driveline loose at yoke/flange Check driveline mounting capscrews for
tightness. If loose, replace capscrews and
torque tighten to the proper specification.
Excessive wear of Poor yoke/flange alignment Check yoke/flange for alignment, run-out and
universal joints and/or run-out balance. Repair or replace as required.
Driveline imbalance Check to see if balance weights are missing or if
driveline is distorted. If driveline is distorted,
replace; if weights are missing, check balance of
driveline dynamically and rebalance.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Capscrew 153 113
1 11 Capscrew 153 113
2 7 Capscrew 153 113
2 8 Capscrew 153 113

* * * *

SM 2178 11-02 5
Drivelines - Front and Rear Drivelines
Section 130-0010

THIS PAGE IS INTENTIONALLY BLANK

6 SM 2178 11-02
 Front Axle Group - Axle Group (Hub)
Section 140-0020

SM - 4005
2 5
3 6
14 9
1

7 10
8 11 63
12
13
64 10
15

19 25
20 16

21 17
22 18
23
24

26 34
27 28

29 30
35 31

32
36 33
39 41
37
40

46
47
48
52
38 53
50 51
62

42 44 54 56
43 45
49 58
59
60

61

55

57
1- Capscrew 17 - Washer 33 - Snap Ring 49- Seal
2- Cover 18 - Bolt 34 - O-ring 50- Hub Carrier
3- O-ring 19 - Slotted Nut 35 - Pin 51- Breather
4- Pin 20 - Shim 36 - Steel Disc 52- Breather
5- Bolt 21 - Ring Gear 37 - Inner Disc 53- Seal ring
6- Planet Carrier 22 - Ring Gear Carrier 38 - O-ring 54- Adaptor
7- Plug 23 - Snap Ring 39 - Seal Ring 55- Bolt
8- Seal ring 24 - Roller Brg 40 - O-ring 56- Seal ring
9- Dowel Pin 25 - Wheel Bolt 41 - Wheel Hub 57- Plug
10 - Washer 26 - Wheel Hub 42 - Washer 58- Dowel Pin
11 - Planet Gear 27 - Cylinder 43 - Bolt 59- Seal ring
12 - Caged Needle Brg 28 - Seal rings 44 - Seal ring 60- Snapring
13 - Planet Pin 29 - Piston 45 - Drain Plugs 61- O-ring
14 - O-ring 30 - Seal rings 46 - Intermediate ring 62 - Axle Housing
15 - Planet Carrier 31 - Disc Spring 47 - Roller Brg 63 - Sun gear shaft
16 - Shear Pin 32 - Thrust Washer 48- Spindle 64- Wheel Nut

Fig. 1 - Exploded View of Planetary and Wheel

SM 2494 Rev1 05-10 1

Front Axle Group - Axle Group (Hub)
Section 140-0020

OPERATION remove tyre and rim assembly from the machine.

Remove opposite road wheel in the same way.
Numbers and letters in parentheses refer to Fig. 1.
7. Place suitable containers under the differential and
Power from the differential is transmitted through a
both hubs (26). Remove differential drain plug and drain
fully floating axle sun gear shaft (9). As sun gear shaft (9)
oil from the differential.
rotates in a clockwise direction, 4-off planet gears (11)
meshed with sun gear shaft (9) rotate anticlockwise. Ring
8. Rotate hubs (26) until drain plug (45) is at its lowest
gear (21) is splined to hub carrier (50) and does not rotate
point. Remove plug (45) and seal ring (44) and drain oil
but causes planet gears (11), which are meshed with ring
from hub.Refer to fig.2
gear (21), to move around it in a clockwise direction. As
planet carrier (6) is bolted to wheel hub (26) the wheel then
rotates in a clockwise direction. WARNING
Be careful during oil drain when oil is at
REMOVAL AND DISASSEMBLY
working temperature and therfore is a scald risk
Numbers in parentheses refer to Fig. 1.
Note: On dismantling, clean all parts in paraffin or
SM - 4007
suitable cleaner, place on a clean work surface.

WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.

To prevent personal injury and property

damage, the procedure for removing tyre and
rim assembly described in Section 160-0050,
Fig. 2 - Oil drain position
WHEEL, RIM AND TYRE, must be strictly
followed.
9. Index mark planet carrier (6) and hub (26) to aid in
installation.
When necessary to drive out components
during disassembly, be sure to use a soft drift
10. Loosen screws (1) then remove prise cover (2) from
to prevent property damage and personal
planet carrier (6), removing o-ring (3) in the
injury.
process.Refer to fig.3
1. Before attempting to remove the road wheels, drive SM - 4008
the vehicle onto a level, solid concrete floor, preferably Fig. 2 - Removal of Sun Gear Shaft
after a short run to warm the oil.

2. Apply the parking brake and switch off the engine.

3. Block the appropriate road wheels, place the

steering lock bar in the 'Locked' position and the
battery master switch in the 'Off' position.

4. Whilst road wheels are still on the ground, loosen

wheel nuts (64).

5. Jack up the axle and support with suitably placed

stands or timbers. Fig. 3 - Loosen allen screws
11. Using a suitable threaded stud locate into threaded
6. Support tyre and rim assembly with a suitable sling SM - 3665
centre on the end of sun gear shaft (63) to remove
and lifting device. Remove wheel nuts (64) and
shaft. Refer to Fig. 4
2 SM 2494 Rev1 05-10
 Front Axle Group - Axle Group (Hub)
Section 140-0020
SM - 4009 SM -4010

Fig. 6- Preheat Slotted Nut

SM - 3669
Fig. 4 - Remove Sungear shaft using threaded stud
12. Pull shaft (9) from the assembly and remove to a
suitable bench area for inspection at a later stage.

13. Using a suitable lifting device, secure to planet

carrier (6).

14. Remove remaining Bolts (5) from planet carrier (6).

Secure carrier and constituent parts i.e. planet gear
assembly and remove from the wheel hub assembly.
SM - 3666

Fig. 7- Opening the groove nut

19. Remove steel discs and inner discs (36 & 37) from
the assembly. Pins (35) can also be removed once the
discs have been removed.

20. Seal ring (39) should be removed from the bore of

the wheel hub (41) as should o-ring (40).

21. Fit locating studs into threaded holes of the axle

Fig. 5 - Securing Wheel Hub housing, into the wheel hub (41). This ensures the
15. Locate 2-off fabricated tool (Fig. 5) over bolts wheel hub (41) will not drop down , which could damage
securing hub carrier (50) to the axle housing and the valve (shown in yellow). Refer to Fig.9
secure into the 2-off locating holes which are capped
on the rear face of the wheel hub (41). SM - 3667

16. Prior to removal of slotted nut (19) it will be

necessary to heat the nut to 200°c to release the
loctite bond. Using a special tool (15503031) or suitable
powered tool, remove slotted nut (19). Refer to Fig 6 & 7

17. Locate fabricated tool onto bolts (25) and screw

wheel hub (26) away from the wheel hub (41). Refer to
Fig 8. Bearing (24) should come out during this step.

18. Cylinder (27), piston (29), seal ring (28), o-ring (34) ,
seal ring (30), disc springs (31), thrust washers (32)
and snap ring (33) can now be removed from the Fig. 8- Removal of Sun Gear Shaft SM - 3668

assembly.
SM 2494 Rev1 05-10 3
Front Axle Group - Axle Group (Hub)
Section 140-0020

1. Install brass bushing into bore of Hub carrier (50).

Ensure oil groove on the bush is at the bottom of the
assembly location i.e. at the opposite end from the flat
face which is on the outer diameter of the hub carrier
(50). Refer to Fig. 10.
Note: Oil groove on bush is a cross groove.
SM - 3641

Oil 'X'
Groove

Fig. 9 - Locating Studs

22. Wheel hub (41) can now be removed by removal of

fabricated tools which were securing it in place.

23. All other components can now be removed from

the assembly. Including Intermediate ring (46) and seal
rings (48 & 49). Fig. 10 - Bush / Seal Installation

24. Remove cover (56), seal rings (58 & 59), o-ring (60) 2. Fit sealrings (58 & 59) and o-ring (61). Secure the
and flange(60) from the hub carrier (50). caradan flange (60).
INSPECTION
3. Secure hub carrier (50) on a suitable table. Fit NBR
Numbers in parentheses refer to Fig. 1. seal (49) and spindle ring (48). Ensure each is fully
home without causing damage to the components.
Thoroughly clean all parts with a suitable solvent and
dry with compressed air. Inspect all parts for damage Note: Bearing (24) should be preheated, prior to fitting
or excessive wear and replace where necessary. onto the hub carrier (50).
Inspect thrust washers (32) to make sure they are free
of burrs and are absolutely flat. Replace all 'O' rings. 4. Secure roller bearing (47) inner race to the hub
carrier (50), again ensure it is fully home. Refer to
ASSEMBLY AND INSTALLATION Fig.11.
Numbers in parentheses refer to Fig. 1 unless
otherwise stated. SM - 3642

Note: Tighten all fasteners without special torques Bearing

specified to standard torques listed in Section 300-
0080, AXLE BOLT AND NUT TORQUE Spindle Ring
SPECIFICATIONS.

WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
Fig. 11 - Hub Carrier Assembly - Brg
secured and of adequate capacity to do the job
safely. 5. Grease o-ring (40) with a thin layer of grease to aid
installation. Fit o-ring (40) on hub carrier (50) as shown
in Fig. 12.

4 SM 2494 Rev1 05-10

 Front Axle Group - Axle Group (Hub)
Section 140-0020

SM - 3643
9. Lower wheel hub (41) onto hub carrier (50) until
O - ring bearing (47) race seats firmly.

Note: Observe that the oil seal slides onto intermediate

ring without damage to seal. Refer to Fig. 15.

10. Fit o-ring (38) then locate pins (35) and dowel pins
(55) into mating holes on the hub carrier (50). Refer to
Fig. 16.
SM- 3644
SM - 3646
Spindle
Fig. 12- Hub Carrier Assembly - O-ring

6. Mount intermediate ring (46) onto carrier (50), using

Hub Carrier
suitable tools, carefully 'punch' ring twice on opposite
sides to seat it home onto the carrier. Refer to Fig. 13.

7. Insert bearing (47) outer race into hub (41), use

punch tool (15503033). Fit cartridge seal (39) to hub
(41) at this stage using punch tool (15503034). Refer to
Fig. 14. Fig. 15 - Wheel hub / Carrier Mating
SM - 3644
SM - 3644

Hub Carrier

o-ring

Fig. 13 - Intermediate Ring Fig. 16 - Locating Pins

Fig. 14 - Brg Outer Race Install SM - 3644

SM - 4012

SM - 3645

8. Fill the tapered cavity within wheel hub (41) with

Fig. 17 - cleaning the steel disks
grease (SKF LGEP 2/18 spec). Ensure an even film is
distributed around the bore. 11. Clean the steel discs (36) of oil.Refer to fig.17

SM 2494 Rev1 05-10 5

Front Axle Group - Axle Group (Hub)
Section 140-0020
12. Assemble alternately; inner discs (37) with steel 13. All inner coated disks must be checked
discs (36). Ensure that all oil channel holes line up and dimensionally. The complete thickness for coating
that one of the oil channels is in the top position. Refer disks in new condition is 5mm. If the coating disks
to Fig. 18 thickness is less than 4.65mm, the disks must be
replaced.Refer to Fig. 20 & 21
SM - 3648
SM - 4014

Oil Channels

Lower Steel Discs

Fig. 18- Locating Brake Discs
Fig. 21 Thickness of inner disks
Note: Top steel disc must lie with its measuring tang
over the wheel hub opening position. The measuring 14. Check also the depth of the oil groove in the
tang of the lower steel disc must line up with the other coating area. the depth has to be 0.7mm. If the dept is
position. Refer to Fig. 19. less than 0.3mm, the disks must be replaced. Refer to
Fig. 22
SM - 3649 SM - 4015

Measuring Tangs

Opening

Fig. 19- Orientate Measuring Tang and Hole

Fig. 22 Depth of oil groove
SM - 4012
SM - 4016

Fig. 20- Checking dimension of inner disks

Fig. 23- Disk Package Adjustment

6 SM 2494 Rev1 05-10

 Front Axle Group - Axle Group (Hub)
Section 140-0020
15. Install the checkout disk package again and make a SM - 4019

new adjustment.Refer to fig.23

SM - 4017

Fig. 25- Measure X3 on ring piston cylinder

Fig. 24 Measure X1 on Spindle

16. Measure X1 on spindle(48). 21.The release gap “S” is following calculated:
Distance from spindle face to the profile step for coated S=X3-(X1+X2)
disks. Refer to fig.24 The setting value is 1.0 – 1.4 mm.
Is the value “S” > 1.4 mm replace so much standard
SM - 4018 steel disks through steel disks with 0.5 mm thicker
size till the setting value is reached.
22.Start to reinstall the disk package with a lined disk.
Install the disk with middle groove on top.Refer to
fig.26

23.Set the lower steel disks (36) out of measuring line

24.Set the top steel disks in direct measuring line.

Then remove the protecting tape.

SM - 4020

Fig. 25- Measure X2 on ring piston cylinder

17.Measure X2 on ring piston cylinder(29).

Distance from piston face to the inner washer. Measure
the distance on the inside diameter.Refer to fig.25

18.Special device WZ 873 for X3 distance

For X3 measurement, set on the special device WZ
873.Screw on the centre nut and tighten by hand.
Simultaneous turn constant the wheel hub, to align the Fig. 26- Disk Package
wheel hub.

19.Load both lever of the device, so that multi disks set

in working condition and becomes pressure. 25. Spray hub carrier with 'Wolfrakote' Paste prior to
assembly of the piston (29) and cylinder (27) to the hub
20.Measure X3 to disks. carrier (50) assembly. Refer to Fig. 27.
Distance from spindle face to the face of coated disk
and directly near the stamp. Refer to fig.25

SM 2494 Rev1 05-10 7

Front Axle Group - Axle Group (Hub)
Section 140-0020

SM - 3650
29. Assemble wheel hub (26) onto wheel hub (41) and
fit bearing (24) onto carrier (50). Ensure that punched
assembly marks on outer diameter of both wheel hubs
(26 & 41) line up. Refer to Figs. 30& 31.
SM - 3653

Coating

Fig. 27- Coating Hub

Line Marks
26. Locate seal ring (30) to brake piston (29). Ensure
correct orientation of seal ring (30).
Fig. 30- Assembly Marks
27. Assemble brake piston (29) to the pack. The
Ø20mm oil holes of the brake cylinder must be placed Preheated Bearing SM - 3654

over the oil channel of the multi-discs. Refer to Fig. 28.

28. Fit o-ring (34) to cylinder (27) then locate cylinder

on brake assembly. Ensure the Ø5mm bore is on the
top as this stage. Refer to Fig. 29.

Top SM - 3651

Oil Hole

Fig. 31- Assembly Marks

30. Assemble ring gear and ring gear carrier (27 & 28),
Bleed Bore spray the face of the ring gear carrier (22) with
'Wolfakote paste'. Refer to Fig. 32.

31. Take ring gear assembly and locate over the hub
Fig. 28- Piston Assembly carrier (50). Refer to Fig. 32.
SM - 3652
SM - 3655

Fig. 29- Cylinder Assembly

8 Fig. 32 - Coated Ring GearSM
Carrier
2494 Rev1 05-10
 Front Axle Group - Axle Group (Hub)
Section 140-0020
32. A number of measurements must be made to SM - 3659
determine the correct selection of shim (20) size.
Follow the procedure listed. Yellow Mark Point

33. Measure dimension 'X1' from the top face of the

hub carrier (50) to the face at the end of thread
engagement. Refer to Fig. 33.
SM - 3656/7

SPINDLE

Fig. 35 - Bearing Preload

"X1" 38. Once the preload has been confirmed, re-install

"X2"
shim (20) and slotted nut (19) , coat engagement face
Fig. 33 - Shim Measurement of nut with loctite 262.

34. The second measurement should be with the ring 39. Taking special tool (15503031) torque slotted nut
gear carrier (22) fixed in place. This should be noted as (19) to a value of 2000 ± 120Nm (1475 ±88 Ibf ft).
dimension 'X2' Refer to Fig. 36 &37.

35. Shim (20) thickness 'd' should fall within the 40. Once the slotted nut (19) has been secured. Mark
following dimensions , refer to Fig34. : the position of the nut with a yellow colour point. Refer
to Fig. 35.
'd' Max = X1 - X2 SM - 3660
'd' Min = (X1 - X2) - 0.12
SM - 3658

"X1"
"d"
"X2"
22
20 Fig. 36 - Slotted Nut Socket
19
SM - 3661
50

Fig. 34 - Shim Measurement

36. Once the shim (20) has been determined, this

should be installed, with the slotted nut (19). The
assembly should be mounted suitably in the horizontal
position to allow the bearing preload to be checked.

37. Bearing (24) preload should be 50 Nm (36.9 Ibf ft)

and must be measured in the horizontal position. Refer Fig. 37 - Torque Tool
to Fig. 35.

SM 2494 Rev1 05-10 9

Front Axle Group - Axle Group (Hub)
Section 140-0020
41. Assemble constituent elements of the carrier (6). 46. Observe that recesses on outer diameters of carrier
Ensure o-ring (14) is fitted prior to planet gears (11), (6) and wheel hub (26) are lined up correctly. Refer to
washers (10), pins (13) and bearings (12). Fig. 38.

42. Secure elements with planet carrier (15), washers 47. Using suitable lifting device (15503032), secure
(17) and bolts (18). planetary assemblies to the axle housing with washers
(42) and bolts (55). Torque bolts (55) to 290Nm (213 lb-
43. Locate cover (2) onto planet carrier (6) and secure ft).
with screw (1). Torque screw (1) to 67Nm (49 Ibf ft)
Refer to Fig. 38. 48. Install differential drain plug. Add gear oil of the type
specified in Section 300-0020, LUBRICATION
SM - 3663
SYSTEM, through the differential filler/level hole until
the oil is level with the bottom of the filler/level hole.

49. Fill the planetary assemblies up to the 'Oil Level

Check Line' with gear oil of the type specified in Section
300-0020, LUBRICATION SYSTEM.

Cover 50. Refit road wheels, securing with wheel nuts (64).
Remove stands or timber supports and lower the
machine to the ground. Fully tighten wheel nuts to a
Fig. 38 - Cover Detail torque of 600 Nm (442 lbf ft). Remove blocks from the
wheels.
44. Insert sun gear shaft (9) into the planetary cage
assembly. Refer to Fig. 39.
Note: Wheel nuts should be checked and tightened if
SM - 3662
necessary, after the first 10 hours of operation. Check
torque every 50 hours (weekly) thereafter.

MAINTENANCE
Proper lubrication of the axle group is essential if axles
are to deliver the service intended. Section
300-0020, LUBRICATION SYSTEM gives full
information on the proper lubrication intervals and the
lubricant which should be used.

The wheel hub - planetary drive and tandem housing

Fig. 39 - Sun Gear Shaft have a common oil chamber. The oil chambers are not
separated from each other, and due to the narrow oil
45. Using suitable lifting tackle mount the complete channels and therefore relatively slow passage of oil,
planetary unit into the wheel hub assembly. Refer to the oil must be filled or added into the correct openings
Fig. 40. provided.

Numbers in parentheses refer to Fig.41 & 42 unless

SM - 3663
otherwise stated.

Note: Perform the planetary oil change when the oil is

warm, simultaneously with the differential.
1. Planetary drive - Turn the wheel hub until the oil
drain plug (1) is at the lowest point to the middle axle.
Clean oil drain plug (1). Remove oil drain plug (1) and
drain oil. Torque oil drain plug (1) to 45 Nm ( 33 Ibf ft).
Fig. 40 - Assembly

10 SM 2494 Rev1 05-10

 Front Axle Group - Axle Group (Hub)
Section 140-0020

SM 3353 2000 Hours

WHEEL HUB
REAR SIDE The multi-discs should be checked for wear. Refer to
Fig. 33 for detail. Should brake wear depth measured
1 be 100mm or less i.e. brake wear across disc set of
2
3mm or greater, then the discs should be replaced.
Brake wear should be measured with the brake applied.
Measurement is made by removing plug (1, Fig 41) and
inserting depth gauge through. Replace and torque plug
when measurement is completed.

SPECIAL TOOLS
The special tools referenced throughout this section
are available from your dealer. Refer to Section
300-0070, SERVICE TOOLS, for part numbers of
general service tools and sealants required.
Fig. 41 - View of Planetary Fill / Drain points
For fabricated tools, refer to the end of this section for
dimensions.
2. Turn wheel hubs back by 90 deg. then remove oil fill
plug (2). Rest oil Drain plugs (1, Fig. 42) on back side AXLE DIAGNOSIS
of planetary. Fill system with oil specified in Section Noises originating in the tyres, transmission, brakes or
300-0020, LUBRICATION SYSTEM, to the bottom drivelines might be attributed by mistake to the axle
edge of the thread of plug (1, Fig. 42). Torque plug (2) components, therefore, all possible sources of noise
to a value of 45 Nm (33 Ibf ft). should be investigated before deciding the axle is at
fault.
Sm 4021

WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.

True axle noises may be located by lifting or jacking

the machine up until all tyres are clear of the floor or
ground. Securely block the machine in this position.
Run power train at moderate speed. Be certain all tyres
are off the ground to prevent damage to the differential
and make sure that there is no brake drag.

SM - 3723

Fig. 42 - View of Planetary Fill / Drain points

3. Refit road wheels, securing with wheel nuts (64).

Remove stands or timber supports and lower the
machine to the ground. Fully tighten wheel nuts to a
torque of 600 Nm (442 lbf ft). Remove blocks from the
disk new = 103mm
wheels. + 0.35
disk worn 103 - 0.3
out = 100mm
Note: Wheel nuts should be checked and tightened if
necessary, at initial inspection and after the first 10
hours of operation. Check torque every 250 hours
(monthly) thereafter. Fig. 43- Break wear Service Drawing

SM 2494 Rev1 05-10 11

Front Axle Group - Axle Group (Hub)
Section 140-0020

AXLE DIAGNOSIS CHART

CONDITION REASON REMEDY
Noises Insufficient or incorrect lubricant Check level. Fill with proper type and grade of
lubricant.
Wheel bearings scored or rough Replace wheel bearings
Gear teeth in planetary chipped Replace gear
Loss of lubricant Lubricant foams excessively Drain and fill with proper type and grade of
lubricant
Worn or broken oil seal Replace oil seal
Loose nuts or bolts Tighten nuts or bolts
Gain of lubricant Incorrect lubricant Drain and fill with proper type and grade of
lubricant
Planetaries running hot Bearings seized Replace bearings

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 1 Capscrew 67 49
1 43 Bolt 290 214
1 45 Drain Plug 55 40.5
1 51 Breather 18 32
1 52 Breather 10 7.4
1 57 Plug Screw 15 11
1 64 Wheel Nuts 600 442

12 SM 2494 Rev1 05-10

 Front Axle Group - Axle Group (Hub)
Section 140-0020

FABRICATED TOOLS
The following tools are necessary to aid in removal / assembly of the axle group.

Sm 3670
97mm 45mm
20mm

Ø30mm
Ø10mm
35mm 8mm

120mm
72mm

80mm Ø17mm

Fig. 33 - Wheel Head Support Bracket Dimensions

Sm 3671

DIMENSIONS IN mm UNLESS STATED OTHERWISE

508
425
1" UNC

Ø1" UNC
12

3" SQ
305
152
90

Ø60
Ø28 Ø80
22
Ø38

Fig. 34 - Bearing Puller

SM 2494 Rev1 05-10 13

THIS PAGE IS INTENTIONALLY BLANK
 Front Axle Group - Differential Lock Controls
Section 140-0020

SM3713

6
2
4

3
5
1 - Port 'P' 4 - Port 'T' (Tank return)
2 - Port 'B' 5 - Solenoid (CT1)
3 - Port 'A' (Plugged) 6 - Valve Block

Fig. 1 - Differential Lock Valve Assembly (Typical)

SM3713
(Figure 5) installed. In any case the cross axle differential
lock works in the same way. Differential lock application
pressure is 42 bar (609 lbf/in²).

For units fitted with the optional transmission retarder,

requesting the transmission retarder via the switch (Figure
3) will energize the appropriate solenoid 'CT3' (Figure 5) in
the block to send pressure from the transmission through
port 'P1' on the valve, via limiting valve 'CT2' which limits
the pressure to 5.5 bar (80 lbf/in²) to the transmission
retarder. Refer to Figures 5,6 and 7.
Fig. 2 - Cross-Axle Differential Lock Request Switch
SM3718

DESCRIPTION & OPERATION

Numbers and letters in parentheses refer to Figure 1.

The Differential Lock Valve is mounted on a bracket at the

rear of the remote-mounted transmission filters.

The purpose of the valve is to, when actuated, allow

hydraulic pressure to flow to each axle to activate the
cross axle differential locks. This is achieved by the
operator requesting the differential lock via the foot
mounted switch (Figure 2).

Two valve configurations are permissible on the vehicle.

This is dependant on whether the vehicle has the standard Fig. 3 - Transmission Retarder Request Switch
set up (Figure 4) or an optional transmission retarder

SM 2473 Rev 1 08-08 1

Front Axle Group - Differential Lock Controls
Section 140-0020

SM - 3714
SM - 3715

TO FRONT TO
AXLE MANIFOLD
MANIFOLD DIFF-LOCK PLATE
FRONT PLATE (FOR TRAILER
TO
AXLE (FOR DIAGNOSTIC
FROM
AXLES)
P1 B
DIFF-LOCK TRAILER
POINT
IN
TRANSMISSION
(PILOT
BATTERY CT1
AXLES) BOX
PRESSURE)
RETURN LINE
TO FILTER
DIAGNOSTIC A B CT1 CT2
T

POINT P
IN
DL
BATTERY BOX P T
T1

CT3
TO
TRANSMISSION
SUMP
FROM TO
PORT DIAGNOSTIC BR
POINT
DL IN
BATTERY
BOX TRANS. RETARDER

Fig. 4 - Differential Lock Schematic (non-retarder) Fig. 5 - Differential Lock Schematic (retarder)

REMOVAL AND DISASSEMBLY SM - 3716

Numbers in parentheses refer to Figure 1
. FRONT TO
AXLE MANIFOLD
DIFF-LOCK PLATE
(FOR TRAILER
Note: On dismantling, clean all parts in paraffin or TO
DIAGNOSTIC
FROM
AXLES)
P1 B
suitable cleaner, place on a clean work surface. POINT
IN
TRANSMISSION
(PILOT
BATTERY CT1
PRESSURE)
BOX
RETURN LINE
FILTER
T
CT2
WARNINGS
P
To prevent personal injury and property
DL
damage, be sure wheel blocks, blocking T1

materials and lifting equipment are properly CT3

secured and of adequate capacity to perform TO
TRANSMISSION
the task safely. TO
SUMP

DIAGNOSTIC BR
POINT
To prevent personal injury and property IN
BATTERY
damage, the procedure for removing tyre and BOX TRANS. RETARDER

rim assembly described in Section 160-0050, Fig. 6 - Differential Lock Schematic (Retarder Applied)
Wheel, Rim and Tyre, must be strictly followed.

When necessary to drive out components SM 3717

FRONT TO
during disassembly, be sure to use a soft drift AXLE MANIFOLD
DIFF-LOCK PLATE
to prevent property damage and personal TO
(FOR TRAILER
AXLES)
DIAGNOSTIC
injury. POINT
FROM
TRANSMISSION
P1 B
IN
(PILOT
BATTERY CT1
PRESSURE)
BOX
1. Apply the parking brake and switch off the engine. RETURN LINE
FILTER
T
CT2

3. Block the appropriate road wheels, place the P

DL
steering lock bar in the 'Locked' position and the T1

battery master switch in the 'Off' position. CT3

TO
TRANSMISSION
SUMP
4. Remove hoses required to remove the valve from TO
BR
DIAGNOSTIC
the vehicle. POINT
IN
BATTERY
BOX TRANS. RETARDER
5. Ensure all hoses are capped and valve ports are
plugged. Fig. 7 - Differential Lock Schematic (Cross Axle Differential
Applied)

2 SM 2473 Rev 1 08-08

 Front Axle Group - Differential Lock Controls
Section 140-0020
diagnostic check point.
6. Note the orientation of the valve on the vehicle and
the corresponding hose/elbow connections to aid in
SM 2849
installation.

7. Thoroughly clean all parts with a suitable solvent

and dry with compressed air. Inspect all parts for
damage or excessive wear and replace where 1
necessary. 2
3
P
8. O-rings should be replaced with new when 4
FB
reinstalling the valve block to the vehicle RB 5
6
ASSEMBLY AND INSTALLATION 7
Numbers in parentheses refer to Figure 1 unless 8
otherwise stated. 9
10
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section 300-
0080, Axle Bolt and Nut Torque Specifications.
1 - Differential Lock Pressure 8 - Trans. Converter Press.
2 - Pump LS Pressure 9 - Body System Press.
WARNINGS 3 - Front Brake Pressure 10 - Trans. System Pressure
4 - Rear Brake Pressure P - Primary Accumulator
To prevent personal injury and property
5 - Park Brake Pressure FB - Front Brake Accumulator
damage, be sure wheel blocks, blocking RB - Rear Brake Accumulator
6 - Steering Pressure
materials and lifting equipment are properly 7 - Trans. Retarder Press.
secured and of adequate capacity to perform
the task safely. Fig. 8 - Diagnostic Pressure Check Points (Battery Box)

1. Reinstall the valve block in reverse order from that Note: Differential lock pressure can only be checked
carried out at the disassembly stage. with the differential lock NOT actuated. While the
differential lock is actuated, the diagnostic point is
2. Ensure all hoses are connected to the correct ports vented to tank via the via the differential lock valve
and that appropriate O-rings are fitted correctly. (CT1 on Figures 4, 5, 6 and 7).

MAINTENANCE
3. Once installed, check the integrity of the circuit,
Limited maintenance of the valve block is available.
ensuring that there are no leaks or problems.
Ensure pressures are set correctly periodically and in
guidance with those listed.
4. Ensure the system is working to the correct
pressures. Where appropriate, carry out pressure SPECIAL TOOLS
adjustments.
The special tools referenced throughout this section
Pressure Checks are available from your dealer. Refer to Section
300-0070, Service Tools, for part numbers of general
The differential lock actuation pressure, 35-42 bar (500-
service tools and sealants required.
609 lbf/in2), is set by pressure reducing valve CT9 on
the main hydraulic valve. Refer to Section 215-0050,
Main Hydraulic Valve Assembly.

Differential lock pressure can be checked at the

diagnostic check point located inside the battery box
(refer to Figure 8). Install a pressure gauge capable of
reading at least 240 bar (3500 lbf/in2) to the correct

SM 2473 Rev 1 08-08 3

Front Axle Group - Differential Lock Controls
Section 140-0020

THIS PAGE IS INTENTIONALL Y BLANK

4 SM 2473 Rev 1 08-08

 CENTRE AXLE - Differential Drive Head
Section 150-0020

DESCRIPTION differential housing (35) to the axle housing (1). Thread

in three puller bolts to break the seal between the
The differential assembly is mounted to the axle
differential and axle housing and to partially pull the
housing. It comprises of a differential for the normal
differential assembly out of the axle housing. Carefully
cross-axle drive function.
remove the differential housing (35) assembly clear of
the axle housing.
REMOVAL AND INSTALLATION
INSTALLATION
Numbers in parentheses refer to Figure 1 unless
Installation is the reversal of the Removal procedure,
otherwise stated..
described above.

WARNING Note: Use sealing compound between the axle housing

and differential housing mounting faces.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
Note: Tighten all fasteners to standard torques listed in
materials and lifting equipment are properly
Section 300-0080, Axle Bolt and Nut Torque
secured and of adequate capacity to performthe
Specifications.
task safely.
Add gear oil of the type specified in Section 300-0020,
1. Position the vehicle in a level work area, raise the
Lubrication System, through the oil filler/level hole,
body and install the body safety prop to secure the
until the oil is level with the bottom of the filler/level
body in the partially raised position.
hole. Fit Plug (3) and O-ring (4). Fill the planetary
assemblies up to the 'Oil Level Check Line'.
2. Apply the parking brake and switch off the engine.
DISASSEMBLY
3. Block all road wheels, place the steering lock bar in
Numbers in parentheses refer to Figure 1, unless
the 'Locked' position and the battery master switch in
otherwise specified.
the 'Off' position.
1. Remove the nut (56) to allow for removal of the
4. Drain the gear oil out of the axle housing and both
flange (72) from the end of the countercase (60).
planetaries into a suitable container from the oil drain
plug (62)on the differential.
2. If not done so previously, remove the bolts (61)
which attach the countershaft case (60) to the
5. Remove the planetary assemblies and axle shafts
differential housing (35), then lift off the countershaft
from the axle housing. Note from which side the long
and short axle shafts are removed. Refer to
Section 160-0030, Axle Group (Hub).

6. Identify the relationship of the front and rear driveline

flanges and differential flanges (6 and 72) with punch
marks.

7. Disconnect the drivelines from the differential

flanges (6 and 72). The drivelines can be removed if it
is convenient to do so.

8. Support the weight of the countershaft case

assembly with suitable lifting equipment. Remove the
bolts (61) securing the countershaft case (60) to the
differential housing (35), and carefully remove the
countershaft case (60) assembly clear of the
differential housing (35).

9. Support the weight of the differential housing (35)

assembly with suitable lifting equipment. Remove the
bolts (38 and 45) and washers (39 and 46) securing the

Sm 2469 Rev 1 05-08 1

Centre Axle - Differential Drive Head
Section 150-0020

SM - 3675

Fig. 1 - Exploded View Of Centre Differential

2 Sm 2469 Rev 1 05-08

 Centre Axle - Differential Drive Head
Section 150-0020

LEGEND FOR FIGURE 1

1 - Banjo / Axle housing 35 - Differential Housing 69 - Cover

2 - Breather 36 - Bearing Cap 70 - Bolt
3 - Plug 37 - Bushing 71 - O-ring
4 - Seal Ring 38 - Bolt 72 - Flange
5 - Nut 39 - Washer 73 - Radial Seal
6 - Flange 40 - Baffle Plate 74 - Ball Bearing
7 - O-ring 41 - Bolt 75 - Gear
8 - Ring 42 - Bushing 76 - Flange
9 - Seal 43 - Stud 77 - Seal
10 - Radial Seal 44 - Seal Ring 78 - Bushing
11 - Cylinder Roller Brg 45 - Bolt 79 - Ball Bearing
12 - Radial Seal 46 - Washer 80 - Grooved Ball Bearing
13 - Through Shaft 47 - Ball Bearing 81 - Disc
14 - Ball Bearing 48 - Adjusting Washer 82 - Axial Needle Bearing
15 - Diff Housing Assembly 49 - Cover 83 - Carrier
16 - Bolt 50 - Bushing 84 - Screw
17 - Washer 51 - Adjusting Washer 85 - Compression Ring
18 - Dowel Pin 52 - Bushing 86 - Disc
19 - Crown Wheel/ Pinion 53 - Ball Bearing 87 - Carrier
20 - Side Gear 54 - Spur Gear 88 - Lining Disc
21 - Shim 55 - Intermediate Ring 89 - Disc
22 - Thrust Washer 56 - Nut 90 - Disc
23 - Cross Shaft 57 - Dowel Pin 91 - Disc
24 - Pinion Gear 58 - Dowel Pin 92 - Piston
25 - Clutch Sleeve 59 - O-ring 93 - Cap Screw
26 - Roller Bearing 60 - Countershaft case 94 - Glyd Ring
27 - Dowel Pin 61 - Bolt 95 - O-ring
28 - Snap Ring 62 - Screw 96 - Cap Screw
29 - Screw 63 - Seal Ring 97 - Piston
30 - Washer 64 - Centering Ring 98 - Rod Seal
31 - Shim 65 - Disc 99 - Flange
32 - Bolt 66 - Radial Seal 100 - Cap Screw
33 - Locking Plate 67 - Seal 101 - Cap Screw
34 - Nut 68 - Washer 102 - O-ring

Sm 2469 Rev 1 05-08 3

Centre Axle - Differential Drive Head
Section 150-0020
case assembly.
INSPECTION
3. Remove the bolts (70) and the cover (69). As The importance of careful and thorough inspection
necessary remove the washer (68), seal (67), radial cannot be overstressed. Thorough inspection, and
seal (66), disc (65) and centering ring (64) from the necessary replacement of parts now, may eliminate
assembled unit. costly and avoidable trouble later.

4. Using suitable lifting equipment, remove the 1. Clean all parts in petroleum base solvent.
complete differential assembly from the axle housing
(1). 2. Immediately after cleaning, dry all parts, except
bearings, with compressed air, or with a soft, clean lint
5. Index mark the bearing cap (36) and the differential free wiping cloth. Compressed air has a corrosive
housing (35). Remove the bushing (37), and bolts from effect on bearings, therefore, they must be wiped dry
the bearing cap (36). with a cloth.

6. Remove the disc lock assembly, items 77 to 100 3. Coat cleaned, dried parts immediately with light oil to
inclusive from the end of the differential housing (15). prevent corrosion. If parts are not to be assembled
immediately, treat them with a good rust preventive
6. Remove the tapered bearing (74), seal (73) and spur and wrap them with treated paper or other suitable
gear (75) from the assembly. material designed to prevent corrosion.

7. Remove the bolt (32) and locking plate (33) from the 4. Before installing the differential assembly to the
nut (34). machine, clean the inside and outside of the axle
housing to remove any foreign material.
8. Remove the differential assembly from the
differential housing (35). 5. Inspect all gears, pinions, and splines for cracked or
broken teeth, excessive wear, and pitted or scored
9. Remove the snap ring (28) from the differential surfaces. Repair or replace as necessary.
assembly.
Note: If either ring gear or pinion gear is defective, both
10. Remove the shim (31), washer (30) and bearing gears must be replaced, because they are serviced
(26) from the housing (15). only as a matched set. Make sure the ring gear and
pinion gear have the same mating numbers.
11. Similarly, remove the bearing (14) from the
opposite end of the housing (15). 6. Check for pitted, scored or worn thrust surfaces of
differential case halves.
12. Remove the bolts (16) and washers (17) . Now
separate both halves of the housing (15) to allow for
disassembly of the gears. ASSEMBLY
Numbers in parentheses refer to Figure 1 unless
13. Remove the clutch sleeve (25) from the housing specified otherwise.
(15), this should allow removal of the washer (21).
Note: Tighten all fasteners without special torques
14. Fully disassemble the pinion and side gears (24 specified to torques listed in Section 300-0080, Axle
and 20) from the cross shaft (23). Bolt and Nut Torque Specifications.

15. The crown wheel (19) should be removed from the Note: During assembly and installation, make sure that
housing (15), along with the adjusting washer (21). mated, punch marked, or otherwise identified parts are
returned to their original positions, if still serviceable.
16. If not already done so, remove the nut (56) to allow
the pinion (19) and elements to be removed from the
differential housing (35). All components should be
retained for inspection/replacement where necessary.

17. Through shaft (13) can be removed from the axle

housing (1), along with all other elements.

4 Sm 2469 Rev 1 05-08

 Centre Axle - Differential Drive Head
Section 150-0020
1. Secure the differential housing (35) on a suitable Selection of adjusting washer for pinion contact
table. Refer to Figure 2. pattern.
SM - 3676
4. To determine the correct thickness of adjusting
washer (48) to be used to attain the correct pinion (19)
gear backlash, the following measurements must be
made. Refer to Figures 5 and 6.
SM3679

Fig. 2 - Differential Housing

2. Assemble the baffle plate (40) to the differential

housing (35). Refer to Figure 3.
SM 3677

Fig. 5 - Differential Measurement

Se = L2 - Le - Lr - L1

where,

Se = Adjusting washer (48)

L2 = Given distance between bearing (47) seat and

middle of differential housing (35).
Fi.g 3 - Baffle Plate
Le = Fitting distance (engraved on pinion [19] face)

3. Secure the bushing (42) in place using 15503090 or Lr = Recorded measurement of pinion gear (19) head
a suitable driver tool. height

L1 = Recorded measurement of the actual thickness of

Note: Rivets are provided for locking the position. the new bearing (47).
Refer to Figure 4.
SM 3680
SM 3678

Fig. 4 - Insert Bushing

Fig. 6 - Measurement

Sm 2469 Rev 1 05-08 5

Centre Axle - Differential Drive Head
Section 150-0020
9. Loosen pinion nut (56) to remove preload. This is
Pinion bearing assembly and washer selection necessary for later adjustment of the crown wheel
bearing preload.
5. Assemble the pinion (19) and put it in the measuring
device to determine the thickness of the adjusting
washer (48). On the pinion head surface, the distance
SM3684
from the middle of the differential cage to the pinion
head is engraved. Refer to Figures 6 and 7.
SM3682

Fig. 7 - Pinion Measurement

6. Insert the selected adjusting washer (48) with its

chamfered side (colour marked) down against the Fig. 9 - Crown Wheel Backlash Measurement
housing (35). Ensure that it is flat in the bore. Refer to
Figure 8.
Selection of Adjusting Washer for Crown Wheel
SM3681
Backlash.

10. The following measurement should be made:

Se = (X1 + X2) - X3

where;

Se = Adjusting washer

X1 = Fitting distance on crown wheel

X2 = Given distance of housing (105 mm)

Fig.
Fig. 88 -- Spacer
Spacer Orientation
orientation X3 = Actual distance measured
7. Assemble the pinion bearing (19) and its constituent
elements to allow the bearing preload to be adjusted. 11. Determine adjusting washer (21) thickness for
correct gear backlash. The required backlash should be
8. The preload should be 0.5-6 Nm without oil seal . Try in the range of 0.15 - 0.25 mm.
various washers till a suitable size is found to achieve
a preload value in the given range.

6 Sm 2469 Rev 1 05-08

 Centre Axle - Differential Drive Head
Section 150-0020
SM3685
SM - 3687

Fig. 10 - Fitting Distance

Fig. 12 - Differential installation

15. Assemble both half shells and adjust the bearing

12. Fitting distance 'X1' is engraved on the crown wheel preload. Refer to Figure 13.
(19). Measure actual distance 'X3' Refer to Figures 9,
10 and 13. SM - 3688

SM3686

Fig. 13 - Assembly of half shells

16. Check bearing preload. Preload should be 1 - 3Nm.

Fig. 11 - Crown Wheel Backlash Measurement Refer to Figure 14.

SM - 3689
13. Using 15503093 or suitable lifting equipment , lift
the differential housing assembly (15) complete with
the bearing (26) and adjusting washer (21).

14. Lift the assembly into the differential housing (35).

Refer to Figure 12.

Fig. 14 - Bearing Preload Check

Sm 2469 Rev 1 05-08 7

Centre Axle - Differential Drive Head
Section 150-0020

SM - 3694
17. Using a suitable dial gauge indicator, inspect gear
backlash and contact pattern. Backlash should be 0.15
- 0.25 mm. Refer to Figures 15 and 16.

SM 3690

Fig. 19 - Contact Pattern

Fig. 15 - Check Gear Backlash

Spur Gear Assembly
SM - 3691
18. Assemble the oil seal (55), the spur gear (54) and
the tapered roller bearing (53). Refer to Figure 20.

SM - 3695

Fig. 16 - Check Contact Pattern

The following should be used as a guide for the correct
gear contact. In each case, follow the recommended
guidelines. Fig. 20 - Spur Gear Assembly
SM - 3692

19. Clean the threads and coat them with Loctite™

262. Tighten the nut (56), within 5 minutes of applying
the Loctite™262.

20. Mount the housing cover (69) [Figure 21].

Fig. 17 - Contact Pattern Adjustment

SM - 3693

Fig. 18 - Contact Pattern Adjustment

8 Sm 2469 Rev 1 05-08
 Centre Axle - Differential Drive Head
Section 150-0020

SM - 3696 23. Measure to determine the thickness of adjusting

washer.

24. Insert an adjusting washer of a suitable thickness

(48) and mount the top cover (69) and oil seals (66 and
67). Refer to Figure 24.

SM 3699

Fig. 21 - Housing Cover Assembly

SM - 3697

Fig. 24 - Insert Adjusting Washer and Oil Seals

25. Turn the differential assembly over to allow the

through shaft (13) to be inserted.

Multiplate Disc Lock Assembly

26. Assemble the elements of the disc assembly,

items 77 to 100 inclusive.

Fig. 22 - Crown Wheel Backlash Measurement 27. Using 15503093 or suitable lifting device, lift the
assembly and slide it on to the differential shaft(13).
21 Tighten the screws (70), then adjust the axial gap Refer to Figure 25.
for the tapered roller bearing (74 [outer]). Refer to Fig.
22. SM 3702

Selection of Adjusting Washer for Axial Gap

SM 3698

Fig. 25 - Assemble Disc to Differential

Fig. 23 - Special Tool Measurement
28. Taking the axle housing (1), using a suitable
fixture, secure the axle in place. Refer to Figure 26.
22. Install tool 15503094 to turn the bearing. Then
install tool 1503095 and press the tapered roller bearing
race until it seats firmly on the bearing. Refer to Figure
23.

Sm 2469 Rev 1 05-08 9

Centre Axle - Differential Drive Head
Section 150-0020
Differential Assembly to Axle Housing MAINTENANCE
29. Take axle housing (1) and position it to allow for the
final assembly stages. Proper lubrication of the differential assembly is
essential if the differentials are to deliver the service
intended. Section 300-0020, LUBRICATION SYSTEM
SM - 3701
gives full information on the proper lubrication intervals
and the lubricant which should be used.

SPECIAL TOOLS
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
Service Tools, for part numbers of general service
tools and sealants required.

Fig. 26 - Axle Housing

SM - 3704

Fig. 27 - Differential installation

30. Mount the complete pre-assembled differential

using the lifting device, 15503096, or using a suitable
tool, into the axle housing (1). Refer to Figure 27.

31. The unit must be evenly pulled on to the two dowel

pins (27) and one shear sleeve using threaded bolts
and nuts.

10 Sm 2469 Rev 1 05-08

 Centre Axle - Differential Drive Head
Section 150-0020

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. PART NAME Nm lbf ft
1 3 Plug 70 51.6
1 5 Nut 800 ( + Loctite 262) 590 ( + Loctite 262)
1 29 Screw 115 84.8
1 32 Bolt 34 25
1 43 Stud 120 88.5
1 56 Nut 800 ( + Loctite 262) 590 ( + Loctite 262)
1 84 Screw 9.6 7.1
1 93 Screw 46 34.0
1 96 Screw 9.6 7.1
1 100 Screw 67 49.4
1 101 Screw 67 49.4

DIFFERENTIAL DIAGNOSIS
Noises and vibrations originating in the tyres,
transmission, planetaries and drivelines are easily
transmitted and may be erroneously attributed to the WARNING
differential. Therefore, all possible sources of noise To prevent personal injury and property
should be investigated before the differential is taken damage, be sure wheel blocks, blocking
apart. materials and lifting equipment are properly
secured and of adequate capacity to do the job
Whenever noises such as a grating or rattle are heard safely.
coming from the differential, stop the unit immediately.
One tooth from a gear can cause damage to all gears WARNING
and bearings. When the differential is definitely at fault, Removing the axle shafts or drivelines will
remove the axle shafts and disconnect the driveline make the parking brake ineffective.
before moving the vehicle.
DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
Lubrication System
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case

* * * *

Sm 2469 Rev 1 05-08 11

Centre Axle - Differential Drive Head
Section 150-0020

THIS PAGE IS INTENTIONALLY BLANK

12 Sm 2469 Rev 1 05-08

 REAR AXLE GROUP - Differential Drive Head
Section 160-0020

DESCRIPTION INSTALLATION
The differential assembly is mounted to the axle is the reversal of the 'Removal' procedure.
housing. It comprises of a differential for the normal
cross-axle drive function. Note: Use sealing compound between the axle housing
and differential housing mounting faces.

REMOVAL AND INSTALLATION Note: Tighten all fasteners to standard torques listed in
Numbers in parentheses refer to Fig. 1 unless Section 300-0080, AXLE BOLT AND NUT TORQUE
otherwise stated.. SPECIFICATIONS.

Add gear oil of the type specified in Section 300-0020,

WARNING LUBRICATION SYSTEM, through the oil fill level hole,
To prevent personal injury and property until the oil is level with the bottom of the filler/level
damage, be sure wheel blocks, blocking hole. Fit Plug (23) and o-ring (20). Fill the planetary
materials and lifting equipment are properly assemblies up to the 'Oil Level Check Line'.
secured and of adequate capacity to do the job
safely.

1. Position the vehicle in a level work area, raise the

body and install the body safety prop to secure the
body in the partially raised position.

2. Apply the parking brake and switch off the engine.

3. Block all road wheels, place the steering lock bar in

the 'Locked' position and the battery master switch in
the 'Off' position.

4. Drain the gear oil out of the axle housing and both
planetaries into a suitable container from the oil drain
plug (23)on the differential.

5. Remove the planetary assemblies and axle shafts

from the axle housing. Note from which side the long
and short axle shafts are removed. Refer to
Section 160-0030, AXLE GROUP (HUB).

6. Identify the relationship of the driveline flanges and

differential flanges (44) with punch marks.

7. Disconnect the drivelines from the differential

flanges . The drivelines can be removed if it is
convenient to do so.

8. Remove bolts (21 & 22) securing differential

housing (19) assembly to the axle housing.

9. Thread in three puller bolts to break the seal

between the differential and axle housing and pull the
differential assembly out of the axle housing. Carefully
remove differential housing (19) assembly clear of axle
housing.

Sm 2463 Rev 2 02-09 1

REAR AXLE GROUP - Differential Drive Head
Section 160-0020

SM - 3709

1 - Snap Ring 16 - Bolt 31 - Nut

2 - Washer 17 - Ball Bearing 32 - O-ring
3 - Shim 18 - O-ring 33 - Ball Bearing
4 - Bearing 19 - Differential Housing 34 - Adjusting Washer
5 - Housing 20 - Washer 35 - Cover
6 - Screw 21 - Bolt 36 - Adjusting Washer
7 - Clutch Sleeve 22 - Bolt 37 - Bushing
8 - Shim 23 - Seal Screw 38 - Ball Bearing
9 - Side Gear 24 - Seal Ring 39 - Radial Seal
10 - Thrust Washer 25 - Bushing 40 - Seal
11 - Pinion Gear 26 - Stud 41 - Cover
12 - Shaft 27 - Seal Ring 42 - Washer
13 - Crown Wheel 28 - Bushing 43 - Bolt
14 - Dowel Pin 29 - Locking Plate 44 - Flange
15 - Washer 30 - Bolt 45 - Nut

Fig. 1 - Exploded View Of Front / Rear Differential

DISASSEMBLY (19). Remove bushing (28), and bolts from the bearing
Numbers in parentheses refer to Fig. 1, unless cap.
otherwise specified.
3. Remove disc lock assembly (Fig. 2) items 46 to 71
Note: Procedure for disassembly is largely the same inclusive from the end of diff housing (19).
as that for the centre differential. If required refer to
section 150-0020 DIFFERENTIAL DRIVE HEAD for 4. Remove nut (45) flange (44) and cover (41).
additional information.
5. Remove Pinion gear (13) and constituent elements
Note: Arrow Fig. 1 shows location of Multi lock from the assembly.
assembly.
6. If necessary, disassemble the differential assembly
1. Remove bolt (30) and locking pin (29). as follows.

2. Index mark bearing cap, and differential housing 7. Remove Snap ring (1), washer (2), shim (3) and

2 Sm 2463 Rev 2 02-09

 REAR AXLE GROUP - Differential Drive Head
Section 160-0020

SM - 3710

46 - Screw 55 - Washer 64 - Screw

47 - Screw 56 - Thrust needle Cage 65 - Disc Carrier
48 - Screw 57 - Thrust Washer 66 - Ball Bearing
49 - O-ring 58 - Disc 67 - Snap Ring
50 - Glyd Ring 59 - Inner Disc 68 - Flange
51 - Piston 60 - Disc 69 - Seal
52 - Screw 61 - Washer 70 - Bushing
53 - Seal ring 62 - Carrier 71 - Flange
54 - Piston 63 - Compression Spring

Fig. 1 - Exploded View Of Multi-Disc Lock Assembly (All Axles)

bearing (4) from the housing (5). 1. Clean all parts in petroleum base solvent.

8. Remove bearing (17) from housing (5). 2. Immediately after cleaning, dry all parts, except
9. Remove bolt (16) washers (15) which secures bearings, with compressed air, or with a soft, clean lint
Housing (5) and crown wheel (13). free wiping cloth. Compressed air has a corrosive
effect on bearings, therefore, they must be wiped dry
10. Remove screws (6) securing both housings (5). with a cloth.
11. Separate housings (5) to allow for removal of
pinion/ side gear assembly. 3. Coat cleaned, dried parts immediately with light oil to
prevent corrosion. If parts are not to be assembled
12. Remove remaining elements of assembly for immediately, treat them with a good rust preventive
inspection. and wrap them with treated paper or other suitable
material designed to prevent corrosion.

INSPECTION 4. Before installing the differential assembly to the

The importance of careful and thorough inspection machine, clean the inside and outside of the axle
cannot be over stressed. Thorough inspection and
necessary replacement of parts now may eliminate
costly and avoidable trouble later.

Sm 2463 Rev 2 02-09 3

REAR AXLE GROUP - Differential Drive Head
Section 160-0020

ASSEMBLY DIFFERENTIAL DIAGNOSIS

Numbers in parentheses refer to Fig. 1 unless specified Noises and vibrations originating in the tyres,
otherwise. transmission, planetaries and drivelines are easily
transmitted and may be erroneously attributed to the
Note: Tighten all fasteners without special torques differential. Therefore, all possible sources of noise
specified to torques listed in Section 300-0080, AXLE should be investigated before the differential is taken
BOLT AND NUT TORQUE SPECIFICATIONS. apart.

Note: During assembly and installation, make sure that Whenever noises such as a grating or rattle are heard
mated, punch marked, or otherwise identified parts are coming from the differential, stop the unit immediately.
returned to their original positions, if still serviceable. One tooth from a gear can cause damage to all gears
and bearings. When the differential is definitely at fault,
Assembly is the main is the reverse of disassembly. remove the axle shafts and disconnect the driveline
For specific measurements and steps required for shim before moving the vehicle.
selection. Refer to Section 150-0020 DIFFERENTIAL
DRIVE HEAD.
WARNING
To prevent personal injury and property
MAINTENANCE damage, be sure wheel blocks, blocking
Proper lubrication of the differential assembly is materials and lifting equipment are properly
essential if the differentials are to deliver the service secured and of adequate capacity to do the job
intended. Section 300-0020, LUBRICATION SYSTEM safely.
gives full information on the proper lubrication intervals
and the lubricant which should be used. WARNING
Removing the axle shafts or drivelines will
make the parking brake ineffective.
SPECIAL TOOLS
The special tools referenced in this section are
available from your dealer. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and sealants required. Housing to remove any
foreign material.

5. Inspect all gears, pinions, and splines for cracked or

broken teeth, excessive wear, and pitted or scored
surfaces. Repair or replace as necessary.

Note: If either ring gear or pinion gear is defective, both

gears must be replaced, because they are serviced
only as a matched set. Make sure the ring gear and
pinion gear have the same mating numbers.

6. Check for pitted, scored or worn thrust surfaces of

differential case halves.

4 Sm 2463 Rev 2 02-09

 REAR AXLE GROUP - Differential Drive Head
Section 160-0020

DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration Broken gear teeth, worn bearings Replace gear or bearings
Continual noise Worn gear or bearings Replace gear or bearings
Noise on drive Ring or pinion gear adjustment tight Adjust
Noise on coast Bearings damaged Replace bearings
Ring and pinion gear adjustment loose Adjust
Excessive pinion gear end play Adjust
Noise on turns Normal limited slip differential operation Use an EP oil with limited slip
additives. Refer to Section 300-0020,
LUBRICATION SYSTEM
Worn pinion gears or side gears Replace gears
Worn or damaged axles (spiders) Replace axles (spiders)
Loss of lubricant Oil seals worn Replace seals
Loose nuts or bolts Tighten nuts or bolts to correct torque
Cracked housing/case Repair or replace housing/case

* * * *

Sm 2463 Rev 2 02-09 5

REAR AXLE GROUP - Differential Drive Head
Section 160-0020

THIS PAGE IS INTENTIONALLY BLANK

6 Sm 2463 Rev 2 02-09

 Rear Axle Group - Axle Group (Hub)
Section 160-0030

SM - 4006
2 3 6
4
1
14
7
10
8 11
12
63 13
10
15

19 5
20 16

21 17
22 18
23
24

26
27 34
28
62 25
61 35
29 30

36 31
32
62 33
39
40 41

46
37 47
48
38 49

50 51
52 53
9
54
42 44
43 45
56
57
55
42
59
60
1- Capscrew 17 - Washer 33 - Snap Ring 58 49- Seal
2- Cover 18 - Bolt 34 - O-ring 50- Hub Carrier
3- O-ring 19 - Slotted Nut 35 - Pin 51- Breather
4- Pin 20 - Shim 36 - Steel Disc 52- Breather
5- Bolt 21 - Ring Gear 37 - Inner Disc 53- Seal ring
6- Planet Carrier 22 - Ring Gear Carrier 38 - O-ring 54- Threaded Stud
7- Plug 23 - Snap Ring 39 - Radial Seal 55- Bolt
8- Seal ring 24 - Roller Brg 40 - O-ring 56- Seal ring
9- Dowel Pin 25 - Wheel Bolt 41 - Wheel Hub 57- Plug
10 - Washer 26 - Wheel Hub 42 - Washer 58- O-ring
11 - Planet Gear 27 - Cylinder 43 - Bolt 59- Seal ring
12 - Caged Needle Brg 28 - Seal rings 44 - Seal ring 60- Snap ring
13 - Planet Pin 29 - Piston 45 - Drain Plug 61- Steel Disc
14 - O-ring 30 - Seal rings 46 - Intermediate ring 62 - Inner Disc
15 - Planet Carrier 31 - Pressure Spring 47 - Roller Brg 63- Wheel Nut
16 - Shear Pin 32 - Thrust Washer 48- Spindle

Fig. 1 - Exploded View of Planetary and Wheel

SM 2363 Rev 3 05-10 1

Rear Axle Group - Axle Group (Hub)
Section 160-0030

OPERATION remove tyre and rim assembly from the machine.

Remove opposite road wheel in the same way.
Numbers and letters in parentheses refer to Fig. 1.
7. Place suitable containers under the differential and
Power from the differential is transmitted through a
both hubs (26). Remove differential drain plug and drain
fully floating axle sun gear shaft . As sun gear shaft
oil from the differential.
rotates in a clockwise direction, 4-off planet gears (11)
meshed with sun gear shaft rotate anticlockwise. Ring
8. Rotate hubs (26) until drain plug (45) is at its lowest
gear (21) is splined to hub carrier (50) and does not rotate
point. Remove plug (45) and seal ring (44) and drain oil
but causes planet gears (11), which are meshed with ring
from hub.
gear (21), to move around it in a clockwise direction. As
planet carrier (6) is bolted to wheel hub (26) the wheel then
9. Index mark planet carrier (6) and hub (26) to aid in
rotates in a clockwise direction.
installation.
REMOVAL AND DISASSEMBLY
10. Loosen screws (1) then prise cover (2) from planet
Numbers in parentheses refer to Fig. 1.
carrier (6), removing o-ring (3) and pin (4) in the
Note: On dismantling, clean all parts in paraffin or
process.
suitable cleaner, place on a clean work surface.
11. Using a suitable threaded stud locate into threaded
WARNINGS centre on the end of sun gear shaft to remove shaft.
To prevent personal injury and property Refer to Fig. 2
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 12. Pull shaft from the assembly and remove to a
secured and of adequate capacity to do the job suitable bench area for inspection at a later stage.
safely.
13. Using a suitable lifting device, secure to planet
carrier (6).
To prevent personal injury and property SM3665

damage, the procedure for removing tyre and

rim assembly described in Section 160-0050,
WHEEL, RIM AND TYRE, must be strictly
followed.

When necessary to drive out components

during disassembly, be sure to use a soft drift
to prevent property damage and personal
injury.

1. Before attempting to remove the road wheels, drive

the vehicle onto a level, solid concrete floor, preferably Fig. 2 - Removal of Sun Gear Shaft
after a short run to warm the oil.
14. Remove remaining Bolts (5) from planet carrier (6).
2. Apply the parking brake and switch off the engine. Secure carrier and constituent parts i.e. planet gear
assembly and remove from the wheel hub assembly.
3. Block the appropriate road wheels, place the
steering lock bar in the 'Locked' position and the
battery master switch in the 'Off' position.

4. Whilst road wheels are still on the ground, loosen

wheel nuts (64).

5. Jack up the axle and support with suitably placed

stands or timbers.

6. Support tyre and rim assembly with a suitable sling

and lifting device. Remove wheel nuts (64) and

2 SM 2363 Rev 3 05-10

 Rear Axle Group - Axle Group (Hub)
Section 160-0030
15. Locate 2-off fabricated tool (Fig. 3) over bolts SM3667
securing hub carrier (50) to the axle housing 62) and
secure into the 2-off locating holes which are capped
on the rear face of the wheel hub (41).

SM3666

Fig. 6 - Removal of Sun Gear Shaft SM - 3668

18. Cylinder (27), piston (29), seal ring (28), o-ring (34) ,
Fig. 3 - Securing Wheel Hub seal ring (30), disc springs (31), thrust washers (32)
and snap ring (33) ca n now be removed from the
assembly.
16. Prior to removal of slotted nut (19) it will be
necessary to heat the nut to 200°c to release the 19. Remove steel discs and inner discs (36 & 37) from
loctite bond. Using a special tool (15503031) or suitable the assembly. Pins (35) can also be removed once the
powered tool, remove slotted nut (19). Refer to Figures discs have been removed.
4 and 5.
20. Seal ring (39) should be removed from the bore of
SM3669
the wheel hub (41) as should o-ring (40).

21. Fit locating studs into threaded holes of the axle

housing, into the wheel hub (41). This ensures the
wheel hub (41) will not drop down , which could damage
the valve (shown in yellow). Refer to Fig. 7.

SM3668

Fig. 4 - Preheat Slotted Nut

17. Locate fabricated tool onto bolts (25) and screw

wheel hub (26) away from the wheel hub (41). Refer to
Fig. 6. Bearing (24) should come out during this step.

SM3661

Fig. 7 - Locating Studs

22. Wheel hub (41) can now be removed by removal of

fabricated tools which were securing it in place.

23. All other components can now be removed from

the assembly. Including Intermediate ring (46)and seal
rings (48and49).

Fig. 5 - Torque Tool

SM 2363 Rev 3 05-10 3

Rear Axle Group - Axle Group (Hub)
Section 160-0030
24. Bolts (55) securing hub carrier (50) to the axle 2. Fit sealring (58 & 59) and o-ring (61). Secure
housing can be removed, along with washers (42). caradan flange(60).

25. Remove seal ring (59), o-ring (60) and o-ring (61) 3. Secure hub carrier (50) on a suitable table. Fit NBR
from the hub carrier (50). seal (49) and spindle ring (48). Ensure each is fully
home without causing damage to the components.
INSPECTION
Numbers in parentheses refer to Fig. 1. Note: Bearing (24) should be preheated, prior to fitting
onto the hub carrier (50).
Thoroughly clean all parts with a suitable solvent and
dry with compressed air. Inspect all parts for damage 4. Secure roller bearing (47) inner race to the hub
or excessive wear and replace where necessary. carrier (50), again ensure it is fully home. Refer to
Inspect thrust washers (32) to make sure they are free Fig.9.
of burrs and are absolutely flat. Replace all 'O' rings.
SM3642

ASSEMBLY AND INSTALLATION

Numbers in parentheses refer to Fig. 1 unless
otherwise stated.
BEARING
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section 300- SPINDLE RING
0080, AXLE BOLT AND NUT TORQUE
SPECIFICATIONS.

WARNINGS Fig. 9 - Hub Carrier Assembly - Bearing

To prevent personal injury and property
damage, be sure wheel blocks, blocking 5. Grease o-ring (40) with a thin layer of grease to aid
materials and lifting equipment are properly installation. Fit o-ring (40) on hub carrier (50) as shown
secured and of adequate capacity to do the job in Fig. 10.
safely.
SM3643

1. Install brass bushing into bore of Hub carrier (50).

Ensure oil groove on the bush is at the bottom of the
assembly location i.e. at the opposite end from the flat
face which is on the outer diameter of the hub carrier O - RING
(50). Refer to Fig. 8.
Note: Oil groove on bush is a cross groove.

SM3641

OIL 'X'
GROOVE
Fig. 10 - Hub Carrier Assembly - O-ring

6. Mount intermediate ring (46) onto carrier (50), using

suitable tools, carefully 'punch' ring twice on opposite
sides to seat it home onto the carrier. Refer to Fig. 11.

7. Insert bearing (47) outer race into hub (41), use

punch tool (15503033). Fit cartridge seal (39) to hub
(41) at this stage using punch tool (15503034). Refer to
Fig. 12.
Fig. 8 - Bush / Seal Installation

4 SM 2363 Rev 3 05-10

 Rear Axle Group - Axle Group (Hub)
Section 160-0030

SM3644 SM3644

HUB CARRIER

O-RING

Fig. 14 - Locating Pins

Fig. 11 - Intermediate Ring

SMSM3645
- 3644 12. Assemble alternately; inner discs (37) with steel
discs (36). Ensure that all oil channel holes line up and
that one of the oil channels is in the top position. Refer
to Fig. 15
SM3648

OIL CHANNELS

Fig. 12 - Brg Outer Race Install

8. Fill the tapered cavity within wheel hub (41) with

grease (SKF LGEP 2/18 spec). Ensure an even film is LOWER STEEL DISCS
distributed around the bore.

9. Lower wheel hub (41) onto hub carrier (50) until Fig. 15 - Locating Brake Discs
bearing (47) race seats firmly. Note: Observe that the
Note: Top steel disc must lie with its measuring tang
oil seal slides onto intermediate ring without damage to
over the wheel hub opening position. The measuring
seal. Refer to Fig. 13.
tang of the lower steel disc must line up with the other
SMSM3646
- 3644 position. Refer to Fig. 16.

SM3649

SPINDLE

HUB CARRIER

MEASURING TANG

Fig. 13 - Wheel Hub/Carrier Mating

OPENING
10. Fit o-ring (38) then locate pins (35) and dowel pins
(9) into mating holes on the hub carrier (50). Refer to
Fig. 14.
Fig. 16- Orientate Measuring Tang and Hole
11. Clean the steel discs (36 and 61)of oil.

SM 2363 Rev 3 05-10 5

Rear Axle Group - Axle Group (Hub)
Section 160-0030
13. All inner coated disks must be checked 17.Measure X2 on ring piston cylinder(29).
dimensionally. The complete thickness for coating Distance from piston face to the inner washer. Measure
disks in new condition is 5mm. If the coating disks the distance on the inside diameter.
thickness is less than 4.65mm, the disks must be
replaced.Refer to Fig. 36 & 37 18.Special device WZ 873 for X3 distance
For X3 measurement, set on the special device WZ
SM - 4014 873.Screw on the centre nut and tighten by hand.
Simultaneous turn constant the wheel hub, to align the
wheel hub.

19.Load both lever of the device, so that multi disks set

in working condition and becomes pressure.

20.Measure X3 to disks.
Distance from spindle face to the face of coated disk
and directly near the stamp.

21.The release gap “S” is following calculated:

S=X3-(X1+X2)
The setting value is 1.0 – 1.4 mm.
Is the value “S” > 1.4 mm replace so much standard
Fig. 36 Thickness of inner disks steel disks through steel disks with 0.5 mm thicker
size till the setting value is reached.

14. Check also the depth of the oil groove in the Available disks:
coating area. the depth has to be 0.7mm. If the dept is Steel disk 03.73440.034.0 has 3.0mm thickness.
less than 0.3mm, the disks must be replaced. Refer to Steel disk 03.73440.056.0 has 3.5mm thickness
Fig. 37
22.Start to reinstall the disk package with a lined disk.
SM - 4015 Install the disk with middle groove on top.

23.Set the lower steel disks (36) out of measuring line

24.Set the top steel disks in direct measuring line.

Then remove the protecting tape.

25. Spray hub carrier with 'Wolfrakote' Paste prior to

assembly of the piston (29) and cylinder (27) to the hub
carrier (50) assembly. Refer to Fig. 17.

Fig. 37 Depth of oil groove

15. Install the checkout disk package again and make

a new adjustment.

16. Measure X1 on spindle(48).

Distance from spindle face to the profile step for coated
disks.

6 SM 2363 Rev 3 05-10

 Rear Axle Group - Axle Group (Hub)
Section 160-0030

SM3652
SM3650

COATING

Fig. 19- Cylinder Assembly

Fig. 17- Coating Hub

16. Assemble wheel hub (26) onto wheel hub (41) and
13. Locate seal ring (30) to brake piston (29). Ensure fit bearing (24) onto carrier (50). Ensure that punched
correct orientation of seal ring (30). assembly marks on outer diameter of both wheel hubs
(26 & 41) line up. Refer to Figs. 20 & 21.
14. Assemble brake piston (29) to the pack. Ensure
that the Ø5mm bleed bore is at the top. The Ø20mm oil SM3653
holes of the brake cylinder must be placed over the oil
channel of the multi-discs. Refer to Fig. 18.

SM3651

TOP
OIL HOLE

LINE MARKS

BLEED
BORE Fig. 20- Assembly Marks

SM3654

PREHEATED BEARING

Fig. 18- Piston Assembly

15. Fit o-ring (34) to cylinder (27) then locate cylinder

on brake assembly. Ensure the Ø5mm bore is on the
top as this stage. Refer to Fig. 19.

Fig. 21- Assembly Marks

SM 2363 Rev 3 05-10 7

Rear Axle Group - Axle Group (Hub)
Section 160-0030

17. Assemble ring gear and ring gear carrier (21 & 22), SM3658

spray the face of the ring gear carrier (22) with

'Wolfakote paste'. Refer to Fig. 22.

18. Take ring gear assembly and locate over the hub
carrier (50). Refer to Fig. 22.

20. A number of measurements must be made to "X1"

determine the correct selection of shim (20) size.
Follow the procedure listed. "d"
"X2"
SM3655 22
20
19
50

Fig. 24 - Shim Measurement

24. Once the shim (20) has been determined, this

should be installed, with the slotted nut (19). The
assembly should be mounted suitably in the horizontal
position to allow the bearing preload to be checked.

Fig. 22 - Coated Ring Gear Carrier

25. Bearing (24) preload should be 50 Nm (36.9 Ibf ft)
and must be measured in the horizontal position. Refer
to Fig. 25.
21. Measure dimension 'X1' from the top face of the
hub carrier (50) to the face at the end of thread SM3659

engagement. Refer to Fig. 23.

SM3656/7

SPINDLE
YELLOW MARK POINT

"X1"
"X2"
Fig. 25 - Bearing Preload
Fig. 23 - Shim Measurement
26. Once the preload has been confirmed, re-install
22. The second measurement should be with the ring shim (20) and slotted nut (19) , coat engagement face
gear carrier (22) fixed in place. This should be noted as of nut with loctite 262.
dimension 'X2'
27. Taking special tool (15503031) torque slotted nut
23. Shim (20) thickness 'd' should fall within the (19) to a value of 2000 ± 120Nm (1475 ±88 Ibf ft).
following dimensions , refer to Fig 24. : Refer to Fig. 26 & 27.

'd' Max = X1 - X2 28. Once the slotted nut (19) has been secured. Mark
'd' Min = (X1 - X2) - 0.12 the position of the nut with a yellow colour point. Refer
to Fig. 25.

8 SM 2363 Rev 3 05-10

 Rear Axle Group - Axle Group (Hub)
Section 160-0030

SM3660 32. Insert sun gear shaft (63) into the planetary cage
assembly. Refer to Fig. 29.

SM3662

Fig. 26 - Slotted Nut Socket

Fig. 29 - Sun Gear Shaft

SM3661 33. Using suitable lifting tackle mount the complete

planetary unit into the wheel hub assembly. Refer to
Fig. 30.
SM3663

Fig. 27 - Torque Tool

Fig. 30 - Assembly

29. Assemble constituent elements of the carrier (6).

34. Observe that recesses on outer diameters of carrier
Ensure o-ring (14) is fitted prior to planet gears (11),
(6) and wheel hub (26) are lined up correctly. Refer to
washers (10), pins (13) and bearings (12).
Fig. 28.
30. Secure elements with planet carrier (15), washers
35. Using suitable lifting device (15503032), secure
(17) and bolts (18).
planetary assemblies to the axle housing (63) with
washers (42) and bolts (55). Torque bolts (55) to 290
31. Locate cover (2) onto planet carrier (6) and secure
Nm (213lb-ft).
with bolts (1). Torque bolts (1) to 67Nm (49 Ibf ft) Refer
to Fig. 28.
36. Install differential drain plug. Add gear oil of the type
SM3663
specified in Section 300-0020, Lubrication System,
through the differential filler/level hole until the oil is
level with the bottom of the filler/level hole.

23. Fill the planetary assemblies up to the 'Oil Level

Check Line' with gear oil of the type specified in Section
300-0020, Lubrication System.

COVER 24. Refit road wheels, securing with wheel nuts (64).
Remove stands or timber supports and lower the
machine to the ground. Fully tighten wheel nuts to a
Fig. 28 - Cover Detail torque of 600 Nm (442 lbf ft). Remove blocks from the
wheels.

SM 2363 Rev 3 05-10 9

Rear Axle Group - Axle Group (Hub)
Section 160-0030
Note: Wheel nuts should be checked and tightened if SM4021
necessary, after the first 10 hours of operation. Check
torque every 50 hours (weekly) thereafter.

MAINTENANCE
Proper lubrication of the axle group is essential if axles
are to deliver the service intended. Section 300-0020,
Lubrication System gives full information on the proper
lubrication intervals and the lubricant which should be
used.

The wheel hub - planetary drive and tandem housing

have a common oil chamber. The oil chambers are not
separated from each other, and due to the narrow oil
channels and therefore relatively slow passage of oil,
the oil must be filled or added into the correct openings
provided. Fig. 32 - View of Planetary Fill / Drain points

Numbers in parentheses refer to Fig. 31 & 32 unless

plug (2). Rest oil Drain plugs (1, Fig. 31 & 32) on back
otherwise stated.
side of planetary. Fill system with oil specified in
Section 300-0020, Lubrication System, to the bottom
Note: Perform the planetary oil change when the oil is
edge of the thread of plug (1, Fig. 31 & 32). Torque
warm, simultaneously with the differential.
plugs (1 & 2) to a value of 45 Nm (33 Ibf ft).
1. Planetary drive - Turn the wheel hub until the oil
drain plug (1) is at the lowest point to the middle axle.
3. Refit road wheels, securing with wheel nuts (64).
Clean oil drain plug (1). Remove oil drain plug (1) and
Remove stands or timber supports and lower the
drain oil. Torque oil drain plug (1) to 45 Nm ( 33 Ibf ft).
machine to the ground. Fully tighten wheel nuts to a
torque of 600 Nm (442 lbf ft). Remove blocks from the
wheels.
SM3353

WHEEL HUB Note: Wheel nuts should be checked and tightened if

REAR SIDE
necessary, at initial inspection and after the first 10
1 hours of operation. Check torque every 250 hours
2 (monthly) thereafter.

BLEEDING THE BRAKES

Numbers in parentheses refer to Figure 1 unless
otherwise stated.

1. Fit a clear hose to the bleed nipple (51) of the rear

axle left-hand wheel hub, and submerge the other end
of the hose in a bucket of clean oil.

2. Start the truck. While the operator is operating the

Fig. 31 - View of Planetary Fill / Drain points parking brake or foot pedal, undo the bleed nipple (51)
using a suitable ring spanner or a special socket..

3. Allow oil to flow through the hose and into the bucket
Numbers in parentheses refer to Fig. 32 unless
until it runs clear (NOT AERATED).
otherwise stated.
4. Close the bleed nipple (51).
2. Turn wheel hubs back by 90 deg. then remove oil fill
5. Deactivate the parking brake or foot pedal.

10 SM 2363 Rev 3 05-10

 Rear Axle Group - Axle Group (Hub)
Section 160-0030

6. Repeat steps 2 to 5 a further eight times until NO air 23. Start the truck. While the operator is operating the
is visible when the nipple is opened. parking brake or foot pedal, undo the bleed nipple (51)
using a suitable ring spanner or a special socket..
7. Remove the hose from the bleed nipple (51) and
tighten the bleed nipple to a torque of 18 Nm (32 lbf ft). 24. Allow oil to flow through the hose and into the
bucket until it runs clear (NOT AERATED).
8. Transfer the hose to the bleed nipple (51) of the rear
axle right-hand wheel hub, and submerge the other end 25. Close the bleed nipple (51).
of the hose in a bucket of clean oil.
26. Deactivate the parking brake or foot pedal.
9. Start the truck. While the operator is operating the
parking brake or foot pedal, undo the bleed nipple (51) 27. Repeat steps 2 to 5 a further eight times until NO
using a suitable ring spanner or a special socket.. air is visible when the nipple is opened.

10. Allow oil to flow through the hose and into the 28. Remove the hose from the bleed nipple (51) and
bucket until it runs clear (NOT AERATED). tighten the bleed nipple to a torque of 18 Nm (32 lbf ft).

11. Close the bleed nipple (51). 29. Transfer the hose to the bleed nipple (51) of the
front axle left-hand wheel hub, and submerge the other
12. Deactivate the parking brake or foot pedal. end of the hose in a bucket of clean oil.

13. Repeat steps 2 to 5 a further eight times until NO 30. Start the truck. While the operator is operating the
air is visible when the nipple is opened. parking braske or foot pedal, undo the bleed nipple (51)
using a suitable ring spanner or a special socket..
14. Remove the hose from the bleed nipple (51) and
tighten the bleed nipple to a torque of 18 Nm (32 lbf ft). 31. Allow oil to flow through the hose and into the
bucket until it runs clear (NOT AERATED).
15. Transfer the hose to the bleed nipple (51) of the
centre axle left-hand wheel hub, and submerge the 32. Close the bleed nipple (51).
other end of the hose in a bucket of clean oil.
33. Deactivate the parking brake or foot pedal.
16. Start the truck. While the operator is operating the
parking brake or foot pedal, undo the bleed nipple (51) 34. Repeat steps 2 to 5 a further three times until NO
using a suitable ring spanner or a special socket.. air is visible when the nipple is opened.

17. Allow oil to flow through the hose and into the 35. Remove the hose from the bleed nipple (51) and
bucket until it runs clear (NOT AERATED). tighten the bleed nipple to a torque of 18 Nm (32 lbf ft).

18. Close the bleed nipple (51). 36. Transfer the hose to the bleed nipple (51) of the
centre axle right-hand wheel hub, and submerge the
19. Deactivate the parking brake or foot pedal. other end of the hose in a bucket of clean oil.

20. Repeat steps 2 to 5 a further eight times until NO 37. Start the truck. While the operator is operating the
air is visible when the nipple is opened. parking brake or foot pedal, undo the bleed nipple (51)
using a suitable ring spanner or a special socket..
21. Remove the hose from the bleed nipple (51) and
tighten the bleed nipple to a torque of 18 Nm (32 lbf ft). 38. Allow oil to flow through the hose and into the
bucket until it runs clear (NOT AERATED).
22. Transfer the hose to the bleed nipple (51) of the
centre axle right-hand wheel hub, and submerge the 39. Close the bleed nipple (51).
other end of the hose in a bucket of clean oil.
40. Deactivate the parking brake or foot pedal.

41. Repeat steps 2 to 5 a further three times until NO

air is visible when the nipple is opened.

SM 2363 Rev 3 05-10 11

Rear Axle Group - Axle Group (Hub)
Section 160-0030

42. Remove the hose from the bleed nipple (51) and tighten the bleed nipple to a torque of 18 Nm (32 lbf ft).
tighten the bleed nipple to a torque of 18 Nm (32 lbf ft).
61. Transfer the hose to the bleed nipple (51) of the
43. Transfer the hose to the bleed nipple (51) of the centre axle left-hand wheel hub, and submerge the
rear axle right-hand wheel hub, and submerge the other other end of the hose in a bucket of clean oil.
end of the hose in a bucket of clean oil.
62. Start the truck. While the operator is operating the
44. Start the truck. While the operator is operating the parking brake or foot pedal, undo the bleed nipple using
parking brake or foot pedal, undo the bleed nipple (51) a suitable ring spanner or special socket.
using a suitable ring spanner or a special socket..
63. Allow oil to flow through the hose and into the
45. Allow oil to flow through the hose and into the bucket until it runs clear (NOT AERATED).
bucket until it runs clear (NOT AERATED).
64. Close the bleed nipple.
46. Close the bleed nipple (51).
65. Deactivate the parking brake or foot pedal.
47. Deactivate the parking brake or foot pedal.
66. Remove the hose from the bleed nipple and tighten
48. Remove the hose from the bleed nipple (51) and the bleed nipple to a torque of18 Nm (32 lbf ft).
tighten the bleed nipple to a torque of 18 Nm (32 lbf ft).
67. Locate the bucket underneath the parking brake
49. Transfer the hose to the bleed nipple (51) of the assembly.
rear axle left-hand wheel hub, and submerge the other
end of the hose in a bucket of clean oil. 68. Activate the parking brake.

50. Start the truck. While the operator is operating the 69. Loosen the hose on the parking brake. Allow oil to
parking brake or foot pedal, undo the bleed nipple (51) escape from the parking brake hose until it runs clear
using a suitable ring spanner or a special socket.. (NOT AERATED).

51. Allow oil to flow through the hose and into the 70. Refit the hose to the parking brake.
bucket until it runs clear (NOT AERATED).
71. Deactivate the parking brake.
52. Close the bleed nipple (51).
72. Repeat steps 67-72 a further twice.
53. Deactivate the parking brake or foot pedal.
73. Check that the hose is correctly tightened to the
54. Remove the hose from the bleed nipple (51) and parking brake on completion.
tighten the bleed nipple to a torque of 18 Nm (32 lbf ft).
74. Stop the truck.
55. Transfer the hose to the bleed nipple (51) of the
centre axle right-hand wheel hub, and submerge the
other end of the hose in a bucket of clean oil.

56. Start the truck. While the operator is operating the

parking brake or foot pedal, undo the bleed nipple (51)
using a suitable ring spanner or a special socket..

57. Allow oil to flow through the hose and into the
bucket until it runs clear (NOT AERATED).

58. Close the bleed nipple (51).

59. Deactivate the parking brake or foot pedal.

60. Remove the hose from the bleed nipple (51) and

12 SM 2363 Rev 3 05-10

 Rear Axle Group - Axle Group (Hub)
Section 160-0030
SM - 3738 Brake wear should be measured with the brake applied.
Measurement is made by removing plug (1, Fig 31) and
inserting depth gauge through. Replace and torque plug
when measurement is completed.

AXLE DIAGNOSIS
Noises originating in the tyres, transmission, brakes or
disk new =80.5mm
drivelines might be attributed by mistake to the axle
disk worn
out =77.5mm components, therefore, all possible sources of noise
+ 1.5
80.5 - 0.7 should be investigated before deciding the axle is at
fault.True axle noises may be located by lifting or
Fig. 33 - Brake Wear Measurement jacking the machine up until all tyres are clear of the
floor or ground. Securely block the machine in this
2000 Hours position. Run power train at moderate speed. Be
certain all tyres are off the ground to prevent damage
The multi-discs should be checked for wear. Refer to to the differential and make sure that there is no brake
Fig. 33 for detail. Should brake wear depth measured drag.
be 77.5mm or less i.e. brake wear across disc set of
3mm or greater, then the discs should be replaced.

AXLE DIAGNOSIS CHART

CONDITION REASON REMEDY
Noises Insufficient or incorrect lubricant Check level. Fill with proper type and grade of
lubricant.
Wheel bearings scored or rough Replace wheel bearings
Gear teeth in planetary chipped Replace gear
Loss of lubricant Lubricant foams excessively Drain and fill with proper type and grade of
lubricant
Worn or broken oil seal Replace oil seal
Loose nuts or bolts Tighten nuts or bolts
Gain of lubricant Incorrect lubricant Drain and fill with proper type and grade of
lubricant
Planetaries running hot Bearings seized Replace bearings

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 1 Capscrew 67 49
1 43 Bolt 290 214
1 45 Drain Plug 55 40.5
1 51 Breather 18 32
1 52 Breather 10 7.4
1 57 Plug Screw 15 11
1 64 Wheel Nuts 600 442

SM 2363 Rev 3 05-10 13

Rear Axle Group - Axle Group (Hub)
Section 160-0030

WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.

SPECIAL TOOLS
The special tools referenced throughout this section
are available from your dealer. Refer to Section
300-0070, SERVICE TOOLS, for part numbers of
general service tools and sealants required.

For fabricated tools, refer to the end of this section for

dimensions.

FABRICATED TOOLS
The following tools are necessary to aid in removal /
assembly of the axle group.

SM3670

97mm 45mm
20mm

Ø30mm
Ø10mm
35mm 8mm

120mm
72mm

80mm Ø17mm

Fig. 34 - Wheel Head Support Bracket Dimensions

14 SM 2363 Rev 3 05-10

 Rear Axle Group - Axle Group (Hub)
Section 160-0030
SM 3671

DIMENSIONS IN mm UNLESS STATED OTHERWISE

508
425
1" UNC

Ø1" UNC
12

3" SQ

305
152
90

Ø60
Ø28 Ø80
22
Ø38
Fig. 35 - Bearing Puller

*****

SM 2363 Rev 3 05-10 15

 Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

Sm - 3603

7
6

8
9

3
1
2

1 - Weel Rim 4 - Key / Driver 7 - Valve Cap

2 - Flange assembly 5 - O-ring 8 - Lock Washer
3 - Lockring 6 - Valve Assembly 9 - Wheel Nut

Fig. 1 - Cutaway View of Wheel Rim

DESCRIPTION AND OPERATION should be used to lift the tyre and rim: chain block and
The rim and wheel assembly are designed to allow the tackle, overhead crane, fork lift truck, boom truck, or
tyre and rim assembly to be replaced with a pre- tripod tyre changing tool.
assembled tyre and rim. The tyre and rim may be
removed from the machine as an assembly and
transported to a more suitable location for removing the PREPARATION FOR SERVICING
tyre from the rim.

Procedures for removing tyre and rim assembly from WARNING

machine, and dismounting tyre from rim, the use of Before performing any service on the tyres or
hand, hydraulic, and special tools, are described in this rim components, to prevent personal injury and
section. property damage, completely deflate the tyre by
removing the valve cap and core. Insert a thin
The rim assembly consists of the following wire through valve to be sure valve is not
components which are illustrated in Fig. 1: Wheel Rim , plugged. Even a flat tyre, in some cases, will
Flange assembly, Lock ring, 'O'-ring and Driver retain sufficient air pressure to blow off a rim
component with enough force to cause bodily
When dismounting a tyre and rim assembly from the injury or death.
machine, special equipment and careful handling are
required because of the size and weight of the tyres.
One of the following pieces of hoisting equipment
SM 2449 Rev 1 04-10 1
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 3605
1
10 9
11
5

7
8 12

1 - Wheel Rim 4 - Key / Driver 7 - Valve Core 10 - Adaptor

2 - Flange assembly 5 - O-ring 8 - Cap 11 - Cap
3 - Lockring 6 - Valve assembly 9 - Tyre 12 - Spud

Fig. 2 - Typical Tyre & Rim Assembly

REMOVING TYRE AND RIM ASSEMBLY SM - 205

FROM MACHINE
Numbers in parentheses refer to Fig. 1.

Note: If tyre and rim assembly is to be replaced pre-

assembled, it is not necessary to remove the tyre from
the rim. It may be removed as an assembly. Fig. 3 - Pry Bar

WARNING SM - 206

To prevent personal injury and property

damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.

1. Position the vehicle in a level work area, apply the

parking brake and shutdown the engine.

2. Block all road wheels, except the one to be raised,

and place the battery master switch in the 'Off'
position.

3. Break wheel nuts (9) loose with tyre still on the

ground, but do not remove from wheel studs.
Fig. 4 - Breaking Typical Tyre Bead

2 SM 2449 Rev 1 04-10

 Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

4. Jack up the axle to the height required to allow 9. Pry lock ring (3) out in the same manner by starting
removal of the tyre and rim assembly. at prying notch in wheel rim (1) assembly, and work all
the way around wheel rim (1) with two pry bars.
5. Place safety blocks under the axle.
10. Remove and discard 'O' ring (5).
6. Support tyre and rim assembly with a suitable sling
and attach a suitable lifting device. 11. Remove lock ring (3).

7. Remove wheel nuts (9) and lock washers (8) securing 12. Breaking slots are provided inside the rims. The
wheel rim base assembly (1) to the wheel. inner bead may be broken as described in Steps 4
through 8. If the tyre and rim assembly is on the
8. With lifting device, remove tyre and rim assembly vehicle, the following procedure may be used for
from the wheel and lift clear of the vehicle. breaking the inner bead.

13. Place jack between inner flange and vehicle frame.

DISMOUNTING TYRE FROM RIM Extend jack until tyre bead is broken. Continue around
Numbers in parentheses refer to Fig. 2, unless the rim until tyre bead is broken at all points.
otherwise specified.
14. Using suitable lifting equipment, remove tyre from
Note: The following instructions apply to use of hand rim. This completes the removal of the tubeless tyre.
tools. For procedures and tooling required to dismount
the tyre from the rim using hydraulic tools, contact the Note: If tyre rim is on the vehicle, and no tyre lifting
relevant tyre manufacturer. equipment is available, 'walk' the tyre off the rim as
follows:

WARNING Force bottom of tyre outward as far as possible; lower

When lifting tyre from the rim, be sure the jack enough to allow weight of tyre to rest on ground;
equipment is of sufficient capacity and properly force top of tyre out as far as possible; raise jack to
secured to do the job safely. original height and repeat the above until the tyre is off
the rim.
1. Remove valve cap (8) and valve core (7) and leave
valve open to prevent trapping of air in tyre. Tape valve
threads for protection. INSPECTION
Tyre
2. Remove driver (4) from flange (2) and wheel rim (1).
Check the interior surface of the tyre to determine its
3. Insert flat hooked end of pry bar into groove of flange condition. Inspect for cuts or fabric breaks that have
(2) betweeen lock ring (3) and flange (2). penetrated the tyre body. The casing should be
inspected closely for any sharp , pointed object that
4. Prying up with the pry bar. Using two pry bars, work may have penetrated the tyre body but is invisible from
completely around wheel rim (1).breaking lock ring (3) the outside. All dust, dirt, water or other foreign matter
and outer flange (2) apart. should be cleaned from the inside of tyre.

See Fig. 4. A pipe over the straight end of the pry bar Rim Assembly
will increase leverage.
Overloading, improper tyre inflation, rough terrain, high
6. A second pry bar may be inserted in the space speed, accidents, dirt accumulation, and corrosion all
between lockring (3) and flange (2). Twist the second tend to reduce the service life of rims and rim
pry bar to maintain the space gained by the first pry bar. components. It is recommended that rims be
inspected, as below, not less often than at every tyre
7. Move the first pry bar around wheel rim (1), twisting change and that, as the warranty limit approaches,
and following with the second pry bar, until the outer consideration be given to periodic replacement.
tyre bead is loose.
The rim and its components are designed with built-in
safety factors, to prevent the components from flying
off with killing force during inflation. Check components

SM 2449 Rev 1 04-10 3

Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 207
for cracks, bends, distortion, or other damage. If
damage is found, the component must be replaced.

WARNING
Never mix components of one manufacturer's
rims with those of another. Using the rim base
of one manufacturer with the lock ring of
another or vice versa is dangerous. The lock
ring of one may not fully engage with the lock
ring groove of the other. Always consult the rim
manufacturer for proper matching and
assembly instructions.

1 - Lock Ring 2 - Drive Lug

WARNING (cont.)
Fig. 5 - Installing Typical Lock Ring
Also, use and servicing of damaged, worn out,
or improperly assembled rim assemblies is a
very dangerous practice. Failure to comply with
the above warnings could result in explosions 1. For off-machine installation, lay wheel rim (1) on
from tyre pressure causing serious personal blocks or mounting stand with 'O' ring groove up.
injury and property damage. Wheel rim (1) should be off the floor enough to allow
tyre to rest on rim and not the floor. Blocks are not to
Clean all rust and dirt from the rim parts and wheel and extend more than 13 mm (0.50 in) beyond rim base.
apply a coat of good grade primer paint. Allow the paint
to dry thoroughly before remounting tyre. 2. Lubricate groove and 'O' ring, with a thin solution of
vegetable base soap and water. Insert new O-ring (5) in
The rim parts used with tubeless tyres form an groove on wheel rim (1).
important part of the air chamber. Therefore, they
should be carefully checked for distortion or mutilation 4. Using suitable lifting equipment, lower tyre onto
that would prevent an effective air seal when the tyre wheel rim (1). Seat tyre firmly against inner flange.
and rim are reassembled.
5. Install outer flange (2) on wheel rim (1).
Rubber 'O' rings are air seals for tubeless tyre and rim
assemblies and therefore should be carefully handled 6. Align driver notch in wheel rim (1) with notch in
to provide an airtight seal when the tyre is remounted flange (2), and install flange (2) on rim.
on the rim. Always use new 'O' rings when mounting a
tubeless tyre. 7. Install lock ring (3) in groove of wheel rim (1) so that
lock ring lug engages both notches. Notches and lock
Note: Handle 'O' rings carefully, as damage will prevent ring lug must line up correctly. If necessary, use only a
an airtight seal for tyre inflation. soft hammer to rotate the lug. Use pry bar for installing
lock ring (3), as shown in Fig. 5.

MOUNTING TYRE ON RIM 8. Make sure all rim components are correctly
Numbers in parentheses refer to Fig. 2, unless assembled.
otherwise specified.
11. Lift the tyre upwards to effect a seal between
For mounting a tyre with rim on or off machine, the flange (2) and 'O' ring (5). In some cases the tyre will
procedure is basically the same. automatically spring out, making this step
unnecessary.

WARNING 12. Refer to heading, 'Tyre Inflation' in this section for

When lifting tyre onto the rim, be sure the the proper procedure for inflating the tyre.
equipment is of sufficient capacity and
properly secured to do the job safely.

4 SM 2449 Rev 1 04-10

 Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

MOUNTING TYRE AND RIM ASSEMBLY A.

ON MACHINE Use an air compressor and reservoir located
Numbers in parentheses refer to Fig. 1. inside a heated building, when available, so
that alcohol, methanol, or other flammable
antifreeze liquids are not needed in the air
WARNING tanks to prevent moisture freezing in the tank
To prevent personal injury and property and lines in subfreezing outside temperatures.
damage, be sure blocking materials and lifting
equipment are properly secured and of B.
adequate capacity to do the job safely. Make sure that paints, lacquers, paint thinners,
or similar materials that produce volatile,
1. Support tyre and rim assembly with a suitable chain, flammable vapours are not used or stored near
or rope sling. Attach sling to overhead lifting device. the air intake of the compressor that supplies
Slide assembly onto wheel of the vehicle, with lock the air for inflating tyres. The compressor
ring (4) and bead seat band (3) facing outward. should be isolated from all such sources of
flammable vapours.
2. Install lock washers (9) and wheel nuts (10) on
wheel studs. Gradually tighten wheel nuts opposite C.
each other until all wheel nuts are snug. Tighten wheel Be sure to thoroughly flush and blow off all
nuts (10) to a torque of 590 Nm (435 lbf ft). Tighten flammable solvents used for cleaning the air
wheel nuts (10) again, after 10 hours of operation. compressor inlet screen before using the
compressor for tyre inflation, or any other
purpose.
TYRE INFLATION
D.
Do not charge batteries, either in or out of a
WARNING machine, near the air inlet of a compressor
To prevent personal injury and property used for inflating tyres. Charging batteries
damage, the tyre and rim assembly should be produces highly explosive hydrogen gas
placed in a safety cage before inflating. If no which can be readily drawn into a nearby
safety cage is available or tyre is on the compressor inlet and pumped into the tyre.
machine, the tyre and rim assembly should be
wrapped with safety chains or with lash cables E.
before inflating. Never exceed the specified concentration of
alcohol when adjusting the alcohol vaporizer,
Even with these precautions remember that air- or adding alcohol to the auxiliary air tank,
blast is a potential hazard. Tyre inflation used on machine air systems to prevent
should be carried out away from busy working freezing or moisture condensate in below-
areas. freezing temperatures. Excessive alcohol,
added to the machines air tanks in this
WARNING manner can produce flammable vapours that
To avoid personal injury and property damage, will be pumped into a tyre when this air
never stand or sit in front of a mounted tyre supply is used for tyre inflation if the tyre
during tyre inflation. Use a clip-on air chuck inflation kit is not equipped with a moisture
with a long hose and stand to one side while filter. Alcohol added to machine air systems in
the tyre is being inflated. recommended concentration to prevent
condensate freezing are below hazardous
WARNING levels for tyre inflation.
To prevent personal injury and property
damage, always prevent flammable vapours F.
that could produce tyre explosions, from being Another source of hazardous flammable
pumped into tyres during inflation, by vapours in tyres is the tyre bead lubricant.
observing the following precautions: Always use bead lubricants that do not
introduce flammable vapours into the tyre.

SM 2449 Rev 1 04-10 5

Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 208 All machines whose tyres are factory inflated with dry
nitrogen gas will be identified by a decal on the body or
frame.

Nitrogen gas improves tyre pressure retention,

increases tyre life by reducing carcass oxidation from
within, minimizes rim rust and has no detrimental
effects on the tyre. It also reduces the potential of a
tyre explosion because it is an inert gas and will not
support combustion inside the tyre.

The same tyre inflation pressure used for air inflation

should be used for nitrogen inflation. Tyre valves
formerly used with air inflation are entirely satisfactory
for use with nitrogen gas.

Nitrogen Tyre Inflation Kit

WARNINGS
Fig. 6 - Typical Safety Cage DO NOT USE charging assembly, Part No.
9359489, for tyre inflation because this
assembly does not include a pressure
Inflation regulator, safety relief valve, and adequate
Note: Always use tyre inflation equipment with an air pressure gauging which is mandatory for tyre
filter that removes moisture from the air supply, when inflation purposes. Tyre volume is as much as
available, to prevent moisture corrosion of internal rim 90 times greater than the average accumulator
parts. volume and hence it takes very much longer to
inflate a tyre - up to 40 minutes or more for very
1. Inflate tyre to 1 bar (15 lbf/in²) initially to seat large tyres.
components and tap lock ring lightly to ensure correct
seating. Visually check that all components are in Nitrogen gas cylinders used to inflate
place, then continue inflation observing all safety tyres are generally charged to approximately
precautions. (See Step 2). 152 bar (2 200 lbf/in2). A tyre blowout and/or rim
failure could occur if inflation equipment is not
2. If the tyre is off the machine, place it in a safety properly used. Proper nitrogen charging
cage after initially inflating to 1 bar (15 lbf/in²) to seat equipment and personnel training for its use is
components. See Fig. 6. a must to avoid over inflation.

3. Inflate tyres to 5.2 bar (75 lbf/in²) to seat beads and 1. A nitrogen tyre inflation kit is available from your
seal the 'O' ring, then adjust to the recommended dealer and consists of the following. Refer to Fig. 7.
inflation pressure.
a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with
4. For recommended operating air pressure, refer to the two dual pressure gauges.
'Tyre Inflation Pressures' table.
b. Safety relief valve, 8.6 bar (125 lbf/in²), that will
assure an upper limit to the pressure available for tyre
NITROGEN TYRE INFLATION inflation.
Note: All Warnings and procedures under 'Tyre
Inflation' will apply, except for differences covered by c. A 15.2 m (50 ft) length of flexible hose with
this passage. interconnecting fittings. On the tyre end of the hose is
a large bore quick connect/disconnect clip-on chuck.
In certain environments it is recommended that tyres
be inflated with dry nitrogen gas, and that the resulting 2. The pressure regulator is connected to a nitrogen
oxygen content of the inflation does not exceed 5%. compressed gas cylinder available from local suppliers.

6 SM 2449 Rev 1 04-10

 Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 1040 Re-inflation of a Mounted Tyre

To re-inflate a tyre with dry nitrogen gas which is now
inflated with air, proceed as follows:

1. Exhaust the tyre until only air at atmospheric

pressure remains in the tyre.

2. Re-inflate the tyre using only dry nitrogen gas to

4.15 bar (60 lbf/in²) gauge as a minimum, or to bead-
seating pressure as a maximum.

3. Adjust to the service inflation pressure required:

a. If the required service inflation pressure is LESS

than 4.1 bar (60 lbf/in²), remove the clip-on chuck and
adjust the pressure with the tyre gauge in the usual
manner.

b. If the required service inflation pressure is greater

than 4.1 bar (60 lbf/in²), further inflate, with dry nitrogen
gas only, to the pressure level required. Then remove
the clip-on chuck and adjust the pressure with the tyre
gauge in the usual manner.

New Tyre Mounts and Remounts

Fig. 7 - Nitrogen Tyre Inflation Kit
To newly mount or remount a tyre to its rim, use only
dry nitrogen gas; this includes the pressure required to
3. The usual procedure for using this type of equipment seat the beads. After seating the tyre beads, remove
is as follows: the clip-on chuck and adjust the pressure with the tyre
gauge in the usual manner.
a. Connect nitrogen tyre inflation kit to nitrogen
compressed gas supply. DO NOT connect clip-on Note: Although a little more nitrogen gas is used to
chuck to the tyre valve at this time. seat beads than that used for re-inflation of a mounted
tyre, refer to 'Re-inflation of a Mounted Tyre', its cost is
b. Open valve on nitrogen supply. generally negligible in comparison to the time and
labour saving and, longer tyre life achievable with the
c. With flexible hose and clip-on chuck connected to reduced oxygen content which results.
nitrogen tyre inflation kit assembly but not connected
to the tyre, adjust pressure regulator so that its output
pressure is not more than 1.4 bar (20 lbf/in²) higher TYRE EXPLOSION HAZARD
than the desired tyre inflation pressure.

d. Connect clip-on chuck to the tyre valve. The tyre will WARNING
now inflate. Tyre pressure can be monitored by Whenever a machines tyre(s) is (are) exposed to
observing the gauge at the pressure regulator. STAY excessive heat such as a machine fire or
AWAY FROM THE TYRE. extremely hot brakes the hazard of a
subsequent violent tyre explosion must be
e. When desired inflation pressure has been achieved, recognized. All persons must avoid
back off the regulator or close the valve on the approaching the machine so as not to be
compressed gas cylinder. physically endangered in the event of an
explosion of the tyre and rim parts.
f. Remove the clip-on chuck and adjust the tyre
pressure with the tyre gauge in the usual manner.

SM 2449 Rev 1 04-10 7

Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SM - 1041

WARNING (cont.)
The machine should be moved to a remote AT LEAST AT LEAST
15 m (50 ft) 460 m (1 500 lbf ft)
area, but only when this can be done with
complete safety to the operator operating or
towing the machine. All other persons should
stay clear of the machine. The fire or
overheated brakes, wheel, etc. should be
extinguished or cooled from a safe distance. Do
not attempt to extinguish the fire or cool the
machine by use of hand-held fire extinguishers.

If it is absolutely necessary to approach a

machine with a suspect tyre, approach only
from the front or the back. Stay at least 15 m (50
ft) from the tread area. Keep observers out of
the area and at least 460 m (1 500 ft) from the
tyre sidewall. Refer to Fig. 8. The tyre(s) should
be allowed at least eight (8) hours cooling time
after the machine is shut down or the fire
extinguished before approaching closer.

There is always a possibility of a tyre

Fig. 8 - APPROACH AREA.
explosion whenever the smell of burning Do Not Approach Tyre in Shaded Area
rubber or excessively hot brakes is detected.
The danger is also present when a fire on the
machine reaches the tyre and wheel area. Under TYRE AND WHEEL RIM MAINTENANCE
such conditions, all personnel must avoid
approaching the machine in a manner that Tyre Repairs
could result in injury should an explosion Prompt repair of tyre injuries will prevent small injuries
actually occur. Move the machine to a remote from enlarging and causing tyre failure. Use the best
area only if it can be done without endangering tyre facilities available. If good repair facilities are not
the operator or other personnel in the area. available, have the nearest dealer make the necessary
repairs.

WARNING Minor cuts, snags, or punctures should be repaired

DO NOT WELD ON OR HEAT RIM upon discovery. Skive with a sharp pointed knife
COMPONENTS. For several years the company around any cut in the tyre tread area that is of
and tyre and rim manufacturers have warned sufficient depth or shape to hold pebbles or dirt. The
users never to weld rim components with the angle of the skive should be no more than sufficient to
tyre mounted on the rim. The gases that build expel all foreign material and should extend no deeper
up inside the tyre during arc welding or heating than the breaker. The skive should go to the bottom of
on rim components can ignite, resulting in one the hole. Tyres with shallow cuts, if treated promptly,
of these explosive-like failures of the tyre and may be allowed to continue in service. If the cut
rim. This warning also applies to nitrogen extends deeper into the tyre carcass, the tyre should
inflated tyres. Ignition will not occur in the be removed for repair.
nitrogen atmosphere, but the pressure buildup
from the heat of welding may be sufficient to The tyre must be removed from the rim to repair larger
cause a blowout severe enough to injure or kill. punctures or cuts. Irregular shaped punctures or cuts
It is recommended to scrap the part if heat is less than 13 mm (0.50 in) in size can be repaired with a
necessary to repair any rim component. plug and hot patch. Insert a repair plug into the hole to
keep out moisture and to back up the hot patch. Trim
the plug off flush with the inside of the casing, buff,
and apply the hot patch according to the instructions
supplied with the hot patch equipment.

8 SM 2449 Rev 1 04-10

 Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
Punctures 13 mm (0.50 in) or larger, large cuts, or Inspect Tyres Regularly
bruise breaks require sectional or reinforced vulcanized
A systematic plan for tyre inspection will more than
repair. Cover the repair patch with a layer of cushion
pay for itself in lowered tyre costs per hour of
gum after application to the tubeless tyre to ensure an
operation. All tyres should be checked regularly for
airtight repair. Any cords of the inside ply that are
cuts, bruises, ply material breaks, excessive or uneven
exposed in buffing and are not covered with repair patch
wear, embedded foreign matter, and any other damage
must be coated with cushion gum to prevent air leakage
which can be repaired. A considerable increase in tyre
into the carcass plies on tubeless tyres.
service can be realized if tyre injuries are repaired
before they have progressed to the irreparable stage.
Recapping and Retreading
The rim mounting nuts should also be checked
There are two general methods employed in restoring
periodically and tightened to the torque specified.
the tread surface of off-the-highway tyres: recapping
and retreading.
Prevent Overloading
A recapped tyre has a new tread cured right over the old
Off-highway machines are designed to carry a
tread surface.
maximum allowable payload. Excessive loading will
overstress both the machine and tyres and shorten the
A retreaded tyre has the old tread removed entirely and
life of both.
a new tread cured directly onto the body of the tyre. A
tyre can be recapped or retreaded if the cord body is
free of cuts, bruises and separation, and is thoroughly Prevent Contact with Oil
sound, including previous repairs.
Prevent tyre contact with petroleum products. Rubber
that is exposed to oil, gasoline, or grease becomes
TYRE CARE soft and spongy and deteriorates rapidly. Always avoid
driving machine through a puddle of gasoline, fuel oil,
To obtain maximum service from off-highway tyres, the
lubricating oil, or grease. Never let a tyre stand in an oil
following common-sense precautions should be
or grease spot overnight.
followed.

Store Tyres Properly

Maintain Correct Inflation
The best of care given to tyres in service by operators
The most common cause of tyre damage is improper
and maintenance personnel can be completely nullified
inflation. Both over-inflation and under-inflation are
by careless storage. Time is not the only contributing
detrimental to tyre life. Tyre pressure should be
factor to the deterioration of rubber products. Therefore,
checked daily, preferably before the machine is placed
tyres that are to be stored must be protected from light,
in operation. Refer to 'Tyre Inflation Pressures' table.
heat, oils, dirt, moisture, and ozone. Stored tyres
should be carefully covered with a tarpaulin or some
The valve cores should be checked for leaks. Keep in
other suitable material, such as opaque plastic
mind that valve cores are delicate mechanisms that
sheeting, to prevent contact with the contaminants
wear out in service; therefore, they should be replaced
listed above.
with new ones when they become worn. Each tyre
should be equipped with a valve cap to prevent dirt from
damaging the valve core and causing air leakage. Proper Handling of Tyres and Wheel Rim
Parts
Maintain Good Haul Roads Tyres should be stored vertically. Horizontal stacking
may compress the tyre walls, making inflation difficult. If
Because haul roads are considered temporary roads
tyres are stored in racks, the lower supporting members
they are frequently neglected. The better the haul road,
should provide as broad a surface as possible to the tyre
the longer the tyre and machine life of off-highway
tread to avoid a concentration of load.
machines.
The beads of tubeless tyres must be protected from
Although it takes time and effort to maintain good haul
damage or a faulty air seal will result. Do not use
roads, the delay and cost of tyres and machine
hooks, cables, or chains in contact with the tyre beads
breakdowns caused by poor haul roads is many times
when lifting these tyres. If forklift trucks are used for
greater.
handling, they should be equipped with broad, well-
SM 2449 Rev 1 04-10 9
Rear Axle Group - Wheel Rim and Tyre
Section 160-0050
rounded arms to distribute the load and prevent
damage to the tyre bead. When handling tyres with the Valve cores should also be stored in a cool, dry and
fork truck do not scrape the fork across the bead. clean place.

Tubeless tyre rims perform an important function as

part of the assembly air seal. Proper care, therefore, MAINTENANCE
must be taken not to distort or mutilate the rim parts Check tyre pressures daily, preferably before the
because they must mate properly to form part of the machine is placed in operation. Refer to 'Tyre Inflation
basic air chamber. Since the rim base and bead seat Pressures' table.
band are mating surfaces, distortion may prevent easy
assembly as well as possibly resulting in no seal. Every 50 hours of operation (weekly), torque tighten
wheel rim nuts to 590 Nm (435 lbf ft).
Never drop, tumble, or roll rim parts.
Check tyres regularly and replace or repair if required.
If rim parts are stored outdoors, they should be given a
protective coat of a good commercial primer.
SERVICE TOOLS
Similar parts should be stacked neatly to prevent distortion. The nitrogen tyre inflation kit shown in Fig. 7 is
available from your dealer. Refer to Section 300-0070,
Babbit or lead hammers, not sledge hammers, should SERVICE TOOLS for part numbers of general service
be used in assembling rim parts. tools required.

'O' rings are seals and should be carefully stored in a

cool, dry place where they will not be injured or
damaged.

TUBELESS TYRE LEAK DIAGNOSIS

Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of leakage,
the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be checked
using a soap solution.
This table lists various causes of air loss and possible remedy.
CAUSE REMEDY
Defective valve Tighten parts. Replace defective parts. Use valve caps.
Cracked rim or weld Replace defective part

WARNING
Do not attempt repair of wheel components.
Twisted or damaged 'O' ring Replace 'O' ring (lubricate)
Tyre cuts and snags Repair tyre damage
Bead area awl holes Repair inner liner (preferred)
Leakage between tyre bead trim With tyre removed from rim:
Clean tyre beads in rim contact area
Clean rim with wire brush
Inspect 5 degree tapered bead seat band and the rim base in the bead
seating area to determine if the transverse weld trims are flat or concave.
Replace defective part(s).
Note: Weld trim should follow rim contour.
Mount tyre using a lubricant such as Murphy's Tyre and tube Mounting
Compound, or equivalent, on tyre beads and rim bead seat area.

10 SM 2449 Rev 1 04-10

 Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Wheel Nut 590 435

TYRE PRESSURES
Tyre pressures on this pages apply to the truck serial number range specified only, Gross Vehicle Weight
(G.V.W.) and axle weights may vary between truck derivatives. Tyre pressure should be recalculated if not shown
for a particular truck. Contact TEREX for assistance.

The tyre inflation pressures listed are manufacturers recommendations for G.V.W. travelling at maximum speed.
TEREX Advise that operators check tyre inflation pressures with tyre manufactures to ensure correct setting for
each particular application.

Front Centre Rear

Truck Brand Size Pattern b lbs/in2 b lbs/in2 b lbs/in2
TA27 Bridgestone 23.5 R25 VLT 4.4 64 4.4 64 4.4 64
A889 Bridgestone 23.5 R25 VMT 4.4 64 4.4 64 4.4 64
A892 Bridgestone 23.5 R25 VKT 4.4 64 4.4 64 4.4 64
Michelin 23.5 R25 XADT 3.8 55 3.4 50 3.8 55
Double Coin 23.5 R25 REM2 4.5 65 4.5 65 4.5 55
Triangle 23.5 R25 TB516 5.2 76 5.2 76 5.2 76
Triangle 23.5 R25 TM518 5.2 76 5.2 76 5.2 76
Triangle 23.5 R25 TL528 5.2 76 5.2 76 5.2 76
Bridgestone 30/65 R25 VLT 3 43 3 43 3 43
Michelin 30/65 R25 XADN 3.1 45 2.8 40 2.8 40
Michelin 750/65 R25 XAD 65 3.1 45 2.8 40 2.8 40

TA30 Bridgestone 23.5 R25 VLT 4.8 69 4.8 69 4.8 69

A894 Bridgestone 23.5 R25 VMT 4.8 69 4.8 69 4.8 69
A908 Bridgestone 23.5 R25 VKT 4.8 69 4.8 69 4.8 69
A897 Michelin 23.5 R25 XADT 4.1 60 4.1 60 4.1 60
A911 Double Coin 23.5 R25 REM2 4.5 65 4.5 65 4.5 65
Triangle 23.5 R25 TB516 5.2 76 7.2 76 5.2 76
Triangle 23.5 R25 TM518 5.2 76 5.2 76 5.2 76
Triangle 23.5 R25 TL528 5.2 76 5.2 76 5.2 76
Bridgestone 30/65 R25 VLT 3.2 46 3.2 46 3.2 46
Michelin 30/65 R25 XADN 3.1 45 3.1 45 3.1 45
Michelin 750/65 R25 XAD 65 3.1 45 3.1 45 3.1 45

**

SM 2449 Rev 1 04-10 11

Rear Axle Group - Wheel Rim and Tyre
Section 160-0050

THIS PAGE IS INTENTIONALLY BLANK

12 SM 2449 Rev 1 04-10

 Parking Brake - Parking Brake and Mounting
Section 170-0010

SM - 3498

1 - Actuator
1 2 - Calliper
3 - Bolt
2 4 - Hardened Washer
5 - Nut
6 - Brake Disc
7 - Lever / Slack adjuster
8 - Bracket Assembly
7 9 - Bolt
3 10 - Washer
3
11 - Nut
4
4
5
5

6 REF. LH
FRAME RAIL 9

8
9

10
11

REF. RH
FRAME RAIL

Fig. 1 - Parking Brake Mounting

Operation is by a spring applied/hydraulically released

actuator (1). Actuator (1) is connected to lever & slack
WARNINGS adjuster (7) via clevis rod and pin (3 and 4 Figure 2).
Use only hydraulic oils meeting specifications Lever (10, Figure 2), is mated to slack adjuster
outlined in Section 300-0020, Lubrication (12, Figure 2) rotor end. This in turn mates to the piston
System. Do Not use Brake Fluid (J1703). Use of (14, Figure 2). Slack adjuster and lever automatically
improper fluids is destructive to rubber maintain brake clearance after each application.
components of brakes resulting in loss of
braking and possible catastrophic failure. A push control on the dash panel activates the park
brake solenoid in the main hydraulic valve, controlling
Exercise extreme caution while working oil pressure from the accumulators to actuator (1).
on the braking system. Application of the push control releases oil from
actuator (1) allowing internal springs in the actuator to
DESCRIPTION AND OPERATION apply the parking brake. Pulling out the push control
directs oil pressure from the accumulators to actuator
Numbers in parentheses refer to Figure 1, unless (1), compressing internal springs, to release the parking
otherwise specified. brake.

The parking brake consists of a sliding calliper (2) Note: The parking brake is automatically applied when
acting on a brake disc (6) on a rear drive line. The the ignition is switched off or the Transmission is in
parking brake is of 'Inverted Design', meaning that it neutral and the transmission output speed is less than
requires pressure to hold the parking brake off. 60 RPM ~ 1MPH

SM 2409 Rev 2 04-10 1

Parking Brake - Parking Brake and Mounting
Section 170-0010

REMOVAL Note: The parking brake will automatically apply on

Numbers in parentheses refer to Figure 2, unless engine shutdown or when the transmission is in neutral
otherwise specified. and output speed is less than 60RPM~1MPH. Ensure
there is sufficient clearance for actuator rod travel.

WARNINGS 11. Switch off the engine and place the battery master
To prevent personal injury and property switch in the 'Off' position.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 12. Disconnect and plug hydraulic line from actuator
secured and of adequate capacity to do the job (1). Cap actuator (1) to prevent ingress of dirt.
safely.
13. Remove nuts (7) and washers (6) securing actuator
Hydraulic fluid pressure will remain (1) to arm (20).
within the braking system after engine shut
down. Operate the treadle pedal continuously 14. Actuator (1) can be removed from the arm (20).
until the pressure has dissipated before
carrying out any work on the braking system or SM - 3986

serious injury could result. 2 4 3

1. Position the vehicle on a level surface, apply the

parking brake, block all road wheels and place the
steering lock bar in the 'Locked' position.
1
2. Raise the body and install body safety prop to
secure in partially raised position.

3. Remove storage box under the Instructor seat by

referring to operator compartment - Instructor seat and
Mountng, Removal and Disassembly Section 260-0110

4. Undo and remove the bolts(3) securing the park 1 - Parkbrake switch 3 - Bolt
brake service switch cover plate(4) . (Refer to fig. 3) 2 - service alarm 4 - park brake switch Cover

5.Press the bottom of the parkbrake service switch(1) Fig. 3 - Park brake over ride switch located under
to release the park brake. Instructor seat

Note: The park brake service alarm (2) will remain on

continously while the auto park brake system is DISASSEMBLY
disabled. (Refer to fig. 3) Numbers in parentheses refer to Figure 2.
6. Pull out push control to release the parking brake. 1. Remove cap plug (8), and insert a 3/8" hex socket
onto the shaft and rotate in the opposite direction of
7. Remove 4-off cotter pins (18) from mounting pins actuation until you feel a positive stop. Do not over
(19). torque.
8. The calliper (17) and constituent parts should be 2. Remove the retaining ring (9) and lever (10) from the
held in place by bracket (8, Figure 1), which the slack adjuster (12) rotor end.
mounting pins (19) are located through.
3. Remove the four bolts (11) and arm (20).
9. Disconnect the clevis rod (3) end from the lever (10)
by removing cotter pin (5) and clevis pin (4). 4. The slack adjuster (12) can now be removed from
the calliper (17) mounting face .
10. Push park brake button in, releasing hydraulic
pressure. This should cause the clevis rod (3) and 5. The O-ring (13), piston (14) and seal (15) should be
clevis pin (4) end to retract away from the lever (10). removed when removing the calliper (17).

2 SM 2409 Rev 2 04-10

 Parking Brake - Parking Brake and Mounting
Section 170-0010

SM - 3498
18

19
18 18
1
19
17 18

4
5
20 15
14
13 16
6
7 12

10
9

8 11

1 - Actuator 6 - Washer 11 - Bolt 16 - Brake Pad /Holder

2 - Jam Nut 7 - Nut 12 - Slack Adjuster 17 - Calliper
3 - Clevis Rod 8 - Cap Plug 13 - O-ring 18 - Cotter Pin
4 - Clevis Pin 9 - Retaining Ring 14 - Piston 19 - Mounting Pin
5 - Cotter Pin 10 - Lever 15 - Dust Seal 20 - Arm

Fig. 2 - Exploded View of Parking Brake Assembly

Note: Ensure that the piston (14) and seal (15) are INSPECTION
pushed through the calliper at removal, thus away from
Numbers in parentheses refer to Figure 2.
slack adjuster end.
Note: Polish any discoloured or stained areas with
6. Remove seal (15), piston (14) and O-ring (13) from
crocus cloth only. Use finger pressure and rotate the
the slack adjuster (12) and calliper (17) bore.
crocus cloth in the bore. Do not use any other kind of
abrasive cloth.
7. Ensure that the calliper housing (17) is held in place.
Remove the mounting pins (19), this should enable the
1. Examine all parts carefully. Parts showing signs of
calliper (17) to be removed from the chassis frame.
excessive wear, damage or corrosion should be
replaced.
8. Should it be necessary to aid in the removal of the
calliper (17), remove the bolts (9, Figure 1), washers
2. Clean all parts with denatured alcohol and either
(10, Figure 1) and nuts (11, Figure 1) securing the
wipe dry with a clean lint free cloth or blow dry with an
bracket (8, Figure 1) to the frame rail. Remove the
air hose.
bracket (8, Figure 1) and the calliper (17).
3. Inspect the calliper housing (17) bore for scoring,
pitting or corrosion. According to the severity of wear or
damage, light scores and stains may be removed. For
more severe damage renew as necessary.

SM 2409 Rev 2 04-10 3

Parking Brake - Parking Brake and Mounting
Section 170-0010
4. Similarly, inspect items whose surfaces may be Note: Ensure that all parts are clean and are suitable
considered 'critical', for example the piston (14) outer for use prior to assembly. When reinstalling the piston
diameter and mating elements. Any such components (14), ensure that it is fitted from the slack adjuster (12)
whose damage will affect operational performance or mounting face end of the calliper (17).
integrity of the system should be replaced where
applicable. 2. Coat the bore of the calliper (17) with silicon grease.

5. Check to see that the brake disc (9, Figure 1) is not 3. Insert a new seal (15) into the calliper (17) bore.
bent of misshapen. Make sure that the seal is not damaged or torn during
this process.
6. Inspect the lever (10) for wear and renew it if
necessary. Note: Care should be exercised when inserting the
piston (14), so as to not damage the piston or other
7. Check to make sure that the mounting pins (19) components during this assembly stage.
slide freely through the mating holes of the calliper
(17). 4. Install the piston (14) into the bore from the same
end as the seal. Push the piston (14) through the seal
8. Check to make sure that the slack adjuster (12) is (15) until the seal (15) is seated fully into the piston
still functioning properly. To do this, rotate the lever (14) groove.
(10) while it is mated to the rotor end of the slack
adjuster (12), in the direction of actuation. The coloured 5. Lubricate and install the O-ring (13) into the end
shaft that is extending through the spring cup should cover groove .
rotate and extend while the rotor is turning.
6. Install the slack adjuster (12) sub-assembly into the
9. If the coloured shaft rotated and extended out while calliper (17) and place the arm (20), with actuator (1)
the rotor was rotated, it should not rotate but only attached into the rotor end of the slack adjuster (12).
retract inwards when the rotor is rotated back to its
home position. 7. Secure it in place using the four bolts (11). Torque
the bolts (11) to a value of 40 - 60 Ibf ft (54 - 81 Nm).
Repeating this procedure several times will show the
coloured shaft properly adjusting outwards, simulating 8. Place the lever (10) on the spline of the rotor end of
adjustment due to pad wear. the slack adjuster (12) in the correct orientation, and
install the retaining ring (9) in the groove.
10. To return the sub-assembly back to its original
starting position, remove the plastic cap plug (8) from 9. Insert a new cap plug (8) into the end of the slack
the rotor end of the slack adjuster (12) , and insert a adjuster (12) rotor.
3/8" socket into the rotor until it seats on the shaft.
Turn the socket the opposite direction of the brake unit
(Counter clockwise for a CW unit, or clockwise for a
INSTALLATION
CCW unit), until you feel a positive stop. Do not over Numbers in parentheses refer to Figure 2, unless
torque. otherwise specified.
11. Inspect the actuator (1) and bracket (20) for
damage or cracks. Renew the entire actuator (1), if the
outer housing, pull rod or hydraulic fitting are damaged, WARNINGS
or if there is any leakage from the unit. To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
ASSEMBLY secured and of adequate capacity to perform
Numbers in parentheses refer to Figure 2. the tasksafely.

1. Take the actuator (1) assembly, which includes the Do not pressurize the actuator until the
clevis rod (3) and pin end, secure it in place to the following instruction has been carried out.
mating surface of the arm (20), using the four washers Pressurizing the actuator beforehand can result
(6) with nuts (7). in serious brake damage.

4 SM 2409 Rev 2 04-10

 Parking Brake - Parking Brake and Mounting
Section 170-0010

12. Actuate the brake several times to allow the slack

1. Examine the brake pads (16) for wear or damage. If adjuster (12) to fully adjust the brake to the proper pad
pad thickness is less than 1/32" (0.79mm), new pads gap, 0.025"-0.030" (0.635 - 0.762mm)
should be fitted. If the pads are within lthe imit, they
can be reused. 13.Switch OFF Parkbrake service switch and refit
Cover and storage Box. (Refer to fig.3 )
2. Ensure that the pads are installed in their original
position. 14. Remove the wheel blocks and place the steering
lock bar in the 'Stowed' position.
Note: The thinner pad should be orientated nearest the
actuator side of the calliper. This maintains the thicker
pad on the carrier side of the calliper. which is MAINTENANCE
necessary for wear reasons, in operation.
Every 250 hours
3. Ensure any new pads have the same friction Test the park brake for proper operation. Check the
material type as the old ones as determined by the brake pads and disc for wear.
code stamped on the pads.

4. Should the bracket assembly (8, Figure 1) have WARNING

been removed, reinstall it to the frame rail, securing it This time interval should only be used as a
in place using the bolts, washers and nuts (9,10 and 11 guide to maintenance, assuming 'normal'
Figure 1). operating conditions, under hard use, checks
should be carried out more frequently, at the
5. Remount the calliper (17) and brake pads (16) in discretion of the operator/serviceman.
place, by locating the mounting pin (19) through the
bracket (8, Figure 1) and the calliper (17). 1. Check that floating parts move freely and that there
is adequate freedom of movement for positive brake
6. Secure the calliper (17) in place between the bracket operation.
(8, Figure 1) support arms, by inserting the four cotter
pins (18) in the mounting pins (19). 2. Check the actuator (1) linkage and verify that there
is adequate freedom of movement for positive brake
7. Remove the cap fitted to the actuator (1), to prevent operation.
dirt ingress at removal.
3. Check the brake disc (9, Figure 1) surface
8. Connect the hydraulic line to the actuator (1). Start condition. Replace if it is badly warped, pitted or below
the vehicle. Ensure the park brake service switch is the minimum recommended thickness. Check for loose
ON and pull the park brake button out.Thus, applying mounting bolts (11) or cracks.
oil pressure into the actuator (1).
4. Check to see if the brake pads are worn to less than
9. Install the clevis pin (4) through the clevis (rod (3) 1/32" (0.79mm) thick. Replace them if they are. In
and lever (10). If the pin does not assemble freely, normal service, pads will need replacing only after
push the park brake button in, thus releasing the oil prolonged use.
pressure from the actuator. At this stage, readjust the
clevis rod (3) using the jam nut.

10. Reapply oil pressure to the actuator (1), by pulling

the park brake button out.

Note: Ensure Parkbrake service switch is in the ON

Position.

11. Repeat steps 8 to 10 until the pin (4) can be freely

assembled. Install the cotter pin (5) and the torque
clevis jam nut (2), hand tight plus ¼ turn, without
causing the clevis to turn and bind the clevis pin (4) in
the lever (10).

SM 2409 Rev 2 04-10 5

Parking Brake - Parking Brake and Mounting
Section 170-0010
Brake Pad Replacement 9. Using a hard wood dowel or flat edge of a large
screwdriver, work the piston (14) back into the bore of
calliper (17), by carefully prying against old pads and
the brake disc.
WARNINGS
To replace the brake pads it is necessary to 10. Remove a cotter pin (18) from one end of each pin
release the park brake by applying hydraulic (19) and remove the pad pins and worn brake pads
pressure to the actuator chamber and rotating (16).
the actuator shaft in the opposite direction from
where the lever is actuated. Replace the brake Note: To replace the pads it may be necessary to slide
pads in pairs only! the calliper in its floating mount and not to remove or
disassemble it.
To prevent personal injury and property
damage, be sure that wheel blocks, blocking
materials and lifting equipment are properly Note: Stamped on the front of each pad is a code. The
secured and of adequate capacity to perform first character is a number that specifies the friction
the task safely. material type. Ensure new pads are the same type as
the worn pads that were removed.
1. Position the vehicle on a level surface, apply the
parking brake, block all road wheels and place the
steering lock bar in the 'Locked' position. 11. Install new brake pads (16) and secure them in
place by reinstalling the pins.
2. Raise the body, and install the body safety prop, to
secure it in the partially raised position. 12. After assembly, insert a 3/8" hex socket on to the
shaft and rotate the shaft in the same direction as the
3. Remove storage box under the Instructor seat by actuation, until a clearance of 0.030" (0.762mm) is
referring to operator compartment - Instructor seat and obtained between the pad and the disc.
Mounting, Removal and Disassembly Section 260-0110
13. Reinstall the cap plug (8). With the unit assembled
4. Undo and remove the bolts(3) securing the park and clearances correctly set, apply and release the
brake service switch cover plate(4) . (Refer to fig. 3) park brake 10 times to allow the slack adjuster to find
its position.
5.Press the bottom of the parkbrake service switch(1)
to release the park brake. 14.Switch off parkbrake switch(1), Refit cover and
storage box.(Refer to fig. 3)
Note: The park brake service alarm (2) will remain on
continously while the auto park brake system is 15.Remove wheel blocks and palce the steering lock
disabled. (Refer to fig. 3) bar in the 'STOWED' Position.

6. Pull out the park brake button to release the parking 16. Apply the brakes lightly several times, allowing
brake. cooling time in between to burnish the new pads.
Always burnish new pads since preburnished pads will
7. Remove the cap plug (8) from the end of the slack have reduced braking power.
adjuster (12).

8. Insert a 3/8" socket into the rotor until it seats on the

shaft. Turn the socket the opposite direction from the
brake unit (counter-clockwise for a clockwise unit, or
clockwise for a counter-clockwise unit), until you feel a
positive stop. Do not over torque.

6 SM 2409 Rev 2 04-10

 Parking Brake - Parking Brake and Mounting
Section 170-0010

SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
Service Tools, for part numbers of general service tools
required. These tools are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
2 11 Bolt 54 - 81 40 - 60

* * * *

SM 2409 Rev 2 04-10 7

Parking Brake - Parking Brake and Mounting
Section 170-0010

THIS PAGE IS INTENTIONALLY BLANK

8 SM 2409 Rev 2 04-10

 SUSPENSION SYSTEM - Front Suspension
Section 180-0020

SM - 2803

18

18
4

5 30
29
12
13
14 15
8 2
27 9,10,11 31 16 31 16

6
16 7
2
7 9,10,11
8
15
19
20 12,13,14
20 19
21
17 16 6

17
22
1
26 25 3 29
23 27
28
24

1 - Suspension Frame 11 - Shim 21 - Link Assy

2 - Spherilastic Bush 12 - Bolt 22 - Spacer
3 - Nut 13 - Bolt 23 - Chain & Shackle
4 - Axle Plate 14 - Bolt 24 - Bolt
5 - Axle Plate 15 - Washer 25 - Lockwasher
6 - Locknut 16 - Hardened Washer 26 - Nut
7 - Inner Bush 17 - Bolt 27 - Shock Absorber
8 - Outer Bush 18 - Rubber Mounts 28 - Bolt
9 - Shim 19 - Stop Screw 29 - Hardened Washer
10 - Shim 20 - Locknut 30 - Nut
31 - Bolt
Fig. 1 - Exploded View of Front Suspension

DESCRIPTION (4 & 5) and front frame. In addition, there are four

Numbers in parentheses refer to Fig. 1. heavy duty double acting shock absorbers (27) (two off
each side) to smooth out the ride. Two chain and
The front axle assembly is mounted on the leading shackle assemblies (23) provide extra retention on
arms of suspension frame (1) which pivots on the front rebound.
frame.

Suspension is provided by two heavy duty rubber REMOVAL

suspension mounts (18) mounted between axle plates Numbers in parentheses refer to Fig. 1.

SM 2182 11-02 1
Suspension System - Front Suspension
Section 180-0020

WARNINGS 11. Using jack, lower suspension frame (1) onto a

To prevent personal injury and property suitable trolley until rubber suspension mounts (18) are
damage, be sure wheel blocks, blocking free of compression.
materials and lifting equipment are properly
secured and of adequate capacity to do the job 12. Remove thread caps and mounting hardware
safely. securing shock absorbers (27) to front frame. Remove
shock absorbers (27), and remove rubber suspension
mounts (18).
Hydraulic fluid pressure will remain
within the braking system after engine shut 13. Support the rear end of suspension frame (1) using
down. Operate the treadle pedal continuously suitable equipment. Loosen and remove locknuts (20)
until the pressure has dissipated before securing stop screw (19) in front frame. Remove stop
carrying out any work on the braking system or screw (19) from front frame.
serious injury could result.
14. Using torque multiplier (see Special Tools), loosen
1. Position the vehicle in a level work area, ensure the nuts (6) securing suspension frame (1) to front frame.
body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel several 15. Remove nuts (6), hardened washers (16) and bolts
times to relieve any pressure in the steering system. (31) securing suspension frame (1) to front frame.

2. Block rear road wheels, place the steering lock bar 16. Remove bolts (12 - 14) and washers (15) securing
in the 'Locked' position and place the battery master outer bushes (8) to front frame. Remove inner bushes
switch in the 'Off' position. (7), outer bushes (8) and shims (9 - 11).

3. Whilst the front road wheels are still on the ground, 17. Carefully lower suspension frame (1) assembly
loosen the wheel nuts. onto the trolley and remove from under the vehicle.

4. Using suitable lifting equipment, raise the machine DISASSEMBLY

until both front tyres are off the ground. Support the
vehicle with suitable stands and blocking at the front Numbers in parentheses refer to Fig. 1.
frame and articulation pivot area.

5. Support one tyre and rim assembly with suitable WARNING

lifting equipment and remove wheel nuts securing the To prevent personal injury and property
rim to the axle. Remove tyre and rim assembly. damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
6. Repeat step 5 for the opposite tyre and rim safely.
assembly.
1. Remove nuts (30), hardened washers (29) and bolts
7. Disconnect hydraulic brake line at tee on front axle (28) securing front axle assembly and axle plates (4 &
assembly. Disconnect differential breather line. Cap 5) to suspension frame (1). Using suitable lifting
lines and fittings to prevent ingress of dirt. equipment, remove front axle assembly from
suspension frame (1).
8. Jack up suspension frame (1) and remove nuts (26),
lockwashers (25) and bolts (24) securing chain and 2. If required, press spherilastic bushes (2) from
shackle assemblies (23) to suspension frame (1) and suspension frame (1) using press tool and power press
link assembly (21). (See Special Tools).

9. Support driveline and remove bolts securing driveline 3. If required, remove bolts (17), spacer (22), washers
to front axle. Refer to Section 130-0010, FRONT AND and nuts (3) securing link assembly (21) to front frame.
REAR DRIVELINES.
ASSEMBLY
10. Remove thread caps and mounting hardware
securing shock absorbers (27) to suspension frame (1). Numbers in parentheses refer to Fig. 1.

2 SM 2182 11-02
 Suspension System - Front Suspension
Section 180-0020
Note: Tighten all fasteners without special torques SM - 2804

specified to standard torques listed in Section FRONT

300-0080, STANDARD BOLT AND NUT TORQUE GAP 'A'
1
FRAME
2
SPECIFICATIONS. 9,10,11
8
7
12,13,14,15
16
WARNING 33,34

To prevent personal injury and property

5
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely. 20
6
19
1. If spherilastic bushes (2) were removed during 16

disassembly, install new spherilastic bushes as

follows:
0.75 -
a. Coat bores in suspension frame (1) with a water 1.25 mm

based lubricant.
1 - Suspension Frame 12 - Bolt
2 - Spherilastic Bush 13 - Bolt
b. Using press tool and power press (See Special
5 - Bolt 14 - Bolt
Tools), install spherilastic bushes (2) in suspension 6 - Locknut 15 - Washer
frame (1). 7 - Inner Bush 16 - Hardened Washer
8 - Outer Bush 19 - Stop Screw
9 - Shim 20 - Locknut
2. Using suitable lifting equipment, position front axle
10 - Shim 33 - Loctite Primer T
assembly on suspension frame (1). Position axle 11 - Shim 34 - Loctite 648
plates (4 & 5) and secure with bolts (28), hardened
washers (29) and locknuts (30). Tighten locknuts (30) Fig. 2 - Sectional View of Suspension Pivot
to a torque of 680 Nm (501 lbf ft).
4. Position suspension frame (1) completely to one
3. If removed, install link assembly (21) to front frame side and take a measurement of the gap between boss
using bolts (17), spacer (22), washers and nuts (3). on front frame and inside face of outer bush (8). Half
this size to obtain the thickness of shim (9 - 11) pack
INSTALLATION required for Gap 'A' (Fig. 2) at both sides.
Numbers in parentheses refer to Figs. 1 & 2. Note: Do not overshim, it is important to leave some
clearance.
WARNING 5. Remove outer bushes (8) and shim Gap 'A' at both
To prevent personal injury and property sides with shims (9 - 11) calculated at Step 4.
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job 6. Reinstall outer bushes (8), bolts (12 - 14) and
safely. washers (15). Hand tighten bolts at this stage.
1. Position suspension frame (1) assembly and trolley 7. Install rubber suspension mounts (18) between axle
under the front frame with spherilastic bushes (2) to the plates (4 & 5) and front frame.
rear.
8. Mount two hydraulic jacks (see Special Tools) below
2. Using suitable lifting equipment, lift suspension suspension frame. Using hydraulic pump to operate
frame (1) assembly and locate inner bushes (7) and hydraulic jacks, compress rubber suspension mounts
outer bushes (8) in front frame. (18) to 300mm (11.8").
3. Install bolts (31), hardened washers (16) and nuts (6) 9. Using torque multiplier (see Special Tools), tighten
through spherilastic bearings (2). Hand tighten nuts (6) nuts (6) to a torque of 1 835 Nm (1 325 lbf ft).
at this stage.
10. Remove bolts (12 - 14) and washers (15). Apply

SM 2182 11-02 3
Suspension System - Front Suspension
Section 180-0020
Loctite Primer T (33) and Loctite 648 (34) to threads of 18. Reconnect hydraulic brake line at tee on front axle
bolts and reinstall bolts (12 - 14) and washers (15). assembly. Reconnect differential breather line. Cap
Tighten bolts (12 - 14) to a torque of 170 Nm (125 lbf lines and fittings to prevent ingress of dirt.
ft).
19. Using suitable lifting equipment, position one tyre
11. Connect chain and shackle assemblies (23) and rim assembly on a front wheel and secure with
between link assembly (21) and suspension frame (1) wheel nuts. Tighten locknuts to a torque of 590 Nm
and secure with bolts (24), lockwashers (25) and nuts (435 lbf ft).
(26).
20. Using suitable lifting equipment, position opposite
12. Install shock absorbers (27) to the front frame and tyre and rim assembly on the opposite front wheel and
secure with locknuts. Tighten upper locknuts to a secure with wheel nuts.
torque of 103 Nm (74 lbf ft). Refit thread caps.
21. Using suitable lifting equipment, raise front frame
13. Align bottom of shock absorbers (27) with mounting sufficiently to remove stands and blocking from the
holes on suspension frame (1) and secure with front frame and articulation pivot. Lower vehicle to the
locknuts. Tighten lower locknuts to a torque of 103 Nm ground and remove lifting equipment. Tighten all wheel
(74 lbf ft). Refit thread caps. nuts to a torque of 590 Nm (435 lbf ft).

14. Install and adjust stop screw (19) to achieve 0.75 - 22. Remove wheel blocks from rear road wheels and
1.25 mm clearance (Fig. 2) between suspension frame place the steering lock bar in the 'Stowed' position.
(1) and stop screw (19).
23. Bleed all air from hydraulic brake lines. Refer to
15. Once clearance is obtained, install and tighten Section 165-0010, BRAKE PARTS - REAR.
locknut (20).

16. Remove trolley from underneath tractor frame. SPECIAL TOOLS

Refer to Section 300-0070, SERVICE TOOLS, for part
17. Install driveline between axle and transmission and numbers of torque multiplier, hydraulic jack, power
secure with bolts removed previously. Refer to Section press, press tool and general service tools and
130-0010, FRONT AND REAR DRIVELINES. sealants required. These tools and sealants are
available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 6 Nut 1835 1325
1 12 - 14 Bolt 170 125
1 30 Locknut 680 501
1 27 Shock Absorber Nut (Upper) 103 74
1 27 Shock Absorber Nut (Lower) 103 74
- - Wheel Nut 590 435

* * * *

4 SM 2182 11-02
 SUSPENSION SYSTEM - Front Suspension
Section 180-0020

SM - 3871

18

18
4

5 30
29
12
13
14 15
8 2
27 9,10,11 31 16 31 16

6
16 7
2
7 9,10,11
8
15
19
20 12,13,14
20 19
21
17 16 6

17
22
1
26 25 3 29
23 27
28
24

1 - Suspension Frame 11 - Shim 21 - Link Assy

2 - Spherilastic Bush 12 - Bolt 22 - Spacer
3 - Nut 13 - Bolt 23 - Chain & Shackle
4 - Axle Plate 14 - Bolt 24 - Bolt
5 - Axle Plate 15 - Washer 25 - Lockwasher
6 - Locknut 16 - Hardened Washer 26 - Nut
7 - Inner Bush 17 - Bolt 27 - Shock Absorber
8 - Outer Bush 18 - Rubber Mounts 28 - Bolt
9 - Shim 19 - Stop Screw 29 - Hardened Washer
10 - Shim 20 - Locknut 30 - Nut
31 - Bolt
Fig. 1 - Exploded View of Front Suspension

DESCRIPTION The front axle assembly is mounted on the leading

Numbers in parentheses refer to Fig. 1. arms of suspension frame (1) which pivots on the front
frame.
This Section applies to new build trucks from the serial
numbers identified on Table 1 below. Suspension is provided by two heavy duty rubber
suspension mounts (18) mounted between axle plates
(4 & 5) and front frame. In addition, there are two heavy
TA27 G7 - from Serial No. A8891011 duty double acting shock absorbers (27) (one on each
TA30 G7 - from Serial No. A8941011 side) to smooth out the ride. Two chain and shackle
TA30 G7 (RS) - from Serial No. A9081011 assemblies (23) provide extra retention on rebound.

Table 1 - Models from which this Section is Effective

SM 2560 11-07 1
Suspension System - Front Suspension
Section 180-0020

REMOVAL 10. Remove thread caps and mounting hardware

Numbers in parentheses refer to Fig. 1. securing shock absorbers (27) to suspension frame (1).

11. Using jack, lower suspension frame (1) onto a

WARNINGS suitable trolley until rubber suspension mounts (18) are
To prevent personal injury and property free of compression.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 12. Remove thread caps and mounting hardware
secured and of adequate capacity to do the job securing shock absorbers (27) to front frame. Remove
safely. shock absorbers (27), and remove rubber suspension
mounts (18).

Hydraulic fluid pressure will remain 13. Support the rear end of suspension frame (1) using
within the braking system after engine shut suitable equipment. Loosen and remove locknuts (20)
down. Operate the treadle pedal continuously securing stop screw (19) in front frame. Remove stop
until the pressure has dissipated before screw (19) from front frame.
carrying out any work on the braking system or
serious injury could result. 14. Using torque multiplier (see Special Tools), loosen
nuts (6) securing suspension frame (1) to front frame.
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and 15. Remove nuts (6), hardened washers (16) and bolts
switch off the engine. Turn steering wheel several (31) securing suspension frame (1) to front frame.
times to relieve any pressure in the steering system.
16. Remove bolts (12 - 14) and washers (15) securing
2. Block rear road wheels, place the steering lock bar outer bushes (8) to front frame. Remove inner bushes
in the 'Locked' position and place the battery master (7), outer bushes (8) and shims (9 - 11).
switch in the 'Off' position.
17. Carefully lower suspension frame (1) assembly
3. Whilst the front road wheels are still on the ground, onto the trolley and remove from under the vehicle.
loosen the wheel nuts.

4. Using suitable lifting equipment, raise the machine DISASSEMBLY

until both front tyres are off the ground. Support the Numbers in parentheses refer to Fig. 1.
vehicle with suitable stands and blocking at the front
frame and articulation pivot area.
WARNING
5. Support one tyre and rim assembly with suitable To prevent personal injury and property
lifting equipment and remove wheel nuts securing the damage, be sure lifting equipment is properly
rim to the axle. Remove tyre and rim assembly. secured and of adequate capacity to do the job
safely.
6. Repeat step 5 for the opposite tyre and rim
assembly. 1. Remove nuts (30), hardened washers (29) and bolts
(28) securing front axle assembly and axle plates (4 &
7. Disconnect hydraulic brake line at tee on front axle 5) to suspension frame (1). Using suitable lifting
assembly. Disconnect differential breather line. Cap equipment, remove front axle assembly from
lines and fittings to prevent ingress of dirt. suspension frame (1).

8. Jack up suspension frame (1) and remove nuts (26), 2. If required, press spherilastic bushes (2) from
lockwashers (25) and bolts (24) securing chain and suspension frame (1) using press tool and power press
shackle assemblies (23) to suspension frame (1) and (See Special Tools).
link assembly (21).
3. If required, remove bolts (17), spacer (22), washers
9. Support driveline and remove bolts securing driveline and nuts (3) securing link assembly (21) to front frame.
to front axle. Refer to Section 130-0010, FRONT AND
REAR DRIVELINES.

2 SM2560 11-07
 Suspension System - Front Suspension
Section 180-0020

ASSEMBLY SM - 2804

Numbers in parentheses refer to Fig. 1. FRONT

GAP 'A' FRAME
1
2
9,10,11
Note: Tighten all fasteners without special torques
8
specified to standard torques listed in Section 7
12,13,14,15
300-0080, STANDARD BOLT AND NUT TORQUE 33,34 16
SPECIFICATIONS.
5

WARNING
To prevent personal injury and property 20
6
19
damage, be sure lifting equipment is properly 16
secured and of adequate capacity to do the job
safely.
0.75 -
1. If spherilastic bushes (2) were removed during 1.25 mm
disassembly, install new spherilastic bushes as
follows: 1 - Suspension Frame 12 - Bolt
2 - Spherilastic Bush 13 - Bolt
a. Coat bores in suspension frame (1) with a water 5 - Bolt 14 - Bolt
based lubricant. 6 - Locknut 15 - Washer
7 - Inner Bush 16 - Hardened Washer
8 - Outer Bush 19 - Stop Screw
b. Using press tool and power press (See Special 9 - Shim 20 - Locknut
Tools), install spherilastic bushes (2) in suspension 10 - Shim 33 - Loctite Primer T
frame (1). 11 - Shim 34 - Loctite 648

Fig. 2 - Sectional View of Suspension Pivot

2. Using suitable lifting equipment, position front axle
assembly on suspension frame (1). Position axle
plates (4 & 5) and secure with bolts (28), hardened through spherilastic bearings (2). Hand tighten nuts (6)
washers (29) and locknuts (30). Tighten locknuts (30) at this stage.
to a torque of 680 Nm (501 lbf ft).
4. Position suspension frame (1) completely to one
3. If removed, install link assembly (21) to front frame side and take a measurement of the gap between boss
using bolts (17), spacer (22), washers and nuts (3). on front frame and inside face of outer bush (8). Half
this size to obtain the thickness of shim (9 - 11) pack
required for Gap 'A' (Fig. 2) at both sides.
INSTALLATION
Numbers in parentheses refer to Figs. 1 & 2. Note: Do not overshim, it is important to leave some
clearance.

WARNING 5. Remove outer bushes (8) and shim Gap 'A' at both
To prevent personal injury and property sides with shims (9 - 11) calculated at Step 4.
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job 6. Reinstall outer bushes (8), bolts (12 - 14) and
safely. washers (15). Hand tighten bolts at this stage.

1. Position suspension frame (1) assembly and trolley 7. Install rubber suspension mounts (18) between axle
under the front frame with spherilastic bushes (2) to the plates (4 & 5) and front frame.
rear.
8. Mount two hydraulic jacks (see Special Tools) below
2. Using suitable lifting equipment, lift suspension suspension frame. Using hydraulic pump to operate
frame (1) assembly and locate inner bushes (7) and hydraulic jacks, compress rubber suspension mounts
outer bushes (8) in front frame. (18) to 300mm (11.8").

3. Install bolts (31), hardened washers (16) and nuts (6) 9. Using torque multiplier (see Special Tools), tighten

SM 2560 11-07 3
Suspension System - Front Suspension
Section 180-0020
nuts (6) to a torque of 1 835 Nm (1 325 lbf ft). secure with bolts removed previously. Refer to Section
130-0010, FRONT AND REAR DRIVELINES.
10. Remove bolts (12 - 14) and washers (15). Apply
Loctite Primer T (33) and Loctite 648 (34) to threads of 18. Reconnect hydraulic brake line at tee on front axle
bolts and reinstall bolts (12 - 14) and washers (15). assembly. Reconnect differential breather line. Cap
Tighten bolts (12 - 14) to a torque of 170 Nm (125 lbf lines and fittings to prevent ingress of dirt.
ft).
19. Using suitable lifting equipment, position one tyre
11. Connect chain and shackle assemblies (23) and rim assembly on a front wheel and secure with
between link assembly (21) and suspension frame (1) wheel nuts. Tighten locknuts to a torque of 590 Nm
and secure with bolts (24), lockwashers (25) and nuts (435 lbf ft).
(26).
20. Using suitable lifting equipment, position opposite
12. Install shock absorbers (27) to the front frame and tyre and rim assembly on the opposite front wheel and
secure with locknuts. Tighten upper locknuts to a secure with wheel nuts.
torque of 103 Nm (74 lbf ft). Refit thread caps.
21. Using suitable lifting equipment, raise front frame
13. Align bottom of shock absorbers (27) with mounting sufficiently to remove stands and blocking from the
holes on suspension frame (1) and secure with front frame and articulation pivot. Lower vehicle to the
locknuts. Tighten lower locknuts to a torque of 103 Nm ground and remove lifting equipment. Tighten all wheel
(74 lbf ft). Refit thread caps. nuts to a torque of 590 Nm (435 lbf ft).

14. Install and adjust stop screw (19) to achieve 0.75 - 22. Remove wheel blocks from rear road wheels and
1.25 mm clearance (Fig. 2) between suspension frame place the steering lock bar in the 'Stowed' position.
(1) and stop screw (19).
23. Bleed all air from hydraulic brake lines. Refer to
15. Once clearance is obtained, install and tighten Section 165-0010, BRAKE PARTS - REAR.
locknut (20).

16. Remove trolley from underneath tractor frame. SPECIAL TOOLS

Refer to Section 300-0070, SERVICE TOOLS, for part
17. Install driveline between axle and transmission and numbers of torque multiplier, hydraulic jack, power
press, press tool and general service tools and
sealants required. These tools and sealants are
available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 6 Nut 1835 1325
1 12 - 14 Bolt 170 125
1 30 Locknut 680 501
1 27 Shock Absorber Nut (Upper) 103 74
1 27 Shock Absorber Nut (Lower) 103 74
- - Wheel Nut 590 435

* * * *

4 SM2560 11-07
 Suspension System - Front Suspension (IFS)
Section 180-0020

SM - 3389

17 18
18

6
25
1
2
21 16,22
8

18

17

3
4

23

18
19
2
7
8

20 5
12
13
15
14
11 9
10

1 - Axle Housing 9 - End Cap 17 - Bumpstop

2 - Knuckle & Wheel Head Assembly 10 - Washer 18 - Spring Mount
3 - Driveshaft 11 - Bolt 19 - Spring
4 - Lower RH Wishbone 12 - Seal Assembly 20 - Bolts
5 - Lower LH Wishbone 13 - Bush 21 - Axle Half Shaft
6 - Upper RH Wishbone 14 - Shim 22 - Bolt
7 - Upper LH Wishbone 15 - Washer 23 - Oil Plug
8 - Wishbone Pivot Block 16 - Washer

Fig. 1 - Front Suspension Assembly Detail

DESCRIPTION Bumpstops are provided to limit the travel of the

suspension assemblies during fully loaded conditions.
Numbers in parentheses refer to Fig. 1 unless
otherwise stated. REMOVAL AND DISASSEMBLY
Numbers in parentheses refer to Fig. 1.
The front axle assembly is mounted to the front
chassis frame, through the top plate of the front axle
WARNING
housing (1). The complete unit is pivoted through the
To prevent personal injury and property
front frame. Suspension is provided by four spring and
damage, be sure wheel blocks, blocking
damper assemblies (2-off each side) which are linked
materials and lifting equipment are properly
to lower wishbones (4 & 5) and are secured at their
secured and of adequate capacity to do the job
tops to the front frame through spring mounts (18).
safely.

SM 2365 02-05 1
Suspension System - Front Suspension (IFS)
Section 180-0020

SM - 3387 13,14

9,10

11

6
15

8,12

1- Bearing
6
2- Retainer
3- Seal "A"
4- Locknut
5- Washer
6- Axle Half Shaft
7- Differential Carrier
8- Bolt
9- Bolt 4
10 - Washer 5
11 - Bolt "A"
12 - Washer 1 3
13 - Oil Breather
14 - Elbow 2
15 - Oil Plug
VIEW ON ARROW 'A'

Fig. 2 - Axle Housing / Differential Assembly Detail

1. Position the vehicle in a level work area, ensure the 8. Remove all dirt and debris from critical access areas
body is fully lowered, apply the parking brake and around the suspension assembly and unit. Ensure
switch off the engine. Turn steering wheel several suitable lifting equipment is used to support
times to relieve any pressure in the steering system. components which may be a danger to service
personnel due to increased weight caused by foreign
2. Block rear road wheels, place the steering lock bar objects / debris build up during normal operation of the
in the 'Locked' position and place the battery master vehicle.
switch in the 'Off' position.
9. Remove clamped steering hoses and guard to allow
3. Whilst the front road wheels are still on the ground, access to axle housing screws which secure the
loosen the wheel nuts. suspension assembly to the front of the chassis frame.

4. Using suitable lifting equipment, raise the machine 10.Support driveline and remove bolts securing
until both front tyres are off the ground. Support the driveline to front axle. Refer to Section 130-0010,
vehicle with suitable stands and blocking at the tractor FRONT DRIVELINES.
frame and articulation pivot area.
11. Loosen bolts securing Transmission mounts to
5. Support one tyre and rim assembly with suitable frame, to allow transmission to be jacked up enough to
lifting equipment and remove wheel nuts securing the gain access to bolts securing front suspension
rim to the axle. Remove tyre and rim assembly. assembly to the chassis frame. Refer to Section 120-
0010 TRANSMISSION AND MOUNTING.
6. Repeat step 5 for the opposite tyre and rim
assembly. 12. Using fabricated tools (Fig. 13 ) to allow access to
axle housing screws. Remove screws securing
7. Disconnect hydraulic brake line at tee on front axle suspension assembly to the frame.
assembly. Dissconnect differential breather line. Cap
lines and fittings to prevent ingress of dirt. 13. Carefully lower front suspension assembly onto a

2 SM 2365 02-05
 Suspension System - Front Suspension (IFS)
Section 180-0020
suitable trolley and remove it from under the vehicle. Numbers in parentheses refer to Fig.5 & 11 unless
otherwise stated.
Numbers in parentheses refer to Fig. 1 unless 17. Remove locknuts and bolts securing suspension
otherwise stated. damper upper spring mount (1) to chassis frame
mounting bracket.
SM - 3398

18. Remove bolts (7) and washers (6). Carefully

release mounting pins (5) from the lower spring mounts
(2). This should allow for complete removal of spring
damper assemblies. Use suitable equipment to prise
dampers from the suspension assembly.

SM - 3400

Fig. 3 Bumpstop Removal

14. Remove locknuts, washers (Fig. 3) and bump

stops (17) from chassis frame.

Numbers in Parentheses refer to Fig. 4 unless

otherwise stated.
Fig. 5 Spring Damper Detail
15. Using special tool (15502116) and a suitable torque
wrench, untorque bolts (1) securing brake callipers (3) 19. If necessary, fully disassembly the suspension
to the calliper carrier plate (4). damper assemblies into individual parts as shown in
Fig. 12.
16. Carefully remove bolts (1), washers (2) and brake
callipers (3) from wheel head (5) assembly. Numbers in parentheses refer to Fig. 1 unless
otherwise stated.
SM - 3399
20. Remove bolts (16) and washers (22) securing
driveshafts (3) to axle half shafts (21) and wheel head
4
(1) flange shaft. Remove driveshafts (3).

21. With suitable supports in place, remove bolts (20)

from lower pivot block (8) assemblies. Now remove
bolts (11), washers (10) and end caps (9) from pivot
3 blocks (8). This should allow for removal/ rotation of
5
the lower wishbone (4 & 5) assemblies from the
housing.
1,2
4
22. Carefully remove the screws (20) from upper pivot
blocks (8), this should allow complete removal of upper
wishbone (6) assemblies.

3 Numbers in parentheses refer to Fig's 1 & 6 unless

otherwise stated.

23. Place wishbones (4,5 & 6), knuckle and wheel head
assemblies (2) onto a suitable surface for complete
Fig. 4 Brake Calliper Removal.
removal of constituent parts of the assembly.

SM 2365 02-05 3
Suspension System - Front Suspension (IFS)
Section 180-0020
SM - 3388 2. Insert bolts (8) and washers (9) into brake calliper carrier
6
plate (6).
5 2
3. Drop knuckle (2) onto wheel head, taking care to align
13
4 slot pin holes.
15

1 14
7
4. Apply loctite (9029849) to screws (3) and pass them
5 3 4 complete with washers (4) through knuckle (2) and wheel
6 8,9
head (1).

7
5. Insert brake calliper carrier plate (7) complete with bolts
10
12
(8) and washers (9) into position.
11

6. Insert half rings (5) into position, take care to ensure

chamfer is on brake disc side.

Fig. 6 Knuckle & Wheel Head Detail. 7. Hand tighten screws (3). Repeat steps 5 to 7 for other
side.
24. Place wheel knuckle and wheel head assembvly 8. Insert 6-off slot pins (10,11 & 12) through knuckle (2),
(1, Fig. 6) into a suitable jig. Untorque bolts (3, Fig. 6), wheel head (1) and brake calliper carrier plate (6).
remove bolts (3) and washers (4) from the knuckle (2).
Note: Rotate pins to ensure they are parallel win the line
25. Remove slot pins (10, 11 & 12) from the knuckle shown (refer to Fig. 6), ensure pins are 180 degree to eahc
(2). Separate knuckle from wheel head assembly. other. Slot pin should be 7mm below knucle face for
correct engagement with brake calliper plate.
26. Refer to section 140-0020 AXLE GROUP HUB for
disassembly of the wheel head and planetary group. 9. Torque screws (3) to a value of 620 Nm (457 Ibf ft).

ASSEMBLY AND INSTALLATION 10. Flip the assembly so that the wheel head (1) points
upwards. The heads of brake calliper retaining bolts (8)
Numbers in parentheses refer to Fig. 1 unless should now be resting against the knuckle.
otherwise stated.
11. Apply loctite (9029849) to one set of brake calliper
Note: Tighten all fasteners without special torques retaining bolts (8).
specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE 12. Slide brake calliper (7) into position and hand tighten
SPECIFICATIONS. retaining bolts (8).

13. Using special tool (15502116) torque bolts (8) to 515

WARNING
Nm (380 Ibf ft). Note: Since special tool ins 150mm in
To prevent personal injury and property length. Torque wrench should be set at 448 Nm (330.5 Ibf
damage, be sure lifting equipment is properly ft) to develop the 515 Nm needed. Ensure torque wrench
secured and of adequate capacity to do the job is aligned with special tool whilst tightening.
safely.
14. Refer to section 140-0060, DIFFERENTIAL DRIVE
Note: Assembly of knuckle and wheel head (2) is largely HEAD, for detailed assembly of the front differential
the reverse of the steps outlined in disassemly. Although group.
the following details highlight critical steps in this sub-
assembly.
Numbers in parentheses refer to Fig. 1 unless
otherwise stated.
Numbers in parentheses refer to Fig. 6 unless otherwise
stated.
15. Using suitable lifting equipment, position axle housing
(1) on bench with differential carrier mounting face in the
1. Place wheel head (1) on table with flange facing upwards position.
upwards.
16. Clean axle housing (1) mounting face and corresponding

4 SM 2365 02-05
 Suspension System - Front Suspension (IFS)
Section 180-0020
face on the differential carrier (7, Fig. 2) with loctite SM - 3396
(15269108).

17. Completely cover these faces in loctite sealant 576.

18. Using suitable lifting equipment, lift differential carrier

assembly (7, Fig. 2) by input flange and drop into axle
housing (1). Take care to ensure that crown wheel is on the
correct side.

19. Clean mounting surfaces with loctite (15269108) and

apply flange sealant 510.

20. Insert and torque 18-off, bolts (11, Fig. 2) to 250Nm

(184 Ibf ft).
Fig. 7 - Secure Housing To Chassis Frame
21. Clean the threads of bolts (8, Fig. 2) with loctite
(15269108) and apply loctite (9029849) . Insert bolts with 27. Clean bolts (20) with loctite (15269108). Apply loctite
washers (12, Fig. 2) and torque to a value of 27Nm (20 Ibf (09029849) and torque bolts (20) to a value of 455 Nm (336
ft). Ibf ft).
22. Clean threads of all fittings; elbow, oil breather and oil 28. Replace pivot block washers (15) and secure special
plugs (13, 14 & 15, Fig. 2) with loctite (15269108) and tool 15502108 at each end with bolts (11) torqued to a
apply loctite 577 thread sealant and secure. value of 94Nm (69 Ibf ft).
23. Note: Check for correct rotation of driving head- anti 29. Measure the gap between each tool and pivot block (8)
clockwise rotation of input flange should cause forward to determine shim (14) thicknessrequired to achieve an
motion. end float of 0.1-0.2mm (0.004"-0.008").

24. Using suitable lifting equipment, position front axle SM - 3383

housing (1) to the front frame assembly.
3
25. Secure axle housing / differential assembly to the 6

chassis frame using 16-off M20 X 2.5 grade 10.9, min

20mm thread engagement cap screws. The correct torque
value should be applied in two stages and the following 4
sequence: 5
6
7

Note: Fabricated tools may be needed to gain adequate 6

access to screws. Refer to Special Tools at the end of this 7 2

section for details. 5

4
1

A. Torque screws in correct order (Fig. 7 ) to a value 2

6
of 225Nm (166 Ibf ft).
Fig. 8 - Exploded View - Lower Wishbone
B. Repeat sequence for final torque value of 450Nm
(336 Ibf ft).
30. Remove special tools 15502108, replace end caps (9)
with the appropriate shims (14). Clean bolts (11) with
26. Move LH lower wishbone (5) into position using loctite (15269108) and torque to a value of 94Nm (69 Ibf
suitable lifting equipment. Remove end caps (9) from ft).
wishbone pivot blocks (8) and apply thermo-paul 1 grease
liberally to wishbone pivot pins (2 & 3, Fig 8.) and the
31. Repeat steps 26 to 30 with RH lower wishbone (4)
inside of pivot blocks (8).
assembly.

SM 2365 02-05 5
Suspension System - Front Suspension (IFS)
Section 180-0020
Numbers in parentheses refer to Fig. 9 unless otherwise SM - 3386
stated.
9
32. Sub-assembly of the upper wishbones, should be
carried out as follows:
8

33. Ensure all surfaces and internal diameters of wishbone 7

(1) are cleaned with loctite (15269108) or equivalent. 10

Apply loctite (09029849) around pins (2 & 3) and inner

faces of wishbone (1) ensuring all faces are covered. 11

2
6
1
34. Press pins (2 & 3) into bush until shoulde contact with 5
4
wishbone (1). Note ensure chamfer on pin (3) coincides
3
with chamfer on wishbone (1).

SM - 3385 Fig. 10 Exploded View - Pivot Block Assembly

3

41. Clean bolts (20) with loctite (15269108). Apply loctite

(09029849) and torque to a value of 455Nm (336 Ibf ft).

1
2 42. Repeat steps 32 to 41 for the right hand side.

43. Move driveshaft (3) into position. Take care to ensure

the shaft seal points downwards when the suspension is
rebounded.
2
44. Clean bolts (22) and washers (16). Coat bolts (22) with
loctite (090209849) then secure input flange to wheel head
2
(2) using bolts (22) with washers (16). Torque bolts (22) to
a value of 94Nm (69 Ibf ft).
Fig. 9 - Exploded View - Upper Wishbone
SM - 3382

Numbers in parentheses refer to Fig.1 unless otherwise 1

stated. 9
11
8 12
35. Move LH upper wishbone (7) into position and repeat 13
steps 13 to 17.

36. Identify top of knuckle and wheelhead assembly (2) as 4

that with the large 20mm diameter spring pins. P

A
R
A
37. Remove lower pivot block (8) end caps, pivot blocks, L
L
E
bushes, seals, shims, washers (9, 8,13,12,14,15) and L

dowels (refer to 8 Fig. 10) from knuckle assembly (2).

38. Apply thermo paul 1 grease liberally to wishbone pivot 2

pins, bushes and seals (2 & 3,4 & 5, 10, Fig. 10).
3

39. Slide seal assemblies (12) and bushes (13) into

position on LH lower wishbone (5) ensure correct orientation
of seal assemblies, Refer Fig.10.
6

7
40.Offer knuckle and wheel head assembly (2) up to lower 5
LH wishbone (5) and replace pivot blocks and dowels (8 10

& 9 Fig. 10).

Fig. 11 Suspension Damper Assembly .

6 SM 2365 02-05
 Suspension System - Front Suspension (IFS)
Section 180-0020
45. Clean bolts (22) and washers (16). Coat bolts (22) with 50. Completely cover spring pivot bused in lower wishbone
loctite (09029849) then secure output flange using bolts (4 & 5) with thermo paul 1 grease.
(22) and washers (16). Torque to a value 94Nm (69 Ibf ft).
51. Position lower spring pin (5) in lower wishbone and
46. Repeat steps 43 to 45 for right hand driveshaft. drop sring assembly into position. Clean pivot block (8)
bolts (20) with loctite (15269108) and apply locitite
47. Check that the hubs and driveshafts are free to rotate (09029849) to bolts. Torque to a value of 455Nm (336 Ibf
at the full "bump and rebound angles". Refer to Fig. 12. ft).

48. Check that turning the input flange at the rear of the 52. Ensure that lower spring mount (2) clears the lower
axle, anti-clickwise, the wheel hubs turn to move the axle wishbone in the full "bump and full" rebound position.
in the forward direction. Refer to Fig. 12.

49. Remove lower spring pin (5, Fig 11) from spring 53. Repeat steps 49 to 52 for remaining spring assemblies.
assemblies and remove half caps from lower spring
mount (2, Fig. 11). 54. Remove lug (23) at front of axle housing (1) and fill to
level of this plug with SAE grade 80W-90LS oil. Note the
volume of oil to fill the differential housing should be 21
SM - 3390
Litres.
1
102˚ 55. Rotate hub until oil level line is horizontal, remove oil
filler plug and fill hub to level of plug with SAE grade 80W-
90LS oil.

56. Repeat steps 54 to 55 for opposite hub.

WARNING
To prevent personal injury and property
damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
safely.
2 93˚

57. Position suspension frame (1) assembly and trolley

uine.

58. Using suitable lifting equipment, position one tyre

and rim assembly on a front wheel and secure with
wheel nuts. Tighten locknuts to a torque of 540 Nm
(400 lbf ft).

59. Using suitable lifting equipment, position opposite

tyre and rim assembly on the opposite front wheel and
3 100˚
secure with wheel nuts.

60. Using suitable lifting equipment, raise tractor frame

sufficiently to remove stands and blocking from the
tractor frame and articulation pivot. Lower vehicle to the
ground and remove lifting equipment. Tighten all wheel
nuts to a torque of 540 Nm (400 lbf ft).

61. Remove wheel blocks from rear road wheels and

place the steering lock bar in the 'Stowed' position.

62. Bleed all air from hydraulic brake lines. Refer to

Fig. 12 Suspension Loading Conditions. Section 165-0010, BRAKE PARTS.

SM 2365 02-05 7
Suspension System - Front Suspension (IFS)
Section 180-0020

MAINTENANCE SPECIAL TOOLS

Proper maintenance of the axle / differential and wheel Refer to Section 300-0070, SERVICE TOOLS, for part
hub elements of the front suspension assembly is numbers of general service tools, special tools and
essential if the unit is to function properly. Section 300- sealants which may be required during routine
0020, LUBRICATION SYSTEM gives full information maintenance. Fabricated tools (Fig. 13) which are
on the proper lubrication intervals and lubricants which shown may need to be created to aid in the overhaul
should be used. The relevant section within the manual procedure of the unit.
should be referred to should greater detail on individual
element service requirements be necessary.

SM - 3397 38mm SM - 3401

(1-1/2")

Dia.17mm

152mm (6")
76mm
(3")

Fig. 14 Special Tool

Note: Hex Bar used on conjuction with fabricated tools to

allow access to Cap Screws which secure the axle
housing to the chassis frame.

Fig. 13 Screws- Fabricated Axle Housing Tool

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
- - Cap Screw 450 332
1 11 Bolt 94 69
1 20 Bolt (PIVOT BLOCKS) 455 336
2 8 Bolt 27 20
2 11 Bolt 250 184
- - Wheel Nuts 540 400

* * * *

8 SM 2365 02-05
 SUSPENSION SYSTEM - Rear Suspension
Section 180-0040

SM3927

24 29 22
23 28 7
9
25 25
26 26 32
31 30 33 13
4 32
21 6 5 34
FR 21 DETAIL C
ON 17 B
T 16 2
48 47
28
14,15 46 48 22
A
20
A 23
21 A C
24
1
47 48
14,15 25
3
A 26
4 14,15
6
22 5
2
28 A 42
23 27 A 44 38
23 A 11

19 3 14,15 40
7 48 45
24 9 41 40
C 20 35 36,37
25 1 11 46
8 48 21
26 A
13
10 45 41
12 A 28 46 47 32
31 40
A 48
32
B
14,15 47 48
35 39
29 24 3313
17 34
21 B 46
2 25 2
25 30
18 14,15 A
26 A 26
DETAIL A DETAIL B DETAIL D

1 - Suspension Link Bracket 17 - Locknut 33 - Washer

2 - Suspension Link Bracket 18 - Bolt 34 - Bolt
3 - SuspensionLink Bracket 19 - Bolt 35 - Elbow
4 - Machined Beam Assembly 20 - Bolt 36 - Bolt
5 - Bushing 21 - Hardened Washer 37 - Washer
6 - V-seal 22 - Bolt 38 - Manifold Plate Assembly
7 - Retainer 23 - Lockwasher 39 - Hose Assembly
8 - Lockwasher 24 - Bolt 40 - P-clip
9 - End Cap 25 - Hardened Washer 41 - Screw
10 - Bolt 26 - Nut 42 - Hose Assembly
11 - Grease Fitting 27 - Locknut 43 - Spacer Plate
12 - Bolt 28 - Interleaf Mount 44 - Elbow
13 - Lockwasher 29 - Bolt 45 - Washer
14 - Control Link 30 - Pin Assembly 46 - Panhard Rod Assembly
15 - Bushing 31 - Retainer 47 - Bearing
16 - Bolt 32 - V-seal Ring 48 - Internal Snap Ring

Fig. 1 - Exploded View of Rear Suspension, Earlier Serial Numbers

DESCRIPTION
Numbers in parentheses refer to Figure 1 or Figure 2, Vehicle Type Effective Serial Number Figure
depending on the Serial Number of the vehicle, as TA30 (894) From A8941011 to A8941635 1
identified below. TA30 (894) From A8941636 2
TA30, IFS (897) From A8971011 to A8971068 1
Vehicle Type Effective Serial Number Figure
TA30, IFS (897) From A8981069 2
TA30, RS (908) From A9081011 to A9081029 1
TA27 (889) From A8891011 to A8891167 1 TA30, RS (908) From A9081030 2
TA27 (889) From A8891168 2
TA27, IFS (892) From A8921011 to A8921012 1
TA27, IFS (892) From A8921013 2

SM 2183 Rev 2 09-08 1

Suspension System - Rear Suspension
Section 180-0040

SM 3926

24 22
23 28 9
25 7

26 32
31
4 32 30 33 13
21 6 5 34
FR 21 DETAIL C
ON 17 B
T 16 2
48 47
14,15 46 49 22
A 48
20
A 23
21 C 28
A
24
1
47 48
14,15 25
29 26
A
4 14,15
6
22 5
2
28 A 42
23 27 A 44 38
23 A 11

19 48 3 14,15 40
24 7 45
49 9 20
41 40
C 35 36,37
25 1 11 46
8 48 21
26 A 10
13 45 41
12 A 28 46 47 32
31 40
A 48
32
B
14,15 47 48
35 39
24 3313
17 34
21 B 46
2 25 30 2
18 14,15 A A 26
DETAIL A DETAIL B DETAIL D

1 - Suspension Link Bracket 18 - Bolt 35 - Elbow

2 - Suspension Link Bracket 19 - Bolt 36 - Bolt
3 - Suspension Link Bracket 20 - Bolt 37 - Washer
4 - Machined Beam Assembly 21 - Hardened Washer 38 - Manifold Plate Assembly
5 - Bushing 22 - Bolt 39 - Hose Assembly
6 - V-seal 23 - Lockwasher 40 - P-clip
7 - Retainer 24 - Bolt 41 - Screw
8 - Lockwasher 25 - Hardened Washer 42 - Hose Assembly
9 - End Cap 26 - Nut 43 - Spacer Plate
10 - Bolt 27 - Locknut 44 - Elbow
11 - Grease Fitting 28 - Interleaf Mount 45 - Washer
12 - Bolt 29 - Suspension Link Bracket 46 - Panhard Rod Assembly
13 - Lockwasher 30 - Pin Assembly 47 - Bearing
14 - Control Link 31 - Retainer 48 - Internal Snap Ring
15 - Bushing 32 - V-seal Ring 49 - Mounting Plate
16 - Bolt 33 - Washer
17 - Locknut 34 - Bolt

Fig. 2 - Exploded View of Rear Suspension, Later Serial Numbers

Each axle is coupled to the chassis by three rubber The rear suspension system requires minimal
bushed control links (14) which provide longitudinal maintenance due to the use of rubber bushings (15)
location and control torque reactions. Lateral location is being used in the control links (14). Lubrication of the
by means of two Panhard rod links (46). The centre spherical bearings (47) in the Panhard rods (46) is
and rear axles are linked by longitudinal equaliser through lube fittings (11). Similarly, lubrication of the
beams (4) which pivot on either side of the chassis. bushings (5) in the equaliser beams (4) is through lube
fittings (11).
Loads which act on the axles are balanced by the
equaliser beams (4), with bonded rubber/metal
laminated interleaf mounts (28) located between the
axles and beam ends providing the cushioning
medium.

2 SM 2183 Rev 2 09-08

 Suspension System - Rear Suspension
Section 180-0040

REMOVAL hydraulic brake lines from the tee pieces at the centre
Numbers in parentheses refer to Figures 1 and 2. and rear axle assemblies. Cap the lines and fittings to
prevent the ingress of contaminants.

WARNING 10. Remove the blocking materials from the equaliser

To prevent personal injury and property beams (4). Remove the locknuts (27), washers (23)
damage, be sure wheel blocks, blocking and bolts (19) securing the interleaf mounts (28) to the
materials and lifting equipment are properly equaliser beams (4).
secured and of adequate capacity to perform
the task safely. 11. Remove the bolts (22) and lockwashers (23)
securing the interleaf mounts (28) to the centre and
rear axles. Remove the interleaf mounts (28).
WARNING
Hydraulic fluid pressure will remain within the 12. Remove the bolts (12) and lockwashers (13)
braking system after engine shut down. Operate securing the end cap (9) to the equaliser beam (4).
the treadle pedal continuously until the Remove the end cap (9).
pressure has dissipated before carrying out any
work on the braking system or serious injury 13. Remove the bolts (10) and lockwashers (8)
could result. securing the retainer (7) to the spindle on the frame.
Remove the retainer (7).
1. Position the vehicle in a level work area, raise the
body and install the body safety prop to secure the 14. Using suitable lifting equipment, support the
body in the partially raised position. equaliser beam (4) and withdraw it from the spindle on
the frame.
2. Apply the parking brake and switch off the engine.
Turn steering wheel several times to relieve any 15. Remove and discard the V-seal (6) from the
pressure in the steering system. bushing (5). If required, remove the bushing (5) from
the spindle on the frame.
3. Block the front road wheels, place the steering lock
bar and oscillation lock pin in the 'Locked' position and 16. Repeat steps 12 to15 inclusive to remove the
the battery master switch in the 'Off' position. opposite equaliser beam (4).

4. Using suitable blocking equipment, block the 17. Remove the locknuts (17), hardened washers (21)
equaliser beams (4) to prevent movement when raising and bolts (16) securing the centre control links (14) to
the trailer frame. the cross shaft mounting brackets.

5. While the rear road wheels are still on the ground, 18. Remove the locknuts (17), hardened washers (21)
loosen the wheel nuts. and bolts (16) securing the centre control links (14) to
the suspension link brackets (3 [and 29, Figure 2]).
6. Using suitable lifting equipment, raise the trailer Remove the centre control links (14).
frame until the rear wheels are off the ground. Support
the vehicle with suitable stands and blocking 19. Remove locknuts (17), hardened washers (21) and
equipment at the trailer frame, articulation pivot area bolts (18) securing the control link (14) to the bracket
and centre and rear axles. assembly (2) on the rear axle and left-hand frame
mounting bracket. Remove the control link (14).
7. Support one tyre and rim assembly with suitable
lifting equipment and remove the wheel nuts and 20. Remove the locknuts (17), hardened washers (21)
lockwashers securing the rim to the axle. Remove the and bolts (18) securing the control link (14) to the
tyre and rim assembly. bracket assembly (1) on the centre axle and left-hand
frame mounting bracket. Remove the control link (14).
8. Repeat Step 7 for the remaining rear tyre and rim
assemblies. 21. Remove locknuts (17), hardened washers (21) and
bolts (18) securing the control link (14) to the bracket
9. With a suitable container in position, disconnect the assembly (2) on the rear axle and right-hand frame
mounting bracket. Remove the control link (14).

SM 2183 Rev 2 09-08 3

Suspension System - Rear Suspension
Section 180-0040
34. Remove the bolts (20) and hardened washers (21)
22. Remove the locknuts (17), hardened washers (21) securing the suspension link bracket (3, Figure 1or 29,
and bolts (20) securing control link (14) to bracket Figure 2 respectively) on the centre axle. Remove the
assembly (2) on the centre axle and the right-hand suspension link bracket (3, Figure 1or 29, Figure 2
frame mounting bracket. Remove control link (14). respectively).

23. Refer to Detail D of Figure 1 or 2 respectively: 35. If either axle assembly requires to be removed from
Remove the hose assemblies (39) and elbows (35) under the vehicle; raise the axle assembly with suitable
from the Panhard rods (46). lifting equipment, remove the blocking from under the
axle assembly, and lower the axle assembly on to a
24. Remove the hose assemblies and elbows (39 and suitable trolley. Slide the axle assembly from under the
44) from the manifold bracket (38). Remove the vehicle to a suitable work area.
remote lube fittings (11) if necessary.
INSTALLATION
25. Remove the bolts (41) securing the P-clips (40) and Numbers in parentheses refer to Figures 1, 2, 3 and 4.
hoses (39) in place. Carefully remove the hose
assemblies and elbows (39 and 35) from the Panhard
rods (46). WARNING
To prevent personal injury and property
26. If necessary remove the manifold bracket (38) from damage, be sure wheel blocks, blocking
the frame, by removing the bolts (36) and washers (37). materials and lifting equipment are properly
secured and of adequate capacity to perform
27. Refer to details B and C of Figure 1 or 2 the task safely.
respectively: Remove bolts (34), washers (33) and
lockwashers (13) from the suspension link brackets (2) 1. Ensure that the centre and rear axle assemblies are
and frame assembly. Remove the pins (30). correctly positioned and securely blocked below the
frame.
28. Remove the V-ring seals (32), spacers (31) and
Panhard rods (46) from the suspension link brackets 2. Install suspension link bracket (3, Figure 1or 29,
(2) and frame assembly. Figure 2 respectively) on the centre axle. Apply Loctite
270 to the bolts (20) and secure the suspension link
29. Remove the locknuts (26), hardened washers (25) bracket (3, Figure 1or 29, Figure 2 respectively) to the
and bolts (24) securing the suspension link bracket (2) centre axle with the bolts (20) and washers (21).
on the rear axle. Remove the suspension link bracket SM1425
(2).
7 5
30. Remove the locknuts (26), hardened washers (25) 8,10
and bolts (24) securing the suspension link bracket (1) FRAME
on the rear axle. Remove the suspension link bracket TRANSVERSE
MEMBER
(1). 9

31. Remove the bolts (20) and hardened washers (21)

securing the suspension link bracket (3) on the rear
axle. Remove the suspension link bracket (3).
11

32. Remove the locknuts (26), hardened washers (25)

and bolts (24) securing the suspension link bracket (1)
on the centre axle. Remove the suspension link 12,13
4 6
bracket (1).

33. Remove the locknuts (26), hardened washers (25) 4 - Equaliser Beam 9 - End Cap
5 - Bushing 10 - Bolt
and bolts (24) securing the suspension link bracket (2) 6 - V-seal 11 - Lubrication Fitting
on the centre axle. Remove the suspension link 7 - Retainer 12 - Bolt
bracket (2). 8 - Lockwasher 13 - Lockwasher

Fig. 3 - Sectional View of Equaliser Beam Installation

4 SM 2183 Rev 2 09-08

 Suspension System - Rear Suspension
Section 180-0040
Tighten the bolts (20) to a torque of 447 Nm (330 lbf ft). SM3298

3. Install the suspension link bracket (2) on the right-

14
hand side of the centre axle. Apply Loctite 243 to the
bolts (24) and secure the suspension link bracket (2) to
the centre axle with bolts (24), hardened washers (25)
and locknuts (26). Tighten the bolts (24) to a torque of:

n 671 Nm (495 lbf ft), Figure 1 or

n 745 Nm (550 lbf ft), Figure 2.
18 21 17
4. Install the suspension link bracket (1) on the left-
hand side of the centre axle. Apply Loctite 243 to the
14 - Control Link 18 - Bolt
bolts (24) and secure the suspension link bracket (1) to
17 - Locknut 21 - Hardened Washer
the centre axle with the bolts (24), hardened washers
(25) and locknuts (26). Tighten the bolts (24) to a
Fig. 4 - Sectional View of Typical Control Link Mounting
torque of:

n 671 Nm (495 lbf ft), Figure 1 or

n 745 Nm (550 lbf ft), Figure 2. 10. If the bushings (5) were removed from spindle
(transverse member) on the frame, thoroughly clean
5. Apply Loctite 243 to the bolts (22) and secure the spindle ends with Loctite activator 'N' and allow them to
interleaf mounts (28) to the centre axle with the bolts dry. Apply Loctite 648 retaining compound all over the
(22) and lockwashers (23). Tighten the bolts (22) to a bushing (5) contact area of the spindle ends and install
torque of 165 Nm (122 lbf ft). the bushings (5) on the spindle ends. Ensure that the
paint dot on each bushing (5) is at TDC, and that one
of the grease channels lines up with the channel on the
6. Install the suspension link bracket (3) on the rear
spindle end face (both grease channels should be at
axle. Apply Loctite 270 to the bolts (20) and secure the
the bottom). Once installed, the end face of spindle
suspension link bracket (3) to the rear axle with the
should protrude by 3mm.
bolts (20) and washers (21). Tighten the bolts (20) to a
torque of 447 Nm (330 lbf ft).
Note: A curing time of fifteen minutes is required for
acceptable handling strength.
7. Install the suspension link bracket (2) on the left-
hand side of the rear axle. Apply Loctite 243 to the
bolts (24) and secure the suspension link bracket (2) to 11. Install new V-seals (6) over bushings (5) with the lip
the rear axle with bolts (24), hardened washers (25) and to the outside, as shown in Figure 3.
locknuts (26). Tighten the bolts (24) to a torque of:
12. Clean the bores of the equalising beams (4) and,
using suitable lifting equipment, install the beams on
n 671 Nm (495 lbf ft), Figure 1 or
the bushings (5). Apply Loctite 243 to the bolts (10)
n 745 Nm (550 lbf ft), Figure 2. and secure the retainers (7) to the spindle ends with
the bolts (10) and lockwashers (8). Tighten the bolts
8. Install the suspension link bracket (1) on the right- (10) to a torque of 149 Nm (110 lbf ft).
hand side of the rear axle. Apply Loctite 243 to the
bolts (24) and secure the suspension link bracket (1) to 13. Apply Loctite 243 to the bolts (12) and Loctite 574
the rear axle with the bolts (24), hardened washers (25) gasket eliminator to the mounting face of the end caps
and locknuts (26). Tighten bolts (24) to a torque of: (9). Secure the end caps (9) to the equalising beams
(4) with the bolts (12) and lockwashers (13). Tighten
n 671 Nm (495 lbf ft), Figure 1 or the bolts (12) to a torque of 75 Nm (55 lbf ft).
n 745 Nm (550 lbf ft), Figure 2.
14. If removed, install the lubrication fittings (11) in the end
9. Apply Loctite 243 to the bolts (22) and secure the caps (9). Lubricate with grease specified in Section 300-
interleaf mounts (28) to the rear axle with the bolts (22) 0020, Lubrication System, until excess lubricant is seen.
and lockwashers (23). Tighten the bolts (22) to a torque
of 165 Nm (122 lbf ft).

SM 2183 Rev 2 09-08 5

Suspension System - Rear Suspension
Section 180-0040
25. If removed, install the lubrication fittings (11) in the
15. Apply Loctite 243 to the bolts (19) and secure the bracket (38). Lubricate with grease specified in Section
interleaf mounts (28) to the equaliser beams (4) using 300-0020, Lubrication System, until excess lubricant is
the bolts (19), lockwashers (23) and locknuts (27). seen.
Tighten the bolts (19) to a torque of 160 Nm (118 lbf ft).
26. Remove the caps and connect the hydraulic brake
16. Install the centre control links (14) between the lines to the tee pieces at the centre and rear axle
suspension link brackets (3, Figure 1or 3 and 29, assemblies. Clip the brake lines with the clips removed
Figure 2 respectively) and the frame cross member during removal.
mounting brackets. Secure the control links (14) at the
cross member mounting brackets with the bolts (18), 27. Using suitable blocking equipment, block the
hardened washers (21) and locknuts (17). Tighten the equaliser beams (4) to prevent movement when
bolts (18) to a torque of 556 Nm (410 lbf ft). installing the rear tyre and rim assemblies.

17. Secure the centre control links (14) at the 28. Using suitable lifting equipment, position one tyre
suspension link brackets (3, Figure 1or 3 and 29, and rim assembly on one rear wheel and secure it with
Figure 2 respectively) with bolts (18), hardened the wheel nuts and lockwashers.
washers (21) and locknuts (17). Tighten bolts (18) to a
torque of 556 Nm (410 lbf ft). 29. Repeat step 28 for remaining tyre and rim
assemblies.
18. Install the control links (14) between the rear and
centre axle suspension link brackets (1 and 2) and the 30. Using suitable lifting equipment, raise the trailer
frame mounting brackets and secure them with the frame sufficiently to remove the stands and blocking
bolts (18), hardened washers (21) and locknuts (17). equipment from the centre and rear axles, articulation
Tighten the bolts (18) to a torque of 556 Nm (410 lbf ft). pivot area and trailer frame. Lower the vehicle to the
ground and remove the lifting equipment.
19. Pre-assemble the Panhard rods (46), spherical
bearings (47) and retainers (48). 31. With the vehicle lowered to the ground, tighten all
wheel nuts to a torque of 590 Nm (435 lbf ft).
20. Refer to Detail B, Figures 1 and 2 respectively:
Install both left-hand and right-hand Panhard rod 32. Place the battery master switch in the 'On' position,
assemblies (46) between the suspension link brackets start the engine and check hydraulic brake lines for
(2) and the frame by taking Panhard rods (46) and leaks. Bleed all air from the hydraulic brake lines as
locating them into the mating slot of the suspension described in Section 165-0020, Hydraulic Braking
link bracket (2), between the spacers (31) and the V- System Schematic.
ring seals (48). Secure them in place by locating the
pins (30) and securing them in place with washers (33), 33. Remove the wheel blocks from the front road
lockwashers (13) and bolts (34). Tighten the bolts (34) wheels and place the steering lock bar and oscillation
to a torque of 75 Nm (55 Ibf ft). lock pin in the 'Stowed' position.

21. Refer to Detail C, Figures 1 and 2 respectively:

Perform the same procedure stated in step 20 for MAINTENANCE
securing the Panhard rods (46) in place at the axle. Numbers in parentheses refer to Figure 1 or Figure 2
respectively.
22. Refer to Detail D, Figures 1 and 2 respectively:
Install the manifold bracket (38) on to the frame and Pre-Starting Inspection: Visually check the condition
secure it in place using the washers (37) and bolts (36). and mounting of the equaliser beams (4), interleaf
mounts (28) and control links (14).
23. Fit the elbows (44) and grease nipples (11) to the
manifold bracket (38). Now fit the elbows (35) to the Every 50 Hours: Lubricate the spherical bearings (47)
Panhard rods (46). in the Panhard rods (46) through the remote lubrication
fittings (11), with grease specified in Section 300-0020,
24. Fit the hose assemblies (39) to the elbows (35) and Lubrication System, until excess lubricant is seen.
run the hoses using the P-clips (40) and the bolts (41)
with washers (45) to secure them in place. Every 250 Hours: Lubricate the bushings (5) in the

6 SM 2183 Rev 2 09-08

 Suspension System - Rear Suspension
Section 180-0040
equaliser beams (4) through the lubrication fittings (11), SERVICE TOOLS
with grease specified in Section 300-0020, Lubrication There are no special tools required for the procedures
System, until excess lubricant is seen. outlined in this section. Refer to Section 300-0070,
Service Tools, for part numbers of general service
tools and adhesives required during the removal and
installation of the rear suspension. These tools and
adhesives are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Bolt 149 110
1 12 Bolt 75 55
1 16 Bolt 556 410
1 18 Bolt 556 410
1 19 Bolt 160
1 20 Bolt 447 239
1 22 Bolt 165 800
1 24 Bolt 671 495
1 29 Bolt 671 495
1 34 Bolt 75 55
2 10 Bolt 149 110
2 12 Bolt 75 55
2 16 Bolt 556 410
2 18 Bolt 556 410
2 19 Bolt 160 118
2 20 Bolt 447 330
2 22 Bolt 165 122
2 24 Bolt 745 550
2 34 Bolt 75 55
- - Wheel Nut 590 435

* * * *

SM 2183 Rev 2 09-08 7

Suspension System - Rear Suspension
Section 180-0040

THIS PAGE IS INTENTIONALLY BLANK

8 SM 2183 Rev 2 09-08

 Electrical System - Circuit Diagrams
Section 190-0000
COMPONENT DESIGNATIONS
A4 - 12V Radio/Cassette L4 - Warning Buzzer S60 - Difflock Request Switch
A5 - Radio/Cassette Speaker L5 - Electric Horn S68 - Eng Diag/Request Switch
L6 - Reverse Camera S69 - Accel Idle Validation Switch
B7 - Coolant Level Sensor L7 - Reverse Camera Monitor S74 - Kickdown Switch
B8 - Fuel Level Sender L8 - Body Raise/lower Joystick S78 - Body Lower Emergency
B13 - Rotational Speed Sensor L9 - Transmission shift lever Switch
B19 - Throttle Position Sensor L11- Transmission Visual Display S79 - Heated Mirror Switch
B21 - Trans Oil Temp Sender Unit S80 - Engine Compression
B32 - Trans Oil retarder Temp L12- Brake service Warning brake Low/High Switch
Sender Buzzer
B35 - Trans Oil Cooler Fan Temp S82 - Engine Compression Brake
Sender M1 - Starter Motor request
B39 - Air-con Potentiometer M3 - Starter Motor S90 - Trans Oil Filter Restriction
E3 - Interior Light M4 - Washer Motor, F Switch
E5 - Reverse Light M5 - Wiper Motor, F S91 - Air - Commpressor Pressure
E7 - Instrument Panel Light M6 - Wiper Motor, B Switch
E11 - Side Marker Light, L M7 - Washer Motor, B S97 - Interior Light Door Switch
E12 - Taillight, L M13 - Air Seat Compressor S106 - Brake Pedal Position Switch
E13 - Side Marker Light, R M16 - Autolube Pump S107 - Cross Axle Diff Lock
E14 - Taillight, R N3- Voltage Convertor Request Switch
E15 - High/Low Beam H'lamp, L N8- Camera Module S111 - Diagnostic inc/dec Switch
E16 - High/Low Beam H'lamp, R N9- Autolube Control Module S112 - Air-Con Fresh/recirc Switch
E19 - Rear Fog Lamp R10 - Rkr Switch 'Locating' LED S113 - Air-Con Defrot Mode Switch
E21 - Rotating Beacon R11 - Rkr Switch 'Function' LED S114- Air-Con On/Off Switch
E23 - Work Light R12 - 12V Work Socket S115- Autolube High Pressure
E26 - High Beam H'lamp, L R13 - 24V Work Socket Switch
E27 - High Beam H'lamp, R S116- Autolube Override Switch
E34 - Flashing Reverse light S1 - Battery Master Switch S117- Parkbrake Service Switch
E35 - Heated Mirror S2 - Starter Keyswitch Y3- Transmission retarder Solenoid
S7 - Emerg/Park Brake Switch Y4- Emerg/Park Brake Solenoid
G1 - Generator/Alternator S8 - Emerg/Park Brake Switch Y7- Difflock Solenoid (mid-axle)
G2 - Battery S9 - Washer Switch, F Y11- Fresh/Recirc Actuator
S10 - Wiper Switch, F Y26- Body Raise Solenoid
H6 - Direction Indicator; F, L S11 - Rear Wash/Wipe Switch Y27- Body Lower Solenoid
H7 - Direction Indicator; B, L S13 - Horn Button Y32- Trans radiator fan solenoid
H8 - Direction Indicator; F, R S14 - Hazard w/l Switch Y33- System Hyd Unloader Valve
H9 - Direction Indicator; B, R S15 - Direction Ind Switch Y34- System Hyd Float Valve
H10 - Brake Light, L S18 - Lights Switch Y36- Trans oil cooler fan isolation
H11 - Brake Light, R S19 - Dipswitch Y48- Defrost Actuator
H29 - Work Socket Illumination S20 - Headlamp Flash Switch Y49- Water valve Actuator
H33 - Autolube Hih Pressure W/L S22 - Body Proximity Switch Wire Colours
H34 - Autolube Override W/L S31 - Park Brake w/l Switch B - Black
K5 - A/C Comp Clutch/Relay S41 - Auxiliary Lights Switch N - Brown
K21 - Trans Shift Clutch S42 - Air-con temperature Switch U - Blue
K22 - Lockup Clutch S48 - Acc Press Switch (Tractor) R - Red
K40 - Engine Cooling Fan Clutch S49 - Acc Press Switch (Trailer) G - Green
L3 - Reverse Alarm S57 - Steering Press Switch L - Light Green
O - Orange
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 Y - Yellow
L - LEFT, R - RIGHT, F - FRONT, B - BACK P - Purple
W - White
DIODE RESISTOR FUSE PLUG S - Slate
K - Pink
TRAILER
CONNECTION

SM 2466 Rev 4 05-10 1

Electrical System - Circuit Diagrams
Section 190-0000

FUSES
Location Fuse No. Circuit Current Rating
2 Keyswitch 15A
3 Hazard Warning Lights 7.5A
4 Rear Wash/Wipe 10A
5 Horn Relay Coil, Front Wash/Wipe 10A
Fuse/Relay 6 Air Seat Compressor 10A
Box 7 Dipped Beam Lights Supply 10A
8 Main Beam/Flash 10A
9 Wiper Park Front 7.5A
10 Transmission TCU Battery 7.5A
11 Transmission TCU Ignition 10A
12 Reverse System 7.5A
13 TOC8 Controler Ignition 30A
14 Interior Light 5A
15 Direction Indicators 5A
16 Emergency/Park Brake 3A
17 Instrument Cluster/CPU Ignition 7.5A
Fuse/Relay 18 Heated Mirrors 15A
Box 19 Ignition Sensed Relays 3A
20 24V Work Socket Battery 15A
21 Neutral Start 3A
22 Front Washer Pump 3A
23 Rear Washer Pump 3A
24 Horns 10A
25 Ignition Sensed Equipment 30A
26 Air Cond/Heater/Ventilation System 15A
27 Reverse Camera 10A
28 Front Working Lights 15A
29 Rear Working Lights 15A
Fuse/Relay 30 Rotating Beacon 5A
Box 31 Engine ECU Ignition 5A
32 Engine ECU Battery 10A
33 Proximity Switch 10A
34 Sound Power Relay Supply 3A
35 Brake Pedals Control 5A
36 12V Work Socket 15A

Fuse/Relay FA Auxiliary Body Down Supply 5A

Box FK Voltage Convertor Battery Supply 20A
FL Engine Battery Supply 10A
FM Instrument Panel/CPU Battery Supply 10A
FJ Autolube System 5A
Battery 61 Alternator Charge Cable (Power Fuse) 100A
Box 62 Cab Busbar Supply Cable (Power Fuse) 100A

Passenger seat 66 Alternator Charge Cable (Power Fuse) 3A

compartment

2 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
Section 190-0000

RELAYS
Location Relay Circuit
Fuse/Relay Box K58 Sound Power 1st / Rev Gear
Column A K57 Sound Power Body Up
K23 Ignition Sensed - A/C / Heater / Hyd. ECU Ignition
Fuse/Relay Box K23 Wiper Ignition
Column B K34 Horns
K15 Headlights
Fuse/Relay Box K17 Reverse Alarm / Lights
Column C K14 Neutral Start
K50 Brake Lights Control
Fuse/Relay Box - K23 Ignition Sensed - Engine ECU Ignition
Column D K33 Engine Cooling Fan
K4 Indicator Flasher Unit
K32 Engine Brake
Fuse/Relay Box - K52 Body Proximity Switch
Column E K27 Differential Lock
K23 Ignition Sensed - Radio

SM - 3725

12 24 36 A B C D E

FD FH FM K23 K17 K50 K32

FC FG FL K23 K14 K23 K52

FB FF FK K58 K34 K5 K27

FA FE FJ K57 K15 K4 K23

Fig. 1 - Main Fuse Box - Fuse/Relay Location

1 13 25

References
A Harness interface - Dash Harness and Main Chassis Harness (48 way connector)
B
Harness interface - Dash Harness and Main Chassis Harrness (102 way connector)
C Harness interface - Main Chassis Harness and Engine Harness (23 way socket housing on
Frame section)
D Harness interface - Main Chassis Harness and Engine Harness (23 way pin housing on Frame
section)
E Harness interface - Main Chassis Harness and Transmission Interface Harness
F Harness interface - Main Chassis Harness and Hydraulic Valve Harness
G Harness interface - Main Chassis Harness and Rear Frame Harness
H Harness Auxilliary Components Connection, Only Cavity Nuber Shown I.E. -1.
All stated dash Harness splices are located in the controls area underneath the instructor seat

SM 2466 Rev 4 05-10 3

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987A

4 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
SM - 3987B Section 190-0000

SM 2466 Rev 4 05-10 5

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987C

6 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
SM - 3987D
Section 190-0000

SM 2466 Rev 4 05-10 7

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987E

8 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987F

SM 2466 Rev 4 05-10 9

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987G

10 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
SM - 3987H Section 190-0000

SM 2466 Rev 4 05-10 11

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987I

12 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
SM --3987H
SM 3987J
Section 190-0000

SM 2466 Rev 4 05-10 13

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987K

14 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987L

SM 2466 Rev 4 05-10 15

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987M

16 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
SM - 3987N Section 190-0000

SM 2466 Rev 4 05-10 17

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987O

low/high

request

18 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
SM - 3987R
Section 190-0000

SM 2466 Rev 4 05-10 19

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987S

20 SM 2466 Rev 4 05-10

 Electrical System - Circuit Diagrams
SM - 3987T Section 190-0000

SM 2466 Rev 4 05-10 21

Electrical System - Circuit Diagrams
Section 190-0000
SM - 3987U

22 SM 2466 Rev 4 05-10

 ELECTRICAL SYSTEM - Hydraulic System ECU
Section 190-0085

SM2858

Fig. 1 - IQAN TOC8 Electronic Control Unit

SM3733
DESCRIPTION
The hydraulic electronic control unit (ECU) (Figure 1) is
a stand alone control which controls the machines
hydraulic systems, including body hoist and
transmission oil cooler fan drive. The IQAN-TOC8
ECU communicates with a variety of input and output
devices. It utilises analog/digital inputs, proportional
current outputs and digital outputs.

The ECU continuously monitors the system and warns

the operator when a fault develops, and also helps B A
diagnose the nature of the fault. ECU is located inside A - Green LED, Power On
B - Yellow/Red LED, Status
the cab, under the instructor seat (see Figure 2).
Fig. 2 - Hydraulic ECU Location

WARNING
ECU Inputs
Before any welding is carried out on a machine
Refer to Figures 3 and 4 and Section 190-0000, Circuit
equipped with an IQAN-TOC8 hydraulic system,
Diagrams.
disconnect the following in this order:
Battery earth cable, battery supply cable,
Ignition Switch - connected to the starter keyswitch,
alternator earth cables, alternator supply
rendering the circuit energized or de-energized.
cables and electrical connections at the engine
ECM, transmission ECU, body control lever,
Starter Motor Relay - when the starter motor relay is
hydraulics ECU and cab bulkhead to avoid
activated, a digital signal is fed to the ECU.
damage to electrical components. Turn off
battery master switch to isolate the batteries
Body Control Lever - this three position lever sends
before disconnecting any components.
analog signals to ECU.
After welding connect all of the above in the
Transmission Cooler Fan Drive Temperature
reverse order.
Sensor - sensor at transmission sends analog signal
to ECU.

SM 2200 Rev 2 10-08 1

Electrical System - Hydraulic System ECU
Section 190-0085

SM - 2859

BODY-UP WARNING LIGHT + IGNITION SWITCH

STARTER MOTOR RELAY

BODY LOWER TRANSMISSION OIL TRANSMISSION OIL

EMERGENCY COOLER FAN DRIVE COOLER FAN DRIVE
SWITCH ISOLATION SOLENOID PROPORTIONAL SOLENOID

1 5
PROPORTIONAL
3 4
2 CONTROL VALVE
(RAISE) 33
8 9
6 7

13
10 11 FLOAT
12 44
SOLENOID
30
16
14 COLD START
IQAN-TOC8 SOLENOID
17
45
18
ECU 32

31 31
15

19 21 22
46
20
25
BODY CONTROL
24
LEVER 23
26

PROPORTIONAL
27
CONTROL VALVE 29
(LOWER)

BODY-UP
+ PROXIMITY
SWITCH ON
2nd GEAR RESTRICTION CHASSIS
TRANSMISSION
COOLER FAN DRIVE
OUTPUT INPUT
TEMPERATURE SENSOR

Fig. 3 - Layout Of Hydraulic ECU System

Body Up Proximity Switch - sends a digital signal to on ECU. For lower proportional control valve, measure
the ECU through relay K52 depending on the position across pins 31 and 32. When the body proximity
of the body. When the body is lowered the proxy switch switch is closed circuit (body lowered) the lower signal
is made. When the body is in a raised position the is inhibited.
proxy switch is open circuit.
Transmission Oil Cooler Fan Drive Proportional
Body Lower Emergency Switch - located in the cab, Solenoid - the transmission cooler fan drive
the switch sends a positive battery supply directly to temperature sensor feeds back to the ECU, which
the float solenoid when pressed. This is used to lower outputs a signal to the fan drive proportional solenoid
the body in the event of system failure. (typically 150-210 mA measured across pins 19 and
20, resulting in a delivery between 38-83 bar (551-1204
lbf/in2)). This causes the fan speed to increase
ECU Outputs proportionally. Refer to Section 215-0050, Main
Cold Start Solenoid - when ECU receives input from Hydraulic Valve Assembly.
starter motor relay, the ECU sends an ouput signal to
activate cold start solenoid. This prevents the engine Transmission Oil Cooler Fan Drive Isolation
starting under hydraulic load. Solenoid - the transmission cooler fan drive
temperature sensor feeds back to the ECU, which
Body Raise/Lower - when ECU receives signals from outputs a signal to the fan drive isolation solenoid.
body control lever, ECU sends output signals to the Refer to Section 210-0060, Transmission Oil Cooler.
raise and lower proportional control valves to shift the
main control valve spool accordingly. Typical output Body-Up Warning Light - the body-up proximity
from ECU is 250 - 800 mA, providing a delivery switch sends a signal to the ECU through relay K52,
pressure between 4 - 25 bar (58 - 363 lbf/in2) at main and depending on the body position, the ECU sends a
control valve spool. For raise proportional control signal to illuminate the warning light in the cab.
valve, measure current output across pins 17 and 18
2 SM 2200 Rev 2 10-08
 Electrical System - Hydraulic System ECU
Section 190-0085

SM - 2860

Voltage In Alarm Out

Temp Sensor [Mv] C1:3 A
A C1:37 A - Body Raise Solenoid
C1:6 B
C1:9 C B - Body Lower Solenoid
Body Control Lever Lower [%] C1:12 D Current Out
C1:5 E Raise/Lower
Analog Inputs A C1:17/31 17 31
C1:7 F Solenoid [%] A B
Body Control Lever Raise [%] C1:8 G +RET C1:18 18 32
C1:10 H -RET C1:32
Current
C1:27 I Trans. Cooler Fan Drive 19
B C1:19/33 Outputs
C1:41 J Proportional Solenoid [%]
+RET C1:20 20
Body Raised - Closed Digital In -RET C1:34
Body Lowered - Open C1:3 A
Body-Up Proximity Switch C1:6 B Digital Out
Energises Cold Starter Motor Signal C1:9 C
A C1:21
Body-Up Warning
Start Solenoid C1:12 D Light
Ignition Switch C1:5 E
B C1:22 Cold Start Solenoid
C1:7 F
Energises or De-energises C1:8 G Body Control Lever
Feed to Solenoids C C1:35
C1:10 H Detente Solenoid
Digital Outputs
C1:27 I
D C1:36 2nd Gear Restriction
C1:41 J
E C1:23 Body Float Solenoid
Frequency In
C1:3 A F C1:24 Trans. Cooler Fan Drive
C1:6 B Isolation Solenoid
C1:9 C
C1:12 D PWM Out

A C1:21/22

Power
B C1:35/36
C1.15 -BAT
C1:28 +BAT
C C1:23/24
C1:4 -VREF-A
Power In C1:2 +VREF-A
C1:13 -VREF-B
C1:11 +VREF-B
C1:29 -BAT2
C1:42 +BAT2

RS-232
C1:25 RX
C1:26 TX
Communication Port C1:39 DSR
C1:40 RES
C1:38 GND

42 29
28 15
14 1

Fig. 4 - IQAN TOC8 ECU (C1) Pin Connections

of cylinders when travelling, ensuring body is resting on

Body Float Solenoid - the body lower emergency the chassis. If body is not resting on the chassis when
switch sends a positive battery supply to energise the travelling, hinge points and cylinders may be damaged,
body float solenoid. This ensures that the hoist side of especially when body is laden.
the body cylinders are vented to tank, allowing body to
lower onto chassis under it's own weight in the event of Check the body float solenoid across pin 23 on ECU
system failure. and vehicle ground. Solenoid is rated at 15 W, 0.6 A,
42 ohms.
The body float solenoid is always energised when the
body-up proximity switch is open circuit (body lowered). Body Control Lever Detent - when the body control
This prevents pressure being trapped in the hoist side lever is pushed fully forward to power down the body,

SM 2200 Rev 2 10-08 3

Electrical System - Hydraulic System ECU
Section 190-0085

SM2862

Status Flash (yellow light)

Normal (no errors)

Error Error Flash (red light)

code
1 Output errors

2 Input errors

3 VREF error

4 Supply voltage
error
5 Temp critical or
checksum error
6 Fatal software
error
Fig. 5 - LED Indicator Showing Different Modes

the ECU energises a detent solenoid within the lever to Memory Test - the ECU will perform a self test during
hold the lever fully forward. This continues until the operation to verify the software. The test includes a
body-up proximity switch is open circuit (body lowered), processor and memory verification, and an internal
when the ECU de-energizes the detent solenoid so that signal verification. If any software error is detected,
the lever returns to the neutral position, and the body appropriate precautions will be taken.
float solenoid is energized (see Body Float Solenoid).

2nd Gear Restriction - when the body-up proximity System Diagnosis

switch is made, the ECU sends a signal to the Refer to Figures 2 and 5.
transmission ECU to restrict the transmission to The two LEDs on the ECU are used to diagnose basic
second forward gear. When the body-up proximity system errors. The ECU indicates error status through
switch is open circuit i.e. body is lowered, full gear the red blinking LED as shown in Figure 5, giving an
range is available. immediate diagnosis as to the nature of the error that
has occurred.

System Safety If there are no errors, the bottom LED flashes yellow
Input/Output Protection - all inputs to the ECU are to indicate normal status. Some errors will cause the
designed to withstand the maximum specified supply ECU to stop operating or at least shut down the
voltage. The outputs are protected against short outputs to increase safety. The green LED indicates
circuit. Additionally, an error on one input/output will power on.
not influence other inputs/outputs. External fuse (10A),
located in the battery box, will blow if supply exceeds
35 V. WARNING
Do not use the machine if an error code is
Current Check - for the current outputs, a current present. Shutdown the machine until the
check is performed. The ECU compares the return problem is resolved.
current with the output's set-value. If current deviation
occurs, the user will be notified through an appropriate Refer to table of error codes for corrective action. The
error code on the unit's LED. ECU has a RS232 interface under theinstructor seat
which plugs directly into a laptop. This allows
If the ECU detects a short circuit to battery supply, the communication with the ECU using IQAN develop
unit will shut off the outputs in order to increase safety. software, and gain more information about the ECU's
status.

4 SM 2200 Rev 2 10-08

 Electrical System - Hydraulic System ECU
Section 190-0085

Error Codes, Messages and Actions

Situation Error Code Action ECU Remarks
ERROR: OUTPUT HIGH
COUT: Error 1 Active output shuts off Check wiring and loads
Current return low or high
COUT: Error 1 Active output shuts off Check application
Both directions
commanded
DOUT: Error 1 Active output shuts off Check load
Overload
PWMOUT: Error 1 Active output shuts off Check application
Both directions
commanded
COUT/DOUT: Error 6 Active output shuts off Replace ECU
Internal driver
failure
ERROR: INPUT
VIN: Error 2 Active input goes to Check wiring and sensors
> specified max or error value
< specified min
ERROR: VREF
VREF_< 4.9 V Error 3 - Check voltage, replace ECU
VREF_> 5.1 V Error 3 - Check voltage, replace ECU
LOW/HIGH SUPPLY VOLTAGE
+BAT < 8.5 V Error 4 - Check voltage supply
+BAT > 34 V Error 4 - Check voltage supply
HIGH TEMPERATURE
Internal temperature Error 5 - Check ambient temperature,
> max temp allow ECU to cool
Internal temperature Error 6 - Replace ECU
sensor error
ERROR: PARAMETER
Parameter error Error 5 No calibration of signals Replace ECU
ERROR: SOFTWARE
Software error Error 6 Unit stops operating Replace ECU

SM 2200 Rev 2 10-08 5

Electrical System - Hydraulic System ECU
Section 190-0085

REMOVAL battery supply cable, before disconnecting harness

from IQAN-TOC8 ECU inside cab.
WARNINGS 4. Remove bolts securing ECU to support below the
To prevent personal injury and property right hand console, and remove ECU.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job INSTALLATION
safely. 1. Secure ECU to support below the right hand console
using bolts removed previously.
High electrical current can cause sparks 2. Firstly connect harness to ECU, then connect
and personal injury from burns. Turn battery battery supply cable and battery ground cable in that
master switch to the 'Off' position before order.
removing any components. Remove battery
ground cable first, and reconnect last, to avoid 3. Turn master switch on, start engine and ensure that
damaging electrical components. the top LED is green which indicates voltage is being
supplied, and that the bottom LED flashes yellow,
1. Position the vehicle in a level work area, ensure the indicating normal status.
body is fully lowered, apply the parking brake and
switch off the engine. 4. Remove wheel blocks from all road wheels.
2. Operate the treadle valve continuously to discharge
the accumulators, block all road wheels, place the SPECIAL TOOLS
steering lock bar in the 'Locked' position and the
There are no special tools required for procedures
battery master switch in the 'Off' position.
outlined in this section. To obtain IQAN develop
diagnostic software, contact your dealer.
3. Disconnect the battery ground cable first, then the

* * * *

6 SM 2200 Rev 2 10-08

 ELECTRICAL SYSTEM - Switches and Sensors
Section 190-0270

SM - 3732

HYD.
2 VALVE

3 9 ACC2S
HEADER TANK 10
FUEL
TANK
1 ACC1S
6
BOTTOM P1S
ELBOW AT
RETARDER
PBS
12
11

15
7

TRANS RETARDER
HOUSING LHS
HYDRAULIC TANK

4 13
IN
25
20 5 14
15
10
7

16
FRONT FRAME RAIL ON AIR CLEANER REAR FRAME RAIL AT FOOT PEDAL

1 - Engine Coolant Temperature Sender 7 - Trans Oil Cooler Fan Temp Sensor 12 - Steering System Pressure Switch
2 - Engine Coolant Level Sensor 8 - Retarder Oil Temperature Sensor 13 - Body Up Proximity Switch
3 - Fuel Level Sender 9 - Rear Brake Pressure Switch 14 - Hydraulic Filter Restriction Gauge
4 - Starter Relay 10 - Front Brake Pressure Switch 15 - Oil Filter Restriction Switch
5 - Air Cleaner Restriction Gauge 11 - Park Brake Pressure Switch 16 - Cross Axle Differential Lock Switch
6 - Transmission Oil Temp Sender

Fig. 1 - Layout View of Switches and Sensors

DESCRIPTION Fig. 2) on the dash panel to alert the operator of a fault

in the engine circuit. Refer to Section 110-0030,
Numbers in parentheses refer to Fig. 1, unless
ENGINE AND MOUNTING.
otherwise specified.
Engine Coolant Temperature Sender (1) - Located
This section describes the location and function of
in the right hand side of the engine. Sends a signal
various switches and sensors fitted to the vehicle to
indicating engine coolant temperature to engine
monitor all major components and systems. Gauges
coolant temperature gauge (1, Fig. 2).
and warning lights located in the dash panel, relay this
information to the operator.
Engine Coolant Level Sensor (2) - Located in the
radiator header tank, the sensor sends a signal to
Note: Always make sure all gauges, warning lights
engine ECM.
and controls are working properly before operating the
vehicle.
Engine Coolant Temperature Gauge (1, Fig. 2) -
Indicates the engine coolant temperature. The gauge
Engine should read in the green zone after the engine has
warmed. If the gauge reads in the red zone, stop
The Quantum engine management system monitors
engine and investigate the cause.
the engine at all times and sends a signal to the
engine check light (8, Fig. 2) and engine stop light (7,

SM 2465 Rev1 02-07 1

Electrical System - Switches and Sensors
Section 190-0270

7 8 SM - 3706
4 5 6 9 10 11
3 12
2 13

2 STOP P
1

20 30 15
19
40 10 20
30 50

20 mph 60
10 40 r / min x100
km/h 5 25
10 70

80
0 0000000 50 30
0000 0

18 1 16 17 15 14

1 - Engine Coolant Temperature Gauge 8 - Engine Check W/L 15 - Dimming Button

2 - Speedometer 9 - Parking Brake Ind/L 16 - Tripmeter Reset Button
3 - Front Brake Accumulator Pressure W/L 10 - Transmission Check W/L 17 - Not Used
4 - Rear Brake Accumulator Pressure W/L 11 - Emergency Steering W/L 18 - Digital Odometer
5 - Headlight Main Beam Ind/L 12 - Differential Lock Ind/L 19 - Visual Display Unit (VDU)
6 - Direction Indicators Ind/L 13 - Tachometer
7 - Engine Stop W/L 14 - Transmission Sump Oil Temp. Gauge

Fig. 2 - Layout View of Instruments and Indicator/Warning Lights

Tachometer (13, Fig. 2) - Driven from the engine Transmission Oil Temperature Sender (6) - The
ECU, the tachometer indicates the number of engine sender, located on the elbow at the retarder housing,
crankshaft revolutions per minute. The needle shows sends a signal to indicate transmission converter oil
the variations in engine operating speed. Never temperature on the bar graph gauge displayed on the
accelerate the engine to speeds indicated by the red VDU (3, Fig. 4).
zone on the dial face.
Transmission Oil Cooler Fan Temperature Sensor
Hourmeter (6, Fig. 4) - Driven from the engine (7) - Located in the retarder housing, the sensor sends
alternator, the hourmeter records the total number of a signal to the hydraulics ECU to operate the
engine hours. transmission oil cooler fan drive at a speed
proportional to transmission oil temperature.
Starter Relay (4) - Mounted on the tractor frame rail,
the starter relay powers up the starter motor when the Trans. Sump Oil Temperature Sensor (8) - The
keyswitch is turned. temperature sensor is located at the retarder housing
and records both the retarder and converter oil
temperature, which is supplied to the transmission
Transmission ECU. When either reaches a out of range condition
Refer to Section 120-0010, TRANSMISSION AND this will cause the tranmission oil temp high warning
MOUNTING, for further information on switches and symbol (2, Fig.3) to be displayed on the VDU.
sensors fitted to the transmission.
Oil Filter Restriction Switch (15) - The restriction
Speedometer (1, Fig. 2) - Driven by a signal from the switch sends a signal to the Transmission TCU to
transmission ECU, the speedometer indicates travel indicate that the Oil filter is restricted, which will in turn
speed in kilometres per hour and miles per hour. send a signal to the check transmission lamp (10, Fig.
2) indicating the need to check for a fault.

2 SM 2465 Rev1 02-07

 Electrical System - Switches and Sensors
Section 190-0270

SM - 3708 Braking System

Rear Brake Pressure Switch (9) - The normally
closed (NC) pressure switch, located in port ACC2S of
1 2 3 the main hydraulic valve, senses the pressure in the
rear brake circuit. The pressure switch sends a signal
to illuminate 'Red' rear brake accumulator pressure
warning light (20, Fig. 2) when pressure drops to 122
bar (1769 lbf/in2). An audible buzzer also sounds.
5

4 Front Brake Pressure Switch (10) - The normally

6 closed (NC) pressure switch, located in port ACC1S of
the main hydraulic valve, senses the pressure in the
front brake circuit. The pressure switch sends a signal
to illuminate 'Red' front brake accumulator pressure
warning light (19, Fig. 2) when pressure drops to 122
8 7 bar (1769 lbf/in2). An audible buzzer also sounds.
1 - Low Fuel
2 - Trans. Oil Temp High Parking Brake Pressure Switch (11) - The normally
3 - Alternator Charging closed (NC) pressure switch, located in port PBS of
4 - Engine Maintenance Monitor the main hydraulic valve, senses pressure in the
5 - Body Up parking brake circuit. The pressure switch closes at a
6 - Wait to Start
7 - Engine Brake pressure of 5 bar (70 lbf/in2) and sends a signal to
8 - Transmission Retarder illuminate 'Green' parking brake indicator light (28, Fig.
2), indicating that the parking brake is applied.

Steering System
Fig. 3 - Warning Symbol Screen Steering System Pressure Switch (12) - The
normally closed (NC) pressure switch is located in port
P1S of the main hydraulic valve. The pressure switch
SM - 3707 closes and sends a signal to illuminate 'Red'
emergency steering warning light (22, Fig. 2) when
Fuel Level
steering pressure drops to 5 bar (70 lbf/in2) or lower.
1 An audible buzzer also sounds.
0 25 50 75 100
Voltmeter

2 8 12 16 20 24 28 32 Hydraulic System
Trans Converter Temp
Hydraulic Filter Restriction Gauge (14) - The
3 50 75 100 125 150
hydraulic filter restriction gauge is located on top of
00000 N hydraulic tank. After 1 000 hours or when the needle
moves into the red zone, whichever comes first, the
hydraulic filter should be changed.
6 4 5 7

Air Cleaner
1 - Fuel Level Air Cleaner Restriction Gauge (5) - Mounted on the
2 - System Voltage air cleaner, the restriction gauge indicates the degree
3 - Transmission Converter Oil Temp.
4 - Transmission Retarder of air cleaner element restriction as the red panel rises
5 - Engine Brake in the gauge window. The filter element(s) should be
6 - Engine Hours Counter replaced if the red band locks in place when the
7 - Transmission Gear selected engine is shut down. Reset the gauge by pressing the
button on the gauge with the engine running.

Fig. 4 - Main Screen Display

SM 2465 Rev1 02-07 3

Electrical System - Switches and Sensors
Section 190-0270

Fuel Tank Note: Never move the vehicle until body up warning
light (5, Fig. 3) goes out, indicating that the body is
Fuel Level Sender (3) - Located at the rear of the fuel
fully lowered onto the trailer frame.
tank, the fuel level sender sends a signal to VDU
display which displays fuel level as a graph (1, Fig. 4)
Note: The proximity switch prevents the body being
to indicate the amount of fuel left in the tank.
fully powered down onto the frame. When the
proximity switch makes contact, the body control lever
Body detent is de-energised and float solenoid at main
hydraulic valve is energised.
Body Up Proximity Switch (13) - Mounted off the
inside of the trailer left hand frame rail. When the body
is raised off the trailer frame, the switch sends a signal
to illuminate body up warning symbol on the VDU
panel (5, Fig. 3).

* * * *

4 SM 2465 Rev1 02-07

 FUEL SYSTEM - Fuel System
Section 200-0040

SM - 2814

18
17 8
15
97 6
16 7
14
19
1

10
5 3 13
4

3
2 11
12

1 - Fuel Tank 7 - Washer 13 - Fuel Line

2 - Bolt 8 - Shims 14 - ECM Cooling Plate
3 - Washer 9 - Nut 15 - Electronic Unit Injector
4 - Shims 10 - Fuel Line 16 - Strainer
5 - Nut 11 - Fuel Line 17 - Filler Cap
6 - Bolt 12 - Fuel Filter/Water Separator 18 - Padlock
19 - Fuel Pump
Fig. 1 - Fuel Lines and Components

DESCRIPTION
Numbers in parentheses refer to Fig. 1. The electronic unit injector (15) is a lightweight,
compact unit that injects diesel fuel directly into the
The fuel system consists of the Quantum Celect Plus combustion chamber. The amount of fuel injected and
electronic fuel system controls, fuel filter (12), fuel the beginning of injection timing is determined by the
pump (19), ECM cooling plate (14), electronic unit electronic control module (ECM). The ECM sends a
injectors (15), fuel tank (1) and the necessary command pulse which activates the injector solenoid.
connecting fuel lines.
The EUI (15) performs four functions:
The fuel filter (12) is mounted inside the battery box,
alongside the oil filter. a - Creates the high fuel pressure required for efficient
injection.
Fuel pump (19) is attached to a drive assembly b - Meters and injects the exact amount of fuel required
mounted on the rear side of the gear case at the front to handle the load.
LH side of the engine and transfers fuel from fuel tank c - Atomizes the fuel for mixing with the air in the
(1), via fuel filter (12), to the electronic unit injectors combustion chamber.
(15). d - Permits continuous fuel flow for component cooling.

SM 2186 12-02 1
Fuel System - Fuel System
Section 200-0040
SM - 2815
11
12

10 19,20,21,22,23

14 17
13 16 18
17
2,3
4

19,20,21,22,23

17
18 15
17
5

9
8
6

1 - Fuel Tank 7 - Bolt 13 - Padlock 19 - Shim

2 - Filler Cap 8 - Bolt 14 - Key 20 - Shim
3 - Filter Assembly 9 - Washer 15 - Bolt 21 - Shim
4 - Strainer 10 - Fuel Sender Guard 16 - Bolt 22 - Shim
5 - Step Plate 11 - Bolt 17 - Hardened Washer 23 - Shim
6 - Step Assy 12 - Washer 18 - Nut

Fig. 2 - Fuel Tank and Mounting

Electronic unit injectors are self compensating and tightening.

virtually eliminate engine tune-ups.
A fuel tank breather/filter assembly is incorporated into
Note: Never apply 12 V directly to terminals on the the fuel filler cap (17), allowing fuel tank (1) to vent to
injector as it will burn out. Before removing injectors, atmosphere, preventing pressure from building up
the fuel passages must be blown out to prevent fuel within fuel tank (1) assembly.
flow from entering the cylinder head.

ECM cooling plate (14) is mounted behind the ECM on OPERATION

the LH side of the engine and absorbs heat generated Numbers in parentheses refer to Fig. 1.
by the ECM. Fuel from fuel pump (19) outlet line flows
through ECM cooling plate (14) to absorb this heat. Fuel is drawn from fuel tank (1) through fuel filter (12)
and enters fuel pump (19). Leaving fuel pump (19)
Flexible fuel lines (10, 11 & 13) are used to facilitate under pressure, the fuel flows through ECM cooling
connection of lines leading to and from fuel tank (1), plate (14) to the engine cylinder head. The fuel flows to
and to minimize the effects of any vibration in the electronic unit injectors (15) in the cylinder head
installation. through passages integral with the cylinder head.
Surplus fuel exits the cylinder head and back to fuel
When installing fuel lines, it is recommended that tank (1) through fuel line (10).
connections be tightened only sufficiently to prevent
leakage of fuel; thus flared ends of the fuel lines will
not become twisted or fractured because of excessive

2 SM 2186 12-02
 Fuel System - Fuel System
Section 200-0040

REMOVAL 13. Remove nuts (18), bolts (15), hardened washers

(17) and shims (19 - 23) securing fuel tank (1)
Numbers in parentheses refer to Fig. 2, unless
assembly to the front frame bumper. Using a suitable
otherwise stated.
lifting device, remove fuel tank (1) assembly from the
vehicle.
WARNING
To prevent personal injury and property DISASSEMBLY
damage, be sure wheel blocks, blocking
Numbers in parentheses refer to Fig. 2, unless
materials and lifting equipment are properly
otherwise stated.
secured and of adequate capacity to do the job
safely.
1. Remove bolts (7) securing step plate (5) to fuel tank
(1).
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
2. Remove bolts (8) and washers (9) securing step
assembly (6) to fuel tank (1).
2. Block all road wheels and place the battery master
switch in the 'Off' position.
3. Remove grab handles from fuel tank (1).
3. Pull on handle to release hood catch mechanism
3. Remove screws and washers securing fuel sender to
and raise hood.
fuel tank (1). Remove fuel sender.
4. Remove transmission oil cooler from vehicle. Refer
to Section 210-0060, TRANSMISSION OIL COOLER. ASSEMBLY
Numbers in parentheses refer to Fig. 2, unless
5. Remove padlock (13) and remove filler cap (2) from
otherwise stated.
fuel tank (1).
1. Install fuel sender to tank (1) using screws and
6. Remove fuel strainer (4) from fuel tank (1) and clean
washers.
with clean diesel fuel.
2. Install grab handles to fuel tank ().
7. With a suitable container in position, remove
drain plug from fuel tank (1) and drain fuel from fuel
3. Install step assembly (6) to fuel tank (1) and secure
tank (1). Reinstall drain plug and tighten securely when
using bolts (8) and washers (9).
fuel tank (1) is completely drained.
4. Install step plate (5) to fuel tank (1) and secure using
8. Identify and tag fuel lines (10, 11 & 13, Fig. 1) and,
bolts (7).
with a suitable container available to catch leakage,
disconnect fuel lines (10, 11 & 13, Fig. 1). Cap open
line ends and adaptors to prevent entry of dirt. INSTALLATION
Numbers in parentheses refer to Fig. 2, unless
9. Remove hose clamp mounting plate from inside face
otherwise stated.
of fuel tank (1) assembly.

10. Remove bolts (11) and washers (12) securing fuel

WARNING
sender guard (10) to fuel tank (1). Remove fuel sender
To prevent personal injury and property
guard (10). Disconnect electrical harness from fuel
damage, be sure wheel blocks, blocking
sender.
materials and lifting equipment are properly
secured and of adequate capacity to do the job
11. Using suitable lifting equipment, support fuel tank
safely.
(1) assembly. Ensure fender is adequately supported.
Remove fasteners securing fender to fuel tank (1)
Note: Tighten all fasteners to standard torques
assembly.
specified in Section 300-0080, STANDARD BOLT AND
NUT TORQUE SPECIFICATIONS.
12. Remove nuts (18), bolts (16), hardened washers
(17) and shims (19 - 23) securing fuel tank (1)
1. Using suitable lifting equipment, position fuel tank
assembly to the front frame rail.
SM 2186 12-02 3
Fuel System - Fuel System
Section 200-0040
(1) assembly to the front frame.
WARNINGS
2. Secure the front of fuel tank (1) assembly to the To prevent personal injury and property
front frame bumper with bolts (15), hardened washers damage, be sure wheel blocks and blocking
(17), shims (19 - 23) and nuts (18). Use shims (19 - 23) materials are properly secured and of adequate
as necessary to improve transverse alignment of fuel capacity to do the job safely.
tank (1) assembly.

3. Secure the inside of fuel tank (1) assembly to the To prevent personal injury or even death,
front frame rail with bolts (16), hardened washers (17), welding of the fuel tank is strictly prohibited at
shims (19 - 23) and nuts (18). Use shims (19 - 23) as all times, due to the hazardous flammable
necessary to improve longitudinal alignment of fuel liquids and vapours present inside the tank,
tank (1) assembly. even when empty.

4. Secure fender to fuel tank (1) assembly using

fasteners previously removed. General
Refill fuel tank (1) at the end of each day's operation to
5. Reconnect electrical harness to fuel sender. Fit fuel prevent condensation from contaminating the fuel.
sender guard (10) using bolts (11) and washers (12). When filling fuel tank (1), check that there is no buildup
of dirt and sludge at fuel strainer (4, Fig. 2) and filler
6. Refit hose clamp mounting plate to inside face of cap (2, Fig. 2). Remove and clean fuel strainer and
fuel tank (1) assembly. filler cap as required.

7. Remove blanking caps and secure fuel lines (10, 11

& 13, Fig. 1) to adaptors, as identified at removal. Every 10 Hours/Daily:
Make a visual check for fuel leaks at all engine
8. Install fuel strainer (4) in fuel tank (1). mounted fuel lines, connections and at the fuel tank
suction and return lines. Examine lines for leaks and
9. Fill fuel tank (1) assembly with clean diesel fuel check all fittings, clamps and ties carefully.
specified in Section 300-0020, LUBRICATION
SYSTEM. Make sure that fuel lines are not resting on or touching
rotating components, heated surfaces including
10. Install filler cap (2) assembly on fuel tank filler exhaust manifolds or sharp edges. If fittings have
neck. Tighten filler cap (2) securely and secure in place loosened or cracked, or if lines have ruptured or worn
with padlock (13). through, take corrective action immediately.

11. Install transmission oil cooler to vehicle. Refer to From time to time, remove fuel sender guard and
Section 210-0060, TRANSMISSION OIL COOLER. check condition of electrical connections at fuel level
sender.
12. Place the battery master switch in the 'On' position,
start the engine and run for a few minutes to ensure Fuel Filter/Water Separator (12) - Drain the water and
fuel is being supplied to the engine. Check for leaks at sediment from the separator daily.
fuel lines (10, 11 & 13, Fig. 1) and tighten if required.
Position the vehicle on a level work area, apply the
13. Remove wheel blocks from all road wheels. parking brake, shut off the engine and, with a suitable
container below the drain valve to catch spillage, open
the drain valve by hand. Turn the valve anticlockwise
MAINTENANCE approximately 1.5 to 2 turns until draining occurs. Drain
Numbers in parentheses refer to Fig. 1. the filter sump until clear fuel is visible. Turn the valve
clockwise to close the drain valve.

Note: Do not overtighten the drain valve as

overtightening can damage the threads.

4 SM 2186 12-02
 Fuel System - Fuel System
Section 200-0040

Every 500 Hours: TROUBLESHOOTING

Check condition of filler cap (2, Fig. 2) and clean fuel
strainer (4, Fig. 2) and filler cap with clean fuel. Locating Air Leaks in Fuel Lines
Air drawn into the fuel system may result in uneven
running of the engine, black or white smoking and
Every 1 000 Hours: stalling when idling, or a loss of power. Poor operation
Fuel Filter/Water Separator (12) - Clean the area is particularly noticeable at lower engine speeds. If air
around the filter head and replace the fuel filter/water is found in the fuel, the source will normally be
separator. between the fuel tank and the fuel pump.

Position the vehicle on a level work area, apply the Check for loose, faulty or improper fuel line
parking brake and switch off the engine. Using a strap connectors. Presence of an air leak may be detected
type filter wrench, remove the fuel filter/water separator by following the procedures under 'Checking Fuel Flow'.
and discard the thread adaptor sealing ring. Clean the
gasket surface of the filter head.
Checking Fuel Flow
Install the new thread adaptor sealing ring (supplied 1. Disconnect the fuel return line from the fitting at the
with new filter) and apply a film of clean engine oil to fuel tank and hold the open end in a suitable container.
lubricate the filter seal. Fill the new fuel filter/water
separator with clean fuel specified in Section 2. Start and run the engine at maximum rev/min and
300-0020, LUBRICATION SYSTEM. immerse the end of the fuel return line in the fuel. Air
bubbles rising to the surface of the fuel will indicate air
Install new fuel filter/water separator on the filter head being drawn into the fuel system on the suction side of
and tighten by hand until the gasket contacts the filter the pump. If air is present, tighten all fuel lines
head surface. Tighten fuel filter/water separator per connections between the fuel tank and fuel pump.
filter manufacturer's instructions.
3. If the fuel flow is insufficient for satisfactory engine
Note: Mechanical tightening of the filter is not performance then proceed as follows:
recommended and may result in seal and/or cartridge
damage. Tighten filter by hand only. a. Replace the fuel filter/water separator, as described
under 'Maintenance'. Start the engine and run it at
Fuel Filler Cap maximum rev/min and recheck for the presence of air.
Remove filler cap (2, Fig. 2) from filler neck. With the If fuel flow is still unsatisfactory, perform step 'b'.
handle in the up and rotated position, remove the two
screws securing the filter assembly (3, Fig. 2) to the b. Check the fuel lines for restrictions due to pinching,
cap. Discard 'O' rings. Clean top of filler cap and valve kinking or other damage. If no problem is found,
cavity. Install new filter assembly to filler cap using substitute another fuel pump that is known to be
new screws and 'O' rings (supplied with new filter). operating correctly and recheck the fuel flow. When
Tighten screws to 10 - 13 in lbs. changing the fuel pump, inspect the fuel pump drive.
Clean all fuel lines with compressed air and be sure all
fuel connections are tight.
Diesel Fuel Oil
The sulphur content of diesel fuel oil should be as low c. Disconnect the fuel lines from the ECM cooling
as possible to avoid premature wear of piston rings plate and, using a suitable connector, connect the two
and line, excessive deposit formation, and minimise fuel lines, bypassing the cooling plate. Run the engine
sulphur dioxide exhausted into the atmosphere. at maximum rev/min and recheck the fuel flow. If the
Limited amounts can be tolerated, but the amount of fuel flow with the cooling plate bypassed is normal, the
sulphur in the fuel and engine operating conditions can cooling plate should be replaced.
influence corrosion and deposit formation tendencies.
The use of diesel fuel oil with a MAXIMUM sulphur
content of 0.5% is recommended for use. Refer to
Section 300-0020, LUBRICATION SYSTEM.

SM 2186 12-02 5
Fuel System - Fuel System
Section 200-0040

SPECIAL TOOLS
There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.

* * * *

6 SM 2186 12-02
 FUEL SYSTEM - Electronic Foot Pedal
Section 200-0051

SM - 3711
4

1 - Pedal Assembly 4 - Transmission Kickdown Switch

2 - Bolt 5 - Idle Validation Switch
3 - Washer

Fig. 1 - Electronic Foot Pedal Assembly

DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.

The electronic foot pedal assembly provides an

electrical signal to the engine's fuel control system in WARNING
proportion to the degree of pedal actuation. Maximum To prevent personal injury and property
and minimum stops are built into the pedal assembly damage, be sure wheel blocks are properly
during manufacture. The pedal assembly comes preset secured and of adequate capacity to do the job
and therefore no adjustment is necessary. safely.

The pedal incorporates an idle validation switch (5) 1. Position the vehicle in a level work area, ensure the
which informs the engine ECM that the pedal is in the body is fully lowered, apply the parking brake and
idle position. Kickdown switch(4) , which can be used switch off the engine.
when automatic range is selected, allows for the
possibility of selecting a lower gear by pressing down 2. Block all road wheels and place the battery master
fully on pedal and holding (see Fig. 2). This can be switch in the 'Off' position.
used to provide a downshift on demand provided that
the vehicle speed is within the range allowable. That is, 3. Disconnect electrical harness from dash harness.
the vehicle is not travelling at a speed that would result
in the engine overspeeding in the lower gear. To 4. Remove bolts (2) and washers (3) securing pedal
disengage the transmission kickdown, release the assembly to cab wall. Remove pedal assembly.
pedal and allow it to return to a light throttle position.
Refer to Section 120-0010, TRANSMISSION AND
MOUNTING.

SM 2472 06-06 1
Fuel System - Electronic Foot Pedal
Section 200-0051

SM - 2798
Note: With the pedal at idle position, the diagnostic
reader should show 0%.

3. Press pedal fully to full throttle position (before

kickdown, ref. Fig. 2) and release three times.

Note: The diagnostic reader should show 100% at full

throttle position.

4. If these figures are achieved, the pedal is correctly

IDLE calibrated. Turn keyswitch off and remove diagnostic
reader.
FULL THROTTLE

KICKDOWN 5. If figures are not realised, the pedal will have to be

Fig. 2 - Accelerator Load Ranges and Kickdown Position re-calibrated. This can only be done by authorised
Cummins personnel. Please contact your local
INSTALLATION Cummins dealer.
Numbers in parentheses refer to Fig. 1.
TROUBLESHOOTING
Note: Tighten all fasteners to standard torques listed in
The pedal can be checked by measuring the voltage
Section 300-0080, STANDARD BOLT AND NUT
signal across the pedal harness.
TORQUE SPECIFICATIONS.
Voltage Ref: Measure voltage across red
1. Position pedal assembly on cab wall and secure with
and black wires - reading
bolts (2) and washers (3). Ensure that pedal assembly
should be 5V.
(1) is free to operate.
Pedal at Idle: Measure voltage across
2. Connect electrical harness to dash harness. Pedal
white and black wires -
must be calibrated before the machine is operated. See
reading should be less than
'Pedal Calibration'.
0.8V.
3. Place the battery master switch in the 'On' position,
Pedal at Full Throttle: Measure voltage across
remove wheel blocks and start the engine. Ensure that
white and black wires -
pedal (2) assembly operates correctly.
reading should be greater
than 3.1V.
Note: The engine should be started with the foot 'OFF'
pedal (2) assembly.
MAINTENANCE
PEDAL CALIBRATION Limited repair of the electronic foot pedal assembly is
by replacement of parts only. Refer to vehicle Parts
The pedal calibration must be checked if the harness is
Book for part numbers.
disconnected or the pedal replaced. Using Cummins
INSITE diagnostic reader, the pedal can be checked as
follows: SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
1. With engine off, turn keyswitch to position '1', and numbers of Cummins engine INSITE diagnostic tools
connect diagnostic reader. which can be used to check pedal calibration. These
tools are available from your dealer.

* * * *

2 SM 2472 06-06
 COOLING SYSTEM - Cooling System
Section 210-0000

SM - 3606

16 2

15
4
1
14

13 5
12 7

11

8
6

9 10

1 - Header Tank 5 - Charge Air Inlet Pipe 9 - Radiator Outlet Pipe 13 - Deaeration Line
2 - Radiator Assembly 6 - Engine Oil Cooler 10 - Radiator Inlet Pipe 14 - Filter Outlet Line
3 - Engine Water Pump 7 - Thermostat Housing 11 - Deaeration Line 15 - Filter Inlet Line
4 - Coolant Filter 8 - Make-up Line 12 - Deaeration Line 16 - Charge Air Outlet Pipe

Fig. 1 - Cooling Lines and Flow

DESCRIPTION The radiator assembly (2) consists of an air-to-air

charge cooler mounted on top of a radiator, with an air
Numbers in parentheses refer to Fig. 1.
conditioning condenser and a hydraulic oil cooler
mounted on the front.
A radiator and fan cooling system is used on the
Quantum engines installed in these vehicles. This
system has a centrifugal type water pump (3) to OPERATION
circulate coolant throughout the system. A full blocking
Numbers in parentheses refer to Fig. 1, unless
type thermostat located in thermostat housing (7),
otherwise specified.
attached to the right hand side of the cylinder head,
controls the flow of coolant.
Upon starting a cold engine or when the coolant is
below operating temperature, the coolant is restricted
The main components of the cooling system are;
at thermostat housing (7) and bypass line provides
header tank (1), radiator assembly (2), engine water
water circulation within the engine during the warm-up
pump (3), DCA4 coolant filter (4), engine oil cooler (6)
period.
and thermostat housing (7).

SM 2455 Rev 1 02-08 1

Cooling System - Cooling System
Section 210-0000
Note: The engine coolant thermostat starts to open at SM - 3276
82° C (180° F) and is fully open at 93° C (199° F). 3

Engine water pump (3) draws coolant from the radiator 1

through radiator outlet pipe (9). Engine water pump (3)
then pumps coolant through engine oil cooler (6) and
engine block and passes up through the cylinder head
to the thermostat housing (7).

When the coolant reaches operating temperature, the

thermostat opens, allowing coolant to flow into the 4
radiator through radiator inlet pipe (10). The coolant
REF: WATER FILTER
passes through a series of tubes in the radiator LHS ENGINE
assembly (2) core, where the coolant temperature is
lowered by the air stream created by the revolving fan,
and, into the radiator outlet pipe (9) to be re-circulated 2
back through the system.

Aerated coolant is drawn off to header tank (1) from the

radiator and engine through the deaeration lines
(11,12 and13). 1 - Air-to-Air Charge Cooler 3 - Outlet Pipe
2 - Inlet Pipe 4 - Inlet Pipe

The use of antifreeze is mandatory with the cooling

system. Refer to 'Recommended Coolants'. The lack of Fig. 2 - Air-to-Air Charge Cooler Lines and Flow
coolant flow through the radiator with the thermostats
closed allows the coolant in radiator assembly (2) to then exits the turbocharger through the inlet pipe (2)
freeze under low ambient temperature conditions. and enters air-to-air charge cooler (1). The hot air
travels through a series of tubes in air-to-air charge
cooler (1) core, where the air temperature is lowered.
Coolant Filter From here the air flows through outlet pipe (3) and into
The cooling system is protected by a replaceable spin- the engine intake manifold through inlet pipe (4). From
on type coolant filter (4) mounted on the left hand side the engine intake manifold the air travels into the
of the engine. The filter provides mechanical filtration cylinders where it mixes with atomized fuel from the
by means of a closely packed element through which injectors. This cooler air aids combustion, thereby
the coolant passes. Any impurities such as sand and increasing fuel economy.
rust particles suspended in the cooling system will be
removed by the straining action of the element. The PREVENTIVE MAINTENANCE
removal of these impurities will contribute to longer To ensure the continued efficient functioning of the
engine water pump (3) life and proper operation of the cooling system, certain checks and operations should
thermostat. be performed at regular intervals.

Coolant flows from the engine block (3) through filter

inlet line (15) and into coolant filter (4). Coolant flows WARNING
through the filter element and exits through filter outlet Do not remove the pressure control cap from
line (14) and back into the engine block. Shut-off cocks the radiator header tank or attempt to drain the
on both filter lines allow coolant filter (4) to be replaced coolant until the engine has cooled. Once the
with the minimum loss of coolant. engine has cooled, use extreme caution when
removing the cap. Remove cap slowly as the
sudden release of pressure from a heated
Air-To-Air Charge Cooling cooling system can result in a loss of coolant
Numbers in parentheses refer to Fig. 2. and possible personal injury (scalding) from
the hot liquid.
In the air system used on the Quantum engines,
outside air is drawn into the engine through the air
cleaner, passes through the air filter element and is
pulled into the turbocharger where it is compressed. It

2 SM 2455 Rev 1 02-08

 Cooling System - Cooling System
Section 210-0000

Every 10 Hours (Daily) Note: Under concentration of DCA4 coolant additive

Check coolant level and add recommended coolant if can result in liner pitting and system corrosion. Over
low. Fill the radiator header tank with coolant until concentration can result in water pump seal leakage.
coolant reaches the bottom of the filler neck and holds Always maintain DCA4 concentration at recommended
at that level. levels.
Note: There is a shut off valve at the coolant inlet and
Note: Any time a significant amount of coolant is outlet lines of coolant filter. Closing these valves will
added, the DCA4 coolant concentration MUST be enable coolant filter to be replaced without an
checked. Failure to use recommended coolant and to excessive loss of coolant.
maintain mixture at sufficient concentration levels can
result in damage to the cooling system and its related WARNING
components. Always maintain concentrations at Do not remove the pressure cap from a hot
recommended levels. Refer to 'Recommended engine. Wait until the coolant temperature is
Coolants'. below 50° C (120° F) before removing the
pressure cap. Heated coolant spray or steam
Check cooling fan for cracks and damage. Check fan can cause personal injury.
mounting and tighten if required. Replace cooling fan if
damaged. 1. Remove the cooling system pressure cap from
header tank.
Check coolant lines, pipes and components for leaks
and wear. Check drive belts for damage. 2. Close shut off valves at coolant filter inlet and outlet
lines and, using filter wrench, remove and discard
coolant filter from engine.
Every 250 Hours
Inspect the radiator and air-to-air charge cooler fins
and, if necessary, clean with a quality grease solvent WARNING
such as mineral spirits and dry with compressed air. A small amount of coolant can leak when
servicing the coolant filter with the shut off
Note: Fuel oil, kerosene or gasoline should not be used valves in the closed position. To avoid personal
to clean fins. injury, avoid contact with hot coolant.

Note: It may be necessary to clean radiator and 3. Clean the filter adaptor with a clean, lint free cloth.
air-to-air charge cooler fins more frequently if the
vehicle is being operated in extremely dusty or dirty 4. Lightly coat new coolant filter seal with clean engine
areas. oil as specified in Section 300-0020, LUBRICATION
SYSTEM.
WARNING 5. Start coolant filter on the filter adaptor and tighten it
To prevent possible injury when using by hand until the seal touches the adaptor filter head.
compressed air, wear adequate eye protection Tighten an additional 1/2 to 3/4 of a turn after contact,
and do not exceed 2.75 bar (40 lbf/in²). or as specified by the filter manufacturer.
Every 500 Hours
Note: Mechanical tightening of coolant filter is not
Check and replenish the DCA4 concentrations as necessary and will distort or crack the adaptor. Tighten
described under 'Coolant Recommendations' in this coolant filter by hand only.
section.
6. Open shut off valves at coolant filter inlet and outlet
The DCA4 coolant filter must be replaced. When lines, and install pressure cap on header tank.
testing the DCA4 concentration, the level of DCA4
determines which coolant should be installed. Refer to 7. Start the engine and check for leaks. If any leaks are
instructions under 'Coolant Recommendations' in this noted, have them corrected. Add recommended coolant
section.

SM 2455 Rev 1 02-08 3

Cooling System - Cooling System
Section 210-0000
as required. 5. Shut off the engine and drain the cooling system.

Note: Any time a significant amount of coolant is added, 6. Fill the cooling system with clean water and operate
the coolant concentration MUST be checked. the engine at high idle for 5 minutes with the coolant
temperature above 85° C (185° F).
Every 4 000 Hours (or two years)
Whichever interval arrives first: Drain and flush the WARNING
cooling system as described under 'Cleaning the Do not remove the filler cap from the radiator
Cooling System' in this section. Fill the cooling system header tank or attempt to drain the coolant until
with the correct mixture of antifreeze, water and DCA4 the engine has cooled to below 50° C (120° F).
liquid as described under 'Coolant Recommendations'
7. Shut off the engine and drain the cooling system.
in this section.
Note: If the water being drained is still dirty, the
Cleaning The Cooling System
system must be flushed again until the water is clean.

8. Refill the cooling system with the proper mix of

WARNING coolant and water and install new DCA4 coolant filter.
Do not remove the pressure control cap from Refer to instructions under 'Recommended Coolants'.
the radiator header tank or attempt to drain the
coolant until the engine has cooled. Once the 9. Install filler cap on the radiator header tank, operate
engine has cooled, use extreme caution when the engine and check for coolant leaks.
removing the cap. Remove cap slowly as the
sudden release of pressure from a heated
cooling system can result in a loss of coolant RECOMMENDED COOLANTS
and possible personal injury (scalding) from
the hot liquid. WARNING
Hazardous substance. To prevent personal
Note: It is recommended to use a cleaner such as injury, wear appropriate personal protective
Fleetguard RESTORE, or equivalent, when cleaning equipment when there is a risk of contact or
the cooling system. inhalation of fumes. Always work in a well
ventilated area.
1. Drain the cooling system. Do not allow the cooling
system to dry out or remove the DCA4 coolant filter.
WARNING
2. Add 3.8 litres (1 US gal) of cleaner for each If substance gets into your eyes, immediately
38 - 57 litres (10 - 15 US gal) of cooling system flush eyes gently with water for at least 15
capacity, and fill the system with clean water. minutes. Seek immediate medical attention.
If substance contacts skin, immediately flush
Note: Fleetguard RESTORE contains no antifreeze and with water for at least 15 minutes. Remove
the cooling system should not be allowed to freeze contaminated clothing. Wash affected area with
during the cleaning operation. soap and water and seek immediate medical
attention.
3. Slide the heater temperature control to high to allow
If substance is swallowed or inhaled, seek
maximum coolant flow through the heater core. The
immediate medical attention.
blower switch does not have to be on.

4. Operate the engine at normal operating temperature,

Heavy duty diesel engines installed in these vehicles
at least 85° C (185° F) for 1 - 1.5 hours.
require a heavy duty coolant for optimum performance.
Heavy duty coolant is defined as a correct mixture of
good quality water, low silicate antifreeze and
WARNING
supplemental coolant additives (SCA's).
Do not remove the filler cap from the radiator
header tank or attempt to drain the coolant until
Water quality is important for cooling system
the engine has cooled to below 50° C (120° F).
performance. Excessive levels of calcium and

4 SM 2455 Rev 1 02-08

 Cooling System - Cooling System
Section 210-0000

magnesium contribute to scaling problems, and pitting, corrode brass and copper, damage heat transfer
excessive levels of chlorides and sulphates cause surfaces and damage seals and hoses.
cooling system corrosion.
DCA4 Test Kit
It is recommended to use a low silicate antifreeze The test kit must be used:
concentrate that meets ASTM D4985 specifications
(less than 0.1% silicate). Low silicate antifreeze must 1. When excessive coolant loss occurs.
be mixed with quality water at a 50/50 ratio (40 to 60%
working range). A 50/50 mixture of antifreeze and water 2. After every 250 hours of operation.
gives a -37° C (-34° F) freeze point and a boiling point
of 109° C (228° F). The actual lowest freeze point of 3. If the concentration is known to be above the high
ethylene glycol antifreeze is at 68%. Using higher limit of 0.8 units per litre. Test at each subsequent oil
concentrations of antifreeze will raise the freeze point change until the concentration decreases below the
of the solution and increase the possibility of a silicate high limit.
gel problem. A refractometer must be used to
accurately measure the freeze point of the coolant. Note: Do not use the test kit to omit or extend the
Refer to 'Special Tool and Test Kit'. service intervals unless the concentration is above
0.8 units per litre.
Supplemental coolant additives (DCA4), or equivalent,
are used in conjunction with water and antifreeze to The test strip container is marked with an expiration
prevent liner pitting, corrosion and scale deposits in the date and the plastic container must be securely
cooling system. The cooling system must be tightened to protect the moisture sensitive strips.
precharged with the correct concentration of DCA4. Discard the strips if there is any doubt about the test
Refer to the relevant 'Precharge Chart' in this section. strip quality.
When coolant is replaced in the field, it must be
replaced with heavy duty coolant precharged with
DCA4. In addition, a service coolant filter must be
Test Instructions
installed. Together, this will result in a total precharge 1. Collect coolant sample from the radiator or pet cock.
of approximately 0.33 DCA4 units per litre of coolant. DO NOT collect from the coolant recovery or overflow
system. Coolant must be between 10° C and 54° C
Proper blending of heavy duty coolant is achieved as when tested.
follows:
2. Remove one strip from the bottle and replace cap
a. Pour water into a suitable clean container. immediately. DO NOT touch the pads on the end of the
strip.
b. Add the same quantity of low silicate antifreeze to
the water. Note: Discard kit if unused strips have turned light
brown or pink.
c. Add the correct quantity of DCA4 liquid for the
cooling system capacity required. Refer to the relevant 3. Dip strip in coolant sample for one second, remove,
'Precharge Chart' in this section for DCA4 quantities. and shake strip briskly to remove excess liquid.
Refer to Section 300-0020, LUBRICATION SYSTEM
for cooling system capacity. 4. 45 seconds after dipping strip compare and record
results in the following order:
d. Thoroughly blend all components.
a. Compare Freeze Point (end pad) to colour chart and
Note: Following the correct order for mixing the heavy record the result.
duty coolant will prevent additive dropout during the
mixing process. b. Next, compare Sodium Molybdate (middle pad) to
colour chart and record the result.
Note: The cooling system must be clean before adding
DCA4 liquid. c. Finally, compare Sodium Nitrate test to colour chart
and record the result.
Note: Do not use soluble oils in the cooling system.
The use of soluble oils will lead to cylinder lining 5. All three readings must be completed no later than

SM 2455 Rev 1 02-08 5

Cooling System - Cooling System
Section 210-0000

75 seconds after dipping the strip. service chart' and the amount specified in the
respective 'Precharge Chart'. Replace the DCA4
6. It is okay to estimate a value between colour blocks, coolant filter.
but if uncertain about the colour match, pick the lower
numbered block. Between 0.3 and 0.8 units per litre - Add the normal
amount of DCA4 liquid as specified in the respective
7. Determine where the Sodium Molybdate level 'Service Chart'. Replace the DCA4 coolant filter.
intersects the Sodium Nitrite level on the chart. The
amount of SCA units per litre in the cooling system is Above 0.8 units per litre - Do not replace the DCA4
given where the Sodium Molybdate row intersects the filter or add liquid DCA4 until the concentration drops
Sodium Nitrite column. below 0.8 units per litre. The concentration must be
tested at every subsequent 250 hour service interval
Note: For best results follow test times carefully. Use a until concentration decreases below 0.8 units per litre.
stopwatch or clock with a sweep second hand.
Comparing the test strip to the colour chart too soon
SPECIAL TOOL AND TEST KIT
before, or too late after, the required test time will result
in incorrect readings and improper treatment, and could Refer to Section 300-0070, SERVICE TOOLS, for part
result in liner pitting and engine damage. numbers of the refractometer and coolant test kit
referenced in this section. These items are available
8. All readings should be recorded on the truck from your dealer.
maintenance record for future reference.
SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
Treatment Instructions numbers of the coolant test strips and general service
If the concentration is: tools required. These strips and tools are available
from your dealer.
Below 0.3 units per litre - Add both the normal
amount of DCA4 liquid as specified in the respective

COOLING SYSTEM DIAGNOSIS CHART

Engine coolant temperature Low coolant level Fill coolant system to correct fill level
too high Check for leaks and repair
Faulty radiator pressure cap Check pressure cap, replace if required
Air in cooling system Purge air from cooling system
Front of radiator obstructed Remove obstruction and clean radiator
preventing free flow of air fins
Fan drive belt broken or Adjust or replace fan belt
slipping
Thermostat not opening Replace thermostat
Restricted cooling system Flush cooling system
passages
Faulty engine water pump Repair or replace engine water pump
Engine coolant temperature Thermostat remains open or Replace thermostat
too low open at too low a temperature
Leakage around thermostat Replace thermostat seal
seal
Extremely cold weather Cover radiator or install radiator shutters

* * * *

6 SM 2455 Rev 1 02-08

 COOLING SYSTEM - Radiator and Mounting
Section 210-0040
36 SM - 3604

42 41 46
1
37 45 47
37 2
43
38 44 48 8
3
39
33 4 49
32 7 50
5 51
35
6

28
35 67
34
68
30
67
66 31 27 29 12
65 26 29 9
25
24 52
14 53
60 20 54
64 15
61
55
62 59 57 56
63
58 21
14 22
23
17 19 14
15 10
14 13
18 14
40
15
14 11
17 16

1 - Bolt 19 - Coolant Inlet Pipe 36 - Bolt 53 - Plate Bent

2 - Washer 20 - Hose Assy 37 - Washer 54 - Washer
3 - Nut 21 - Connector 38 - Nut 55 - Grommet
4 - Bolt 22 - Shut-Off Valve 39 - Bracket Assembly 56 - Lockwasher
5 - Snubbing Washer 23 - Plug 40 - Snubbing Washer 57 - Bolt
6 - Rubber Mounting 24 - Elbow 41 - Clip 58 - Nut
7 - Nut 25 - Reducer 42 - bolt 59 - Clip
8 - Support Bracket 26 - Connector 43 - Washer 60 - Nut
9 - Connector 27 - Clamp 44 - Nut 61 - Washer
10 - Snubbing Washer 28 - Deaeration Line 45 - Spring Loaded Clamp 62 - Clip
11 - Bolt 29 - Connector 46 - Clip 63 - Bolt
12 - Connector 30 - Deaeration Line 47 - Washer 64 - Plate Bent
13 - Rubber Mounting 31 - Make-up Line 48 - Nut 65 - LockNut
14 - Clamp 32 - Header Tank 49 - Clip 66 - Washer
15 - Hose 33 - Filler Cap 50 - Washer 67 - Tee
16 - Coolant Outlet Pipe 34 - Deaeration Line 51 - Nut 68 - Clamp
17 - Clamp 35 - Connector 52 - Bolt
18 - Hose
Fig. 1 - Exploded View of Radiator Mounting and Hoses

DESCRIPTION conditioning condenser and a hydraulic oil cooler

mounted on the front. Refer to Section 210-0000,
Numbers in parentheses refer to Fig. 1, unless
COOLING SYSTEM.
otherwise specified.
Fan plate assembly (9, Fig. 2) improves the engine
Radiator assembly is mounted in front of the engine
cooling fan efficiency, provides a more uniform
cooling fan at the front end of the vehicle. It is fed from
distribution of air over charge air cooler core (1, Fig. 2)
header tank (32) located in front of the operators
and radiator core (2, Fig. 2) and helps restrict
compartment and mounted to the goalpost
recirculation of air within the engine compartment.
arrangement.
Recirculation baffles (11 &12), incorporated in the hood
The radiator assembly consists of an air-to-air charge
assembly prevent hot air from the engine cooling fan
cooler mounted on top of a radiator, with an air
being reintroduced into the cooling air circuit.

SM 2325 Rev1 03-06 1

Cooling System - Radiator and Mounting
Section 210-0040

SM - 3296

13

5
1
11
10
6
12
9

7 2

1 - Charge Air Cooler Core 5 - LH Column 9 - Fan Plate Assy

2 - Radiator Core 6 - RH Column 10 - Fan Cowl Assy
3 - Top Column 7 - LH Fan Guard 11 - LH Baffle Plate
4 - Bottom Column 8 - RH Fan Guard 12 - RH Baffle Plate
13 - Bent Plate

Fig. 2 - Exploded View of Radiator Assembly

REMOVAL
WARNING
Numbers in parentheses refer to Fig. 1, unless To prevent personal injury and property
otherwise specified. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
WARNING safely.
Do not remove the pressure control cap from
the radiator header tank or attempt to drain the 1. Position the vehicle in a level work area, apply the
coolant until the engine has cooled. Once the parking brake and switch off the engine.
engine has cooled, use extreme caution when
removing the cap. Remove cap slowly as the 2. Block all road wheels and place the battery master
sudden release of pressure from a heated switch in the 'Off' position.
cooling system can result in a loss of coolant
and possible personal injury (scalding) from 3. Pull on handle to release hood catch mechanism
the hot liquid. and raise hood.

4. Remove hood assembly from the vehicle. Refer to

Section 100-0040, HOOD AND MOUNTING.

2 SM 2325 Rev1 03-06

 Cooling System - Radiator and Mounting
Section 210-0040
5. Disconnect electrical harness from horns, and SM - 3276
3
remove horns and mounting from front of radiator.
Disconnect electrical harness from engine cooling fan.
1
6. Remove filler cap (33) carefully from header tank
(32).

7. Remove plug (23) and open shut-off valve (22) at the

bottom of radiator assembly and drain coolant into a
suitable container. Close shut-off valve (22) when
coolant is completely drained and refit plug (23). 4
REF: WATER FILTER
LHS ENGINE
8. Remove bolt (4), snubbing washer (5) and nut (7)
securing support bracket (8) to the engine bracket.

9. Remove bolts (1), washers (2) and nuts (3) securing 2

support bracket (8) to mounting brackets on radiator
assembly. Remove support bracket (8).

10. Ensure air conditioning lines from condenser 1 - Charge Air Cooler 3 - Outlet Pipe
mounted on front of charge air cooler (1, Fig. 2), and 2 - Inlet Pipe 4 - Inlet Pipe
from receiver drier mounted at rear left hand side of
radiator assembly are identified for ease of installation.
Fig. 3 - Air-To-Air Charge Cooler Piping
Disconnect air conditioning lines. Fit blanking caps to
open lines and ports.
16. Remove nut, washers and clamp securing air outlet
Note: Refer to Section 260-0130, AIR CONDITIONING pipe (3, Fig. 3).
before disturbing the air conditioning circuit.
17. Slacken clamps securing cooler hoses to air outlet
11. Ensure hydraulic lines connected to hydraulic oil pipe (3, Fig. 3) and remove air outlet pipe (3, Fig. 3)
cooler mounted on front of radiator (2, Fig. 2) are from charge air cooler (1, Fig. 3) and inlet pipe (4, Fig.
identified for ease of installation and with suitable 3).
containers available to catch leakage, disconnect
hydraulic lines. Fit blanking caps to open lines and 18. Slacken clamps (14) and remove coolant inlet pipe
ports. (19), hoses (15) and clamps (14) from radiator
assembly and engine thermostat housing.
12. Disconnect deaeration line (28) from connector (9)
in radiator and deaeration lines (30 & 34 ) from elbows 19. Slacken clamps (14 & 17) and remove coolant
(29) in engine and pipe (19). Identify lines for ease of outlet pipe (16), hoses (15 & 18) and clamps (14 & 17)
installation and cap open lines and elbows. from bottom of radiator assembly and engine water
pump inlet.
13. Disconnect all clips and clamps securing air
conditioning lines, hydraulic lines and deaeration lines 20. Install two eye bolts in lifting bosses on side of
to radiator assembly. Move all lines away from radiator radiator assembly. Using suitable lifting equipment
assembly to prevent fouling on removal of radiator support radiator assembly.
assembly.
21. Remove bolts (11), washers (10), snubbing
14. Remove bolts, washers and nuts securing fan washers (40) and mounts (13) securing radiator
guards (7 & 8, Fig. 2) to radiator assembly. Remove assembly to the frame.
fan guards (7 & 8, Fig. 2) from radiator assembly.
22. Remove radiator assembly from the vehicle to a
15. Slacken clamps securing cooler hoses to air inlet clean area for disassembly. Support radiator standing
pipe (2, Fig. 3) and remove air inlet pipe from charge air upright to allow access to front and rear of radiator.
cooler (1, Fig. 3) and engine turbocharger.
Note: If Header Tank (32) requires to be removed,
follow steps 23 through 28.

SM 2325 Rev1 03-06 3

Cooling System - Radiator and Mounting
Section 210-0040
23. Disconnect electrical harness from coolant level Remove fan cowl assembly (10) from radiator
sensor at bottom of header tank (32). assembly.

24. With a suitable container available to catch 7. Remove remaining bolts and washers securing top
leakage, remove drain plug from radiator header tank column (3), LH column (5), RH column (6) and bottom
(32) and drain coolant. Apply Loctite 225 to drain plug column (4) to charge air cooler core (1) and radiator
and reinstall in header tank. core (2).

25. Ensure all cooling lines connected to header tank

are identified for ease of installation and with suitable INSPECTION
containers available to catch leakage, disconnect Numbers in parentheses refer to Fig. 2.
deaeration lines (28 & 30) and overflow line (34). Fit
blanking caps to all open lines. 1. Steam clean all parts thoroughly with a suitable
solvent.
26. Slacken clamp (27) and disconnect make-up line
(31) from header tank (32). Blank off open line end. 2. Examine charge air cooler core (1), radiator core (2),
condenser core and hydraulic oil cooler core carefully
27. Following removal instructions in Section for possible damage. Repair any damage discovered if
100-0040, HOOD AND MOUNTING, remove goalpost equipped to do so, or, have repairs made at a reputable
and header tank (32) as an assembly from the vehicle. radiator repair shop.

28. Remove bolts (36), nuts (38) and washers (37)

securing header tank (32) to goalpost. Remove header ASSEMBLY
tank (32) from goalpost. Numbers in parentheses refer to Fig. 2, unless
otherwise specified.

DISASSEMBLY Note: Tighten all fasteners to standard torques listed in

Numbers in parentheses refer to Fig. 2, unless Section 300-0080, STANDARD BOLT AND NUT
otherwise specified. TORQUE SPECIFICATION.

Note: Take care not to damage charge air cooler core 1. Fit RH column (6) and LH column (5) to charge air
(1), radiator core (2), condenser core and hydraulic oil cooler core (1) and radiator core (2) using fasteners
cooler core during disassembly. removed during 'Disassembly'. If baffle plates (11 & 12)
were removed during disassembly; refit accordingly.
1. Remove nut (58), bolt (52) and clip (59) from bracket
(53) allowing removal of drain cock assembly (12, 20 & 2. Secure mounts (7) to bottom column (4) with bolts
23, Fig. 1) from bottom of radiator core (2). Remove removed during 'Disassembly'.
connector (9, Fig. 1) from radiator core (2).
3. Fit top column (3) and bottom column (4) to radiator
2. Remove receiver drier and mounting from rear of assembly using fasteners removed during
radiator assembly. 'Disassembly'.

3. Remove mounting hardware securing hydraulic oil 4. Position fan cowl assembly (10) to radiator
cooler to radiator assembly. Remove hydraulic oil assembly and secure with fasteners removed during
cooler from radiator assembly. 'Disassembly'.

4. Remove mounting hardware securing air conditioning 5. Position fan plate assembly (9) to radiator assembly
condenser to radiator assembly. Remove condenser and secure with fasteners removed during
from radiator assembly. 'Disassembly'.

5. Remove bolts, washers and nuts securing fan plate Note: When installing radiator, ensure clearance around
assembly (9) to radiator assembly. Remove fan plate cooling fan tips to plate assembly is of equal
assembly (9) from radiator assembly. dimension all round.

6. Remove bolts and washers securing fan cowl

assembly (10) to radiator assembly.

4 SM 2325 Rev1 03-06

 Cooling System - Radiator and Mounting
Section 210-0040
6. Install air conditioning condenser and hydraulic oil 7. Secure air outlet pipe (3, Fig. 3) with clamp, nut and
cooler to radiator assembly picking up mounting washers removed during 'Removal'.
locations and hardware as identified at 'Disassembly'.
8. Install air inlet pipe (2, Fig. 3) between engine
7. Fit connector (9, Fig. 1) to radiator core (2), torque turbocharger and charge air cooler (1, Fig. 3) and
connector (9) to 35 Nm ( 26 Ibf ft). secure with hoses and clamps.

8. Fit drain cock assembly (12, 20 & 23, Fig. 1) to 9. Feed electrical harness from engine cooling fan
bottom of radiator core (2). Secure in place using clip through hole in fan plate assembly (9, Fig. 2). Fit
(59), bolts (52) nut (58) located on plate (53). grommet if previously removed.

9. Install receiver drier to rear of radiator assembly 10. Connect engine cooling fan electrical harness to
picking up mounting locations and hardware as main electrical harness.
identified at 'Disassembly'.
11. Install LH and RH fan guards (7 & 8, Fig. 2) to
radiator assembly with bolts, washers and nuts
INSTALLATION removed during 'Removal'.
Numbers in parentheses refer to Fig. 1, unless
otherwise specified. 12. Remove blanking caps from deaeration lines
(28 , 30 & 34) and connect deaeration line (28) to
Note: Tighten all fasteners without special torques connector (9) in radiator assembly, deaeration line (30)
specified to standard torques listed in Section to connector (29) in engine and deaeration line (34) to
300-0020, STANDARD BOLT AND NUT TORQUE pipe (19). Do not clip lines at this point.
SPECIFICATIONS.
13. Remove blanking caps from hydraulic oil cooler
lines and fittings. Connect all hydraulic lines to
WARNING hydraulic oil cooler as identified at removal.
To prevent personal injury and property
damage, be sure lifting equipment is properly 14. Remove blanking caps from air conditioning lines
secured and of adequate capacity to do the job and fittings. Connect air conditioning lines to condenser
safely. and receiver drier. Refer to Section 260-0130, AIR
CONDITIONING for procedure on charging the system.
1. Using suitable lifting equipment, position radiator
assembly on the frame and secure with bolts (11), 15. Secure all lines with clips and clamps as removed
washers (10), mounts (13) and snubbing washers (40). during removal. Ensure no lines are chaffing on sharp
edges or resting against areas where heat will be
2. Position support bracket (8) on mounting brackets at evident.
top of radiator assembly and secure in place with bolts
(1), washers (2) and nuts (3). 16. Ensure fittings, lines and pipes are securely
tightened to prevent leaks at initial fill and start up.
3. Secure support bracket (8) to engine bracket with
bolt (4), snubbing washer (5), rubber mounts (6) and nut Note: If Header Tank (32) was removed and has not
(7). yet been installed, proceed from step 17, however, if
header tank (32) was not removed or has been
4. Install coolant outlet pipe (16) between radiator outlet reinstalled, proceed from step 24.
port and engine water pump inlet, and secure with
hoses (15 & 18) and clamps (14 & 17). 17. Fit header tank (32) to goalpost and secure using
bolts (36), nuts (38) and washers (37).
5. Install coolant inlet pipe (19) between radiator inlet
port and engine thermostat housing, and secure with 18. Following installation instructions in Section
hoses (15) and clamps (14). 100-0040, HOOD AND MOUNTING, install header tank
(32) and goalpost assembly on the vehicle.
6. Install air outlet pipe (3, Fig. 3) between engine inlet
pipe (4, Fig. 3) and charge air cooler (1, Fig. 3) and 19. Remove blanking from make-up line (31) and
secure with hoses and clamps. connect to header tank (32). Secure with clamp (27).

SM 2325 Rev1 03-06 5

Cooling System - Radiator and Mounting
Section 210-0040
20. Remove blanking caps from deaeration lines Rapid circulation or agitation with compressed air will
(28 & 30) and connect to appropriate fittings on header reduce the time for cleaning.
tank (32), as noted on removal.
Note: If scale deposits within the radiator are
21. Secure all lines with clips and tie clips as removed exceptionally heavy, concentrations up to 200 kg/m³
during removal. Ensure no lines are chaffing on sharp may be used.
edges or resting against areas where heat will be The most convenient method of use is to prepare a
evident. concentrated solution by mixing the powder in hot
water in a tank and then adding the concentrated
22. Connect electrical harness to coolant level sensor solution to water contained in the radiator.
at bottom of header tank (32).
Note: The solvent must always be added carefully to
23. Refer to Section 210-0000, COOLING SYSTEM for water, not water to solvent.
correct selection of coolant. Fill the cooling system
through filler in header tank (32) with coolant until
coolant level stabilizes at the bottom of filler neck. External Cleaning
Note: If a build up of dirt is apparent during routine
24. Check all line and pipe connections for leaks prior inspection, the following cleaning procedure should be
to starting the vehicle. Tighten as required. adopted.

25. Switch the battery master switch to the 'On'

position, start up the engine and check for leaks. WARNING
Tighten lines and fittings and top up coolant level as To prevent possible injury when using
required. compressed air or steam jet, wear adequate eye
protection and do not exceed pressure values
26. Install filler cap (33) on header tank (32) after the stated.
coolant level has stabilized at the bottom of filler neck.
1. Direct a steam jet at 100 - 300 kN/m², or
27. Following installation instructions in Section compressed air at 500 - 700 kN/m² on to the faces of
100-0040, HOOD AND MOUNTING, install hood the radiator core.
assembly on the vehicle.
2. Liberally brush a liquid detergent on to those
28. Remove wheel blocks from road wheels. surfaces which were not satisfactorily cleaned at
step 1. Leave to soak for at least 1 hour.

CLEANING 3. Apply a high pressure steam jet at 100 - 300 kN/m², or

compressed air at 500 - 700 kN/m² on to the treated
Internal Cleaning - Water Tubes surfaces, forcing the fouling material out from the radiator
If scale deposits are present inside the water tubes of core.
the radiator, it is necessary to use a suitable scale
remover such as 'Powdered Scale Solvent', or 4. Leave radiator core to dry before reinstalling the
equivalent. This material is a free-flowing powder, cooling equipment.
inhibited to prevent attack on the cooling system
materials. Note: In the case of grossly fouled surfaces which are
not cleaned adequately in steps 1 through 4, the
following procedure may be used.
WARNING
Take care to avoid contact of skin or eyes with 5. Ensure that the radiator core is dry.
the solvent. If contact is made it should be
washed off immediately with clean water and 6. Liberally brush on to both sides of the radiator core
medical advice should be taken. an emulsifying cleaner such as 'Gunk', or equivalent,
and leave to soak for at least 1 hour.
For general cleaning use it is recommended to use a
concentration of 50 - 100 kg/m³ of water at a
temperature of up to 60° C.

6 SM 2325 Rev1 03-06

 Cooling System - Radiator and Mounting
Section 210-0040
7. Apply a high pressure steam jet at 100 -300 kN/m², MAINTENANCE
or compressed air at 500 - 700 kN/m² on to the treated
Refer to Section 210-0000, COOLING SYSTEM for
surfaces, from several different angles, forcing the
recommended preventive maintenance procedures,
fouling material out from the radiator core.
service intervals and coolant selection procedures.
8. For surfaces with stubborn deposits, it may be SPECIAL TOOLS
necessary to repeat steps 5 through 7, brushing the
There are no special tools required for procedures
surfaces between stages using a stiff bristle brush.
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
9. Leave radiator core to dry before reinstalling the tools and adhesives required. These tools and
cooling equipment. adhesives are available from your dealer.

* * * *

SM 2325 Rev1 03-06 7

Cooling System - Radiator and Mounting
Section 210-0040

THIS PAGE IS INTENTIONALLY BLANK

8 SM 2325 Rev1 03-06

 COOLING SYSTEM - Transmission Oil Cooler
Section 210-0060

SM - 2821

12,
13,14
6

16
TRANS. RETARDER 21
HOUSING 5
7
19

12,
13,14

16
8,9,10,11 3 TRANSMISSION
OIL COOLER
15
2 8,9,10,11

15 20
1 17
18
TO HYDRAULIC TO HYDRAULIC
TANK OIL COOLER
TRANSMISSION OIL
TEMP. SENDER
FROM MAIN
HYDRAULIC
VALVE

1 - Elbow 6 - Bracket 11 - Bolt 16 - Elbow

2 - Elbow 7 - Bracket 12 - Clamp 17 - Hose
3 - Hose 8 - Clamp 13 - Plate 18 - Hose
4 - Tube Assy 9 - Bushing 14 - Screw 19 - Hose
5 - Tube Assy 10 - Stacking Nut 15 - 'O' Ring 20 - Hose
21 - Motor
Fig. 1 - Transmission Oil Cooler Lines

DESCRIPTION AND OPERATION The fan motor (21) is proportionally controlled by the
Numbers in parentheses refer to Fig. 1, unless hydraulic ECU. The higher the transmission
otherwise stated. temperature, the more hydraulic oil is supplied to the
fan motor (21) through hose (18). Refer to Section 215-
The transmission oil cooler (1, Fig. 2) is mounted on 0050, MAIN HYDRAULIC VALVE. Hydraulic oil leaving
the right hand side of the tractor, on top of the fuel the fan motor (21) returns through hose (20) to the
tank. The transmission oil cooler is an air blast cooler, hydraulic tank via the hydraulic oil cooler.
using hydraulic oil from the main hydraulic circuit to
supply the fan motor (21). An isolation solenoid valve also controls flow to the fan
motor (21), preventing hydraulic oil being supplied to
Transmission oil to be cooled exits from the bottom the motor (21) until the transmission oil temperature
port of transmission retarder housing and flows through increases to 90° C (194° F). This prevents the
hose (17) and tube assembly (5) into bottom of cooler transmission oil being overcooled. Refer to Section
(1, Fig. 2). Transmission oil flows through the crossflow 215-0050, MAIN HYDRAULIC VALVE.
core and is cooled by air flow produced by the rotation
of fan (4, Fig. 2), which is driven by motor (21). Cooled The isolation solenoid valve, mounted on the right hand
transmission oil then exits the top of cooler (1, Fig. 2) fender, is failsafe i.e. if the solenoid fails, the valve will
and flows through tube assembly (4) and hose (3) and default to an open position, allowing hydraulic oil to the
into the top port of transmission retarder housing. motor (21). The solenoid valve is controlled by the
hydraulic ECU (refer to Section 190-0085, HYDRAULIC
SYSTEM ECU).

SM 2190 Rev1 12-04 1

Cooling System - Transmission Oil Cooler
Section 210-0060

SM - 3374

24
23

25 1
21
9 8
10
13

11 26 14
20 12 15
19 16
18

19 20 6
18
29
9 5
8
17

3
25

24
3
2 22
7
23
25

20
19
18

1 - Cooler 8 - Bolt 14 - Washer 20 - Washer

2 - Fan Ring Assy 9 - Washer 15 - Lockwasher 21 - Bracket
3 - Motor 10 - Nut 16 - Nut 22 - Bracket
4 - Fan 11 - Toothed Washer 17 - Fan Guard 23 - Bolt
5 - Adaptor 12 - Washer 18 - Bolt 24 - Washer
6 - Mounting 13 - Nut 19 - Lockwasher 25 - Seal
7 - Elbow 26 - Beading

Fig. 2 - Exploded View of Transmission Oil Cooler Assembly

REMOVAL switch in the 'Off' position.

Numbers in parentheses refer to Fig. 4, unless
otherwise specified. 3. Pull on handle to release hood catch and raise hood.

4. Remove hood assembly from the vehicle. Refer to

WARNING Section 100-0040, HOOD AND MOUNTING.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 5. Open drain valve (14) at the bottom of the cooler
materials and lifting equipment are properly assembly and drain transmission oil into a suitable
secured and of adequate capacity to do the job container. Close drain valve when oil is completely
safely. drained.

1. Position the vehicle in a level work area, apply the 6. Remove bracket from rear of cooler. It may be
parking brake and switch off the engine. Turn steering possible to remove bracket without disturbing hoses.
wheel several times to relieve any pressure in the
steering circuit. Operate brake pedal continuously to 7. With a suitable container available to catch leakage,
relieve pressure in the braking system. disconnect supply hose (18, Fig. 1), case drain hose
(19, Fig. 1) and return hose (20, Fig. 1) from fan motor
2. Block all road wheels and place the battery master (21, Fig. 1) and secure clear of transmission oil cooler.

2 SM 2190 Rev1 12-04

 Cooling System - Transmission Oil Cooler
Section 210-0060

SM - 2823

4
7 10

1
9
6
3 2
8
11

5 12

1 - Cooler Core 5 - Bottom Channel 9 - Baffle

2 - Side Column 6 - Cowl Assy 10 - Baffle
3 - Side Column 7 - End Column 11 - Baffle
4 - Top Channel 8 - End Column 12 - Adaptor

Fig. 3 - Exploded View of Transmission Oil Cooler

Fit blanking caps to open lines and ports. DISASSEMBLY

Numbers in parentheses refer to Fig. 2, unless
8. With a suitable container available to catch leakage, otherwise stated.
disconnect transmission hoses (3 & 17, Fig. 1) from
tube assemblies (4 & 5, Fig. 1). Fit blanking caps to Note: Take care not to damage cooler core during
open lines and ports. disassembly.

9. Support transmission oil cooler assembly with 1. Remove clamp (6, Fig. 1) and mounting hardware
suitable lifting equipment. (12 - 14, Fig. 1) securing tube assembly (4, Fig. 1) to
cooler (1).
10. Remove nuts (11), bolts (1), hardened washers (8 &
9), isolators (5) and washers (10) from cooler brackets 2. Disconnect tube assembly (4, Fig. 1) from elbow
(2) and support plate (6). (16, Fig. 1) and remove. Remove elbow (16, Fig. 1)
from cooler (1), noting orientation.
11. Using suitable lifting equipment, remove
transmission oil cooler from machine to a clean area 3. Remove clamp (7, Fig. 1) and mounting hardware
for disassembly. (12 - 14, Fig. 1) securing tube assembly (5, Fig. 1) to
cooler (1).

SM 2190 Rev1 12-04 3

Cooling System - Transmission Oil Cooler
Section 210-0060

SM - 2824

1
8
16

13
9
4 1

6
8
5
4 1
12 10
11
9

5 8

7 10 9
3 11 15
5
14
2

10 7
11 3

1 - Bolt 5 - Isolator 9 - Hardened Washer 13 - Bolt

2 - Cooler Bracket 6 - Support Plate 10 - Washer 14 - Drain Valve
3 - Washer 7 - Bolt 11 - Locknut 15 - Seal
4 - Washer 8 - Hardened Washer 12 - Nut 16 - Plug

Fig. 4 - Transmission Oil Cooler Mounting

4. Disconnect tube assembly (5, Fig. 1) from elbow 9. Remove bolts (8) and washers (9) securing motor (3)
(16, Fig. 1) and remove. Remove elbow (16, Fig. 1) to mounting (6), and remove motor (3).
from cooler (1), noting orientation.
10. Remove nuts (16), lockwashers (15) and washers
5. Remove bolts (18), lockwashers (19) and washers (14) securing fan ring assembly (2) to cooler (1).
(20) securing fan guard (17) to fan ring assembly (2), Remove fan ring assembly (2) from cooler (1).
and remove fan guard (17).
11. Remove bolts (23) and washers (24) securing
6. Remove bolts (18), lockwashers (19) and washers brackets (21 & 22) to cooler (1).
(20) securing mounting (6) to cooler (1). Remove
mounting (6) complete with motor (3), fan (4) and 12. Remove mounting hardware securing cowl
adaptor (5). assembly (6, Fig. 3) to cooler (1), and remove cowl
assembly (6, Fig. 3).
7. Remove nut (13), toothed washer (11) and washer
(12) securing fan (4) and adaptor (5) to motor (3) shaft. 13. Remove mounting hardware securing end columns
Pull fan (4) and adaptor (5) from motor (3) shaft. (7 & 8, Fig. 3) to top and bottom channels (4 & 5, Fig.
3).
8. Remove bolts (8), washers (9) and nuts (10)
securing fan (4) to adaptor (5). 14. Remove remaining mounting hardware to allow end

4 SM 2190 Rev1 12-04

 Cooling System - Transmission Oil Cooler
Section 210-0060
columns (7 & 8, Fig. 3), side columns (2 & 3, Fig. 3) 12. Fit elbows (16, Fig. 1) to cooler (1) in correct
and baffles (9 - 11, Fig. 3) to be removed. orientation.

15. Remove mounting hardware securing top and 13. Fit bracket (6, Fig. 1) to cooler. Fit tube assembly
bottom channels (4 & 5, Fig. 3) to cooler core (1, Fig. (4, Fig. 1) to top elbow (16, Fig.1) and secure with
3), and remove channels (4 & 5, Fig. 3). clamp (12, Fig. 1), plate (13, Fig. 1) and screws (14,
Fig. 1).

ASSEMBLY 14. Fit bracket (7, Fig. 1) to cooler. Fit tube assembly
Numbers in parentheses refer to Fig. 2, unless (5, Fig. 1) to bottom elbow (16, Fig.1) and secure with
otherwise stated. clamp (12, Fig. 1), plate (13, Fig. 1) and screws (14,
Fig. 1).
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. INSTALLATION
Numbers in parentheses refer to Fig. 4, unless
1. Secure top and bottom channels (4 & 5, Fig. 3) to otherwise specified.
cooler core (1, Fig. 3) using mounting hardware
removed previously. Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
2. Fit end columns (7 & 8, Fig. 3), side columns (2 & 3, TORQUE SPECIFICATIONS.
Fig. 3) and baffles (9 - 11, Fig. 3) to cooler core (1,
Fig. 3) and secure using mounting hardware removed
previously. WARNING
To prevent personal injury and property
3. Secure cowl assembly (6, Fig. 3) to cooler (1) using damage, be sure lifting equipment is properly
mounting hardware removed previously. secured and of adequate capacity to do the job
safely.
4. Secure brackets (21 & 22) to cooler (1) using bolts
(23) and washers (24). 1. Using suitable lifting equipment, position
transmission oil cooler assembly on machine and
5. Secure fan ring assembly (2) to cooler (1) using nuts secure to cooler brackets (2) and support plate (6) with
(16), lockwashers (15) and washers (14). nuts (11), bolts (1), hardened washers (8 & 9), isolators
(5) and washers (10).
6. Fit motor (3) to mounting (6) using bolts (8) and
washers (9). 2. Connect transmission hoses (3 & 17, Fig. 1) to tube
assemblies (4 & 5, Fig. 1).
7. Assemble fan (4) to adaptor (5) using bolts (8),
washers (9) and nuts (10). 3. Fit bracket to rear of cooler, using fasteners
removed previously.
8. Press fan (4) and adaptor (5) onto motor (3) shaft,
ensuring key is fitted. 4. Connect supply hose (18, Fig. 1), case drain hose
(19, Fig. 1) and return hose (20, Fig. 1) to fan motor
9. Secure fan (4) and adaptor (5) using washer (12), (21, Fig. 1).
toothed washer (11) and nut (13).
5. Following installation instructions in Section
10. Install mounting (6) complete with motor (3), fan (4) 100-0040, HOOD AND MOUNTING, install hood
and adaptor (5) to cooler (1). assembly on the vehicle.

Note: When installing mounting, ensure clearance 6. Fill transmission oil cooler with transmission oil
around fan (4) tips to fan ring assembly (2) is of equal specified in Section 300-0020, LUBRICATION
dimension all round. SYSTEM. Refer to Section 120-0010,
TRANSMISSION AND MOUNTING, for filling
11. Secure fan guard (17) to fan ring assembly (2) procedure and level check.
using bolts (18), lockwashers (19) and washers (20).
7. Top up hydraulic tank as necessary with hydraulic

SM 2190 Rev1 12-04 5

Cooling System - Transmission Oil Cooler
Section 210-0060
oil specified in Section 300-0020, LUBRICATION Every 250 Hours
SYSTEM. Inspect the transmission oil cooler fins and, if
necessary, clean with a quality detergent (see
8. Check all line and pipe connections for noticeable Cleaning).
leaks prior to starting the vehicle.
Note: Fuel oil, kerosene or gasoline should not be used
9. Switch the battery master switch to the 'On' to clean fins.
position, start up the engine and check for leaks.
Tighten lines and fittings and top up systems as Note: It may be necessary to clean cooler fins more
required. frequently if the machine is being operated in extremely
dusty or dirty areas.
10. Lower hood assembly and remove wheel blocks.

CLEANING
MAINTENANCE
External Cleaning
Motor Overhaul
Numbers in parentheses refer to Fig. 2.
Internal parts of the motor are lubricated by the
operating fluid itself; therefore preventive maintenance Note: If a build up of dirt is apparent during routine
is limited to keeping the fluid in the system clean. Dirt inspection, the following cleaning procedure should be
should not be allowed to accumulate on the motor or adopted.
around the shaft seal. Check frequently that all fittings
and bolts are tight.
WARNING
Every 10 Hours To prevent possible injury when using
compressed air or steam jet, wear adequate eye
Check cooling fan for cracks and damage. Check fan
protection and do not exceed pressure values
mounting and tighten if required. Replace cooling fan if
stated.
damaged.
1. Direct a steam jet at 100 - 300 kN/m², or
Check lines and components for leaks and damage.
compressed air at 500 - 700 kN/m² on to the faces of
the cooler core (1).
Check the fan and motor for debris or damage. Clean
or replace as required.
2. Liberally brush a liquid detergent on to those
surfaces which were not satisfactorily cleaned at
Note: The fan is a non-serviceable component. step 1. Leave to soak for at least 1 hour.
However, the following instructions must be strictly
adhered to:
3. Apply a high pressure steam jet at 100 - 300 kN/m²,
or compressed air at 500 - 700 kN/m² on to the treated
1. DO NOT clean around fan drive with steam or high
surfaces, forcing the fouling material out from the
pressure jet.
cooler core (1).
2. DO NOT add any fluids or lubricants to the drive.
Note: In the case of grossly fouled surfaces which are
not cleaned adequately in steps 1 through 3, the
3. DO NOT restrict fan rotation during engine operation following procedure may be used.
for ANY reason.
4. Ensure that the cooler core (1) is dry.
4. DO NOT operate a machine with a damaged fan
assembly. Replace a damaged fan as soon as the
5. Liberally brush on to both sides of the cooler core (1)
fault is noted.
an emulsifying cleaner such as 'Gunk', or equivalent,
and leave to soak for at least 1 hour.
5. IMMEDIATELY investigate and correct ANY
operator complaint involving drive or cooling 6. Apply a high pressure steam jet at 100 - 300 kN/m²,
performance. or compressed air at 500 - 700 kN/m² on to the treated
surfaces, from several different angles, forcing the

6 SM 2190 Rev1 12-04

 Section 210-0060
fouling material out from the core. 2. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through cooler (1). Solution should
7. For surfaces with stubborn deposits, it may be be circulated through cooler (1), in the reverse direction
necessary to repeat steps 4 through 6, brushing the to normal flow, for approximately 15 minutes, after
surfaces between stages using a stiff bristle brush. soaking for 10 minutes. The duration of circulation
depends on how badly clogged the cooler is. Flush
thoroughly with clean hot water.
Internal Cleaning - Tubes
In the event of a major mechanical failure, the
transmission oil cooler assembly should be cleaned SERVICE TOOLS
thoroughly or replaced. There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
1. Clean transmission oil cooler before sludge hardens. SERVICE TOOLS, for part numbers of general service
After transmission oil cooler is completely drained, tools and adhesives required. These tools are available
circulate a solution of Agmasol PS40 through the from your dealer.
cooler core (1) to remove sludge.

* * * *

SM 2190 Rev1 12-04 7

Cooling System - Transmission Oil Cooler
Section 210-0060

THIS PAGE IS INTENTIONALLY BLANK

8 SM 2190 Rev1 12-04

 COOLING SYSTEM - Hydraulic Oil Cooler
Section 210-0100

SM - 2826

17

15 7
11 3
4
10 6

16

16
6
5 1
TO TANK RETURN
4 5
TUBE ASSY.
OUT 4
8
18
14
9
13
2
19
12
IN
8

7 9
4
10

11
FROM TEE AT CHECK
VALVE ON RH FENDER

1 - Hydraulic Oil Cooler 8 - Adaptor 14 - Bolt

2 - Bracket Assembly 9 - Elbow 15 - Adaptor
3 - Bracket Assembly 10 - Hose 16 - Tee
4 - Bolt 11 - Hose 17 - Elbow
5 - Washer 12 - Bracket 18 - Hose
6 - Locknut 13 - Clamp 19 - Hose
7 - Washer
Fig. 1 - Exploded View of Hydraulic Oil Cooler and Mounting

DESCRIPTION AND OPERATION

Numbers and letters in parentheses refer to Fig. 1. WARNING
To prevent personal injury and property
The air cooled hydraulic oil cooler is mounted on the damage, be sure wheel blocks and lifting
front of the radiator assembly, with the purpose of equipment are properly secured and of
cooling hydraulic oil circulating through the hydraulic adequate capacity to do the job safely.
tank.
1. Position the vehicle in a level work area, apply the
Hydraulic oil from the transmission oil cooler motor parking brake and switch off the engine. Turn steering
enters hydraulic oil cooler (1) through inlet line (10). wheel several times to relieve any pressure in the
steering circuit. Operate brake pedal continuously to
The hydraulic oil is cooled by the air flow through the relieve pressure in the braking system.
fins and exits through outlet line (11) and flows back to
the hydraulic tank. 2. Block all road wheels and place the battery master
switch in the 'Off' position.

REMOVAL 3. Remove drain plug from hydraulic tank remote drain

Numbers in parentheses refer to Fig. 1. fitting. Drain oil in the hydraulic tank into a suitable
container and re-install drain plug.

4. Remove mounting hardware securing front grille on

the hood assembly. Remove front grille from the hood.

SM 2191 1-03 1
Cooling System - Hydraulic Oil Cooler
Section 210-0100
5. Remove inlet line (10) from elbow (9) and connector
(8) in hydraulic oil cooler (1). Drain oil from inlet line WARNING
(10) into a suitable container. Plug inlet line and cap To prevent personal injury and property
port to prevent ingress of dirt. damage, be sure wheel blocks and lifting
equipment are properly secured and of
6. Remove outlet line (11) from elbow (9) and connector adequate capacity to do the job safely.
(8) in hydraulic oil cooler (1). Drain oil from outlet line
(11) into a suitable container. Plug outlet line and cap 1. If removed, secure bracket assemblies (2 & 3) to
port to prevent ingress of dirt. the radiator assembly with bolts (4) and hardened
washers (5), and install horns.
7. Remove mounting hardware securing hydraulic oil
cooler (1) to bracket assemblies (2 & 3). Remove 2. Secure hydraulic oil cooler (1) to bracket
hydraulic oil cooler (1) from its mounting. assemblies (2 & 3) with mounting hardware, as
removed at 'Removal'.
8. If required, remove horns along with bolts (4) and
washers (7) securing bracket assemblies (2 & 3) to the 3. Install inlet line (10) and outlet line (11) in their
radiator assembly. respective ports, as removed at 'Removal'.

CLEANING AND INSPECTION 4. Fill hydraulic tank with oil. Refer to Section
230-0040, HYDRAULIC TANK, for correct fill level and
1. Inspect fins on hydraulic oil cooler carefully, for Section 300-0020, LUBRICATION SYSTEM for
trapped debris and damage. If hydraulic oil cooler fins specifications of oil to be used.
show signs of leakage or are excessively damaged, it
must be replaced as an assembly. 5. Place the battery master switch in the 'On' position,
start engine and operate the body hydraulics several
2. Check connectors in hydraulic oil cooler ports for times to circulate the oil. Check hydraulic oil cooler (1)
damaged threads. Replace if required. and lines for leaks. Tighten fittings as required.
3. After hydraulic oil cooler is completely drained, 6. Install front grille assembly to the hood with
circulate a solution of Agmasol PS40 through the mounting hardware, as removed at 'Removal'.
cooler tubes.
7. Remove wheel blocks from all road wheels.
4. If cooler tubes are badly clogged, circulate an oakite
or alkaline solution through the hydraulic oil cooler, in
the reverse direction to normal flow, for approximately MAINTENANCE
15 minutes. The duration of circulation depends on Check and clean hydraulic oil cooler every 4 000
how badly clogged the cooler tubes are. Flush hours, or more frequently, if required. Debris in the
thoroughly with clean hot water. cooling fins can restrict the flow of air through the
cooler which significantly reduces the cooling effect.
INSTALLATION
Note: In the event of a hydraulic failure, hydraulic oil
Numbers in parentheses refer to Fig. 1. cooler should be removed and cleaned to prevent
clogging.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. SERVICE TOOLS
There are no special tools required for procedures
Note: Tighten all hydraulic lines fitted with ORFS outlined in this section. Refer to Section 300-0070,
connections, as described in Section 220-0000, SERVICE TOOLS, for part numbers of general service
STEERING SYSTEM SCHEMATIC. Renew all tools and adhesives required. These tools are available
'O' rings where used. from your dealer.

* * * *

2 SM 2191 1-03
 MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
SM - 2828 closed. As the main pump starts rotating it builds up
residual pressure and the priority valve opens, feeding
the main pump pressure through to the fan drive (17 &
18) & body tipping (5 & 29) valves.

During the body tipping operations and whilst the fan is

running, if the demand pressure at the brake charging
or the steering circuit is less than these functions, the
priority valve (15) remains open, but the oil takes the
path of the least resistance and the requirements of the
charging or steering circuits are met.

If the demand pressure for charging or steering is

higher than that demanded by the fan drive or body
tipping function, this higher pressure will be fed to the
main pump load sense line via the shuttle valves (21 &
25) and therefore enable the main pump to meet the
Fig. 1 - Main Hydraulic Valve Assembly charging or steering pressure requirements. At the
same time the higher load sense pressure assists the
DESCRIPTION spring in the priority valve (15), the priority valve will
Numbers in parentheses refer to Fig. 2 then close to reduce the flow to the fan or body tipping
circuit and therefore making sure the brake charging &
The Main Hydraulic Valve Assembly is mounted on the steering always has priority over the other functions.
left hand side of the tractor frame next to the
transmission.
Steering Function
The Main Hydraulic Valve Assembly controls the Refer to Section 220-0000, STEERING SYSTEM
following functions;
Steering actuation pressure is controlled by steering
(a) System relief protection for main pump. load sense orifice (20).The steering load sense orifice
(b) Priority function (20) controls main pump pressure in the steering load
(c) Steering function. sense line. As pressure increases through steering
(d) Brake charging function. load sense orifice (20), main pump pressure increases
(e) Park/emergency function. lifting steering check valve (24) allowing steering
(f) Body control function. actuation pressure to access the steering orbitrol
(g) Transmission cooler fan drive. control valve.
(h) Cold start function.

Valves that control all the above functions are Emergency Steering
integrated into the Main Hydraulic Valve Assembly and Refer to Section 220-0000, STEERING SYSTEM.
are identified in Figs. 2 through 7.
The emergency valve (19) forms part of the emergency
steering system. It is connected to the main output line
System Relief of the wheel driven Emergency Steering Pump
The system relief valve (14) protects the main mounted on the transmission.
hydraulic valve assembly components against
pressure spikes. This system relief valve is pre-set at
265 bar (3850 lbf/in2 )and is non-adjustable. Brake Charging Function
Refer to Section 250-0000, BRAKE SYSTEM.

Priority Function Brake charge valve (8) and brake pressure reducer
This function automatically ensures that the steering valve (7) are integral valves that form part of the brake
and brake charging circuits are given preference over charging function. Brake charge valve (8) ensures that
the fan and body tipping functions. there is sufficient load sense pressure to the main
pump to allow the charge pressure to be generated.
When the pump is not running, the priority valve (15) is Brake pressure reducer valve (7) maintains a safe

SM 2192 Rev3 02-07 1

2
1 5

3 4
2
Section 215-0050

47
8 9 33

6 7

13
10 11

12 44 30

16
14
17
45
15 18
32

31 31

19 21 22
46
20
25

24
23
26

29
27

1 - Orifice 10 - Check Valve 19 - Emergency Steer Valve 29 - Proportional Pressure Control Valve
2 - Bleed Down Sequence Valve 11 - Orifice 20 - Orifice 30 - Body Control Spoo
3 - Check Valve 12 - Orifice 21 - Shuttle Valve 31 - Load Sense Copy Spoolsl
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly

4 - Check Valve 13 - Float Solenoid 22 - Shuttle Valve 32 - Load Sense Dump Valve
5 - Proportional Pressure Control Valve 14 - Relief Valve 23 - Check Valve 33 - Make Up Check Valve
6 - Park/Emergency Brake Solenoid 15 - Priority Valve 24 - Check Valve 44 - Orifice
7 - Pressure Reducing Valve 16 - Cold Start Solenoid 25 - Shuttle Valve 45 - Orifice
8 - Brake Charge Valve 17 - Hydraulic Proportional Control Valve 26 - Body System Relief Valve 47 - Relief Valve
9 - Pressure Reducing Valve 18 - Pressure Compensating Valve 27 - Emergency Steer Relief Valve
SM2918

Fig. 2 Main Hydraulic Valve Assembly Schematic - Based on Engine Shutdown

SM 2192 Rev3 02-07

 MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
operating pressure within the front and rear brake transmission oil temperature reaches 90°C (195°F).
accumulators.
The hydraulic ECU receives an electrical signal from
the transmission cooler fan drive temperature switch,
Park/Emergency Brake Function mounted on the transmission retarder housing. Once
Refer to Section 250-0000, BRAKE SYSTEM. an electrical signal reflecting a transmission oil
temperature of 90°C (195°F) has been received, the
Park/Emergency brake solenoid (6) is the integral valve hydraulic ECU sends a signal to de-energise the fan
that controls hydraulic pressure to the park and drive solenoid valve, allowing actuation pressure to
emergency brake function of the truck. access the fan drive circuit. This fan drive solenoid
valve is a fail safe system. If power or connection is
lost the fan drive solenoid valve will de-fault to the
Body Control Function open (de-energised) condition.
Refer to Section 230-0000, BODY SYSTEM
The hydraulic ECU (Refer to Section 190-0085) sends
Proportional pressure control valve (5) is the integral an electrical signal from Pin C1:24 to the fan drive
valve that controls the body tipping function. This valve solenoid valve. This signal de-energises the fan drive
is operated via the body control lever located in the solenoid, opening the transmission cooler fan drive
operators cab. The body control lever sends an circuit.
electrical signal to the hydraulic ECU. (Refer to Section
190-0085). The hydraulic ECU processes this signal The transmission cooler fan speed pressure is
and delivers an actuating electrical signal to the controlled by the Electro-Hydraulic Proportional Control
proportional pressure control valve (5). The proportional Valve (17). A varying current input into this valve of
pressure control valve (5) converts this electrical signal between 150 to 210 mA controls the pressure between
into a pilot pressure, that then is allowed to stroke the 34 bar (490 psi) and 87 bar (1260 psi). This pressure
body control spool to the lift position. then acts upon the Shuttle Valve (22) and onto the
main pump load sense connection via Shuttle Valve
Proportional pressure control valve (29) is the integral (25). This pressure acts upon the spring chamber of
valve that controls the body lower function. This valve the Logic Valve (18) that controls the pressure at the
is operated via the body control lever located in the fan.
operators cab. The body control lever sends an SM2829
1
electrical signal to the hydraulic ECU (Refer to Section
190-0085). The hydraulic ECU processes this signal
and delivers an actuating electrical signal to the
proportional pressure control valve (29). The
proportional pressure control valve (29) converts this
electrical signal into a pilot pressure, that then is
allowed to stroke the body control spool to the lower 2
position.

Body relief valve (47) is located on the raise side of the

circuit and prevents pressure spikes at maximum
extension of the cylinders when the body is raised at
maximum engine speed. Relief valve (47) is set at 230
bar (3 335 lbf/in2 ).

3
Transmission Cooler Fan Drive
The transmission cooler fan speed is modulated by
proportionally controlling the pressure at the fan motor.
Fan speed is a function of the pressure at the fan RHS
motor. 1 - Transmission Oil Temp. Sender
2 - Trans. Cooler Fan Drive Temp. Switch
On a cold start, the transmission cooler fan will not 3 - Retarder Oil Temperature Switch
rotate. A fan drive solenoid valve, mounted on the right
hand fender next to the transmission cooler, will remain Fig. 3 - Trans. Cooler Fan Drive Temperature Switch
closed, blocking actuating pressure until the
SM 2192 Rev3 02-07 3
MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050

Trans. Cooler Fan Drive Temperature Switch - Typical Analog Outputs (Mv) Vs' Oil Temperature (°C)

Temp.(°C) 20 25 35 50 70 90 95 120 140 150

Mv. 900 780 760 330 170 95 80 40 35 0

The hydraulic ECU receives an analog input from the Cold start solenoid (16) energises when starter motor
Transmission Cooler Fan Drive Temperature Switch at signal is high, this dumps all load sense pressure from
Pin C1:3. The temperature sensor output is calibrated the main hydraulic pump, rendering the pump off-load.
against actual temperature within the hydraulic ECU. This reduces parasitic losses during engine cranking
The hydraulic ECU converts the analog signal into a procedure.
varying current output. This varying current output,
from Pin C1:19, controls Electro-Hydraulic Proportional There is about a 2 second delay before de-energising
Control Valve (17) increasing and decreasing pressure cold start solenoid (16) (starter motor signal low). This
at the fan motor. The fan speed increases and de- function prevents brake charging during engine start
creases proportionally between transmission oil up, which is particularly important in cold climates.
temperatures of 90 to 140°C (195 to 285°F).
A starter motor high signal is received by the hydraulic
The Fan Drive Solenoid will remain de-energised until ECU at Pin C1:9. The hydraulic ECU converts this high
the transmission oil temperature falls to 87°C (188°F). signal into digital output signal at Pin C1:22, energising
At this point the oil flow to the transmission cooling fan the cold start solenoid (16). The signal to energise the
will stop. cold start solenoid (16) will remain on until a starter
motor low signal is received by the hydraulic E.C.U. at
Refer to troubleshooting charts. Pin C1:9, this will negate the digital output signal from
Pin C1:22.
(Refer to section 190-0085 for full Hydraulic E.C.U.
Cold Start Function detail.)
Cold Start Solenoid (16) is the integral valve that
controls the cold start function of the Main hydraulic
valve assembly
SM2833

16

16 - Cold Start Solenoid

17 - Hydraulic Proportional Control Valve
18 - Pressure Compensating Valve
22 - Shuttle Valve
44 - Orifice
45 - Orifice

Valve (16) Coil Rating

Ohms Amps Watts
42 0.6 15
44
Voltage: 24V
45 Valve (17) Coil Rating
Ohms Amps Watts
22
25 0.9 21
17 Voltage: 24V

18

Fig. 4 - Main Hydraulic Valve Assembly - Transmission Cooler Fan Valves/Cold Start Solenoid

4 SM 2192 Rev3 02-07

 MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
SM2834

25

15 15 - Priority Valve
21 - Shuttle Valve
25 - Shuttle Valve

21

Fig. 5 - Main Hydraulic Valve Assembly - Transmission Cooler Fan Valves

Transmission Cooler Fan Drive Trouble Shooting

Symptom Possible Cause Remedy
Fan will not rotate once transmission Hydraulic E.C.U. no receiving Replace transmission cooler fan
oil temperature is >90°C (195°F). appropriate signal from transmission drive temperature switch. (Ref. Fig.
cooler fan drive temperature switch, 3)
when transmission oil is >90°C
(195°F).

Fan drive solenoid, located on right (a) Check signal from hydraulic
hand fender remains closed. E.C.U. - Pin C1:24. Should be
low signal.
(b) Check electrical connections.
(c) Replace fan drive solenoid.

Check for output fault at hydraulic Ref. Output from Pin C1:19. Ref.
E.C.U. Section 190-0085 Hydraulic E.C.U.

Fan control logic valve (18) sticking in Replace fan control logic valve (18).
the open position.

Contamination in load sense orifices Disconnect fan at main hydraulic

(44 &45) and/or shuttle valves (22 & valve assembly and plug port DF.
25). Raise and lower the body several
times to flush out system. If this is
unsuccessful, replace main
hydraulic valve assembly.

SM 2192 Rev3 02-07 5

MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050

Transmission Cooler Fan Drive Trouble Shooting

Symptom Possible Cause Remedy
Fan will not modulate its speed over Residual current at hydraulic Check current at valve (17).
the desired temperature range. proportional valve (17).

No voltage at hydraulic proportional (a) Check electric connections at

valve (17). valve (17).
(b) Check annalog signal from
Trans. Cooler Fan Drive
Temperature Switch.
(c) Check output signal from
Hydraulic E.C.U. Pin C1:19.

Fan Proportional Solenoid Valve(17) Replace Valve(17).

Faulty.

Contamination or Air in Load Sense Disconnect the fan and plug port
Drillings or Shuttle Valves (22 & 25) DF. Raise and lower the body
several times to flush out the
system. If this does not work
change the whole manifold block.

Fan Pressure Modulating Valve(18) Replace valve(18).

Faulty

Contamination in Orifices(44 & 45) Clean Orifices (44 & 45).

Fan Speed too low. Fan Proportional Solenoid(17) Faulty. Replace Valve(17).

Faulty Fan Motor. Replace Fan Motor. Ref. Section

210-0060 Transmission Oil Cooler

Fan unstable over the speed range Orifices(44 or 45) Blocked. Clean Orifices
when another function is selected.
Fan Proportional Pressure Solenoid Replace Valve(17)
(17) Faulty.

Fan Pressure Modulating Logic Replace Valve(18)

Valve(18) Faulty.
Check Main Pump setting. Ref.
Section 230-0050 Main Hydraulic
Pump

6 SM 2192 Rev3 02-07

 MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050

REMOVAL 7. Disconnect mounting hardware securing main

hydraulic valve assembly to vehicle.
WARNING
To prevent personal injury and property DISASSEMBLY
damage, be sure wheel blocks, blocking
All integral valves on the main hydraulic valve
materials and lifting equipment are properly
assembly can easily be removed. On removal of all
secured and of adequate capacity to do the job
integral valve assemblies, clean and examine for wear
safely.
or damage.
1. Position the vehicle in a level work area, apply the
If integral valve is badly damaged, inpect bore of main
parking brake and switch off the engine. Turn battery
hydraulic valve housing. If the main hydraulic valve
master switch to the 'off' position. Relieve stored
housing is damaged, the main hydraulic valve
pressure in accumulators (x3). This is achieved by
assembly will have to be completely replaced.
pressing and releasing foot brake pedal continuously
until all accumulator pressure is relieved.
Always replace all o-rings and seals after inspection.

WARNING ASSEMBLY
Accumulators are charged with Nitrogen. The
All integral valves must be re-installed into correct
service pressure is 95 bar (1380 lbf/in²) at 20° C
locations on the main hydraulic valve assembly. All
(68o F). To prevent personal injury and property
integral valves must be torqued to correct value.
damage do not attempt to remove any valves or
fittings until all nitrogen pressure is completely
1. Re-install O.R.F.S. connectors into correct ports.
relieved.
Replace o-rings and seals. Ref. Fig. 6
SM - 1335
2. Block all road wheels and place battery master
switch in the 'Off' position. FITTING NUT
TUBE
3. Remove blanking cap from remote drain line at the
bottom of the hydraulic tank. Install a length of hose on
remote drain fitting, open drain cock and drain hydraulic
oil into a suitable container. Close drain cock, remove
hose and reinstall blanking cap.

4. Main hydraulic valve assembly is accessed by

SLEEVE
raising the operator cab. (Refer to Section 260-0010, 'O' RING 'O' RING
CAB AND MOUNTING.)
Fig. 6 - Assembly of Typical ORFS Connector
WARNING 2. Install M10 eye bolt into clamp mounting hole at port
Never work under or near an unsupported 'T' located on top of main hydraulic valve assembly.
raised operator cab assembly. Always ensure Support main hydraulic valve assembly with suitable
cab safety prop is in correct position. lifting equipment, using eye bolt.

5. Clean outer area of the main hydraulic valve 3. Manoeuvre main hydraulic valve assembly into
assembly with a suitable cleaning solvent. Ensure all position and secure to vehicle with mounting hardware.
hydraulic lines connected to the main hydraulic valve
assembly are identified for ease of installation. With 4. Remove blanking caps from all hydraulic lines and
suitable containers catch any oil leakage when fittings. Re-connect hydraulic lines to correct fittings
disconnecting hydraulic lines. Install blanking caps to astagged at removal.
all open lines and fittings.
5. Lower operator cab and secure. Ref. Section 260-
6. Install M10 eye bolt into clamp mounting hole at port 0010, CAB AND MOUNTING.
'T' located on top of main hydraulic valve assembly.
Support main hydraulic valve assembly with suitable 6. Fill hydraulic tank with hydraulic oil as described in
lifting equipment, using eye bolt. Section 300-0020, LUBRICATION SYSTEM. Ensure

SM 2192 Rev3 02-07 7

MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
arear around fill area is clean. Install filler cap on 9. Bleed brake system after main hydraulic valve
hydraulic tank. removal. Ref. Section 165-0010 BRAKE PARTS.

7. Turn battery master switch to 'on' position, remove

any wheel blocks, start engine. Operate body and
steering systems. Check hydraulic lines and fittings for
leaks. Tighten where required.

8. Check hydraulic tank oil level and replenish if

required.
Main Hydraulic Valve Assembly - Integral Valve Tightening Torques

Valve No. Description Qty. Tighten Torque Nm

2 Directional Control Bleed Down Valve 1 50

3 Check Valve 1 30

4 Check Valve 1 30

5 Body Raise Solenoid Valve 1 3

6 Park Brake Valve 1 30

24 Volt Coil 1 3.5

Coil Nut 1 3.5

7 Brake Accumulator Pressure Valve 1 60

8 Brake Pressure Low Setting 1 60

9 Servo Pressure Reducing Valve 1 60

10 Check Valve 1 30

11 M6 Orifice Screw 1 3

12 M6 Orifice Screw 1 3

13 Float Solenoid Valve 1 30

24 Volt Coil 1 3

Coil Nut 1 3

14 Shock Relief Valve (265 Bar) 1 60

15 System Press. Generating Logic Valve 1 40

16 Cold Start Solenoid Valve 1 30

24 Volt Coil 1 3

Coil Nut 1 3

8 SM 2192 Rev3 02-07

 MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050
Main Hydraulic Valve Assembly - Integral Valve Tightening Torques

Valve No. Description Qty. Tighten Torque Nm

17 Fan Proportional Press. Control Valve 1 60

CoilNut 1 3.5

18 Fan Control Logic Valve 1 115

19 Emergency Steering Valve 1 100

20 Steering Pressure LS Orifice 1 115

21 Shuttle Valve 1 10

22 Shuttle Valve 1 10

23 Check Valve 1 100

24 Check Valve 1 100

25 Shuttle Valve 1 10

26 Body Raise LS – Relief Valve 1 10

27 Emergency Steering Relief Valve 1 60

29 Body Lower Solenoid Valve 1 3

31 Plug – G1/8” 3 15

32 Plug – G1/4” 1 30

33 Plug – G3/8” 3 45

34 Plug 9/16 UNF 1 30

35 Plug – G1/4” 1 30

40 Nut – M12 3 80

44 M6 Orifice Screw 1 3

45 M6 Orifice Screw 1 3

46 M6 Orifice Screw 1 3

47 Relief Valve 1 80

SM 2192 Rev3 02-07 9

MAIN HYDRAULIC VALVE - Main Hydraulic Valve Assembly
Section 215-0050

SM2919
1 - Orifice 4 32 26 7
9
2 - Bleed Down Sequence Valve
3 - Check Valve 24
4 - Check Valve 3
5 - Proportional Pressure Control Valve 11
6 - Park/Emergency Brake Solenoid
7 - Pressure Reducing Valve
8 - Brake Charge Valve
9 - Pressure Reducing Valve
10 - Check Valve
11 - Orifice 16
12 - Orifice 13 10/12
13 - Float Solenoid
14 - Relief Valve 2
15 - Priority Valve
16 - Cold Start Solenoid 34
17 - Hydraulic Proportional Control Valve 20
18 - Pressure Compensating Valve
19 - Emergency Steer Valve
20 - Orifice 6
21 - Shuttle Valve
22 - Shuttle Valve
23 - Check Valve
24 - Check Valve 29
44
25 - Shuttle Valve
26 - Body System Relief Valve
27 - Emergency Steer Relief Valve
45
29 - Proportional Pressure Control Valve
5 22/46
44 - Orifice
45 - Orifice
47 - Relief Valve 17
18

31 8
19 27
33
23

35 14

25

15

21

47

Fig. 7 - Main Hydraulic Valve Assembly - Integral Valve Positions

10 SM 2192 Rev3 02-07

 STEERING SYSTEM - Steering System Schematic
Section 220-0000
SM - 2842

1 - Steering Orbitrol Valve

2 - Steering Cylinders
2 2 3 - Emergency Steering Pump
4 - Main Hydraulic Pump

L R Integral Valves to Main Hydraulic Valve Assembly

1 14 - Relief Valve
15 - Priority Valve
19 - Emergency Steer Valve
20 - Steering Load Sense Orifice
23 - Check Valve
24 - Check Valve
25 - Shuttle Valve
27 - Emergency Steering Relief Valve

T LS P

14

15

19 21

20
25

24
23

27

Fig. 1 - Steering System Schematic

DESCRIPTION of the cab floor, is connected to the steering column

and controls hydraulic oil flow to the steering cylinders.
Numbers in parentheses refer to Figure 1.

Steering Orbitrol Valve (1) The steering valve is of a closed centre design,
indicating oil is 'dead headed' at the valve until it is
Refer to Section 220-0090, Steering Valve.
operated.
The steering valve, which is mounted on the underside

SM 2197 Rev 1 08-08 1

STEERING SYSTEM - Steering System Schematic
Section 220-0000

Steering Cylinders (2) OPERATION

Refer to Section 220-0120, Steering Cylinder.
PRIORITY FUNCTION
There are two single stage, double acting cushioned Numbers in parentheses refer to Figure 1
steering cylinders on the machine. The cylinder base
end is connected to the front frame, and the piston rod The priority function automatically ensures that the
end is connected to the articulation and oscillation steering and brake charging circuits are given
pivot. Single stage double acting means that the piston preference over the transmission cooler fan and tipping
rod can have oil applied to either side, extending or functions.
retracting the piston rod.
When the main pump (4) is not running, the priority
Cylinder mounting is by pins, spacers, seals and, valve (15) is closed. As the main pump (4) starts
spherical bearings secured with circlips. Spherical rotating it builds up residual pressure entering the main
bearings permit a limited amount of cylinder hydraulic valve assembly at port P1. The pressure
misalignment when travelling over rough terrain. opens priority valve (15), feeding the main pump
pressure through to the transmission cooler fan drive
the lift valve.
Emergency Steering Pump (3)
The emergency steering ground driven pump, mounted During the tipping operations and while the
on the transmission, provides flow to the steering transmission cooler fan is running, if the demand
circuit in the event that the main pump (4) can no pressure at the brake charging or the steering circuit is
longer function effectively. less than these functions, the priority valve (15)
remains open, but the oil takes the path of the least
resistance and the requirements of the brake charging
Main Hydraulic Pump (4) or steering circuits are met.
Refer to Section 230-0050, Main Hydraulic Pump.
If the demand pressure for brake charging or steering
The main hydraulic pump, mounted on the circuit is higher than that demanded by the
transmission power take off (PTO), supplies hydraulic transmission cooler fan drive or tipping function, this
oil for operating the steering, body, brakes and higher pressure will be fed to the main pump load
transmission cooler fan drive circuits. sense line via the shuttle valves (21 and 25) and
therefore enables the main pump (4) to meet the brake
The main hydraulic pump is an axial piston, variable charging or steering circuit pressure requirements. At
displacement type, with load sense and pressure the same time the higher load sense pressure assists
regulator. the spring in the priority valve (15). The priority valve
(15) will then close to reduce the flow to the
transmission cooler fan or tipping circuit and therefore
Valves 14, 15, 19, 20, 23, 24, 25 and 27 making sure the brake charging and steering circuit
These valves for part of the steering and emergency always has priority over the other vehicle functions.
steering circuit and are an integral part of the main
hydraulic valve assembly, mounted on the left hand
side of the tractor frame. Refer to Section 215-0050, PRIORITY FLOW CONTROL TO
Main Hydraulic Valve Assembly. STEERING

This function ensures that the flow from the steering

Diagnostic Test Point
valve (1) is maintained at all times regardless of the
Steering and load sense pressures can be checked at other pressure demand within the system.
the diagnostic check points located inside the battery
box. Refer to Figure 2. To achieve this function the pressure at the steering
valve (1) has to be at a level equal to that demanded
The steering system pressure is set at 240 bar (3500 by the steering plus the differential control pressure set
lbf/in2) by the steering valve.

Load Sense (LS) pressure is set 25 bar (360 lbf/in2) The pressure demanded by the steering is fed back to
below steering system pressure, therefore at maximum the main pump (4) and the priority valve (15) via the
setting, LS pressure will be 215 bar (3120 lbf/in2).

2 SM 2197 Rev 1 08-08

 STEERING SYSTEM - Steering System Schematic
Section 220-0000
shuttle valve (21). The priority valve (15) will close and The check valve (24) prevents the emergency steer
the main pump will increase its displacement to make flow going towards the main pump (4), which may
sure there is enough flow and pressure available to already have failed.
meet that demanded by the steering.

The steering load sense orifice (20) feeds oil from the STEERING PRESSURE SETTING
main pump supply, to boost the load sense pressure
back to the main pump during the steering operation. WARNING
This is to make sure an adequate flow is always The machine has to fully articulate to set the
available from the main pump (4) to meet that steering pressure, therefore the steering lock
demanded by the steering. This is commonly known as bar cannot be 'Locked'. To prevent personal
a dynamic load sense system. injury and property damage, exercise extreme
caution while working around articulation and
Note: The maximum steer pressure is set by the oscillation pivot area.
pressure cut off (compensator) on the main hydraulic
pump (240 bar [3500 lbf/in2]). Refer to Section 230- The maximum steer pressure is set by the pressure
0050 Main Hydraulic Pump. cut off (compensator) on the main pump (240 bar [3500
lbf/in2]). Refer to Section 230-0050, Main Hydraulic
Pump.
EMERGENCY STEERING
The emergency steering ground driven pump (3) Steering pressure can be checked at the diagnostic
provides flow to the steering circuit in the event that check point located inside the battery box (refer to
the main pump (4) can no longer function effectively. Figure 2). Install pressure gauge capable of reading at
least 240 bar (3500 lbf/in2) to the correct diagnostic
Engine failure, transmission failure or internal failure of check point.
the main pump (4) could cause ineffective
performance. Steer the truck over the relief (against the steering
stops) to observe the maximum cut-off pressure of 240
The emergency steering pump (3) will also assist with bar (3500 lbf/in2). Adjust pressure cut-off screw on
flow from the main pump to articulate the vehicle if the main pump (4) if necessary. Refer to Section 230-0050,
main pump cannot deliver the flow required by the Main Hydraulic Pump.
steering circuit. This can happen at low engine speed SM - 2849
when the vehicle is moving and the operator attempts
to articulate the vehicle rapidly.

To protect the ground driven emergency steering pump

(3) the maximum pressure at the pump is set by the
1
relief valve (27) to 179 bar (2600 lbf/in2).
2
3
The emergency steering valve (19) is sensing the main P
FB 4
pump (4) pressure and the load sense pressure at the
RB 5
spring end of the valve (19). During normal operation
the differential pressure between the main pump (4) 6

outlet and the load sense line will be approximately 25 7

bar (360 lbf/in2) and the emergency steering valve (19) 8

will stroke against its spring dumping the emergency 9

steer pump (3) flow to tank. 10

In the event of the main pump (4) not been able to

supply sufficient flow for the steering, the differential
pressure between the main pump (4) outlet and the 1 - Differential Lock Pressure 8 - Trans. Converter Press.
2 - Pump LS Pressure 9 - Body System Press.
load sense line will be reduced. As soon as the 10 - Trans. System Pressure
3 - Front Brake Pressure
differential pressure drops below 8.5 bar (125 lbf/in2) 4 - Rear Brake Pressure P - Primary Accumulator
the emergency steering valve (19) will close and the 5 - Park Brake Pressure FB - Front Brake Accumulator
ground driven pump (3) flow will be diverted across 6 - Steering Pressure RB - Rear Brake Accumulator
7 - Trans. Retarder Press.
check valve (23) and supply the steering system.
Fig. 2 - Diagnostic Pressure Check Points (Battery Box)

SM 2197 Rev 1 08-08 3

STEERING SYSTEM - Steering System Schematic
Section 220-0000

24

20

19 27

23

14

25

15

14 - Relief Valve
15 - Priority Valve 21
19 - Emergency Steer Valve
20 - Steering Load Sense Orifice
23 - Check Valve
24 - Check Valve
25 - Shuttle Valve
27 - Emergency Steering Relief Valve

Fig. 3 - Steering System Valves Integral to Main Hydraulic Valve Assembly

4 SM 2197 Rev 1 08-08

 STEERING SYSTEM - Steering System Schematic
Section 220-0000

O-RING FACE SEALS (ORFS)

Where hydraulic lines are fitted with ORFS WARNING
connections, the following procedure should be carried Do not operate the machine until all air is bled
out during 'Installation'. Refer to Figure 4. from the oil.

a. Ensure that the O-ring/seal is in place and that the b. When the oil in the tank is clear (not cloudy or
joining surfaces are clean. If necessary, retain the O- creamy), the system is free of air.
ring/seal in place with a light coating of grease or
vaseline. Note: Slight creep or drift of the steering wheel is
normal.
b. Initially, the nuts should be tightened by hand.
c. Fill the hydraulic tank to the recommended level and
c. Where a hose is fitted, ensure that it is not twisted install the filler cap.
or kinked when the nuts are tightened so that it is
allowed to adopt a natural position. Hydraulic Oil
d. Where a tube is fitted, ensure that the connection is The steering system should be kept filled with
aligned correctly. hydraulic oil as listed in Section 300-0020, Lubrication
System.
e. Tighten the nut a further 1/4 to 1/2 a turn using the
correct size spanner (wrench). MAINTENANCE
f. Check that a satisfactory hose or tube routing has Maintenance instructions, intervals and warnings, in
been achieved. the individual steering and body hydraulic component
Sections of this manual, should be adhered to at all
SM - 1335 times.
FITTING NUT
TUBE
SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, Service
SLEEVE Tools, for part numbers of these tools.
'O' RING 'O' RING

Fig. 4 - Assembly of Typical ORFS Connector Multi-Gauge

FILLING AND BLEEDING THE STEERING The multi-gauge, 15269784, is basically four pressure
gauges in one. Continuous system pressure readings
SYSTEM
are indicated on one of three simultaneously reading
1. Fill hydraulic tank to maximum level. Be ready to gauges through a pressure range of 30 in of vacuum to
add oil when the engine is started. Do not let oil drop 5 000 lbf/in².
below the pump suction line to prevent air entering the
system. The following items should be added to the multi-gauge
to enable the gauge to be used on the diagnostic
2. Start engine and let it idle. Immediately add oil to the pressure check points;
tank as required. When no more oil can be added and 15018226 Diagnostic Coupling
oil is clear, proceed as follows: 00118748 Connector (2 off)
15004085 Hose Assembly (-04 HP, 2130 mm long)
a. Turn the steering wheel from lock to lock to bleed
the air in the steering cylinders and lines.
Non-contact Infrared Thermometer
Note: Immediately upon valve spool actuation oil must The infrared thermometer, 15269785, can be used to
be added to the hydraulic tank to replenish the oil spot heat problems early in electrical, mechanical and
moving into the circuit. hydraulic systems. Hand held and easy to use, you

SM 2197 Rev 1 08-08 5

STEERING SYSTEM - Steering System Schematic
Section 220-0000

simply aim, pull the trigger, and read the temperature. O-ring Face Seals (ORFS) - Seal Kit
Since there is no need to touch what you are
measuring, temperatures of hard-to-reach or moving The steering system utilizes 'O' Ring Face Seal (ORFS)
components can be taken without getting burned or connectors. An ORFS kit, 15271082, is available. This kit
shocked. contains a minimum stock requirement of all sizes of ORFS
type seal.

Steering System Trouble Shooting

Symptom Possible Cause Remedy
System does not reach the maximum Fault with main pump or pressure cut- Refer to Section 230-0050, Main
operating pressure off incorrectly set Hydraulic Pump

Faulty relief valve (14) Replace valve (14)

Priority valve (15) sticking open or Replace valve (15)

wrong spring setting

Fault in LS orifice (20) Replace/clean orifice (20)

Heavy steering due to not enough Fault with main pump or standby Refer to Section 230-0050, Main
flow being available at the steering pressure incorrectly set Hydraulic Pump
valve but differential pressure
between the main pump outlet and Faulty steer valve Refer to Section 220-0090, Steering
the load sense port is between 15 - Valve
22 bar (218 - 319 lbf/in2)
Priority valve (15) - sticking open or Replace valve (15)
wrong spring setting

Fault in LS orifice (20) Replace/clean (20)

Leaking shuttle valve (21) Replace valve (21)

No steering flow available whilst the Ground driven pump faulty Replace ground driven pump at
vehicle is still travelling and engine is transmission.
switched off
Emergency steer valve (19) sticking Replace valve (19)
open

Emergency steer relief valve (27) Replace valve (27)

pressure setting too low.

With no functions operated pressure Emergency steer valve (19) spool Replace valve (19)
at ground driven pump too high. sticking closed.

* * * *

6 SM 2197 Rev 1 08-08

 STEERING SYSTEM - Steering Valve
Section 220-0090

SM - 2016

12 11 10 8 16 7 6 5 4

1
15

19

2
17

18 14

20 13 9 3

1 - Capscrew 7 - Valve Housing 13 - Bearing Race 19 - Gerotor Gear

2 - End Cap 8 - Sleeve 14 - 'O' Ring 20 - Retainer
3 - 'O' Ring 9 - Ball - Check 15 - Dust Seal 21 - 'O' Ring
4 - Gerotor Housing 10 - Pin 16 - Spool 22 - 'O' Ring
5 - Spacer Plate 11 - Centring Springs 17 - Seal 23 - Roll Pin
6 - Driveshaft 12 - Needle Bearing 18 - Backup Ring 24 - Ball valve

Fig. 1 - Sectional View of Steering Valve

DESCRIPTION the road shock, to the opposite end of the cylinders.

Numbers in parentheses refer to Fig. 1. This shock, if left unchecked, might damage steering
linkage components.
The steering valve can be identified as item 1 in Section
220-0000, STEERING SYSTEM SCHEMATIC. The main components of the steering valve are valve
housing (7), gerotor housing (4), gerotor gear (19),
The steering valve, mounted off the underside of the driveshaft (6), sleeve (8) and spool (16).
cab floor and connected to the steering column,
controls hydraulic flow in the steering system. The There are five ports on valve housing (7) as follows:
steering valve is of a closed centre design, which
means that the valve does not have any flow through it Port 'P' - Supply from main hydraulic valve
when it is in the neutral or no steering position. The Port 'T' - Return to tank
steering valve has integral cylinder relief valves which Port 'R' - Cylinder supply for right hand turn
relieve shock loads on the steering cylinders by Port 'L' - Cylinder supply for left hand turn
transferring excessive pressure applied to the oil by Port 'LS' - Load Sensing to main hydraulic valve

SM 2193 1-03 1
Steering System - Steering Valve
Section 220-0090
Turning action of the steering wheel is transmitted SM - 282
through the steering column to sleeve (8) and
POCKETS
driveshaft (6), which is fastened to the sleeve with
centring pin (10). Rotation of driveshaft (6) causes
gerotor gear (19) to rotate in gerotor housing (4).
When gerotor gear (19) rotates, oil in gerotor housing
(4) pockets (see Fig. 2) is forced out and flows through
spool (16) and sleeve (8) to the steering cylinder port.

Spool (16) contains porting matched to sleeve (8) and

rotates within sleeve (8) to provide directional control
of the oil. See Fig. 3.
GEROTOR HOUSING GEROTOR GEAR

OPERATION Fig. 2 - Gerotor Gear Set

Numbers in parentheses refer to Fig. 1.

SM - 283

When the operator turns the steering wheel a certain RIGHT LEFT
number of degrees for either a left or right hand turn, SYSTEM TURN TURN
the movement is transmitted through the steering PRESSURE FEED FEED
column to spool (16). After a minimum rotation of 2.5 METER TO
PORTS TANK
degrees, the ports in spool (16) start to align with ports
in sleeve (8). When the steering wheel is rotated to a
maximum of 10 degrees the ports are fully aligned
allowing full oil flow. After 10 degrees of travel in either
direction the spool and sleeve rotate as an assembly
through centring pin (10).

Oil from the priority valve flows into valve housing (7)
at port 'P' and is channelled through sleeve (8) and
spool (16) to gerotor housing (4). Porting in gerotor
housing (4) permits oil to flow into pockets formed by Fig. 3 - Porting of Spool and Sleeve
gerotor housing (4) and gerotor gear (19). As spool
(16) rotates, driveshaft (6) also rotates which, in turn, REMOVAL
rotates gerotor gear (19) to which it is splined. When
gerotor gear (19) rotates it progressively forces oil out Numbers in parentheses refer to Fig. 4.
of the pockets (see Fig. 2) of gerotor housing (4). The
oil is channelled through sleeve (8) and spool (16) and
exits valve housing (7) through port 'R' for a right hand WARNING
turn, or port 'L' for a left hand turn. Oil then travels To prevent personal injury and property
through steering lines to the steering cylinders. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
As the steering cylinder pistons move, oil forced out of secured and of adequate capacity to do the job
the steering cylinders returns to valve housing (7). The safely.
return oil passes through valve sleeve (8) and spool
(16) and exits through port 'T' to tank. 1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering
When the steering effort is released, centring spring wheel several times to relieve any pressure in the
(11) which was put under tension by the rotation of steering circuit. Operate brake pedal continuously to
spool (16), forces sleeve (8) to rotate back to its relieve pressure in the braking system.
original position. This puts the ports out of alignment
and stops pump oil flow to the steering cylinders. The 2. Block all road wheels and place the battery master
vehicle stops turning further but will hold the present switch in the 'Off' position.
turning radius until spool (16) is rotated past the 2.5
degree minimum. 3. Remove hydraulic tank remote drain plug and drain

2 SM 2193 1-03
 Steering System - Steering Valve
Section 220-0090

SM - 2827

12 22
20 21

13

14

18

19
12

7
6 9 16
5
10
4 11 17

3
2 8

1 15

1 - Steering Valve 9 - Nitrile Seal 16 - Beading

2 - Locknut 10 - Bolt 17 - Steering Column Assy
3 - Washer 11 - Lockwasher 18 - Bracket
4 - Rubber Mount 12 - Joint 19 - Column Cover
5 - Mounting Plate 13 - Bellows 20 - Steering Wheel
6 - Washer 14 - Steering Shaft 21 - Nut
7 - Bolt 15 - Lever 22 - Cap
8 - Stub Shaft
Fig. 4 - Exploded View of Steering Valve Installation

hydraulic oil into a suitable container. Reinstall drain 6. Slide bellows (13) over steering shaft (14) to gain
plug in hydraulic tank remote drain fitting. access to bottom joint (12) and loosen bolt which
tightens joint (12) onto stub shaft (8).
4. Pull floor mat back to allow access to bolts (7).
Raise cab and secure with prop. Refer to Section 260- 7. Support steering valve (1) and remove bolts (7),
0010, CAB AND MOUNTING. locknuts (2) and washers (3 & 6) securing mounting
plate (5) to cab floor. Remove steering valve (1) and
5. Clean outer area of steering valve (1) with a suitable mounting plate (5) to a clean area for disassembly.
solvent. Ensure all hydraulic lines connected to Remove nitrile seal (9) and discard rubber mounts (4),
steering valve (1) are identified for ease of installation if damaged.
and with suitable containers available to catch
leakage, disconnect hydraulic lines. Cap all lines and
plug all ports to prevent entry of dirt.

SM 2193 1-03 3
Steering System - Steering Valve
Section 220-0090

SM - 2017

9 11 13 12 13
16 20 14 17 18 15

3 4 19 21 5
1
22

6
8
10

24
23

1 - Capscrew 7 - Valve Housing 13 - Bearing Race 19 - Gerotor Gear

2 - End Cap 8 - Sleeve 14 - 'O' Ring 20 - Retainer
3 - 'O' Ring 9 - Ball - Check 15 - Dust Seal 21 - 'O' Ring
4 - Gerotor Housing 10 - Pin 16 - Spool 22 - 'O' Ring
5 - Spacer Plate 11 - Centring Springs 17 - Seal 23 - Roll Pin
6 - Driveshaft 12 - Needle Bearing 18 - Backup Ring 24 - Ball valve

Fig. 5 - Exploded View of Steering Valve

DISASSEMBLY SM - 2018

Numbers in parentheses refer to Fig. 5, unless

otherwise specified. 19

Note: Steering valves fitted with anti-cavitation valves

must be disassembled and assembled in the vertical
postion to prevent ball valves (24) becoming trapped in
the wrong cavities within the valve housing (7).

1. Remove bolts (10, Fig. 4) and washers (11, Fig. 4)

securing mounting plate (5, Fig. 4) to steering valve (1,
Fig. 4).

2. Clamp steering valve assembly horizontally in a soft 19 - Gerotor Gear

jawed vice and break loose the seven capscrews (1).
With capscrews (1) loosened, place steering valve Fig. 6 - Gerotor Gear and Splined Drive Engaged

4 SM 2193 1-03
 Steering System - Steering Valve
Section 220-0090

SM - 2019 vertically in vice, end cap (2), up.

11 Note: Hidden pin. If tension on this pin is released

19
before these parts are fully disengaged and the pin is
not horizontal, the pin can drop and lockup can occur.

3. Remove cap screws (1) securing end cap (2),

gerotor housing (4) and spacer plate (5) to valve
housing (7). Remove end cap (2) from valve
housing (7) and discard 'O' ring (3).

4. Remove gerotor housing (4) and gerotor gear (19)

10 from valve housing (7). Remove and discard 'O' ring
10 - Pin 19 - Gerotor Gear (21) from gerotor housing (4).
11 - Centring Springs
Fig. 7 - Compressing Centering Spring 5. Remove spacer plate (5) from valve housing (7).

6. Remove and discard 'O' ring (22) from valve

SM - 2020
housing (7).

19 7.Using a cloth to protect the hand, place gerotor gear

(19) over end of drive shaft (6) and engage special tool
with splined end of spool (16). Refer to Fig. 6.

8. Hold gerotor gear (19) and prevent drive shaft (6)

from turning. Twist special tool to compress centering
spring (11) radially CW or CCW, decreasing the coil
diameter of the centering spring (11) allowing spool
and sleeve assembly to be removed. Refer to Fig. 7.

9. With drive held stationary and centering spring (11)

19 - Gerotor Gear compressed, carefully push spool (16), sleeve (8), ball
checks (9), drive shaft (6), pin (10), bearing races (13),
Fig. 8 - Removing Spool and Sleeve Assembly retainer (20) and needle thrust bearing (12), as a complete
assembly, from valve housing (7). Refer to Fig. 8.
SM - 2021
10. Remove bearing race (13) and needle thrust
bearing (12) from spool and sleeve assembly.
6 8 11 13

20 11. Using suitable pliers, remove retainer (20) and

bearing race (13) from spool (16) and sleeve (8)
assembly. Refer to Fig. 9.

12. Remove centering spring (11) from spool (16) and

sleeve (8) assembly. Refer to Fig. 9.

13. Remove pin (10) and slide drive shaft (6) from
spool (16) and sleeve (8) assembly. Refer to Fig. 9.

9 9 10 16 14. Carefully remove spool (16) and ball checks (9)

from sleeve (8). Refer to Fig. 9.
6 - Driveshaft 11 - Centring Springs
8 - Sleeve 13 - Bearing Race 15. Use a soda straw as a guide tool to remove the roll
9 - Ball - Check 16 - Spool
10 - Pin 20 - Retainer pin (23) and ball valve (24) from the anti-cavitation
valve ports. Insert two soda straws, one in each anti-
Fig. 9 - Sectional View of Spool and Sleeve Assembly cavitation valve bore. Remove valve housing (7) from

SM 2193 1-03 5
Steering System - Steering Valve
Section 220-0090

SM - 2022 vice and tilt until roll pins (23) and ball valves (24) slide
PORT FACE through the straws and out of the valve housing (7).
Refer to Fig. 10.

16. Remove and discard 'O' ring (14), seal (17) and
backup ring (18) from valve housing (7).
PORT
FACE
17. Using a thin blade screwdriver, pry dust seal (15)
from valve housing (7). Take care not to damage dust
seal seat.
TOP
VIEW

24
INSPECTION
Anti-Cavitation Valves -
Insert Soda Straws (2), 1. Clean all metal parts in a suitable solvent and blow
one into each of these dry with compressed air. Do not wipe dry with cloth or
two threaded holes. 23 paper towel as lint or other matter may get into the
hydraulic system and cause damage.

TILT 2. Check all mating surfaces and replace any parts that
HOUSING have scratches or burrs that could cause leakage.

SODA STRAW 3. Do not use course grit or try to file any metal parts.

Note: Replace all 'O' rings and seals with new 'O' rings
23 - Roll Pin
24 - Ball Valve
and seals at 'Assembly'. Lubricate all 'O' rings and
seals with a petroleum jelly.
Fig. 10 - Removing Ball Valves

ASSEMBLY
SM - 2023
PORT FACE Numbers in parentheses refer to Fig. 5, unless
otherwise specified.
23

Note: Tighten all fasteners without special torques

specified to standard torques listed in Section
24 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.

GUIDE TOOL Note: Steering valves fitted with anti-cavitation valves

(Soda Straw)
must be disassembled and assembled in the vertical
postion to prevent ball valves (24) becoming trapped in
the wrong cavities within the valve housing (7).
Anti-Cavitation Valves
1. Use a soda straw as a guide tool to insert the roll pin
(23) and ball valve (24) into the anti-cavitation valve
ports. Insert soda straw into anti-cavitation valve bore.
Drop ball valve (24) through straw into bore. Remove
straw and drop roll pin (23) into bore. Repeat for
second anti-cavitation valve bore. Refer to Fig. 11.

2. Apply a light coating of clean hydraulic fluid to spool

(16). Slide spool (16) and ball checks (9) into sleeve
23 - Roll Pin (8). Refer to Fig. 12.
24 - Ball Valve
Fig. 11 - Installing Ball Valves

6 SM 2193 1-03
 Steering System - Steering Valve
Section 220-0090
SM - 2024 SM - 2027

6 8 11 13

6 8
16

10
6 - Drive Shaft
8 - Sleeve
9 - Ball Check
10 - Pin 9 9 10 16
16 - Spool
9
Fig. 12 - Installing Spool and Ball Checks

SM - 2025

17
6 16
18
6 - Drive Shaft
20
8 - Sleeve
9 - Ball Check 12 14
8 10 10 - Pin
11 - Centring Springs 16 - Spool
12 - Needle Bearing 17 - Seal
6 - Drive Shaft 10 - Pin 13 - Bearing Race 18 - Backup Ring
8 - Sleeve 16 - Spool 14 - 'O' Ring 20 - Retainer
Fig. 13 - Installing Centring Pin and Drive Shaft Fig. 15 - Sectional View of Seals and Bearings

SM - 2026 end of spool (16). Compress centring spring (11)

radially (CCW) and engage free end of spring into slot
in spool (16). See Fig. 14.

5. Install bearing race (13) onto spool (16). Using

suitable pliers install retainer (20) onto spool (16). See
Fig. 14.

6. Apply a light coating of petroleum jelly to the inside

11 16 13 20 diameter of dust seal (15) and install in valve housing (7).

7. Apply a light coating of petroleum jelly to needle

11 - Centring Springs 16 - Spool thrust bearing (12), bearing race (13), 'O' ring (14),
13 - Bearing Race 20 - Retainer
seal ring (17) and backup ring (18). Install each item
Fig. 14 - Installing Bearing Race and Retainer onto spool (16), as shown in Fig. 15.

Note: Needle thrust bearing is positioned between the

3. Insert drive shaft (6) into spool (16) in sleeve (8) two bearing races (13) and must be centered around
carefully so that holes line up. Install pin (10) through retainer (20).
sleeve (8), spool (16) and drive shaft (6) assembly
until pin (10) becomes flush at both sides of sleeve (8). Note: Clamp steering valve housing (7) vertically in a
See Figs. 12 & 13. soft jawed vice.

4. Position one end of centring spring (11) into slotted

SM 2193 1-03 7
Steering System - Steering Valve
Section 220-0090

SM - 2028 SM - 2029

Fig. 16 - Compressing Centering Spring Fig. 17 - Installing Spool and Sleeve Assembly

SM - 2030

7
3 4 19 21 5
1
22

1 - Capscrew 4 - Gerotor Housing 19 - Gerotor Gear

2 - End Cap 5 - Spacer Plate 21 - 'O' Ring
3 - 'O' Ring 7 - Valve Housing 22 - 'O' Ring

Fig. 18 - Installing Seals and Gerotor Assembly

8. Using a cloth to protect the hand, place gerotor gear valve housing (7). Align bolt holes in spacer plate (5) with
(19) over end of drive shaft (6). Insert special tool tapped holes in valve housing (7). Refer to Fig. 18.
through valve housing (7) and engage with splined
end of spool (16) and sleeve (8) assembly. Twist tool 13. Lubricate and install new 'O' ring (21) in groove in
to compress centering spring (11) radially CW or spacer plate (5). Refer to Fig. 18.
CCW. Refer to Fig. 16.
14. Install gerotor housing (4) on valve housing (7).
9. Keep centering spring (11) compressed and Align bolt holes in gerotor housing (4) with tapped
carefully insert assembled parts into valve housing (7), holes in valve housing (7). Refer to Fig. 18.
as shown in Fig. 17.
15. Align gerotor gear (19) on driveshaft (6) and
10. Release tension on centering spring (11) and gerotor housing (4), as shown in Fig. 18.
remove special tool and gerotor gear (19).
16. Lubricate and install new 'O' ring (3) in groove in
11. Lubricate and install new 'O' ring (22) in groove in gerotor housing (4).
valve housing (7). Refer to Fig. 18.
17. Install end cap (2) on gerotor housing (4), as
12. Install spacer plate (5) with the 'O' ring groove up, on shown in Fig. 18.

8 SM 2193 1-03
 Steering System - Steering Valve
Section 220-0090

SM - 313 5. Remove plugs from steering valve ports and caps

from steering lines and install steering lines to steering
valve (1), as identified at removal.

6. Lower cab and secure with pins. Refer to Section

260-0010, CAB AND MOUNTING.

7. Fill hydraulic tank with hydraulic oil, as specified in

Section 300-0020, LUBRICATION SYSTEM. Refer to
'Filling and Bleeding The Steering System'.
Fig. 19 - Cap Screw Tightening Sequence

8. Remove wheel blocks from all road wheels, place

18. Align cap screw (1) holes and install seven dry cap the battery master switch in the 'On' position and start
screws (1) in end cap (2). Pre-tighten cap screws (1) to the engine. Operate the steering and check hydraulic
17 Nm (12.5 lbf ft) then tighten to a torque of 34 Nm lines for leaks. Tighten lines and fittings as required.
(25 lbf ft), in the sequence shown in Fig. 19.

19. Using bolts (10, Fig. 4) and washers (11, Fig. 4)

FILLING AND BLEEDING THE STEERING
secure mounting plate (5, Fig. 4) to steering valve (1, SYSTEM
Fig. 4). 1. Fill hydraulic tank to Maximum level. Be ready to
add oil when the engine is started. Do not let oil drop
below the pump suction line to prevent air entering the
INSTALLATION system.
Numbers in parentheses refer to Fig. 4.
2. Start engine and let it idle. Immediately add oil to the
Note: Tighten all fasteners to standard torques listed hydraulic tank as required. When no more oil can be
in Section 300-0080, STANDARD BOLT AND NUT added and oil is clear, proceed as follows:
TORQUE SPECIFICATIONS.
a. Turn the steering wheel from lock to lock to bleed
Note: Tighten all hydraulic lines fitted with ORFS the air in the steering cylinders and lines.
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all Note: Immediately upon valve spool actuation oil must
'O' rings where used. be added to the hydraulic tank to replenish the oil
moving into the circuit.

WARNING
To prevent personal injury and property WARNING
damage, be sure wheel blocks, blocking Do not operate the vehicle until all air is bled
materials and lifting equipment are properly from the oil.
secured and of adequate capacity to do the job
safely. b. When the oil in the tank is clear (not cloudy or
creamy), the system is free of air.
1. Make certain area of installation is clean.
Note: Slight creep or drift of the steering wheel is normal.
2. Install rubber mounts (4) if removed, and secure
steering valve (1) and mounting plate (5) to cab floor c. Fill hydraulic tank with hydraulic oil specified in
with bolts (7), washers (3 & 6) and locknuts (2). Section 300-0020, LUBRICATION SYSTEM. Refer to
Section 230-0040, HYDRAULIC TANK, for correct fill
3. Install nitrile seal (9) to steering shaft (14). level. Install filler cap on tank.

4. Slide bottom joint (12) of steering shaft (14) over

stub shaft (8) and secure by tightening bolt. Slide
bellows (13) down over bottom joint (12) and stub
shaft (8).

SM 2193 1-03 9
Steering System - Steering Valve
Section 220-0090

SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for
details of the centring spring installation tool
referenced in this section. This tool is available from
your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
5 1 Capscrew 34 25

STEERING CONTROL DIAGNOSIS

CONDITION REASON REMEDY
Steering wheel does not centre Binding in steering linkage to valve Align as required
Worn gerotor Replace parts
Broken centring springs Replace centring springs, drain
and flush system
Burrs on sleeve or spool Disassemble and repair or replace
parts
Apparent inability to steer when Dirt in system Drain and flush system. Refill with
wheel is turned slowly clean oil
Slow steering Excessive wear in sleeve and spool Replace sleeve and spool
Excessive wear in gerotor Replace gerotor
Hard steering See 'Slow Steering'
Opposite steering Lines hooked up incorrectly Reconnect correctly
Wrong orientation between gerotor Realign per instructions
and gerotor drive
Steering wheel rocking back See 'Opposite Steering'
and forth
Steering wheel continues to turn Input linkage binding Align as required
Burr on sleeve or spool Disassemble and repair or replace
Dirt in system Drain and flush system. Refill with
clean oil
Broken centring springs Replace centring springs, drain and
flush system
No steering action Sleeve and spool locked together Disassemble and repair or replace

* * * *

10 SM 2193 1-03
 STEERING SYSTEM - Steering Cylinder
Section 220-0120

SM - 3372

14
13

10 11 9
1 11 12
7 15,16 5
3 6
14
13

4 4
20 2 8
18
19 18 20
19
PART OF
FRAME PART OF
17 FRAME
17
ORIENTATION OF
CUSHION SLEEVE

21
21
22
23

1 - Cylinder Body 7 - Wiper 12 - Piston Seal 17 - Pin

2 - Piston Rod 8 - Cushion Sleeve 13 - Spherical Bearing 18 - Hardened Washer
3 - End Cap 9 - Piston 14 - Circlip 19 - Lockwasher
4 - Lube Fitting 10 - Grub Screw 15 - Back Up Ring 20 - Bolt
5 - 'O' Ring 11 - Wear Ring 16 - 'O' Ring 21 - Spacer
6 - Rod Seal 22 - Spacer

Fig. 1 - Sectional View of Steering Cylinder and Mounting

DESCRIPTION (17), spacerls (21), spacers (22) and spherical bearings

(13) secured with circlips (14). Spherical bearings (13)
Numbers in parentheses refer to Fig. 1.
permit a limited amount of cylinder misalignment when
travelling over rough terrain.
The steering cylinders can be identified as item 2 in
Section 220-0000, STEERING SYSTEM
SCHEMATIC. OPERATION
When the operator turns the steering wheel for a
There are two single stage, double acting cushioned
steering operation, movement of the piston rod
steering cylinders on the machine. The piston rod (2)
generates force required to pivot the tractor frame.
end is connected to the articulation and oscillation
pivot, and, the cylinder base end is connected to the
In the neutral position, with the steering valve
front frame. Single stage double acting means that
centralized, oil movement between the steering
piston rod (2) can have oil applied to either side,
cylinders and the steering valve is stopped. Trapped
extending or retracting the piston rod.
oil in the system locks both steering cylinders and the
angle of steering set by the operator is maintained.
Rod end cylinder mounting is by pins (17), seals (21),
Refer to Section 220-0090, STEERING VALVE, for
spacers (22) and spherical bearings (13) secured with
operation of the steering valve.
circlips (14). Base end cylinder mounting is by pins

SM 2195 Rev1 12-04 1

Steering System - Steering Cylinder
Section 220-0120

REMOVAL DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.

WARNINGS WARNING
To prevent personal injury and property To prevent personal injury and property
damage, be sure wheel blocks, blocking damage, be sure lifting equipment is properly
materials and lifting equipment are properly secured and of adequate capacity to do the job
secured and of adequate capacity to do the job safely.
safely.
1. Ensure clean working conditions, remove any port
Hydraulic fluid pressure will remain plugs thus allowing easy entry of air into the cylinder,
within the system after engine shutdown. preventing a vacuum when parts are withdrawn from
Operate the treadle pedal continuously until the cylinder body (1).
pressure has dissipated before carrying out any
work on the hydraulic system or serious injury 2. Remove circlips (14) from base end of cylinder body
could result. (1) and piston rod (2) end. Press out spherical
bearings (13).
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Turn steering 3. Using special tool which can be fabricated as shown
wheel several times to relieve any pressure in the in Fig. 2, unscrew end cap (3) until thread is
steering circuit. Operate brake pedal continuously to disengaged from cylinder body (1).
relieve pressure in the braking system.
4. Pull end cap (3) and piston rod (2) out of cylinder
2. Place steering lock bar in the 'Locked' position. body (1) as an assembly.
Block all road wheels and place the battery master
switch in the 'Off' position. 5. Place piston rod (2) on supports which will not
damage the chrome piston rod diameter.
3. Identify, tag and with a suitable container in position
to catch the spillage, disconnect all hydraulic lines on 6. Remove and discard piston seal (12) and wear rings
one steering cylinder. Cap all lines and fittings to (11) from piston (9).
prevent ingress of dirt.
7. Remove grub screw (10) from wear ring groove in
4. Support steering cylinder with a suitable lifting piston (9).
device.
8. Provide an anti-torsion device through piston rod (2)
5. Remove bolt (20), lockwasher (19) and hardened eye to allow unscrewing of piston (9). Using special
washer (18) securing pin (17) at base end of the tool which can be fabricated as shown in Fig. 3,
cylinder. Remove pin (17) securing base end to the unscrew piston (9) from piston rod (2).
front frame.
9. Remove and discard 'O' ring (5) from piston (9).
6. Remove bolt (20), lockwasher (19) and hardened Remove and retain cushion sleeve (8) from piston rod
washer (18) securing pin (17) at piston rod (2) end of (2).
the cylinder. Remove pin (17) securing piston rod (2)
end to the articulation and oscillation pivot. 10. Pull end cap (3) assembly off piston rod (2).
Remove and discard back up ring (15) and 'O' ring (16)
7. Remove cylinder assembly from the machine. from end cap (3) outer grooves. Remove and discard
Spacers (22 & 21) will come free at this time. wiper (7) and rod seal (6) from end cap (3) inner
grooves.
8. Remove cylinder assembly to a clean area for
disassembly. Drain oil from cylinder assembly into a 11. If damaged, remove lube fittings (4) from cylinder
suitable container. body (1) and piston rod (2).

9. Repeat steps 3 through 8 for opposite steering

cylinder assembly.

2 SM 2195 Rev1 12-04

 Steering System - Steering Cylinder
Section 220-0120

INSPECTION 8. Insert piston grub screw (10), through wear ring

groove in piston (9), into groove machined in piston rod
Numbers in parentheses refer to Fig. 1
(2). Tighten grub screw (10) to a torque of 13 - 20 Nm
(10 - 15 lbf ft). Ensure the extreme of grub screw (10)
1. Clean all parts of the cylinder with a suitable solvent
is below the level of wear ring groove.
and dry with clean, lint-free cloths. Clean all grooves
carefully to remove any foreign material.
9. Insert new piston seal (12) and new wear rings (11)
in piston (9) external grooves.
2. Check cylinder body (1), end cap (3) grooves and
outer diameter of piston (9) for scratches, cracks or
10. Fully grease piston (9) OD and 'O' ring (16) in end
other signs of damage. Remove ridges, nicks and
cap (3).
scratches with a fine stone and re-clean. Replace any
components which cannot be repaired.
11. Ensure bore of cylinder is well lubricated with
hydraulic oil. Carefully insert piston rod (2) and end
3. Inspect piston rod (2) for distortion, cracks or other
cap (3) assembly into cylinder body (1).
defects. Replace piston rod (2) if defective area is
irreparable.
12. Engage end cap (3)/cylinder body (1) thread and
screw up fully. Using special tool which can be
4. Check spherical bearings (13) for wear and replace if
fabricated as shown in Fig. 2, tighten end cap (3) to a
necessary.
torque of 542 - 610 Nm (400 - 450 lbf ft).

ASSEMBLY 13. Replace lube fittings (4) if required.

Numbers in parentheses refer to Fig. 1.
INSTALLATION
Numbers in parentheses refer to Fig. 1.
WARNING
To prevent personal injury and property
Note: Tighten all fasteners to standard torques listed
damage, be sure lifting equipment is properly
in Section 300-0080, STANDARD BOLT AND NUT
secured and of adequate capacity to do the job
TORQUE SPECIFICATIONS.
safely.
Note: Tighten all hydraulic lines fitted with ORFS
1. Press spherical bearings (13) in base end of cylinder
connections, as described in Section 220-0000,
body (1) and piston rod (2) end. Secure spherical
STEERING SYSTEM SCHEMATIC. Renew all
bearings (13) with circlips (14).
'O' rings where used.
2. Install new rod seal (6) into bore of end cap (3) with
the lip pointing towards the internal face of end cap (3).
WARNING
Install new wiper (7) into bore of end cap (3).
To prevent personal injury and property
damage, be sure lifting equipment is properly
3. Install new back up ring (15) and 'O' ring (16) in
secured and of adequate capacity to do the job
external groove of end cap (3).
safely.
4. Guide end cap (3) assembly onto piston rod (2),
1. Install a suitable strap, or other lifting device, around
taking care not to damage rod seal (6) on the thread.
one cylinder assembly and position cylinder assembly
on the vehicle, with piston rod (2) end of cylinder ready
5. Install cushion sleeve (8) into piston rod (2) counter
for mounting.
bore. Note correct orientation, spigot face abuts
counter bore face (see Fig. 1).
2. Install spacers (21) and spacers (22) either side of
piston rod (2) end of cylinder and insert pin (17).
6. Install new 'O' ring (5) into internal groove of piston
Secure pin (17) to articulation and oscillation pivot with
(9).
bolt (20), lockwasher (19) and hardened washer (18).
7. Using special tool which can be fabricated as shown
3. Install spacers (21) and spacers (22) either side of
in Fig. 3, screw piston (9) on piston rod (2). Tighten
base end of cylinder and insert pin (17). Secure pin (17)
piston (9) to a torque of 746 - 813 Nm (550 - 600 lbf ft).
to front frame with bolt (20), lockwasher (19) and

SM 2195 Rev1 12-04 3

Steering System - Steering Cylinder
Section 220-0120
hardened washer (18). 9. Place the battery master switch in the 'On' position,
start the engine and operate the steering, from lock to
4. Connect hydraulic lines to steering cylinder ports, as lock several times, to purge air out of the hydraulic
tagged during removal. lines. Check hydraulic lines and fittings for leaks.
Tighten lines and fittings as required.
5. Repeat steps 1 through 4 for installation of opposite
steering cylinder.
MAINTENANCE
6. Lubricate pins (17) through lube fittings (4) with Inspect steering cylinders regularly for leaks or
lubricant, as specified in Section 300-0020, damage, repair as required. Lubricate cylinder pins
LUBRICATION SYSTEM. every 250 hours, as specified in Section 300-0020,
LUBRICATION SYSTEM.
7. Check oil level in hydraulic tank and add oil if low.
Refer to Section 230-0040, HYDRAULIC TANK, for
correct fill level. Refer to Section 300-0020, SPECIAL TOOLS
LUBRICATION SYSTEM, for the type of oil used. Special tools can be fabricated as shown in Figs. 2 & 3.
Refer to Section 300-0070, SERVICE TOOLS, for part
8. Place the steering lock bar in the 'Stowed' position numbers of general service tools required. These tools
and remove wheel blocks. are available from your dealer.

SM - 407

DRILL
RAD
DEEP

RAD TYP
BURN OUT

SQUARE

SECURE ALUMINIUM DRILL AND REAM THROUGH

COLLAR WITH (3) M8 AND FIT 8 (0.315) Ø
CAP SCREWS HARDENED DOWEL
TORQUE PINS 2 PLACES

Dimensions in mm (inches)
Fig. 2 - End Cap Torque Tool

4 SM 2195 Rev1 12-04

 Steering System - Steering Cylinder
Section 220-0120

SM - 633

SILVER STEEL
SQUARE

OUTER SHIELD TO BE SECURED DOM TUBE

TO INNER BODY WITH 2BA CAPSCREWS

Dimensions in mm (inches)
Fig. 3 - Piston Torque Tool

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 9 Piston 746 - 813 550 - 600
1 3 End Cap 542 - 610 400 - 450
1 10 Grub Screw 13 - 20 10 - 15

* * * *

SM 2195 Rev1 12-04 5

Steering System - Steering Cylinder
Section 220-0120

THIS PAGE IS INTENTIONALLY BLANK

6 SM 2195 Rev1 12-04

 BODY SYSTEM - Body System Schematic
Section 230-0000
SM2847

18

LOWER

RAISE

ACC3
1
DL

5
PPA

PP B A
1
9 33 47

T
13

30
R

15 32
P1
31 31
L
LSM
21 22
46

25

PP

26

PPB
29

T LSP T

1 - Body Cylinders 21 - Shuttle Valve 31 - Copy Spool

5 - Proportional Control Valve (Raise) 22 - Shuttle Valve 32 - Load Sense Dump Valve
9 - Pressure Reducing Valve 25 - Shuttle Valve 33 - Make Up Check Valve
13 - Float Solenoid 26 - Relief Valve 46 - Orifice
15 - Priority Valve 29 - Proportional Control Valve (Lower) 47 - Relief Valve
18 - Primary Accumulator 30 - Control Spool

Fig. 1 - Body System Schematic

DESCRIPTION A brief description of the individual components used in

Numbers in parentheses refer to Figures 1 and 4. the body hydraulic system is provided below. Detailed
service and operating instructions can be found in the
Other useful reference reading: Section 190-0000, relevant component sections of this manual.
Circuit Diagrams; Section 215-0050, Main Hydraulic
Valve Assembly; Section 230-0081, Body Control Body Control Lever
Lever.
Refer to Section 230-0081, Body Control lever.
The body hydraulic system enables the operator to lift
and lower the body in a safe manner using an electric The body control lever is mounted on the right-hand
output from the body control lever. side dash panel inside the operator's cab. The body
control lever is manually operated to control the lift and
lower functions of the body assembly.

SM 2199 Rev 4 10-08 1

Body System - Body System Schematic
Section 230-0000

Accumulator pressure is monitored by pressure

Body Cylinders (1) switches in the brake lines (Ref. Section 250-0000,
Refer to Section 230-0130, Body Cylinder. Braking System).

There are two single stage, double acting body hoist

cylinders, cushioned at both ends of the stroke, on the Valves 5, 9, 13, 15, 21, 22, 25, 26, 29, 30, 31,
vehicle. Each cylinder base end is connected to the 32, 33, 46 and 47
trailer frame and each piston rod eye end is connected These valves form part of the brake circuit and are an
to the body. Single stage, double acting means that the intregal part of the main hydraulic valve assembly,
piston rod can have oil applied to either end, extending mounted on the left hand side of the tractor frame.
or retracting the piston rod. Refer to Section 215-0050, Main Hydraulic Valve
Assembly.
The cushioning effect when the cylinder is being
extended is obtained by a tapered spear on the piston
rod passing through a cushioned sleeve. This gradually OPERATION
slows the piston which in turn helps to control
destructive shock effects when the piston reaches the LIFTING THE BODY
full extent of its travel. Refer also to Sections 190-0000 Circuit Diagrams and
215-0050 Main Hydraulic Valve Assembly.
The cushioning effect when the cylinder is being
retracted is obtained by a tapered spear at the base When the operator pulls back on the body control lever,
end of the cylinder body entering a cavity in the piston a voltage between 0 and 5 volts is sent to the hydraulic
rod through a cushioning ring. This gradually slows the ECU, Pin C1:8. The hydraulic ECU converts this signal
piston which in turn helps to control destructive shock to an output current at Pin C1:17 to between 250 and
effects when the piston bottoms. 800 mA, determined by how far the lever is moved.
This current is delivered to the Electro-hydraulic
Cylinder mounting is by pins, spacers and spherical Proportional Pressure Control Valve (5) which converts
bearings secured in place by circlips. Spherical this current into a pilot pressure.
bearings permit a limited amount of cylinder
misalignment. The primary accumulator (18) pressure is reduced to a
35 bar (508 lbf/in2) pilot control pressure by a pressure
reducing valve (9). This pilot control pressure acts on
Accumulators (18) the proportional pressure control valve (5), which in turn
Refer to Section 250-0060, Accumulator. reduces the pilot pressure to between 4 bar (58 lbf/in 2
)
and 25 bar (363 lbf/in), depending on the current output
2

The primary accumulators are mounted inside the from the hydraulic ECU. This pilot pressure then
battery box, which in turn is located on the front left selects the main spool (30) in the lift valve section of
hand side of the tractor. The primary accumulators the main hydraulic valve assembly to the raise
support the service brake system and the body pilot position.
pressure system. The primary accumulators are of the
piston type and are each precharged with nitrogen to a When the main spool (30) has been stroked to the raise
pressure of 95 bar (1380 lbf/in²). Each comprises a position, oil from the main pump flows through the
charging valve assembly, a cylinder assembly and a control spool (30), out of port 'A' on the main hydraulic
piston. The charging valve is equipped with a locking valve, and on to the tip cylinders (1).
feature which, when the valve is opened, will allow the
precharge to be checked or charging of the When oil from the main pump flows through the control
accumulator to be facilitated. spool (30), a pressure is created at the head of the
copy spool (31). The copy spool (31) strokes down,
Each piston acts as a separator, dividing the allowing a 'load sense' pressure to be fed back to the
respective cylinder assembly into two sections. The load sense port of the main pump, via shuttle valves
section nearest the charging valve contains the (22 and 25). The main pump then increases its
nitrogen precharge. Hydraulic oil from the accumulator displacement and flow passes to port 'A' lifting the
charge valve flows through accumulator check valves body. Returning flow from the tipping cylinders (1)
in the brake manifold valve and into the other section passes to Port 'B', through the control spool (30) back
of the accumulator. to tank.

2 SM 2199 Rev 4 10-08

 Body System - Body System Schematic
Section 230-0000

SM2866 of the circuit, and prevents pressure spikes at

maximum extension of the cylinders when the body is
raised at maximum engine speed. The relief valve (47)
is set at 230 bar (3 335 lbf/in2 ).

LOWERING THE BODY

When the operator pushes forward on the body control
lever, a voltage of between 0 and 5 volts is sent to the
hydraulic ECU, Pin C1:12. The hydraulic ECU converts
this signal to an output current at Pin C1:31 of between
250 and 800 mA, determined by how far the lever is
moved. This current is seen at the Electro-hydraulic
Fig. 2 - Body Control Lever (Operator's Cab) Proportional Pressure Control Valve (29) that converts
this current into a pilot pressure.
SM2867

The pilot control pressure of 35 bar (508 lbf/in2),

created by pressure reducing valve (9), is reduced by
the proportional pressure control valve (29) to between
4 bar (58 lbf/in2) and 25 bar (363 lbf/in2), depending on
the current output from the hydraulic ECU. This pilot
pressure selects the main spool (30) in the lift valve
section of the main hydraulic valve assembly to the
lower position.

When the main spool (30) has been stroked to the

lower position, oil from the main pump flows through
the control spool (30) out of port 'B' on the main
hydraulic valve, and on to the tip cylinders (1).

When oil from the main pump flows through the control
spool (30), a pressure is created at the head of the
copy spool (31). The copy spool (31) strokes down
allowing a 'load sense' pressure to be fed back to the
load sense port of the main pump via shuttle valves
(22 and 25). The main pump then increases its
displacement and flow passes to port 'B' lowering the
body. Returning flow from the tipping cylinders (1)
passes to Port 'A', through the control spool (30) back
to tank.
Fig. 3 - Body Control Lever Positions
During lowering, the operator can fully select the body
control lever on to an electric detent within the lever
The load sense pressure created by the copy spool base which is connected to the hydraulic ECU pin
(31) is controlled to a maximum of 195 bar (2830 lbf/in 2
) C1:35, This detent holds the lever in the power down
by the relief valve (26). This will result in a maximum position, allowing the operator to drive the vehicle
main pump delivery pressure for the body raise circuit whilst the body is still lowering.
of 220 bar (3200 lbf/in2). This is a result of the 195 bar
(2830 lbf/in2) maximum load sense pressure, plus the A proximity switch is located on the chassis, which
25 bar (360 lbf/in2) stand by pressure of the main supplies a 24 Volt signal to the hydraulic ECU pin
pump. Refer to Section 230-0050, Main Hydraulic C1:6. When the body reaches the proximity switch the
Pump. 24 Volt signal is switched off, which in turn signals the
hydraulic ECU to de-energize the electric detent,
The body relief valve (47) is located on the raise side allowing the lever to spring back to the mid position. At

SM 2199 Rev 4 10-08 3

Body System - Body System Schematic
Section 230-0000

SM - 2920

5 - Proportional Control Valve (Raise)

9 - Pressure Reducing Valve - Pilot Pressure
13 - Float Solenoid
15 - Priority Valve
21 - Shuttle Valve
22 - Shuttle Valve
25 - Shuttle Valve
26 - Relief Valve - Body Raise Pressure LS
29 - Proportional Control Valve (Lower)
31 - Copy Spools 25 PORT 'DL'
32 - Load Sense Dump Valve
46 - Orifice
47 - Relief Valve

15
Valve (5 & 29) Coil Rating
Ohms Amps Watts
21 1.1 25
Voltage: 24V

Valve (13) Coil Rating 31

Ohms Amps Watts (x2 HIDDEN)
42 0.6 15
Voltage: 24V 21

PORT 'B'

PORT 'A'

26 47
9 32 PORT 'T'

LOWER PILOT PRESSURE INLET TO MAIN SPOOL

13

29

5 22/46

RAISE PILOT PRESSURE INLET TO MAIN SPOOL

REF. LIFT VALVE SECTION

Fig. 4 - Main Hydraulic Valve Assembly - Body Control Valve Locations

4 SM 2199 Rev 4 10-08

 Body System - Body System Schematic
Section 230-0000

the same time the hydraulic ECU ramps back the SM 3911
current to proportional pressure control valve (29) to
de-select the main spool (30), and energizes the coil
on the float solenoid valve (13), allowing the body to
float down to the chassis over the last few centimeters
of travel.

To prevent damage to the body hinge points or the tip

cylinders (1) the float solenoid valve (13), which is
connected to Pin C1:23 on the hydraulic ECU is
energized all the time the body is on the chassis and
the engine is running. This ensures that the head side
of the tip cylinders (1) is always vented to tank and the
body is sitting firmly on the chassis. Fig. 5 - Body Lower Emergency Switch

When the body meets the proximity switch on the SM 2849

chassis, the control spool is de-selected and reverts to

the neutral position. This action closes the copy spool
(31). The load sense dump valve (32) allows a
controlled load sense pressure drain back to the
hydraulic tank.
1

When the control spool (30) moves to the neutral 2

position, oil delivery from the main pump is blocked. P
3
To compensate for this over the last few centimetres FB 4
of travel, make up check valve (33) opens allowing a RB 5
controlled oil flow via port 'B' to the lower side of the tip 6
cylinders (1). The make up check valve (33) opening 7
safeguards the system against cavitation when the 8
main pump flow is blocked during the lowering 9
procedure of the body. 10

BODY LOWER EMERGENCY SWITCH

A switch is provided on the console, immediately to 1 - Differential Lock Pressure 8 - Trans. Converter Press.
the right of the operator's seat, which initiates lowering 2 - Pump LS Pressure 9 - Body System Press.
of the body in the event of an engine, hydraulic or 3 - Front Brake Pressure 10 - Trans. System Pressure
4 - Rear Brake Pressure P - Primary Accumulator
hydraulic ECU failure. The switch (S78 on Page 11 of FB - Front Brake Accumulator
5 - Park Brake Pressure
the Circuit Diagrams [Section 190-0000]), when 6 - Steering Pressure RB - Rear Brake Accumulator
operated, powers the solenoid of the float switch (13) 7 - Trans. Retarder Press.
directly from the batteries. The cause of the failure Fig. 6 - Diagnostic Pressure Check Points (Battery Box)
must be investigated and rectified.

Note: If an electrical fault occurs that results in the

WARNING
main spool (30) defaulting to the Neutral (Hold)
Always disconnect the body control lever
position, while the body is raised, lowering can be
before welding on the machine.
achieved by pressing the body lower Emergency
switch, which will allow it to drop under its own weight.
The body must remain lowered with the lever in the
Neutral position until it is necessary to operate the
body again. Failure to comply with this may result in
overheating of the hydraulic oil and failure of the
hydraulic system components.

SM 2199 Rev 4 10-08 5

Body System - Body System Schematic
Section 230-0000

EMERGENCY BODY LOWERING 1. Position the vehicle in a level work area, apply the
PROCEDURE, FOLLOWING LOSS OF parking brake and switch off the engine. Turn the
battery master switch to the 'off' position.
HYDRAULIC AND ELECTRICAL POWER
If the body is raised and the vehicle has lost electrical 2. Block all road wheels and place the battery master
AND hydraulic power, it is possible to make switch in the 'Off' position.
adjustments to the threaded end stops at the body
spool of the Main Hydraulic Valve, that will force a 3. The Main Hydraulic Valve assembly is accessed by
controlled lowering of the body. The procedure for raising the operator's cab. Using the hydraulic hand
carrying out this operation is detailed below. pump inside the battery box, tilt the cab and secure it.
Refer to Section 260-0010, Cab and Mounting.

WARNINGS WARNING
Never work under or near an unsupported
To prevent personal injury and property raised operator's cab assembly. Always ensure
damage, be sure wheel blocks, blocking that the cab safety prop is in the correct
materials and lifting equipment are properly position.
secured and of adequate capacity to perform
the task safely.
4. Locate the spool screws identified as A and B
Exercise extreme caution when accessing the
respectively on Figure 7. Measure and record the
Main Hydraulic Valve in order to lower the
height of the outer face of each screw from the casing
body. Do not put yourself in any danger from
of the Body Section of the Main Hydraulic Valve.
impact with the lowering body.

SM 3928

A B
A PORT B PORT
SCREW SCREW

15852
YYWW

T2 LSU

Fig. 7 - Body Valve Spool Screws

6 SM 2199 Rev 4 10-08

 Body System - Body System Schematic
Section 230-0000

5. Loosen the lock nut on spool screw B, then unscrew CHECKING THE MAIN BODY SYSTEM
screw B until the threaded shoulder of the screw is PRESSURE
flush with the face of the casing.
1. Position the vehicle in a level work area, apply the
parking brake, switch off the engine and turn the
6. Loosen the lock nut on spool screw A, then screw in
steering wheel in both directions several times to
screw A until the body lowers slowly and in a controlled
relieve any pressure in the steering circuit.
fashion.
2. Operate the brake treadle valve continuously to
WARNING relieve pressure in the accumulators. Block all road
wheels, place the steering lock bar in the 'Locked'
Keep well clear of the body as it is lowering.
position and the battery master switch in the 'Off'
position.
RESETTING MAIN HYDRAULIC VALVE
AFTER HYDRAULIC AND ELECTRICAL 3. This following procedure will check that the body
raise pressure is properly set. Connect a hydraulic
POWER IS RESTORED gauge, capable of recording a pressure of 0 - 345 bar (0
- 5000 lbf/in²), to the body system pressure diagnostic
1. Start the engine. pressure point inside the battery box (9, Figure 6).

2. Raise the body until it is 50% raised. 4. Place the battery master switch in the 'On' position,
start the engine and allow all systems to be charged
3. Unscrew spool screw A until its outer face is normally.
returned to the original height above the casing,
measured in Step 4 of the Emergency Lowering 5. Pull back body control lever. Allow body to raise
procedure given above. Lock the screw in this position over relief. The pressure observed on the pressure
using the lock nut. gauge should be 220 bar (3200 lbf/in 2
).

4. Screw in screw B until its outer face is returned to 6. Pressure setting can be adjusted by adjusting relief
the original height above the casing, measured in Step valve (26) on the main hydraulic valve assembly. Relief
4 of the Emergency Lowering procedure given above. valve (26) actually sets the load sense pressure for the
Lock the screw in this position using the lock nut. body circuit, controlling the load sense to a maximum
of 195 bar (2830 lbf/in2). This will result in a maximum
5. Using the hydraulic hand pump inside battery box, main pump delivery pressure for the body raise circuit
lower the cab and secure it. Refer to Section 260-0010, of 220 bar (3200 lbf/in2). This is due to the 195 bar
Cab and Mounting. (2830 lbf/in2) maximum load sense pressure, plus the
25 bar (360 lbf/in2) stand by pressure of the main
CHECKING SYSTEM PRESSURES pump. Refer to Section 230-0050, Main Hydraulic
Pump. The operator's cab has to be raised to facilitate
access to the relief valve (26). Refer to Section 260-
WARNINGS 0010, Cab and Mounting.
To prevent personal injury and property
damage, be sure wheel blocks and blocking 7. Adjust relief valve (26) until 220 bar (3200 lbf/in2) is
materials are properly secured and of adequate observed on the pressure gauge, while raising the body
capacity to do the job safely. over relief.

Hydraulic fluid pressure will remain 8. Shut off the engine and remove the pressure gauge
within the system after engine shut down. from the diagnostic check point.
Operate the brake treadle pedal continuously
until the pressure has dissipated before 9. Remove the wheel blocks, place the steering lock
carrying out any work on the system or serious bar in the 'Stowed' position, start the engine and check
injury could result. the body system for proper operation.

SM 2199 Rev 4 10-08 7

Body System - Body System Schematic
Section 230-0000

CHECKING THE PILOT CONTROL

a. Ensure that the O-ring/seal is in place and that the
PRESSURE
joining surfaces are clean. If necessary, retain the O-
1. Position the vehicle in a level work area, apply the ring/seal in place with a light coating of grease or
parking brake, switch off the engine and turn steering vaseline.
wheel in both directions several times to relieve any
pressure in the steering circuit. b. Initially, the nuts should be tightened by hand.

2. Operate the brake treadle valve continuously to c. Where a hose is fitted, ensure that it is not twisted
relieve pressure in the accumulators. Block all road or kinked when the nuts are tightened so that it is
wheels, place the steering lock bar in the 'Locked' allowed to adopt a natural position.
position and the battery master switch in the 'Off'
position. SM1335

FITTING NUT
3. Connect a hydraulic gauge, capable of recording a
pressure of 0 - 345 bar (0 - 5000 lbf/in
2
), into the differential TUBE
lock diagnostic pressure point inside the battery box (1,
Figure 6).

4. Place the battery master switch in the 'On' position,

start the engine and allow all systems to be charged
normally.
SLEEVE
O-RING O-RING
5. A hydraulic pressure of 35-42 bar (500-609 lbf/in
2
)
should be observed on the pressure gauge.
Fig. 8 - Assembly of Typical ORFS Connector

6. Pressure setting can be adjusted by adjusting

pressure reducing valve (9) on the main hydraulic d. Where a tube is fitted, ensure that the connection is
valve. Adjust pressure reducing valve (9) until 35-42 aligned correctly.
bar (500-609 lbf/in2) is observed on the pressure gauge.
e. Tighten the nut a further 1/4 to 1/2 a turn using the
Note: Differential lock (pilot) pressure can only be correct size spanner (wrench).
tested with the differential lock NOT actuated. When
the differential lock is engaged the diagnostic pressure f. Check that a satisfactory hose or tube routing has
point is vented to tank. been achieved.
7. Check the body system for proper operation.
HYDRAULIC OIL
8. Shut off the engine and remove the pressure gauge The hydraulic system should be kept filled with
from port 'DL'. hydraulic oil as specified in Section 300-0020,
Lubrication System.
9. The operator's cab should be lowered into the travel
position. Check the hydraulic lines for any leakage. Whenever there is a hydraulic system failure, the oil
should be drained, the entire system flushed, oil filters
10. Remove wheel blocks, place the steering lock bar replaced, oil screens thoroughly cleaned and clean
in the 'Stowed' position, start the engine and check the hydraulic oil added to eliminate all metal particles or
body system for proper operation. foreign matter.

O-RING FACE SEALS (ORFS) SERVICE TOOLS

Where hydraulic lines are fitted with ORFS It is recommended that the following service tools are
connections, the following procedure should be carried used when carrying out pressure and temperature
out during 'Installation'. Refer to Figure 6. checks during maintenance procedures. These tools,

8 SM 2199 Rev 4 10-08

 Body System - Body System Schematic
along with other general service tools, are available Section 230-0000
from your dealer. Refer to Section 300-0070, Service
Tools, for part numbers of these tools.

Multi-Gauge
The multi-gauge, 15269784, is basically four pressure
gauges in one. Continuous system pressure readings
are indicated on one of three simultaneously reading
gauges through a pressure range of 30 in of vacuum to
5000 lbf/in².

The following items should be added to the multi-gauge

to enable the gauge to be used on the diagnostic
pressure check points;
15018226 Diagnostic Coupling
00118748 Connector (two)
15004085 Hose Assembly (-04 HP, 2130 mm long)

Non-contact Infrared Thermometer

The infrared thermometer, 15269785, can be used to
spot heat problems early in electrical, mechanical and
hydraulic systems. Hand held and easy to use, you
simply aim, pull the trigger, and read the temperature.
Since there is no need to touch what you are
measuring, temperatures of hard to reach or moving
components can be taken without getting burned or
shocked.

O-ring Face Seals (ORFS) - Seal Kit

The braking system utilizes O-ring Face Seal (ORFS)
connectors. An ORFS kit, 15271082, is available. This
kit contains a minimum stock requirement of all sizes
of ORFS type seal.

SM 2199 Rev 4 10-08 9

Body System - Body System Schematic
Section 230-0000

Body System Trouble Shooting

Symptom Possible Cause Remedy
Body will not lift Pressure Level in the system is not Check the pressure at the pump
high enough and re-adjust the Relief Valve (26).
Refer to Section 230-0050, Main
Hydraulic Pump.

Relief valve (47) stuck open.

No electric current at the proportional Check voltage at the electric

control valve (5) connector of for Valve (5) when
pulling back on the lever in the cab.
If no voltage present refer to
Sections190-0085 Hydraulic ECU
and 230-0081, Body Control Lever

Replace Valve (5)

Proportional control valve (5) faulty
Check output from lever. Refer to
Control lever in the cab faulty Sections190-0085 Hydraulic ECU
and 230-0081, Body Control Lever

Main control spool (30) in the lift Replace lift section of the main
section of the main hydraulic valve hydraulic valve assembly
assembly sticking

Copy spool (31) sticking Check condition of copy spool,

replace if necessary. Replace Main
Hydraulic Valve Assembly

Contamination in the load sense Clean orifice (46). Replace Main

drillings and the orifice (46) Hydraulic Valve Assembly

Main pump faulty Refer to Section 230-0050 Main

Hydraulic Pump, for correct setting
procedures

Lift function too slow. Proportional control valve (5) current Check output from body control
not high enough lever. Refer to Sections190-0085
Hydraulic ECU and 230-0081, Body
Control Lever

Main control spool (30) not fully Replace lift section of main
selecting. hydraulic valve assembly.

Contamination in the load sense Clean orifice (46).

drillings and the orifice (46).
Replace Main Hydraulic Valve
Assembly.

Main pump faulty. Refer to Section 230-0050 Main

Hydraulic Pump, for correct setting
procedures.

10 SM 2199 Rev 4 10-08

 Body System - Body System Schematic
Section 230-0000

Body System Trouble Shooting

Symptom Possible Cause Remedy
Lift function too slow (cont.) Control lever in the cab faulty. Check lever outputs. Refer to
Sections 190-0085 Hydraulic ECU
and 230-0081 Body Control Lever

Can affect pump delivery. Check

Engine RPM too low. throttle pedal for correct signals.

Body will not lower. Supply fuse to hydraulic ECU blown. Check that the green LED on the
hydraulic ECU is illuminated.
Replace fuse F48 located inside
fuse box. Refer to Section190-0000
Circuit Diagrams

No electric current at proportional Check the link between the body

control valve (29) control lever and the hydraulic
ECU, and between the hydraulic
ECU and the proportional control
valve (29). Refer to Sections 190-
0085 Hydraulic ECU and 230-0081
Body Control Lever

Proportional control valve (29) faulty. Check connections. Replace

proportional control valve (29).

Control lever in the cab faulty. Check for output from control lever.
Refer to Sections 190-0085
Hydraulic ECU and 230-0081 Body
Control Lever

Proximity switch on chassis reading Check connections/replace

LOW (float condition) proximity switch.

Loss of hydraulic and electrical power Follow the Emergency Body Lower
Procedure
Body lowers too slow.
Not enough electric current at the Check output from body control
proportional control valve (29) lever. Refer to Sections 190-0085
Hydraulic ECU and 230-0081 Body
Control Lever

Pilot pressure not high enough Re-set the pilot pressure at the
pressure reducing valve (9). If it
cannot be reset, replace the
pressure reducing valve (9).

Main control spool (30) sticking. Replace the lift section of the main
hydraulic valve assembly.

Faulty main pump. Refer to Section 230-0050 Main

Hydraulic Pump, for correct setting
procedures.

SM 2199 Rev 4 10-08 11

Body System - Body System Schematic
Section 230-0000

Body System Trouble Shooting

Symptom Possible Cause Remedy
Body lowers too slow.(continued) Contamination in the load sense Clean the orifice (46). Replace the
drillings and the orifice (46). main hydraulic valve assembly.

Body will not hold Oil by-passing between control spool Replace lift section of main
(30) and valve body hydraulic valve aseembly

Oil by-passing body lift cylinders (1) Repair the lift cylinders (1)

Control spool (30) not centring Check that there is zero pilot
pressure at both ends of control
spool (30). Either of proportional
control valves (5/29) could remain
active

Check the body control lever.

Should be zero ouput signal from
control lever when in the neutral
position

Control spool (30) damaged.

Replace control spool (30)
Power down available when body is Faulty proximity switch on chassis Check connections. Replace
on the chassis proximity switch. Refer to Section
190-0085 Hydraulic ECU, for check
tool

Body fails too slow down when Faulty proximity switch on chassis Check gap between body plate and
reaching the proximity switch on the proximity switch. Max. gap 15mm.
chassis Replace proximity switch

Faulty hydraulic ECU or connections Refer to Section 190-0085

Hydraulic ECU for check
procedure.

Main spool (30) sticking Replace main hydraulic valve

assembly

Faulty float solenoid valve (13) Check connections. Replace

valve(13). Refer to Section 190-
0085 Hydraulic ECU

Check connections at valve (13)

Body fails too go into float and stops No voltage at the float solenoid valve
and hydraulic ECU. Refer to
before it reaches the chassis (13)
Section 190-0085 Hydraulic ECU

* * * *

12 SM 2199 Rev 4 10-08

 BODY SYSTEM - Hydraulic Tank
Section 230-0040

SM - 3316

25 24 14 13 12
6

19 18
19 17
11 9
10
5

2,3,4

15

23
22

20 27
21 28
16
26
18
8
7

1 - Hydraulic Tank 9 - 'O' Ring 16 - Lockwasher 23 - Plug

2 - Filter Assembly 10 - Gasket 17 - Breather 24 - 'O'-Ring
3 - Element 11 - Cover Plate 18 - Bolt 25 - Guard
4 - 'O' Ring 12 - Cap 19 - Washer 26 - Bolt
5 - Sight Gauge 13 - 'O' Ring 20 - 'O' Ring 27 - Nut
6 - Bolt 14 - Filter Restriction Gauge 21 - Access Cover 28 - Lockwasher
7 - Drain Valve 15 - Drain Adaptor Hose 22 - 'O' Ring
8 - Seal

Fig. 1 - Exploded View of Hydraulic Tank and Mounting

DESCRIPTION cover (21). Located on top of the tank is filler cap (12),
breather (17) and filter restriction gauge (14).
Numbers in parentheses refer to Fig. 1.

The hydraulic tank (1) is the common reservoir for the OPERATION
steering, braking, body hoist and transmission oil Numbers in parentheses refer to Fig. 2.
cooler fan drive systems. It is mounted off the frame at
the rear right hand side of the tractor. Oil is added to the hydraulic tank (4) through filter
assembly (2). The hydraulic oil is drawn from hydraulic
Integral with hydraulic tank (1) assembly are filter tank (4) by main hydraulic pump (1) and pumped to the
assembly (2), oil level sight gauge (5) and access main hydraulic valve to supply the various hydraulic

SM 2350 10-04 1
Body System - Hydraulic Tank
Section 230-0040

SM - 2864
EMERGENCY
SUPPLY TO
SUPPLY TO
MAIN
MAIN HYDRAULIC RETURN
HYDRAULIC
VALVE TO TANK
VALVE

1 3
2

5 5

1 - Main Hydraulic Pump

2 - Emergency Pump 3 - Hydraulic Oil Cooler 4 - Hydraulic Tank 5 - Filter Assembly

Fig. 2 - Hydraulic Schematic of Hydraulic Tank

systems. Refer to Section 215-0050, MAIN MAINTENANCE

HYDRAULIC VALVE ASSEMBLY.
Numbers in parentheses refer to Fig. 1.
Emergency steering oil is drawn from hydraulic tank (4)
Note: Tighten all fasteners without special torques
by emergency pump (2), mounted off transmission, and
specified to standard torques listed in Section
is also pumped to the main hydraulic valve. Should a
300-0080, STANDARD BOLT AND NUT TORQUE
failure occur at the main hydraulic pump (1) the
SPECIFICATIONS.
emergency pump (2) will supply the steering system
with oil to enable the vehicle to be brought to a safe
halt. Refer to Section 220-0000, STEERING SYSTEM
WARNING
SCHEMATIC.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
Return oil from the hydraulic systems flows through
materials and lifting equipment are properly
hydraulic oil cooler (3) (if fitted) and filter assembly
secured and of adequate capacity to do the job
(5) before entering the tank storage area. The filter
safely.
assembly has a bypass valve which allows oil to
bypass element (3, Fig. 1) when it is cold or when the
filter element is plugged. The bypass valve opens at a Checking Oil Level
pressure differential of 1.5 bar (22 lbf/in2). Filter
1. Operate the body hoist and steering systems
restriction gauge (14, Fig. 1) shows red when element
several times to bring the oil to correct operating
(3, Fig. 1) requires to be changed.
temperature.

2. Position the vehicle in a level work area, ensure the

body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel in both
directions several times to relieve any pressure in the

2 SM 2350 10-04
 Body System - Hydraulic Tank
Section 230-0040
steering circuit. Operate treadle valve continuously to directions several times to relieve any pressure in the
discharge accumulators. steering circuit. Operate treadle valve continuously to
discharge accumulators.
3. Block all road wheels, place the steering lock bar in
the 'Locked' position and the battery master switch in 2. Block all road wheels, place the steering lock bar in
the 'Off' position. the 'Locked' position and the battery master switch in
the 'Off' position.
4. Check oil level and add if low. Oil should at least
reach the minimum level in the sight gauge (5). If oil is 3. Remove blanking cap from remote drain valve (7) on
required, remove filler cap (12) from hydraulic tank (1) the bottom of hydraulic tank (1). Install a hose adaptor
and fill hydraulic tank with hydraulic oil specified in (15) on remote drain fitting, open drain cock and drain
Section 300-0020, LUBRICATION SYSTEM. Install hydraulic oil into a suitable container. Close drain cock,
filler cap (12) on hydraulic tank (1) and tighten. remove hose and reinstall blanking cap on remote drain
valve (7).
Replacing Hydraulic Oil 4. Remove bolts (6 & 18) and washers (19) securing
Hydraulic oil should be changed every 2 000 hours. guard (25) and cover plate (11) to top of hydraulic tank
Refer to Section 300-0020, LUBRICATION SYSTEM, (1). Remove guard (25), cover plates (11) and gasket
for hydraulic oil used in the system. (10) from hydraulic tank (1). Discard gasket (10).

Note: When replacing the hydraulic oil due to a 5. Remove filter assembly (2) from hydraulic tank (1).
hydraulic failure, or at recommended change interval,
element (3) must be replaced and hydraulic tank (1) 6. Remove and discard element (3) from filter
cleaned thoroughly using a suitable solvent. assembly (2). Discard 'O' ring (4).

7. Remove bolts (18) and lockwashers (16) securing

Replacing Breather access cover (21) to tank (1). Remove access cover
Every 1 000 hours of operation, or sooner if the vehicle (21) and discard 'O' ring (20).
is being operated in extremely dusty conditions, the
hydraulic tank breather should be replaced.
WARNING
1. Position the vehicle in a level work area, ensure the Splashing liquid. Wear a suitable face shield
body is fully lowered, apply the parking brake and when using compressed air to dry hydraulic
switch off the engine. Turn steering wheel in both tank and components.
directions several times to relieve any pressure in the
steering circuit. Operate treadle valve continuously to 8. Clean out the inside of hydraulic tank (1) with a
discharge accumulators. suitable solvent and dry with compressed air.

2. Block all road wheels, place the steering lock bar in 9. Install new element (3) in filter assembly (2).
the 'Locked' position and the battery master switch in
the 'Off' position. 10. Install filter assembly (2) in tank (1), complete with
new 'O' ring (4).
3. Unscrew breather (17) and remove from tank (1).
Discard 'O' ring (9). 11. Place new gasket (10), cover plate (11) and guard
(25) on hydraulic tank (1). Secure with bolts (6 & 18)
4. Install new 'O' ring (9) and breather (17) to tank (1). and washers (19).

12. Install new 'O' ring (20) and secure access cover
Replacing Filter Element plate (21) on hydraulic tank (1) with bolts (18) and
Every 2 000 hours of operation or when filter restriction lockwashers (16).
gauge (14) shows red, whichever comes first, clean
filter assembly (2) and install new element (3). 13. Remove filler cap (12) from hydraulic tank (1) and
fill hydraulic tank with hydraulic oil specified in Section
1. Position the vehicle in a level work area, ensure the 300-0020, LUBRICATION SYSTEM. Install filler cap
body is fully lowered, apply the parking brake and (12) on hydraulic tank (1) and tighten.
switch off the engine. Turn steering wheel in both

SM 2350 10-04 3
Body System - Hydraulic Tank
Section 230-0040
14. Place the battery master switch in the 'On' position Inspection
and the steering lock bar in the 'Stowed' position,
Numbers in parentheses refer to Fig. 1.
remove all wheel blocks, start the engine and operate
the steering, braking and body hoist systems to
circulate the oil. WARNING
Splashing liquid. Wear a suitable face shield
15. Switch off the engine, check for leaks and check
when using compressed air to dry hydraulic
oil level as described under 'Checking Oil Level'.
tank and components.

TANK ASSEMBLY 1. Clean hydraulic tank (1) and components with a

suitable solvent and dry with compressed air.
Removal
2. Inspect hydraulic tank (1) for weld cracks and
Numbers in parentheses refer to Fig. 1.
security of internal pipes and weld fitments.

3. Inspect breather (17), filter restriction gauge (14) and

WARNING
filter assembly (2) for damage. Replace if required.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Installation
secured and of adequate capacity to do the job
Numbers in parentheses refer to Fig. 1.
safely.
Note: Tighten all fasteners without special torques
1. Position the vehicle in a level work area, ensure
specified to standard torques listed in Section
the body is fully lowered, apply the parking brake and
300-0080, STANDARD BOLT AND NUT TORQUE
switch off the engine. Turn steering wheel in both
SPECIFICATIONS.
directions several times to relieve any pressure in
the steering circuit. Operate treadle valve continuously
Note: Tighten all hydraulic lines fitted with ORFS
to discharge accumulators.
connections, as described in Section 230-0000,
BODY SYSTEM SCHEMATIC. Renew all 'O' rings
2. Block all road wheels, place the steering lock bar in
where used.
the 'Locked' position and the battery master switch in
the 'Off' position.
WARNING
3. Remove blanking cap from remote drain valve (7) on
To prevent personal injury and property
the bottom of hydraulic tank (1). Install a length of hose
damage, be sure lifting equipment is properly
on remote drain fitting, open drain cock and drain
secured and of adequate capacity to do the job
hydraulic oil into a suitable container. Close drain cock,
safely.
remove hose and reinstall blanking cap on remote drain
valve (7).
1. Using a suitable lifting device, position hydraulic
tank (1) in position on the vehicle and secure with
4. Ensure all hydraulic lines connected to hydraulic
bolts (26), lockwashers (28) and nuts (27).
tank (1) are identified for ease of installation and, with
suitable containers available to catch leakage,
2. Remove eyebolts that were installed to lift hydraulic
disconnect hydraulic lines. Fit blanking caps and
tank (1). Reinstall two bolts (18) and washers (19) on
plugs to all open lines and fittings.
top of tank (1).
5. Remove two bolts (18) and washers (19) from top of
3. Install new 'O' rings and install all hydraulic lines and
hydraulic tank (1) and install eyebolts. Attach a
fittings to hydraulic tank (1), as tagged at removal.
suitable lifting device to eyebolts and remove nuts (27),
lockwashers (28) and bolts (26) securing hydraulic tank
4. Remove filler cap (12) and fill hydraulic tank (1) with
(1) to fender and support bracket.
hydraulic oil specified in Section 300-0020,
LUBRICATION SYSTEM. Install filler cap (12) on
6. Carefully remove hydraulic tank (1) assembly from
hydraulic tank (1) and tighten.
the unit to a clean work area for inspection.

4 SM 2350 10-04
 Body System - Hydraulic Tank
Section 230-0040
5. Place the battery master switch in the 'On' position SPECIAL TOOLS
and the steering lock bar in the 'Stowed' position,
There are no special tools required for the procedures
remove all wheel blocks, start the engine and operate
outlined in this section. Refer to Section 300-0070,
the steering, braking and body hoist systems to
SERVICE TOOLS, for part numbers of general service
circulate the oil.
tools required. These tools are available from your
dealer.
6. Switch off the engine, check for leaks and check oil
level as described under 'Checking Oil Level'.

* * * *

SM 2350 10-04 5
Body System - Hydraulic Tank
Section 230-0040

THIS PAGE IS INTENTIONALLY BLANK

6 SM 2350 10-04
 BODY SYSTEM - Main Hydraulic Pump
Section 230-0050

SM - 2837
59
70 71 69 48 66 72 61 60 58
68

72
3
75 4
76
5
51 62
50
64 1
83
82
79
81
80

54
55
78
77
84

49 47 45 44 46 52 43 41 65 2 40
53
1 - Valve Cover 47 - Shoe Plate 60 - O-ring 75 - O-ring
2 - Bolt 48 - Tilting Bush 61 - Servo Piston 76 - Plug
3 - Bolt 49 - Swash Plate 62 - O-ring 77 - Snap Ring
4 - Nut 50 - Swash Plate Support 64 - Pin 78 - Bearing Spacer
5 - Set Screw 51 - Pump Casing 65 - Pin 79 - Roller Bearing
40 - Needle Bearing 52 - O-ring 66 - Tilting Pin 80 - Driveshaft
41 - Valve Plate 53 - Plug 68 - Eye Bolt 81 - Oil Seal
43 - Cylinder Spring 54 - O-ring 69 - Spring Seat 82 - 'O' Ring
44 - Spherical Bush 55 - Plug 70 - Outer Spring 83 - Seal Cover
45 - Set Plate 58 - Stopper 71 - Inner Spring 84 - Bolt
46 - Piston & Shoe 59 - Back-up Ring 72 - Plug

Fig. 1 - Sectional View Of Hydraulic Pump

DESCRIPTION The pump supplies hydraulic oil for the steering,

braking and body hoist systems, as well as the
Numbers in parentheses refer to Figures 1 and 7.
transmission oil cooler fan drive system.
The Hydraulic Pump can be identified as item 5 in
The components of the pump can be divided into three
Section 250-0000, Braking System Schematic.
sub-groupings:
The hydraulic pump is mounted off the rear of the
Rotating Group - Provides the main rotary pumping
transmission. It is an axial piston, variable
action. Consists of the driveshaft (80), cylinder block
displacement pump with load sense and pressure
(42), piston and shoe (46), set plate (45), spherical
regulator to match the flow and pressure to the
bush (44) and cylinder springs (43).
demand. The pump displaces 140 cc/rev, and the
pressure regulator is set to 240 bar (3500 lbf/in
2
).
Swash Plate Group - Varies the pump's delivery flow

SM 2196 Rev 1 08-08 1

Body System - Main Hydraulic Pump
Section 230-0050

SM - 2845

A - Outlet Port
B - Outlet Kidney Slot 41 - Valve Plate 47 - Shoe Plate
C - Inlet Port 42 - Cylinder Block 80 - Driveshaft
D - Inlet Kidney Slot 46 - Piston and Shoe

Fig. 2 - Pump Rotation and Oil Flow

SM - 603

MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
VIEW A VIEW B VIEW C
Fig. 3 - Variable Displacement Action

rate. Consists of the swash plate (49), shoe plate (47), When the pump's driveshaft (80) rotates, the cylinder
swash plate support (50), tilting bush (48), tilting pin block (42), being spline coupled to the shaft, will also
(66), servo piston (61) and servo assist springs (70 and rotate. If the swash plate (49) has been tilted, the
71). pistons and shoes (46) arranged in the cylinder block
(42) due to the shoes being retained on the shoe plate
Valving Cover Group - Provides the switching of oil (47) will both rotate with the cylinder block and
between suction and delivery ports. Consists of valve reciprocate once per revolution.
cover (1), valve plate (41) and valve plate pin (65).
Paying attention to one such piston, then it will move
away from the valve plate (41) for half a rotation
OPERATION (suction stroke), and move towards the valve plate (41)
Numbers in parentheses refer to Figures 1, 2 and 7. for the second half of rotation (delivery stroke). The
Refer to Figures 4 - 6 for hydraulic schematics of larger the tilt angle of the swash plate (49), the longer
pump. the piston (46) stroke and the higher the pump's
displacement. As the swash plate (49) tilting angle

2 SM 2196 Rev 1 08-08

 Body System - Main Hydraulic Pump
Section 230-0050

LS LINE FROM MAIN HYDRAULIC VALVE SM - 2844A approaches zero, the piston (46) does not stroke and
Pl
therefore delivers minimum displacement. (Refer to
Figure 3).

DIFFERENTIAL Pressure Regulator

PRESSURE SPOOL
DELIVERY LINE Numbers in parentheses refer to Figures 1 and 7.

CUT-OFF
PRESSURE
Pressure regulator (6) is a pilot operated differential
SPOOL pressure type spool regulator for load sense control.
The load sense feedback signal from the main
A
hydraulic valve is fed to load sense port (PL) on top of
T air
the pressure regulator (6) (see Figure 8). This feedback
signal acts on the spring chamber end of the spool
Dr B (23).

Unregulated Condition - Refer to Figure 4. Pump

Fig. 4 - Pump Schematic - Unregulated Condition pressure is low and the load sense signal is wide open.
The cut-off pressure spool spring (18 and 20) preload
LS LINE FROM MAIN HYDRAULIC VALVE SM - 2844B shifts the cut-off pressure spool (24) to its extreme
Pl
right position. Since the pressure drop across the main
hydraulic valve is low, both sides of the differential
pressure spool (23) see the same pressure and
therefore the spool (23) remains in the extreme right
DIFFERENTIAL
PRESSURE SPOOL
position. This condition causes the oil at the servo
DELIVERY LINE piston (61) to be vented, causing spring (70 and 71)
force to move the servo piston (61) and swash plate
CUT-OFF
PRESSURE
(49) to maximum pump displacement.
SPOOL

A
Regulated Condition - Refer to Figure 5. Pump
pressure is still relatively low but the pressure drop
T air
across the main hydraulic valve increases. The cut-off
pressure spool spring (18 and 20) preload still retains
Dr B the spool (24) in its extreme right position. However,
since the pressure drop is increased, the pressure on
the right hand side of the differential pressure spool
Fig. 5 - Pump Schematic - Regulated Condition (23) (pump delivery pressure) overcomes the
combination of spring (17 and 19) preload and pressure
LS LINE FROM MAIN HYDRAULIC VALVE SM - 2844C in the load sense line in the left hand side of the
Pl differential pressure spool (23). Therefore the spool (23)
moves to the left, blocking the vent line and causing
the pressure to the large side of the servo piston (61)
to increase, overcoming spring (70 and 71) force. This
DIFFERENTIAL
PRESSURE SPOOL
reduces the swash plate (49) angle and hence the
DELIVERY LINE pump displacement.

CUT-OFF
PRESSURE
This will continue until the pump flow across the main
SPOOL hydraulic valve reduces the pressure drop to the value
determined by the differential spool spring (17 and 19)
A
preload.
T air
Stand-by Condition - Refer to Figure 6. When no
Dr B hydraulic operations are required, the pump stand-by
condition is reached. The load sense line is vented to
tank. The differential pressure spool (23) shifts to the
Fig. 6 - Pump Schematic - Standby Condition extreme left due to pump outlet pressure. This allows

SM 2196 Rev 1 08-08 3

Body System - Main Hydraulic Pump
Section 230-0050
oil pressure to pass through the cut-off pressure spool blanking caps to all open lines and fittings.
(24) and reach the large side of the servo piston (61),
overcoming spring (70 and 71) force and reducing the 5. Support the pump assembly with suitable lifting
swash plate (49) angle to zero. equipment. It is possible to set up a sling arrangement
using the exhaust cradle. Remove the bolts (56) and
The pump also has a pressure limiting function, used lock-washers (57) securing the pump to the
for example when steering cylinder reaches the end of transmission. Remove the pump from the
it's stroke. In this condition the delivery pressure will transmission.
rise, and the load sense control will try to raise delivery
pressure above the now 'dead head' pressure. This 6. Remove the O-ring from the pump. Wash the
causes differential pressure spool (23) to shift to the outside of the pump thoroughly with a suitable solvent
extreme left, allowing oil pressure to pass through cut- and move it to a clean work area for disassembly.
off pressure spool (24) and reach the large side of the Discard the O-ring.
servo piston (61), overcoming spring (70 and 71) force
and reducing the swash plate (49) angle to zero.
DISASSEMBLY
Numbers in parentheses refer to Figures 1 and 7.
REMOVAL
Numbers in parentheses refer to Figures 1 and 7. Note: Discard and renew all O-rings and seals
removed during disassembly.

WARNINGS 1. Remove the drain plug (53) and drain the oil from the
To prevent personal injury and property pump casing (51).
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 2. Remove the bolts (26) and then remove the
secured and of adequate capacity to perform the regulator casing (25) from the pump casing (51).
task safely. Ensure that the O-ring does not drop from the gasket
surface of the regulator. Fit blanking caps to all open
Hydraulic fluid pressure will remain ports.
within the system after engine shut down.
Operate the treadle pedal continuously until the 3. Remove the bolts (2 and 3) securing the valve cover
pressure has dissipated before carrying out any (1) to the pump casing (51).
work on the braking system or serious injury
could result. 4. Separate the valve cover (1) from the casing (51).
The valve plate (41) may detach from the valve cover.
1. Position the vehicle in a level work area, apply the Ensure that the contact faces of the valve cover (1)
parking brake, switch off the engine and turn the and casing (51) are not damaged.
steering wheel in both directions several times to
relieve any pressure in the steering circuit. 5. If necessary, remove the needle bearing (40) and
valve plate (41) from the valve cover (1). Only remove
2. Operate the treadle valve continuously to relieve the needle bearing (40) if it is nearing the end of its life.
pressure in the braking system. Block all road wheels Do not loosen the nut (4), as this will influence the
and place battery master switch in the 'Off' position. delivery flow rate.
Place steering lock bar in the 'Locked' position.
6. Pull the cylinder block (42) out from the pump
3. Remove blanking cap from remote drain line at the casing (51) straight over the driveshaft (80). Pull out
bottom of the hydraulic tank. Install a length of hose on the pistons and shoes (46), set plate (45), spherical
remote drain fitting, open the drain cock and drain the bush (44) and cylinder springs (43) at the same time.
hydraulic oil into a suitable container. Close the drain Be careful not to damage the sliding surfaces of
cock, remove the hose and reinstall the blanking cap. components.

4. Clean the pump housing and surrounding area with a 7. Cover the splined end of the shaft with plastic tape
suitable solvent. Ensure that all hydraulic lines to prevent the oil seal (81) being damaged. Remove
connected to the pump are identified for ease of the bolts (84) and seal cover (83), ensuring that the oil
installation and, with suitable containers available to seal (81) is not damaged.
catch leakage, disconnect the hydraulic lines. Fit

4 SM 2196 Rev 1 08-08

 Body System - Main Hydraulic Pump
Section 230-0050

SM 2836

58
59
60
69 66 61
70 63 62
71 63
68 63

72 64

73
74
75
76
51 50
79
52
78 53

77 54
80 78 55

81 56
82 57
83
84

28 30 31 33
32 34 4
26 27 29
5
72
35
21 23
17 19 37 36
13 15
12 25 38
9 3
24
8
20 22
16 18 39
7 11 14
10 6 40
8 41
42 2
1
43 65
44
45
46
48 47

49

Fig. 7 - Exploded View Of Hydraulic Pump

SM 2196 Rev 1 08-08 5

Body System - Main Hydraulic Pump
Section 230-0050

LEGEND FOR FIG. 7

1 - Valve Cover 22 - Spring Seat 43 - Cylinder Spring 64 - Pin

2 - Bolt 23 - Spool 44 - Spherical Bush 65 - Pin
3 - Bolt 24 - Spool 45 - Set Plate 66 - Tilting Pin
4 - Nut 25 - Casing 46 - Piston & Shoe 68 - Eye Bolt
5 - Set Screw 26 - Bolt 47 - Shoe Plate 69 - Spring Seat
6 - Pressure Regulator 27 - Plug 48 - Tilting Bush 70 - Outer Spring
7 - Set Screw 28 - Orifice 49 - Swash Plate 71 - Inner Spring
8 - Nut 29 - O-ring 50 - Swash Plate Support 72 - Plug
9 - Plug 30 - Plug 51 - Pump Casing 73 - Plug
10 - Plug 31 - Plug 52 - O-ring 74 - O-ring
11 - O-ring 32 - O-ring 53 - Plug 75 - O-ring
12 - O-ring 33 - Plug 54 - O-ring 76 - Plug
13 - Stopper 34 - Plug 55 - Plug 77 - Snap Ring
14 - Stopper 35 - Orifice 56 - Bolt 78 - Bearing Spacer
15 - O-ring 36 - Plug 57 - Lockwasher 79 - Roller Bearing
16 - O-ring 37 - Plug 58 - Stopper 80 - Driveshaft
17 - Spring 38 - O-ring 59 - Back-up Ring 81 - Oil Seal
18 - Spring 39 - O-ring 60 - O-ring 82 - O-ring
19 - Spring 40 - Needle Bearing 61 - Servo Piston 83 - Seal Cover
20 - Spring 41 - Valve Plate 62 - O-ring 84 - Bolt
21 - Spring Seat 42 - Cylinder Block 63 - O-ring

4. If necessary, remove the plugs (27, 31, 34 and 36)

8. Hold the front of the driveshaft (80), and using a
and orifice (28 and 35).
plastic hammer, tap the driveshaft (80) out of the pump
casing (51). Do not remove the roller bearing (79)
unless it is considered to be near the end of its ASSEMBLY
expected life.
Numbers in parentheses refer to Figures 1 and 7.
9. Push down the servo piston (61), and remove the
This is largely the reverse sequence to disassembly,
shoe plate (47) and swash plate (49).
but note the following:
10. Remove the swash plate support (50) from the
a) Ensure that all damaged parts are fixed or renewed
pump casing (51).
before assembly.
11. If necessary, remove the servo piston (61), tilting
b) Before assembly wash each part with clean oil and
pin (66), outer spring (70), inner spring (71), spring seat
dry them with compressed air. Assemble the pump in a
(69) and plug (76). Ensure that the servo piston (61)
clean work area to prevent contamination.
and tilting pin (66) are not damaged when being
removed.
c) When assembling, apply clean oil on the sliding
surfaces and bearings.
Pressure Regulator
d) When assembling parts that easily detach, for
1. Remove the plug (9) and then remove the springs
example O-rings, apply clean grease to prevent them
(17 and 19) and the spring seat (21). Be careful not to
from being misplaced.
drop the spool (23) after removing the plug (9). Do not
remove the nut (8), set screw (7) or stopper (13) unless
1. Install servo piston (61), tilting pin (66), outer spring
required.
(70), inner spring (71), spring seat (69) and plug (76) in
pump casing (51). Apply adhesive on the thread of the
2. Remove the plug (10) and then remove the springs
servo piston (61).
(18 and 20) and spring seat (22). Be careful not to drop
the spool (24) after removing the plug (10). Do not
2. Fit the swash plate support (50) in the pump casing
remove the nut (8), set screw (7) or stopper (14) unless
(51). Make sure that the pin (64) enters into the slit of
required.
the swash plate support (50). Be careful not to install
the swash plate support (50) in an angular attitude.
3. Loosen the plug (33) and remove the spools (23 and
24).

6 SM 2196 Rev 1 08-08

 Body System - Main Hydraulic Pump
Section 230-0050
3. Push down the servo piston (61) and insert the tilting 5. If removed, install the nut (8), set screw (7) and
pin (66) into the tilting bush (48) of the swash plate stopper (14). Insert the springs (18 and 20) and spring
(49). Install the swash plate (49) and shoe plate (47) seat (22) into the plug (10).
into the groove of the swash plate support (50)
correctly. 6. Install the plug (10) in the regulator casing (25).

4. Insert the driveshaft (80) into the pump casing (51), 7. Ensure that the O-rings (38) are in place and install
tapping the driveshaft (80) lightly so that the end of the the regulator casing (25) on the pump casing (51) using
roller bearing (79) is slightly above the surface of the the bolts (26).
pump casing (51). This prevents the swash plate
support (50) from being displaced.
INSTALLATION
5. Cover the splined end of the driveshaft (80) with Numbers in parentheses refer to Figures 1 and 7.
plastic tape. Apply grease to the lip of the oil seal (81)
installed in the seal cover (83). Insert the seal cover Note: Tighten all hydraulic lines fitted with ORFS
(83) slightly into the pump casing (51). Tighten the connections, as described in Section 250-0000,
bolts (84) uniformly to locate the seal cover (83), then Braking System Schematic. Renew all O-rings where
tighten bolts to the standard torque. used.

6. Sub-assemble the cylinder block (42), pistons and

shoes (46), spherical bush (44), set plate (45) and WARNING
cylinder springs (43). To prevent personal injury and property
damage, be sure lifting equipment is properly
7. Place the pump casing (51) horizontally with the secured and of adequate capacity to do the job
surface of the regulator downward. Install the piston- safely.
cylinder sub-assembly in the pump casing (51).
1. Install a new O-ring to the pump.
8. Install the valve plate (41) on the valve cover (1).
When installing the valve plate (41), ensure that the pin 2. Push the pump inward to engage with the coupling in
(65) enters into the slit of the valve plate (41). If the the transmission. Secure the pump assembly to the
stopper (58), max flow set screw (5) and max flow set transmission with the bolts (56) and lock-washers (57).
screw lock nut (4) have been removed, reinstall these Tighten the bolts (56) to a torque of 230 Nm (170 lbf ft).
parts on the valve plate (41) beforehand.
3. Remove the caps and connect the outlet, inlet and
9. Install the valve cover (1) on the pump casing (51) load sense lines to the pump. Before connecting the
and secure it using the bolts (2 and 3). case drain line, fill the pump casing through the drain
port with clean hydraulic oil as used in the hydraulic
10. Install regulator casing (25) to pump casing (51) tank. Connect the case drain line to the pump. Fill the
and secure with bolts (26). hydraulic tank with oil specified in Section 300-0020,
Lubrication System.

Pressure Regulator Note: It is very important that the pump casing is

1. If removed, install the plugs (27, 31, 34 and 36) and completely filled with hydraulic oil. This will ensure
orifice (28 and 35) into the regulator casing (25). proper lubrication of the internal parts of the pump
when it is initially operated. Fill the pump casing
2. Install the plug (33) and insert the spools (23 and through the drain port. Filling only the suction line is
24). When inserting the spools, care should be taken totally insufficient.
not to damage the sliding surface of the spools.
4. Refer to 'Pump Starting Procedure' for proper start-
3. If removed, install the nut (8), set screw (7) and up procedure.
stopper (13). Insert the springs (17 and 19) and spring
seat (21) into the plug (9).
PUMP STARTING PROCEDURE
4. Install the plug (9) in the regulator casing (25). 1. Be sure the pump case drain line is free from
obstructions that restrict the pump case drain flow

SM 2196 Rev 1 08-08 7

Body System - Main Hydraulic Pump
Section 230-0050
back to tank and is a cause of high case drain pressure SM - 2849
which can lead to an early pump failure.

2. Ensure that all hydraulic controls are set to a neutral

position, the steering lock bar is in the 'Locked' position
and the battery master switch is placed in the 'On' 1
2
position. Start the engine and allow the pump to run
3
unloaded for a period to ensure that all residual air P
FB 4
within the system is released. RB 5
6
3. Check for external leakage, abnormal noise and 7
vibrations. 8
9

4. Remove the wheel blocks and place the steering 10

lock bar in the 'Stowed' position. Start the engine and

check the hydraulic systems for proper operation.

1 - Differential Lock Pressure 8 - Trans. Converter Press.

PRESSURE CHECKS 2 - Pump LS Pressure 9 - Body System Press.
To check pump delivery pressure (cut-off pressure) the 3 - Front Brake Pressure 10 - Trans. System Pressure
steering should be operated full lock against the stops. 4 - Rear Brake Pressure P - Primary Accumulator
5 - Park Brake Pressure FB - Front Brake Accumulator
The pump is checked against the steering system as 6 - Steering Pressure RB - Rear Brake Accumulator
this is the highest pressure requirement in the hydraulic 7 - Trans. Retarder Press.
circuit. Fig. 8 - Diagnostic Test Points
heavy, the pump delivery pressure is likely to be low
WARNING and pump setting should be checked.
The machine has to fully articulate to check the
pump pressures, therefore the steering lock bar If the difference (∆P) between delivery pressure and
cannot be 'Locked'. To prevent personal injury load sense pressure is equal to 25 bar (360 lbf/in
2
),
and property damage, exercise extreme caution proceed to the 'Pump Setting Procedure - Pump
while working around the articulation and Delivery Pressure Setting'.
oscillation pivot area.
However, if the ∆P is not equal to 25 bar (360 lbf/in2)
Delivery Pressure (cut-off pressure) carry out the complete 'Pump Setting Procedure'.
Install a pressure gauge capable of at least 240 bar (3
500 lbf/in2) into the STR diagnostic checkpoint in the
battery box (6, Fig. 8). When steering against the
PUMP SETTING PROCEDURE
stops, the pressure should be 240 bar (3500 lbf/in2
). Note: It is very important that the pump casing is
completely filled with hydraulic oil before the pump is
Differential Pressure (load sense pressure) operated. Fill the pump casing through the drain port.
Install a pressure gauge capable of at least 240 bar (3 Filling only the suction line is totally insufficient.
500 lbf/in2) into the STR diagnostic checkpoint in
battery box (6, Fig. 8). Install a pressure gauge capable
of at least 240 bar (3 500 lbf/in2) into the LS VAL
Differential Pressure Setting
diagnostic checkpoint in battery box (2, Fig. 8). With Numbers in parentheses refer to Figures 1 and 7,
the steering in the neutral position, the pressure at the unless otherwise stated.
STR gauge should be 25 bar (360 lbf/in 2
) greater than
the pressure at the LS VAL gauge. 1. Install a pressure gauge capable of at least 240 bar
(3500 lbf/in2) into the STR diagnostic checkpoint in the
If these pressures are not observed, then pump may battery box (6, Figure 8), to measure the pump delivery
need to be reset (refer to Troubleshooting). pressure (cut-off pressure) (Gauge A).

2. Install a pressure gauge capable of at least 240 bar

TROUBLESHOOTING (3500 lbf/in2) into the LS VAL diagnostic checkpoint in
If the steering cannot be operated or is excessively the battery box (2, Figure 8) to measure the load

8 SM 2196 Rev 1 08-08

 Body System - Main Hydraulic Pump
Section 230-0050

SM - 2846 ∆P pressure, or counter-clockwise to decrease ∆P

pressure.
BACK OF PUMP

Note: Adjustment of ∆P pressure = 5 bar (70 lbf/in2)

increase per quarter turn of set screw (7). This is a
Load Sense
result of an increase of 7 bar (100 lbf/in2) on the pump
Port (PL)
delivery pressure and an increase of 2 bar (30 lbf/in 2
)
on the LS pressure.

Delivery Note: Pressure should always be adjusted on the

Pressure increase. Hence if ∆P pressure is too high, the set
(Cut-off screw (7) should be turned counter-clockwise
Pressure)
approximately 2 turns, then turn the set screw (7)
clockwise to attain 25 bar (360 lbf/in2).

6. Recheck the readings on both the pressure gauges.

The pump delivery pressure (Gauge A) should be 25
Differential bar (360 lbf/in2) greater than the load sense pressure
Pressure (Gauge B).
(Load Sense
Pressure)
7. Once the correct ∆P is achieved, tighten the nut (8)
at the differential pressure (load sense) port to 16 Nm
(12 lbf ft).
Fig. 9 - Pump Adjustment At Pressure Regulator
8. The differential pressure (∆P) is now set. Switch off
sense pressure setting (Gauge B). the engine and relievethe system pressures as
described in 'Removal'.
3. Ensure that all hydraulic controls are set to a neutral
position, the steering lock bar is in the 'Locked' position 9. Remove the pressure gauges from the diagnostic
and place the battery master switch in the 'On' position. pressure points in the battery box.
Start the engine and allow to run at low idle. This
allows the pump to run unloaded for a period to ensure
that all residual air within the system is released. Pump Delivery Pressure Setting
Check for external leaks. Numbers in parentheses refer to Figures 1 and 7,
unless otherwise stated.
4. Check readings on both pressure gauges. Pump
delivery pressure (Gauge A) should always be greater
than load sense pressure (Gauge B). This differential WARNING
pressure (∆P) should be equal to 25 bar (360 lbf/in2). If The machine has to fully articulate to set the
the ∆P pressure differs from 25 bar (360 lbf/in2), then pump, therefore the steering lock bar cannot be
carry out steps 5 through 9. 'Locked'. To prevent personal injury and
property damage, exercise extreme caution
Note: Typical readings - while working around the articulation and
STR = 34 - 38 bar (500 - 550 lbf/in2) oscillation pivot area.
LS Val = 11 - 13 bar (160 - 180 lbf/in2)
There should be no requirement to adjust the set screw
Note: If the pump delivery pressure (Gauge A) is less (7) at the delivery pressure (cut-off pressure) port (see
than 25 bar (360 lbf/in2), disconnect transmission oil Figure 9) as this is factory set. The cut-off pressure
cooler fan solenoid, causing solenoid valve to default sets the pump delivery pressure. If the set screw (7) or
to an open position, allowing hydraulic oil to the fan nut (8) has been moved, follow the procedure below to
motor. This will place a demand on the pump, causing reset the pump delivery pressure :
pump delivery pressure to increase.
1. Install a pressure gauge capable of at least 240 bar
5. At the differential pressure (load sense) port (see (3500 lbf/in2) into the STR diagnostic checkpoint in the
Figure 9), unlock the nut (8) and turn the set screw (7) battery box to measure the pump delivery pressure
clockwise (looking straight at set screw) to increase (cut-off pressure).

SM 2196 Rev 1 08-08 9

Body System - Main Hydraulic Pump
Section 230-0050

2. Start the engine and run it at full throttle. Steer full Note: If there are still problems with the pump
lock against the stops. Observe the pressure on the pressures after completing the 'Pump Setting
gauge. This cut-off pressure should be 240 bar (3500 Procedure', ensure that the set screw (5) has not been
lbf/in2). If the pressure reading differs or the steering is adjusted. As a dimensional check, the distance
excessively heavy, then carry out steps 3 to 8 between the end of the set screw (5) to the face of the
inclusive. nut (4) should be 16 mm (0.63").

Note: The steering has to be operated over relief

(against the stops) as this is the maximum pressure LUBRICATION
the pump must deliver. Setting the pump against any Refer to Section 300-0020, Lubrication System, for the
other operation would result in the pump being set at a recommended periodic oil change periods and oil
lower maximum delivery pressure. specifications.

3. At the delivery pressure (cut-off pressure) port (see All pump parts are lubricated by hydraulic oil, and
Figure 9), unlock the nut (8) and turn the set screw (7) therefore the oil must be kept clean to minimize pump
clockwise to increase the cut-off pressure, or counter- wear. Whenever there is a hydraulic system failure, the
clockwise to decrease the cut-off pressure (adjustment oil should be drained, the entire system flushed, oil
90 bar [1305 lbf/in2] per turn). filter replaced and clean hydraulic oil added to
eliminate all metal particles or foreign matter.
Note: The pressure should always be adjusted on the
increase. Hence if the cut-off pressure is too high, the
set screw (7) should be turned counter-clockwise to PUMP WEAR LIMITS
decrease cut-off pressure below 240 bar (3500 lbf/in 2
), Before reassembling the pump after disassembly, the
then turn the set screw (7) clockwise to attain 240 bar Pump Wear Limits table should be consulted to
(3500 lbf/in2). establish which components should be replaced.

4. Once the correct cut-off pressure has been attained,

revert the steering to the neutral position, then steer full SPECIAL TOOLS
lock against the stops. Observe the gauge to confirm There are no special tools required for the procedures
outlined in this section. Refer to Section 300-0070,
that the cut-off pressure is set to 240 bar (3500 lbf/in2).
Service Tools, for part numbers of general service
Note: A change in pump tone should be heard when the tools required. These tools are available from your
cut-off pressure is reached, as the pump de-strokes to dealer.
standby condition.

5. If no change in pump tone is heard, the cut-off

pressure is too high. Return to step 3 of the procedure.
If the problem persists, refer to Section 220-0000,
Steering System Schematic.

6. Tighten the nut (8) at the cut-off pressure port to 16

Nm (12 lbf ft).

7. The differential pressure (load sense) and cut-off

pressure are now set. Switch off the engine and relieve
the system pressures as described in 'Removal'.

8. Remove the pressure gauge from the diagnostic

pressure point in the battery box.

10 SM 2196 Rev 1 08-08

 Body System - Main Hydraulic Pump
Section 230-0050

PUMP WEAR LIMITS

INITIAL LIMIT FOR
ITEM VALUE REPLACING ACTION
Clearance between cylinder (42) 0.039 mm 0.067 mm Replace piston/cylinder
bore and piston (46)
Endplay between piston 0.1 mm 0.3 mm Replace piston-shoe assembly
and shoe (46)
Thickness of shoe 4.9 mm 4.7 mm Replace piston-shoe assembly
Free height of cylinder 39.5 mm 38.8 mm Replace cylinder spring
spring (43)
Combined height of set 23.0 mm 22.0 mm Replace set plate
plate (45) and spherical bush (44)

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 8 Nut 16 12
1 56 Bolt 230 170

* * * *

SM 2196 Rev 1 08-08 11

Body System - Main Hydraulic Pump
Section 230-0050

THIS PAGE IS INTENTIONALL Y BLANK

12 SM 2196 Rev 1 08-08

 BODY SYSTEM - Body Control Lever
Section 230-0081

DESCRIPTION AND OPERATION SM - 3728

The body control lever is mounted on the right hand

side dash panel, next to the transmission shift
controller.

When the body control lever is operated, a voltage is

sent to the hydraulic ECU, which converts voltage to
current. This current controls the body raise and lower
proportional pressure control valves, producing a pilot
pressure to shift the control spool in the main hydraulic
valve. This allows the flow of oil to reach the body
cylinders, to either raise or lower the body. Refer to
Section 230-0000, BODY SYSTEM SCHEMATIC and
Section 215-0050, MAIN HYDRAULIC VALVE. Fig. 1 - Body Control Lever

The three operating positions of the joystick from front

to rear are as follows:
WARNING
Power Down - Pushing the lever forward provides Always disconnect body control lever before
hydraulic force to power-down the body. Pushing the welding on the machine.
lever fully forward will engage the electric detent. When
the body reaches the body proximity switch, the lever
springs back to 'NEUTRAL' and power down is ramped MAINTENANCE
back to allow the body to float down onto the chassis. The body control lever is a non-serviceable item and
should be replaced completely, if damaged, as follows:
Neutral - If the body is above the body proximity
switch, the lever in this position will stop and hold the Note: Tighten all fasteners to standard torques listed in
body at any desired height. If the body is below the Section 300-0080, STANDARD BOLT AND NUT
proximity switch, the hydraulic ECU defaults the TORQUE SPECIFICATIONS.
control spool in the main hydraulic valve to the neutral
position and energises the float solenoid, allowing the
body to float down onto the chassis. The body should WARNINGS
be fully lowered and in the 'NEUTRAL' position while To prevent personal injury and property
the machine is in motion. The lever will remain in the damage, be sure wheel blocks, blocking
'NEUTRAL' position when released. materials and lifting equipment are properly
secured and of adequate capacity to do the job
Raise - Pulling the lever back and holding it in this safely.
position directs oil to extend the body hoists and raise
the body. When released, the lever will spring back to Hydraulic fluid pressure will remain
the 'NEUTRAL' position. within the system after engine shut down.
Operate the treadle pedal continuously until the
A body lower emergency switch in the cab is pressure has dissipated before carrying out any
connected directly to the float solenoid, within the main work on the hydraulic system or serious injury
hydraulic valve, to enable the lowering of the body in could result.
the event of an engine, hydraulic or hydraulic ECU
failure. The cause of the failure must be investigated 1. Position the vehicle in a level work area, apply the
and corrected. parking brake and switch off the engine.

Note: The body must remain lowered with lever in the 2. Operate the treadle valve continuously to relieve
'NEUTRAL' position until it is necessary to operate the pressure in the hydraulic system.
body again. Failure to comply to this could result in
overheating the hydraulic oil and failure of the hydraulic 3. Block all road wheels, place the steering lock bar in
system components. the 'Locked' position and the battery master switch in
the 'Off' position.

SM 2202 Rev1 02-07 1

Body System - Body Control Lever
Section 230-0081
4. Disconnect body control lever harness from main
harness. 10. Remove wheel blocks and place the steering lock
bar in the 'Stowed' position.
5. Support body control lever and remove screws
securing body control lever on the right hand dash
panel. TROUBLESHOOTING
A faulty body control lever will cause an input error at
6. Remove body control lever from mounting location. the hydraulic ECU. Refer to Section 190-0085,
HYDRAULIC SYSTEM ECU.
7. Secure new body control lever on the right hand
dash panel with screws.
SPECIAL TOOLS
Note: Ensure harness from body control lever is at the There are no special tools required for procedures
front when lever is installed. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
8. Reconnect main harness to body control lever tools required. These tools are available from your
harness. dealer.

9. Place the battery master switch in the 'On' position,

start the engine and bring hydraulic oil to operating
temperature. Operate the body control lever to ensure
correct operation.

* * * *

2 SM 2202 Rev1 02-07

 BODY SYSTEM - Body Cylinder
Section 230-0130

SM - 2468

20 21 23 7 22,6 17,18 9 4 5 11 14 13 14 18 19 23 21 20

3 10 1 16 12 15

BODY MOUNTING FRAME MOUNTING

26
28
GROOVE 27
THIS SIDE
26
ORIENTATION OF 25
CUSHION SLEEVE
25
29
24 28 27

1 - Cylinder Body 8 - 'O' Ring 15 - Grub Screw 22 - Nylon Ring

2 - Piston Rod 9 - 'O' Ring 16 - 'O' Ring 23 - Lube Fitting
3 - End Cap 10 - Lock Ring 17 - Back Up Ring 24 - Upper Pin
4 - Cushion Sleeve 11 - Cushion Spear 18 - Cushion Sleeve 25 - Spacer
5 - Circlip 12 - Piston 19 - Circlip 26 - Bolt
6 - Rod Seal 13 - Piston Seal 20 - Spherical Bearing 27 - Lockwasher
7 - Wiper 14 - Wear Ring 21 - Circlip 28 - Washer
29 - Lower Pin
Fig. 1 - Sectional View Of Body Cylinder and Mounting

DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.

There are two single stage, double acting body hoist

cylinders, cushioned at both ends of the stroke on the WARNINGS
vehicle. The cylinder base end is connected to the To prevent personal injury and property
trailer frame and piston rod (2) end is connected at the damage, be sure wheel blocks, blocking
body. Single stage double acting means that piston materials and lifting equipment are properly
rod (2) can have oil applied to either side, extending or secured and of adequate capacity to do the job
retracting the piston rod. safely.

Cylinder mounting is by pins (24 & 29), spacers (25) Hydraulic fluid pressure will remain
and spherical bearings (20) secured in place with within the body hoist system after engine
circlips (21). Spherical bearings (20) permit a limited shutdown. Operate the treadle pedal
amount of cylinder misalignment. continuously until the pressure has dissipated
before carrying out any work on the hydraulic
system or serious injury could result.

SM 2207 9-05 1
Body System - Body Cylinder
Section 230-0130

DISASSEMBLY
WARNING Numbers in parentheses refer to Fig. 1.
Exercise extreme caution when lowering
the cylinders from the body. The cylinders will
swing out sharply as they leave their WARNING
mountings. To prevent personal injury and property
damage, be sure lifting equipment is properly
1. Position the vehicle in a level work area, ensure the secured and of adequate capacity to do the job
body is fully lowered, apply the parking brake and safely.
switch off the engine.
1. Ensure clean working conditions, remove any port
2. Press and hold down body hoist bleed down switch plugs thus allowing easy entry of air into cylinder body
and operate the body control joystick continually to (1), preventing a vacuum when parts are withdrawn
relieve pressure in the body hoist system. from cylinder body (1).

3. Block all road wheels, place the steering lock bar in 2. Remove circlips (21) from base end of cylinder body
the 'Locked' position and the battery master switch in (1) and piston rod (2) end. Press out spherical bearings
the 'Off' position. (20).

4. Install a suitable strap around the cylinder and 3. Remove lock ring (10) from end cap (3).
attach to a lifting device.
4. Using special tool which can be fabricated as shown
5. Position a suitable container at the base end of one in Fig. 2, unscrew end cap (3) until thread is
cylinder. Identify and remove the hydraulic lines. Cap disengaged from cylinder body (1).
hydraulic lines and cylinder ports to prevent entry of
dirt. 5. Support piston rod (2) at the rod eye and withdraw
piston rod (2) from cylinder body (1). Ensure centre
6. Remove bolt (26), lockwasher (27), washer (28) and lines of piston rod (2) and cylinder body (1) remain
upper pin (24) connecting piston rod (2) end of the coincidental during removal of piston rod (2).
cylinder to the body. If due to lack of maintenance the
upper pin can not be removed from the front, there is 6. Place piston rod (2) on supports which will not
plate on the inside of the body that can be removed to damage the piston rod diameter.
allow access to the rear of the pin to ease removal.
This plate is tack welded in place so a grinder is 7. Remove and discard piston seals (13) and wear
required to remove it. rings (14) from piston (12).

7. Lower cylinder slowly and remove spacers (25). 8. Remove grub screw (15) from wear ring (14) groove
in piston (12).
Note: Cylinder will swing out sharply as it leaves its
mounting. 9. Provide an anti-torsion device through piston rod (2)
eye to allow unscrewing of piston (12). Using special
8. Remove bolt (26), lockwasher (27), washer (28) and tool which can be fabricated as shown in Fig. 3,
lower pin (29) connecting base end of the cylinder to unscrew piston (12) from piston rod (2).
the frame.
10. Remove cushion spear (11) and 'O' rings (16) from
9. Remove spacers (25) and remove cylinder assembly piston rod (2). Discard 'O' rings (16).
to a clean area for disassembly.
11. Remove cylinder end cap (3) from piston rod (2).
10. Repeat steps 4 through 9 for opposite cylinder. Remove and discard cushion sleeve (4), circlip (5), rod
seal (6), nylon ring (22), wiper (7), 'O' rings (8 & 9) and
back up ring (17).

2 SM 2207 9-05
 Body System - Body Cylinder
Section 230-0130

INSPECTION 6. Ensure cushion sleeve (18) and circlip (19) are

Numbers in parentheses refer to Fig. 1 secure in piston (12).

1. Clean all parts of the cylinder with a suitable solvent 7. Insert new piston seal (13) and new wear rings (14)
and dry with clean, lint-free cloths. Clean all grooves in piston (12).
carefully to remove any foreign material.
8. Fully grease piston (12) OD and 'O' rings (8 & 9) in
2. Check cylinder body (1) and outer diameter of piston end cap (3).
(12) for scratches, cracks or other defects. Remove
ridges, nicks and scratches with a fine stone and re- 9. Sling assembled piston rod (2) in a manner to allow
clean. Replace any components which cannot be careful leading of the assembled piston rod into
repaired. cylinder body (1). Take care not to damage piston seal
(13) on cylinder body (1) threads.
3. Inspect piston rod (2) for distortion, cracks or other
defects. Replace piston rod if defective area is 10. After piston (12) is inserted in cylinder body (1), push
irreparable. the piston rod assembly into cylinder body (1) maintaining
coincidental centre lines of piston rod and cylinder body.
4. Check spherical bearing (20) for wear and replace if
necessary. 11. Before piston rod (2) is fully home and, with slings
still taking some of piston rod (2) weight, engage end
cap (3) thread and screw home.
ASSEMBLY
Numbers in parentheses refer to Fig. 1. 12. Push piston rod (2) to the fully retracted position and
tighten end cap (3) to a torque of 237 Nm (175 lbf ft).

WARNING 13. Re-drill end cap (3) for lock ring (10), 3 x 12 mm
To prevent personal injury and property (0.125 x 0.50 in) deep, if necessary. Insert lock ring
damage, be sure lifting equipment is properly (10) in end cap (3).
secured and of adequate capacity to do the job
safely.
INSTALLATION
1. Press spherical bearing (20) in base end of cylinder Numbers in parentheses refer to Fig. 1.
body (1) and piston rod (2) end. Secure spherical
bearings (20) with circlips (21). Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY
2. Install new cushion sleeve (4), circlip (5), rod seals (6), SYSTEM SCHEMATIC. Renew all 'O' rings where used.
nylon ring (22), 'O' rings (8 & 9) and back up (17) in end cap
(3). Load end cap (3) over piston rod (2) thread, taking care
not to damage rod seal (6) on the thread. WARNING
To prevent personal injury and property
3. Install new 'O' rings (16) on piston rod (2) and damage, be sure lifting equipment is properly
replace cushion spear (11). secured and of adequate capacity to do the job
safely.
4. Apply Loctite 243 to first two threads of piston (12).
Using special tool which can be fabricated as shown in 1. Install a suitable strap around the cylinder and
Fig. 3, screw on piston (12) and tighten to a torque of position cylinder on unit with base end of cylinder ready
1 356 Nm (1 000 lbf ft). for mounting.

5. Insert piston grub screw (15) through wear ring (14) 2. Install spacers (25) in base end of cylinder and
groove in piston (12) and into groove machined in insert lower pin (23) through mounting bores, spacers
piston rod (2). Tighten grub screw (15) to a torque of 49 (25) and cylinder. Secure lower pin (23) with washer
Nm (36 lbf ft). Ensure the extreme of grub screw (15) is (28), lockwasher (27) and bolt (26). Tighten bolt (26) to
below the level of wear ring (14) groove. a torque of 66 Nm (49 lbf ft).

SM 2207 9-05 3
Body System - Body Cylinder
Section 230-0130
3. Install spacers (25) in rod end of cylinder, align start the engine, operate the body and check cylinder lines
spherical bearing with bores in body and install upper for leaks. Tighten lines and fittings as required.
pin (24) through mounting bores, spacers (25) and
cylinder. Secure upper pin (24) with washer (28), 8. Remove wheel blocks from road wheels.
lockwasher (27) and bolt (26). Tighten bolt (26) to a
torque of 66 Nm (49 lbf ft).
MAINTENANCE
4. Connect the hydraulic oil lines to the cylinder ports Every 250 hours: Lubricate cylinder pins as described
as tagged during removal. in Section 300-0020, LUBRICATION SYSTEM. Inspect
cylinders for leaks, if leaks are found, replace seals
5. Lubricate pins at lube fittings (22) with lubricant as with seals contained in the Service Repair Kit, as
specified in Section 300-0020, LUBRICATION SYSTEM. specified in the parts book.

6. Check oil level in hydraulic tank and add if low.

Refer to Section 230-0040, HYDRAULIC TANK, for SPECIAL TOOLS
correct fill level. Refer to Section 300-0020, Special tools can be fabricated as shown in Figs. 2 & 3.
LUBRICATION SYSTEM, for the type of oil used. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of general service tools required. These tools are
7. Place the battery master switch in the 'On' position, available from your dealer.

SM - 2469

50 25
160 (6.299) (1.9680) (0.984)

10
90 (3.54) DRILL 13 (0.51) 11
(0.394)
RAD X 25 (0.984) (0.433)
DEEP

10 (0.394)
RAD TYP
150 (5.90) DIA

110 (4.33) DIA

120 (4.724)

(3.154 - 0.000 )

(4.724 - 0.005 )
+0.002

120.00 - 0.13
(1.9680)
80.10 - 0.00
+0.05
94 (3.7)

+
50

19 (0.75)
SQUARE

SECURE ALUMINIUM FIT 2 OFF B&T BUSH 12 (0.472) ID

COLLAR WITH (3) M8 25 65 18 (0.708) OD AND 2 OFF 12 DIA DOWEL
CAP SCREWS (0.984) (2.560) DRIVE FIT IN BUSH
110 (4.33)
Dimensions in mm (in)
Fig. 2 - End Cap Torque Tool

4 SM 2207 9-05
 Body System - Body Cylinder
Section 230-0130

SM - 2470

89 (3.5)
38.1 (1.5)

(0.375)
9.525

DIA
(0.470)
11.938
124.45 - 0.000 (4.899 - 0.000 )
+0.005

DIA
90 - 0.05 (3.543 - 0.002 )
SILVER STEEL

136 (5.35)
+
25.4 (1.0)
SQUARE

+0.13
+

(0.500)
12.7
EN3B

DIA
MILD STEEL

OUTER SHELL TO BE SECURED DOM TUBE

TO INNER BODY WITH 2BA CAP SCREWS 10.16 25.4
(0.4) (1.0)

Dimensions in mm (in)
Fig. 3 - Piston Torque Tool

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 3 End Cap 237 175
1 12 Piston 1 356 1 000
1 15 Grub Screw 49 36
1 26 Bolt 66 49

* * * *

SM 2207 9-05 5
Body System - Body Cylinder
Section 230-0130

THIS PAGE IS INTENTIONALLY BLANK

6 SM 2207 9-05
 BRAKING SYSTEM - Braking System Schematic
Section 250-0000
SM 2848

9 TO PARKING 17 17 18
PP BRAKE

FROM
TRANSMISSION

P1
A
TO FRONT 13 13
SERVICE BRAKES T1

ACC2

ACC1

ACC1

ACC2

ACC3
PBP

PB
TS
1
P2
A
TO REAR 3 4
SERVICE BRAKES 2
T2
14
8
6 7

10 11

12

19 16

15
P1

21

25

5
LSP T

1 - Orifice 6 - Park Brake Solenoid Valve 11 - Orifice 16 - Cold Start Solenoid Valve
2 - Directional Control Valve 7 - Brake System Relief Valve 12 - Orifice 17 - Brake Accumulators
3 - Check valve 8 - Brake System Charge Valve 13 - Pressure Switch 18 - Primary Accumulator
4 - Check Valve 9 - Brake Treadle Valve 14 - Pressure Switch 19 - Pressure Switch
5 - Main Hydraulic Pump 10 - Check Valve 15 - Priority Valve 21 - Shuttle Valve
25 - Shuttle Valve
Fig. 1 - Brake System Schematic

DESCRIPTION Service Brakes

Numbers in parentheses refer to Figures 1, 2 and 9. Refer to Section 165-0010, Brake Parts.

The hydraulic braking system is of closed centre The service brakes are of the oil immersed multi disc-
design wherein constant pressure is stored in type. The service piston is designed for use with
accumulators and is regulated as required to retard or hydraulic oil as specified in Section 300-0020,
stop the machine. Lubrication System.
DO NOT USE BRAKE FLUID (J 1703).
A brief description of the individual components used
in the braking system are listed below. Detailed The brake head is bolted to a mounting plate on the
service and operating instructions can be found in the axle housing. There are two brake heads at each of the
relevant component sections of this manual. six road wheels.

SM 2485 Rev 3 04-10 1

Braking System - Braking System Schematic
Section 250-0000
right-hand side of the tractor.
When the treadle valve is actuated, hydraulic oil enters
Integral with the hydraulic tank assembly are the
the brake head and forces the piston against the brake
hydraulic oil filter, oil strainer and oil level sight gauge.
discs which are in turn forced against each other ,
Located on the top of the tank assembly is the filler
locking together and thus preventing the spindle from
cap and breather.
further movement, slowing or stopping wheel rotation.

In an emergency situation, application of the park/ Main Hydraulic Pump (5)

emergency valve will actuate the service brakes and
Refer to Section 230-0050, Main Hydraulic Pump.
the parking brake to bring the machine to a halt. In this
condition, a restriction in the 'PB' line will slow oil flow
Mounted off the transmission power takeoff, the main
from the parking brake allowing the service brakes to
hydraulic pump supplies hydraulic oil for operating the
actuate momentarily ahead of the parking brake.
steering, body, brakes and transmission cooler fan
drive circuits.
Parking Brake
The main hydraulic pump is an axial piston, variable
Refer to Section 170-0010, Parking Brake and
displacement type, with load sense and pressure
Mounting.
regulator.
The parking brake consists of a sliding calliper acting
on a brake disc on a rear driveline and is of 'Inverted Parking Brake Pressure Switch (14)
Design', which means that it requires pressure to hold it
Located on the main hydraulic valve assembly it
off.
senses pressure in the parking brake (PB) line. The
pressure switch closes at a pressure of 5 bar (70 lbf/
Operation is by a spring applied/hydraulically released in²) and sends a signal to illuminate the parking brake
actuator. The actuator is connected through a slack indicator light when the parking brake is applied.
adjuster to the power screw shaft that is screwed into
the piston in the calliper head assembly. The calliper
head assembly slides on anchor plate guides in a Brake Circuit Pressure Switches (13)
bracket assembly bolted to the trailer frame. Front and rear brake circuit pressure switches are both
located on the main hydraulic valve assembly. The
A push control on the right hand dash panel activates pressure switches sense pressure in the front and rear
the park brake solenoid valve (6) on the main hydraulic brake circuits and sends a signal to warning lights on
valve assembly, controlling oil pressure from the rear the dash (a buzzer also sounds) when the pressure
brake circuit accumulator to the actuator. Application of drops below 122 bar (1770 lbf/in²). The warning lights
the push control releases oil from the actuator allowing will remain illuminated until the pressure rises above
internal springs in the actuator to apply the parking 135 bar (1960 lbf/in2).
brake. Pulling out the push control and selecting the
transmission gear, directs oil pressure from the rear
brake circuit accumulator to the actuator, compressing Brake Accumulators (17/18)
internal springs, to release the parking brake. Refer to Section 250-0060, Accumulator.
In an emergency situation, application of the park/ There are three accumulators mounted inside the
emergency valve will actuate the service brakes and battery box located on the front left-hand side of the
the parking brake to bring the machine to a halt. In this tractor; one for the front brake system and one for the
condition, a restriction in the 'PB' line will slow oil flow rear. The front and rear brake accumulators are
from the parking brake allowing the service brakes to supplemented by a third (primary) accumulator (18),
actuate momentarily ahead of the parking brake. also mounted inside the battery box. The primary
accumulator supports the service brake system and
Hydraulic Tank the body pilot pressure system. All three accumulators
are of the piston type and are precharged with nitrogen
Refer to Section 230-0040, Hydraulic Tank. to 105 bar (1500 lbf/in²). It consists of a charging valve
assembly, cylinder assembly and piston. The charging
The hydraulic tank is the common reservoir for the valve is equipped with a locking feature which, when
steering, braking and body hoist systems. It is opened, will allow precharge to be checked or the
mounted on the frame and fender bracket, on the rear

2 SM 2485 Rev 3 04-10

 Braking System - Braking System Schematic
Section 250-0000
accumulator charged. engine ECM requesting the engine brake.

The piston acts as a separator dividing the cylinder The first 5° (±1°) movement of the brake pedal
assembly into two sections. The bottom section engages the Engine Brake, provided the transmission
nearest the charging valve contains the nitrogen is in 'lockup'. Further movement of the brake pedal
precharge. Hydraulic oil from the main hydraulic pump applies the service brakes in addition to the engine
flows through check valves in the main hydraulic valve brake. The engine brake will disengage when the brake
and into the top section of the accumulators. pedal is released, or when any of the operating
Accumulator pressure is monitored by pressure conditions become out of range.
switches (13) in the brake lines.

A diagnostic pressure point is provided local to each Valves 1, 2, 3, 4, 6, 7, 8, 10, 11, 12, 15, 16,
brake accumulator, to facilitate the fitting of pressure 21 and 25
test apparatus. These valves form part of the brake cuircuit and are an
intregal part of the main hydraulic valve assembly,
mounted on the left hand side of the tractor frame. Ref.
Brake Treadle Valve (9)
Section 215-0050, Main Hydraulic Valve Assembly.
Refer to Section 250-0070, Treadle Valve.
SM2855

OPERATION
Numbers in parentheses refer to Figures 1, 2 and 9.

Brake Charging
13
(F)
The valves integral of the main hydraulic valve
assembly automatically maintain the brake
accumulator pressures between a lower and upper
13
14 limit.

(R) Accumulators (17) are charged from accumulator (18)

via brake system relief valve (7), to limit the pressure
in these accumulators to 155 bar (2248 lbf/in2) and then
via check valves (3 and 4) respectively.

If the pressure in accumulator (18) is below the lower

charge limit of 165 bar (2390 lbf/in2) the brake system
charge valve (8) spring closes the brake system
charge valve (8). The pressure then builds up in the
load sense line from brake system charge valve (8) to
the shuttle valve (21) and on to the priority valve (15)
13 - Service Brake Circuit Pressure Switches spring chamber where it helps this valve to close,
14 - Park Brake Pressure Switch ensuring flow priority is to the brake charging. At the
Fig. 2 - Brake System Pressure Switch Locations same time it also acts on the main hydraulic pump load
sense line via shuttle valve (25) to supply sufficient
flow to charge the accumulators.
The treadle valve controls the level of hydraulic fluid
pressure applied to front and rear brakes and the As soon as the pressure in accumulator (18) reaches
maximum pressure available to these circuits. It is the upper charge limit of 185 bar (2680 lbf/in2) the brake
operated by a foot pedal in the operator's cab and, with system charge valve (8) opens and unloads the load
the engine running, is automatically applied by the park sense line to tank. This action unloads the main
brake solenoid valve (6) on the main hydraulic valve. hydraulic pump back to its standby pressure of 25 bar
(360 lbf/in2).

Advanced Engine Braking The accumulators (17 and 18) are also automatically
A microswitch is mounted on the brake treadle valve, charged every time the pressure at the main hydraulic
which on foot pedal activation sends a signal to the pump rises above the pressure in accumulator (18). It
is therefore possible to achieve pressures up to the

SM 2485 Rev 3 04-10 3

Braking System - Braking System Schematic
Section 250-0000
main hydraulic pump cut off pressure of 240 bar (3500 SM 3729
lbf/in2) in this accumulator (18) (for example when
steering over the relief). The brake system relief valve
(7) will still limit the pressure in accumulators (17) to
155 bar (2248 lbf/in2).

The orifice (12) is rated at 6 l/min and would protect all

three accumulators (17/18) against abnormally high 1 - Microswitch
pressure spikes. However, accumulator (18) can see
system pressure if any of the main hydraulic functions
are held over the relief for a period of time.

Brake Apply
The minimum pressure required at the brake treadle
valve is 117 bar (1696 lbf/in2) and the accumulator pre-
charge pressure is 90% of this at 105 bar (1522 lbf/in2).

12 24 36
SM - 3730

FD FH FM K23 K17 K50 K32

FC FG FL K23 K14 K23 K52

FB FF FK K58 K34 K5 K27

FA FE FJ K57 K15 K4 K23

1 13 25 Fig. 4 - Brake Treadle Microswitch

Fig. 3 - Fuse Box Layout (Operator's Cab) (Advanced Engine Brake)
The brake treadle valve controls the level of hydraulic conditions become out of range.
pressure applied to front and rear brakes and the
maximum pressure available to these circuits. It is Park/Emergency Brake Function
operated by the foot pedal in the operator's cab and in The park/emergency brake function is designed to
an emergency with the engine running, is automatically electrically operate the park brake and with the engine
applied by the park brake solenoid valve (6) in the main running automatically actuates the service brakes also
hydraulic valve assembly (Refer to the Park/ during this operation.
Emergency Brake Function description).
When the engine is running, a transmission hydraulic
Mounted on the the brake treadle valve is a pilot pressure acts against the spring at the directional
microswitch (S106). This microswitch sends a signal to control valve (2). The directional control valve (2)
activate the engine brake and rear brake lamps. The creates an open circuit between the main hydraulic
brake pedal microswitch energizes K50, brake lamp valve assembly and port 'PP' on the brake treadle
relay and K32, engine brake relay. Both relays are valve. This permits a flow of oil to either energize the
located in operator's cab fuse/relay box. When these 'PP' port at the treadle valve, or to exhaust the 'PP' port
relays are energized an electrical circuit is completed through the main hydraulic valve assembly to tank,
to energize appropriate lamps and request signals. dependant on operation of the park brake solenoid
valve (6). The park brake solenoid valve (6) is
The first 5° (±1°) movement of the brake pedal controlled by the park/emergency control switch inside
engages the Engine Brake, providing the transmission the operator's cab and also the transmission T.C.U
is in 'lockup'. Further movement of the brake pedal which controls the parkbrake OFF relay.
applies the service brakes in addition to the engine
brake. The engine brake will disengage when the brake When the park/emergency control switch is activated
pedal is released, or when any of the operating (pushed in), the electrical signal between the switch
and park brake solenoid valve (6) is opened. This
action de-energizes the park brake solenoid valve (6).
Oil flows through park brake solenoid valve (6) and

4 SM 2485 Rev 3 04-10

 Braking System - Braking System Schematic
Section 250-0000
through the directional control valve (2). The oil travels SM - 2851

through the directional control valve and into the 'PP'

port in the treadle valve for an emergency brake
application. A
P(r)
P
Return oil from the parking brake circuit enters the
main hydraulic valve assembly. The oil flows through A(r)
T T(r)
park brake solenoid valve (6) and exits the main P
P(f)
hydraulic valve assembly to the hydraulic tank. With no
pressure in the parking brake circuit to hold the parking T T(f)
A(f)
brake off, the parking brake is applied. A

When the emergency brake switch is deactivated PP

(pulled out) and the transmission is in gear, the park
brake OFF relay contacts close.The electrical signal PP
between the switch and park brake solenoid valve (6) is
closed, energizing the park brake solenoid valve (6).
Oil flows through the park brake solenoid valve (6) and
exits the main hydraulic valve assembly to the parking
brake circuit, to release the parking brake.

Return oil from the 'PP' port on the brake treadle valve
flows through the directional control valve (2) through
the park brake solenoid cartridge (6) and exits the main
hydraulic valve assembly to the hydraulic tank.

When the engine is shut down, transmission pilot

pressure at directional control valve (2) is lost, causing
the directional control valve (2) to move to the right
under the influence of the compressed spring. This
movement links the 'PP' port at the brake treadle valve
with the hydraulic tank through the main hydraulic
valve assembly. This action results in a controlled A(f) - Pressure to Front Brakes
A(r) - Pressure to Rear Brakes
bleed down of the applied service brakes to the
P(f) - Pressure from Front Brake Accumulator
hydraulic tank. This controlled bleed down permits a P(r) - Pressure from Rear Brake Accumulator
synchronized service brake release/mechanical park T(f) - Tank Return - Front Brakes
brake application. T(r) - Tank Return - Rear Brakes
PP - Emergency/Park Pilot Pressure

When the transmission is in neutral and transmission Fig. 6 - Brake Treadle Valve Porting Arrangement
output speed is less than 60RPM~1MPH, the
Parkbrake OFF relay contacts open. Thus, the park
brake solenoid valve (6) is automatically de-energized WARNINGS
(fail safe). Park brake hold off pressure is allowed to To prevent personal injury and property
return to tank through the park brake solenoid valve (6), damage, be sure wheel blocks and blocking
causing the park brake to apply (spring applied). The materials are properly secured and of adequate
vehicle is now held with the park brake only. capacity to do the job safely.

Hydraulic fluid pressure will remain

within the system after engine shut down.
CHECKING SYSTEM PRESSURES Operate the brake treadle pedal continuously
Numbers in parentheses refer to Figures 1, 2 and 9, until the pressure has dissipated before
unless otherwise stated. carrying out any work on the system or serious
injury could result.

1. Position the vehicle in a level work area, apply the

parking brake, switch off the engine and turn the

SM 2485 Rev 3 04-10 5

Braking System - Braking System Schematic
Section 250-0000
SM2849

6. Connect a hydraulic gauge, capable of recording a

pressure of 0 - 345 bar (0 - 5000 lbf/in²), to the front
brake diagnostic pressure point (3, Figure 7) inside the
battery box.
1
7. Place the battery master switch in the 'On' position,
2
start the engine and apply park/emergency brake (push
3
P button in), to apply service brakes. Monitor system
FB 4 pressure gauge. Brake actuating pressure for the front
RB 5 brake circuit is 60 ±5.1 bar (870 ±75 lbf/in²).
6
7 8. Repeat steps 6 and 7 at the rear brake diagnostic
8
pressure point (4, Figure 7) inside the battery box. The
9
brake actuating pressure for the rear brake circuit is 60
±5.1 bar (870 ±75 lbf/in²).
10

Note: When the brakes are released, a residual

pressure of 0.5 bar (7 lbf/in²) should remain.

9. If necessary, the pressure setting can be adjusted

1 - Differential Lock Pressure 8 - Trans. Converter Press.
2 - Pump LS Pressure 9 - Body System Press. via the brake system relief valve (7) on the main
3 - Front Brake Pressure 10 - Trans. System Pressure hydraulic valve assembly. The operator's cab will
4 - Rear Brake Pressure P - Primary Accumulator require to be raised to access the brake system relief
5 - Park Brake Pressure FB - Front Brake Accumulator valve (7). Refer to Section 260-0010, Cab and
6 - Steering Pressure RB - Rear Brake Accumulator
7 - Trans. Retarder Press.
Mounting.

Fig. 7 - Diagnostic Pressure Check Points (Battery Box) 10. Shut off the engine and remove the pressure gauge
from the diagnostic pressure point.

steering wheel in both directions several times to 11. Remove the wheel blocks, place the steering lock
relieve any pressure in the steering circuit. bar in the 'Stowed' position, start the engine and check
the braking system for proper operation.
2. Operate the brake treadle valve continuously to
relieve pressure in the braking system. Block all road
wheels, place the steering lock bar in the 'Locked' BLEEDING THE BRAKING SYSTEM
position and the battery master switch in the 'Off' Refer to Section 165-0010, Brake Parts.
position.

3. Connect a hydraulic gauge, capable of recording a O-RING FACE SEALS (ORFS)

pressure of 0 - 345 bar (0 - 5 000 lbf/in²), to the park Where hydraulic lines are fitted with ORFS
brake diagnostic pressure point (5, Figure 7) inside the connections, the following procedure should be carried
battery box. out during 'Installation'. Refer to Figure 8.

4. Place the battery master switch in the 'On' position, a. Ensurethat the O-ring/seal is in place and that the
start the engine and release the park/emergency button joining surfaces are clean. If necessary, retain the O-
(pull out), to energize the park brake line. Monitor the ring/seal in place with a light coating of grease or
system pressure gauge. The pressure setting should vaseline.
be 155 bar (2248 lbf/in²).
b. Initially, the nuts should be tightened by hand.
5. If necessary, the pressure setting can be adjusted
via the brake system relief valve (7) on the main c. Where a hose is fitted, ensure that it is not twisted
hydraulic valve assembly. The operator's cab will or kinked when the nuts are tightened, so that it is
require to be raised to access brake system relief allowed to adopt a natural position.
valve (7). Refer to Section 260-0010, Cab and
Mounting. d. Where a tube is fitted, ensure that the connection is

6 SM 2485 Rev 3 04-10

 Braking System - Braking System Schematic
Section 250-0000

aligned correctly. pressure check points:

15018226 Diagnostic Coupling
e. Tighten the nut a further 1/4 to 1/2 a turn using the 00118748 Connector (2 off)
correct size spanner (wrench). 15004085 Hose Assembly (-04 HP, 2130 mm long)

f. Check that a satisfactory hose or tube routing has

been achieved. Non-contact Infrared Thermometer
The infrared thermometer, 15269785, can be used to
SM1335 spot heat problems early in electrical, mechanical and
hydraulic systems. Hand held and easy to use, you
FITTING NUT simply aim, pull the trigger, and read the temperature.
TUBE Since there is no need to touch what you are
measuring, temperatures of hard-to-reach or moving
components can be taken without getting burned or
shocked.

O' Ring Face Seals (ORFS) - Seal Kit

SLEEVE The braking system utilizes O-ring Face Seal (ORFS)
O-RING O-RING
connectors. An ORFS kit, 15271082, is available. This
kit contains a minimum stock requirement of all sizes
Fig. 8 - Assembly of Typical ORFS Connector
of ORFS type seal.

HYDRAULIC OIL
The braking system should be kept filled with hydraulic
oil as specified in Section 300-0020, Lubrication
System.

Whenever there is a hydraulic system failure, the oil

should be drained, the entire system flushed, oil filters
replaced, oil screens thoroughly cleaned and clean
hydraulic oil added to eliminate all metal particles or
foreign matter.

SERVICE TOOLS
It is recommended that the following service tools are
used when carrying out pressure and temperature
checks during maintenance procedures. These tools,
along with other general service tools, are available
from your dealer. Refer to Section 300-0070, Service
Tools, for part numbers of these tools.

Multi-Gauge
The multi-gauge, 15269784, is basically four pressure
gauges in one. Continuous system pressure readings
are indicated on one of three simultaneously reading
gauges through a pressure range of 30 in of vacuum to
5 000 lbf/in².

The following items should be added to the multi-gauge

to enable the gauge to be used on the diagnostic

SM 2485 Rev 3 04-10 7

Braking System - Braking System Schematic
Section 250-0000
SM - 2834/2854
4 7

3
11

10/12

25

Valve (6) Coil Rating

Ohms Amps Watts
42 0.6 15 15
Voltage: 24V

1 - Orifice
2 - Directional Control Valve
3 - Check valve
4 - Check Valve
6 - Park/Emergency Solenoid Valve
7 - Brake System Relief Valve
8 - Brake System Charge Valve
10 - Check Valve
11 - Orifice 21
12 - Orifice
15 - Priority Valve
21 - Shuttle Valve
25 - Shuttle Valve

Fig. 9 - Brake System Valves Integral to Main Hydraulic Valve Assembly

8 SM 2485 Rev 3 04-10

 Braking System - Braking System Schematic
Section 250-0000

Braking System Trouble Shooting

Symptom Possible Cause Remedy
Front and Rear Brake Accumulators Brake System Relief Valve (7) Re-set valve (7) to the correct
(17) not reaching the correct hydraulic not set correctly or faulty setting or replace if faulty
charge pressure
Pressure at Primary Accumulator (18) Set the Charge Valve (8) to the
not high enough due to Brake System correct setting.
Charging Valve (8) not being set Replace valve (15)
correctly

Pre-charge gas pressure in the Check Pre-charge gas pressure in

accumulator not at the correct level the accumulator. Refer to Section
250-0060, Accumulator

Front and Rear Brake Accumulators Check Valves (3) or (4) leaking Replace Check Valves (3) or (4)
(17) do not hold their charge pressure
Pre-charge gas pressure in the Check Pre-charge gas pressure in
accumulator not at the correct level the accumulator. Refer to Section
250-0060, Accumulator

Faulty seal in the piston of the Replace the accumulator/seals.

accumulator

Brake Treadle Valve leaking Refer to Section 250-0070, Treadle

Valve

Brake Charging System Fails to Cold Start Solenoid Valve (16) Replace Valve (16). Refer to
charge at initial engine start up remains open Section 215-0050, Main Hydraulic
Valve Assembly

Faulty Brake System Charge Valve Replace valve (8)

(8)

Contamination in orifice(11) Replace orifice (11)

Air or contamination in the Load Lift the body of the truck up and
Sense System, especially when first down several times to purge the
running the truck after new main system.
hydraulic valve is fitted.

Primary Accumulator (18) does not Front and Rear Brake Accumulators See previous symptoms.
hold its charge pressure. (17) are not holding their charge.

Pre-charge gas pressure in the Check Pre-charge gas pressure in

accumulator not at the correct level the accumulator. Refer to Section
250-0060, Accumulator

Leakage across the Valves (10, 9, 5 Replace each valve one at a time
or 29) is too high. (in order stated) until the fault is
found.

Accumulator Piston Seal leaking Replace the accumulator

SM 2485 Rev 3 04-10 9

Braking System - Braking System Schematic
Section 250-0000

Braking System Trouble Shooting

Symptom Possible Cause Remedy
Ineffective Park Brake Fault with Park Brake caliper Refer to Section 170-0010, Parking
and Mounting

Park Brake Solenoid Valve (6) not Check if there is hydraulic pressure
functioning. Sticking in the selected at the Park Brake port. If there is
position pressure present, replace Valve(6).

Park Brake fails to release. No voltage at Park Brake Solenoid Check park/emergency switch in
Valve (6) when the switch is activated operators cab.
in the cab and the park brake OFF
relay is energised. Check wiring between park/
emergency switch and park brake
OFF relay and park brake Solenoid
(6).

Park Brake Solenoid Valve(6) fails to Check Parkbrake service switch

operate due to fault. wiring.

Insufficient hydraulic charge pressure Replace valve(6).

in rear brake accumulator
Check warning lights in cab and
pressure at the Park Brake
diagnostic check point.
See trouble-shooting Brake
Accumulator Charging

Service brakes fail to come on when Faulty Brake Treadle Valve. Spool not Refer to Section 250-0070, Treadle
Parking Brake is selected when the stroking when pressure at port 'PP'. Valve.
engine is running.
No transmission pressure at Port TS Check piping and see instructions
on main hydraulic valve assembly. for the transmission.

Directional Control Valve (2) not Replace Valve (2)

selecting.

Fault with Park Brake System See previous trouble-shooting

Service Brakes come on when Directional Control Valve (2) sticking Replace Valve (2)
Parking Brake is selected and Engine in the selected position.
is not running.

Inadequate Braking. Low system pressure. Check hydraulic oil level.

Check oil condition.

Check for major leakage.

Check accumulator pressures.

Refer to Section 250-0060,
Accumulators

10 SM 2485 Rev 3 04-10

 Braking System - Braking System Schematic
Section 250-0000

Braking System Trouble Shooting

Symptom Possible Cause Remedy
Inadequate Braking (cont.) Brake treadle valve delivery pressure Check front and rear brake pressure
below normal setting.
Check brake treadle valve
operation. Refer to Section 250-
0070, Treadle Valve

Insufficient brake surfaces. Check brake disc/pads for wear.

Refer to Section 165-0010, Brake
Parts.

Replace seals and pistons as

required. Refer to Section 165-
0010, Brake Parts.

* * * *

SM 2485 Rev 3 04-10 11

Braking System - Braking System Schematic
Section 250-0000

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12 SM 2485 Rev 3 04-10

 BRAKING SYSTEM - Accumulator
Section 250-0060

SM 3277
19
18
17 20
16
15
14 21
13
12
11
10
24 25 27 28
23 22
26 9
Charge Valve Assembly

7
6
5

4
8
3

2
1

1 - Nut 8 - Cylinder Body 15 - O-Ring 22 - Nut

2 - Washer 9 - Piston 16 - Back-up Ring 23 - Washer
3 - Charging valve Assembly 10 - Seal Ring 17 - End Cap 24 - Cap
4 - O-ring 11 - Washer 18 - Mounting Bracket 25 - Valve Core
5 - Cylinder Cap 12 - O-Ring 19 - Bolt 26 - Lock-nut
6 - Back-up Ring 13 - Washer 20 - Elbow 27 - O-Ring
7 - O-Ring 14 - Seal Ring 21 - Bolt 28 - Valve Body

Fig. 1 - Exploded View of Accumulator Assembly

DESCRIPTION The cylinder pressure will increase or decrease

Numbers in parentheses refer to Figure 1. proportionally with temperature changes. An
accumulator pressure reading can vary about 4.3 bar
The accumulators can be identified as items 17 and (62 lbf/in²) with 22 °C (72 °F) temperature change. Such
18, and the pressure switches as items 13 in Section temperature changes could easily occur between noon
250-0000, Braking System Schematic. and midnight of the same day. Refer to the table on
Page 7 of this Section for nitrogen pressures at
There are three accumulators mounted inside the ambient temperatures of other than 20 °C (68 °F).
battery box located on the front left hand side of the
tractor; one for the front brake system and one for the Each accumulator consists of a charging valve
rear. The front and rear brake accumulators are assembly (3), end cap (17), cylinder (8) and piston (9).
supplemented by a third (primary) accumulator. Refer The charging valve (3) is equipped with a locking
to Figure 2. The primary accumulator supports the feature. Loosening locknut (26) will open the valve so
service brake system and the body pilot pressure that the precharge can be checked or the accumulator
system. All three accumulators are of the piston type charged.
and are precharged with nitrogen to 103 bar (1494 lbf/
in²), at 20 °C (68 o F). A diagnostic pressure point is provided local to each
brake accumulator, to facilitate the fitting of pressure
Note: The nitrogen pressure in an accumulator is test apparatus.
directly influenced by changes in nitrogen temperature.

SM 2326 Rev 2 09-08 1

Braking System - Accumulator
Section 250-0060

SM 2849 SM 1273

5
6

4 8 9
1 1
2
3
P
FB 4
RB 7
5
10
6
7
8 2
9
10

1 - Differential Lock Pressure 8 - Trans. Converter Press.

2 - Pump LS Pressure 9 - Body System Press.
3 - Front Brake Pressure 10 - Trans. System Pressure
4 - Rear Brake Pressure P - Primary Accumulator 1 - Line 6 - Tank Valve
5 - Park Brake Pressure FB - Front Brake Accumulator 2 - Valve Chuck 7 - Gland Fitting
6 - Steering Pressure RB - Rear Brake Accumulator 3 - Valve Extension 8 - Gland Nut
7 - Trans. Retarder Press. 4 - Cylinder Valve 9 - Cylinder Adaptor
5 - Pressure Gauge 10 - Bleeder Valve

Fig. 2 - Accumulator Mounting Fig. 3 - Charging Assembly Kit

OPERATION
Numbers in parentheses refer to Figure 1. TESTING
Piston (9) acts as a separator dividing cylinder (8) into
two sections. The bottom section nearest charging WARNING
valve (3) contains the nitrogen precharge. Hydraulic oil To prevent personal injury and property
from the main hydraulic pump flows through check damage, be sure wheel blocks are properly
valves in the main hydraulic valve and into the top secured and of adequate capacity to perform
section of the accumulators. the task safely.

Accumulator pressure is monitored by pressure WARNINGS

switches located in the main hydraulic valve, which Accumulators are charged with nitrogen.
send a signal to illuminate warning lights in the dash The service pressure is 105 bar (1523 lbf/in²) at
panel when the pressure drops below 122 bar (1769 lbf/ 20 °C (68 °F). To prevent personal injury and
in²). The warning lights will remain illuminated until the property damage do not attempt to remove any
pressure rises above 135 bar (1958 lbf/in²). valves or fittings until all nitrogen pressure is
completely relieved.

Hydraulic fluid pressure will remain

within the system after engine shut down.
Operate the treadle pedal continuously until the
pressure has dissipated before carrying out any
work on the braking system or serious injury
could result.

Testing Charging Valve For Leakage

Numbers in parentheses refer to Figure 1.

2 SM 2326 Rev 2 09-08

 Braking System - Accumulator
Section 250-0060
1. Remove the cover plate from the bottom of the 5. Turn 'T' handle clockwise until the charging valve
battery box. core is depressed. Be sure that the bleeder valve (10)
is tight and does not leak, and the valves (4 and 6) are
2. Remove the cap (24) from the charging valve (3) and closed.
loosen the locknut (26). Coat the open end of the
charging valve (3) with soapy water. Bubbles indicate a 6. To read the accumulator precharge pressure, slowly
leaky valve core (25). open the cylinder valve (4). The pressure gauge (5) will
register the precharge pressure, it should be 103 bar
3. Attempt to reseat the valve core by depressing and (1494 lbf/in²) at 20 °C (68 °F) ambient temperature.
releasing it quickly once or twice. Recheck for leakage. Refer to the table at the end of this section for the
If leakage continues, discharge the accumulator as nitrogen pressures at ambient temperatures of other
described under 'Discharging Nitrogen' in this section. than 20 °C (68 °F).

4. Replace the valve core (25). Tighten the locknut (26) 7. Close the cylinder valve (4) and open the bleeder valve
to 11 Nm (100 lbf in) and replace the valve cap (24) (10) to dissipate the gauge pressure. Close the bleeder
finger tight. valve (10) after the pressure is relieved. If the accumulator
needs to be charged, leave the line (1) and valve chuck (2)
attached to the charging valve (3 , Figure 1). Charge the
Testing Precharge Pressure
accumulator as described under 'Charging The
Numbers in parentheses refer to Figure 3, unless Accumulator'.
otherwise specified.
8. If the precharge pressure is correct, rotate the 'T'
Note: The nitrogen pressure in an accumulator is handle anticlockwise until it stops. Tighten the locknut
directly influenced by changes in nitrogen temperature. (26, Figure 1) on the charging valve (3, Figure 1) to 11
The cylinder pressure will increase or decrease Nm (100 lbf in). Loosen the swivel nut and remove the
proportionally with temperature changes. An gauging head.
accumulator pressure reading can vary about 4.3 bar
(62 lbf/in²) with 22 °C (72 °F) temperature change. Such 9. Install the cap (24, Figure 1) on the charging valve
temperature changes could easily occur between noon (3, Figure 1) and tighten it finger tight.
and midnight of the same day. Refer to the table on
Page 7 of this Section for nitrogen pressures at 10. Remove the wheel blocks and place the battery
ambient temperatures of other than 20 °C (68 °F). master switch in the 'On' position.

To test the accumulator precharge pressure or to

charge the accumulator, a charging assembly kit can CHARGING THE ACCUMULATOR
be used. Refer to Figure 3. Numbers in parentheses refer to Figure 3, unless
otherwise specified.
1. Position the vehicle in a level work area, apply the
parking brake, switch off the engine and turn steering Note: Either oil or water pumped nitrogen can be used
wheel in both directions several times to relieve any to charge the accumulator. Both types are readily
pressure in the steering circuit. available from a local compressed gas dealer.

2. Operate the treadle valve continuously to relieve

pressure in the braking system. Block all road wheels
and place battery master switch in the 'Off' position.

3. Check the accumulator mountings confirm that the

accumulator is held tightly in position.

4. Remove the cap (24, Figure 1) from the accumulator

charging valve (3, Figure 1). Attach the charging line
(1) to the charging valve by rotating the 'T' handle of
the valve chuck (2) anticlockwise until it stops, then
screw the swivel nut down on the valve. Loosen the
locknut (26, Figure 1) by turning it anticlockwise one to
two turns.

SM 2326 Rev 2 09-08 3

Braking System - Accumulator
Section 250-0060

1) and tighten it finger tight.

WARNINGS
Do not use oxygen or any gas other than DISCHARGING NITROGEN
nitrogen to charge an accumulator. Oxygen Numbers in parentheses refer to Figure 1.
under pressure coming into contact with oil or
grease will cause a violent explosion. Always Make sure that the charging valve (3) is closed
double check to make sure you are using internally by turning the locknut (26) clockwise.
nitrogen to prevent personal injury and Remove the cap (24) and the core (25) from the
property damage. charging valve (3). Slowly turn the locknut (26)
anticlockwise to open the charging valve (3).
A high pressure nitrogen pressure
regulator must be used with the charging Do not remove the charging valve (3) until all the gas
assembly kit. Failure to use pressure regulator has been completely evacuated.
could cause property damage, personal injury
or death.
WARNING
1. Attach the line (1) and the swivel nut to the charging Do not try to discharge the accumulator by
valve (3, Figure 1), as described in steps 1 through 4 depressing charging valve core (25).
under the heading 'Testing Precharge Pressure'.
Ensure that the valves (4 and 6) are closed.
REMOVAL
2. Attach the gauging head to the nitrogen bottle by
screwing down on the gland nut (8). WARNINGS
To prevent personal injury and property
3. Open the tank valve (6) slowly. The pressure shown damage, be sure wheel blocks, blocking
on the pressure gauge (5) is tank pressure. materials and lifting equipment are properly
secured and of adequate capacity to perform
4. Open the cylinder valve (4) slowly and charge the the task safely.
accumulator to 103 bar (1494 lbf/in2) at 20 °C (68 °F)
ambient temperature, closing the valve occasionally. Accumulators are charged with nitrogen.
Refer to the table at the end of this Section for nitrogen The service pressure is 103 bar (1494 lbf/in²) at
pressures at ambient temperatures of other than 20 °C 20 °C (68 ° F). To prevent personal injury and
(68 °F). property damage do not attempt to remove any
valves or fittings until all nitrogen pressure is
5. To check the accumulator charge, close the tank completely relieved.
valve (6), relieve the pressure between the tank and
the pressure gauge (5), by opening the bleeder valve 1. Position the vehicle in a level work area, apply the
(10) momentarily. This will allow the gauge needle to parking brake, switch off the engine and turn steering
settle, thus giving a correct pressure reading of the wheel in both directions several times to relieve any
accumulator charge. pressure in the steering circuit.

6. When the correct pressure for the ambient 2. Operate the treadle valve continuously to relieve
temperature has been reached, close the valves (4 and pressure in the braking system. Block all road wheels
6) tightly. Bleed the pressure off the pressure gauge (5) and place battery master switch in the 'Off' position.
by opening the bleeder valve (10). Close the bleeder
valve when all pressure is bled off from the gauge and 3. Remove the cover plate from the bottom of the
unscrew the gland nut (8) from the nitrogen bottle. battery box.

7. Rotate the 'T' handle of the valve chuck (2) 4. Discharge nitrogen from the accumulators as
anticlockwise until it stops. Tighten the locknut (26, described under 'Discharging Nitrogen'.
Figure 1) to 11 Nm (100 lbf in). Loosen the swivel nut
and remove the gauge head. 5. Disconnect the hydraulic lines from the top of the
accumulators and plug the accumulators to prevent oil
8. Check the charging valve (3, Figure 1) for leakage spillage. Cap open lines and fittings to prevent the
using soapy water. Reinstall the valve cap (24, Figure entry of dirt.

4 SM 2326 Rev 2 09-08

 Braking System - Accumulator
Section 250-0060
apparent imperfections have been removed. Renew the
6. Support the accumulators with an adequate sling complete accumulator assembly if the inside of the
and lifting device. Remove the bolts, nuts, washers cylinder (8) is excessively scored or worn.
and clamps. Remove the accumulators and drain the
oil from the top section into a suitable container. 4. Inspect the threads in the end cap (17) and the
threads in the cylinder (8) for damage. Renew all parts
7. Remove the accumulators to a clean area for worn or damaged beyond repair.
disassembly.
ASSEMBLY
DISASSEMBLY Numbers in parentheses refer to Figure 1.
Numbers in parentheses refer to Figure 1.
1. Lubricate the O-rings (7,11 and 15), the back-up
rings (6 and 16), the seal rings (10 and14), the washers
WARNING (11 and 13) and the inside of the cylinder body (8) with
Accumulators are charged with Nitrogen. The hydraulic oil prior to assembly.
service pressure is 103 bar (1494 lbf/in²) at 20
°C (68 ° F). To prevent personal injury and 2. Install the O-ring (15) and the backup ring (16) on
property damage, do not attempt to remove any the end cap (17).
valves or fittings until all nitrogen pressure is
completely relieved. 3. Install the end cap (17) on the cylinder body (8).

1. Ensure that all nitrogen gas has been released 4. Install new seal rings (10 and 14), washers (11and
before starting to disassemble the accumulator. Refer 13) and O-ring (12) on the grooves of the piston (9).
to 'Discharging Nitrogen'.
5. Insert the piston (9) into the bore of the cylinder
2. Remove the charging valve assembly (3) from the body (8) with the cupped end facing the open end of
end cap (17). the cylinder body (8). Taking care not to damage any
components on the threads of the Cylinder body (8) on
3. With the accumulator lying horizontal, hold the insertion.Use a hammer and wood block to carefully
accumulator cylinder (8) with a strap wrench. tap the piston (9) into place until the piston (9) is 50.8
mm (2.0 in) below the beginning of the honed bore.
4. Install pins in three equally spaced holes in the end Keep pressure against the piston (9) while tapping it
cap (17), then use a long bar working against the pins into place, to ensure that the piston (9) does not resist
to remove the end cap from the cylinder (8). Remove movement and force its way back.
and discard the back-up ring (6) and the O-ring (7).
6. Install the O-ring (7) and the back-up ring (6) on to
5. Grip the cast web of the piston (9) with pliers, and the cylinder cap (5), and install the cylinder cap into the
while rotating it, pull the piston from the cylinder (8). bore of the cylinder body (8). Tighten the cap so that it
Remove and discard the seal rings (10 and 14), is flush with the end of the cylinder body (8), within 1.6-
washers (11 and 13) and the O-ring (12). 2.4 mm (0.062 - 0.094 in) above or below.

7. Install the charging valve assembly (3). Torque

INSPECTION tighten the locknut (26) clockwise to 11 Nm (100 Ibf in)
Numbers in parentheses refer to Figure 1. to close the charging valve (3). Insert the valve core
(25) and torque it to 0.5 Nm ( 5 Ibf in). Replace the
1. Wash metal components with a suitable solvent and valve cap (24) and tighten it hand tight.
thoroughly air dry them.

2. Inspect the piston (9) for cracks or burrs. Replace INSTALLATION

the piston (9) if it is excessively scored or worn. Note: Tighten all fasteners without special torques
specified to torques listed in Section 300-0080,
3. Use an inspection lamp to check the bore of the Standard Bolt and Nut Torque Specifications.
accumulator cylinder (8) for scratches or scoring. Minor
nicks, scratches or light scoring of the bore can be Note: Tighten all hydraulic lines fitted with ORFS
removed by using crocus cloth. Dress the bore until all

SM 2326 Rev 2 09-08 5

Braking System - Accumulator
Section 250-0060

connections, as described in Section 250-0000, 5. Install the cover to the bottom of the battery box.
Braking System Schematic. Renew all O-rings where
used. 6. Check the oil level in the hydraulic tank and add oil
as required. Refer to Section 230-0040, Hydraulic
Tank, for the correct fill level and Section 300-0020,
WARNING Lubrication System, for the oil specification.
To prevent personal injury and property
damage, be sure lifting equipment is properly 7. Place the battery master switch in the 'On' position,
secured and of adequate capacity to perform start the engine and check for leaks. Tighten the lines
the task safely. and fittings as required. Remove the wheel blocks.

1. Position the accumulators in the battery box with the

oil inlet ports at the top. MAINTENANCE
Inspect the accumulator assembly for leaks. If leaks
2. Attach the clamps securely with the nuts, washers are found, disassemble and replace all O-rings and
and bolts. seals. Inspect all hydraulic lines for wear and leaks.
Renew/tighten lines as required.
3. Remove the caps installed at removal and install
hydraulic lines securely to the oil inlet ports at the top
of the accumulators. SPECIAL TOOLS
Refer to Section 300-0070, Service Tools, for part
4. Charge the accumulator with Nitrogen gas as numbers of the charging assembly kit and other
described under 'Charging the Accumulator' in this general service tools required. These tools are
section. available from your dealer.

SPECIAL TORQUE SPECIFICATIONS TABLE 017

TORQUE

FIG. No. ITEM No. Nm lbf ft lbf in

1 26 11 8 97

6 SM 2326 Rev 2 09-08

 Braking System - Accumulator
Section 250-0060

AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE

AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE

°C °F bar lbf/in2

-20 -4 88.94 1290

-10 14 92.45 1341

0 32 95.97 1391

10 50 99.48 1443

20 68 103 1494

30 86 106.52 1545

40 104 110.03 1596

50 122 113.55 1647

60 140 117.06 1698

70 158 120.58 1749

80 176 124.09 1800

90 194 127.61 1851

100 212 131.12 1902

110 230 134.64 1953

120 248 138.15 2004

WARNING
This vehicle is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the vehicle or cylinders by any method while
cylinders are charged. For shipment, contact the appropriate agency in the country involved. Consult
your dealer for further permit information.

* * * *

SM 2326 Rev 2 09-08 7

Braking System - Accumulator
Section 250-0060

THIS PAGE IS INTENTIONALLY BLANK

8 SM 2326 Rev 2 09-08

 BRAKING SYSTEM - Treadle Valve
Section 250-0070

SM - 3731

3
4 14
5 15
11
6
23
7

16 24
8
25
9 26 35

27
17
10 28
18 29
19
11
20 30

12
21 31

13 32 1
22
33

34

1 - Pedal Assembly 10 - Spool 19 - Shims 28 - O-ring

2 - Nut 11 - O-ring 20 - Spring 29 - Backup Ring
3 - Washer 12 - Sleeve 21 - Spring 30 - Pilot Housing
4 - O-ring 13 - Spool 22 - Spring 31 - Screw
5 - End Plug 14 - Cup 23 - Bearing 32 - Spring
6 - Retainer 15 - Spacer 24 - Piston 33 - Push Rod
7 - Spring 16 - Valve Housing 25 - Backup Ring 34 - Boot
8 - O-ring 17 - O-ring 26 - O-ring 35 - Microswitch
9 - Sleeve 18 - Retainer 27 - Piston

Fig. 1 - Exploded View of Treadle Valve Assembly

DESCRIPTION Refer to Section 215-0050, Main Hydraulic Valve

Assembly.
Numbers in parentheses refer to Figure 1.
In the normal position, brake pedal assembly (1) is in
Note: The treadle valve can be identified as item 9 in
the up position. In this condition the regulated pressure
Section 250-0000, Braking System Schematic.
outlet ports of the valve 'A1' and 'A2' are directly linked
to the hydraulic tank ports 'T1' and 'T2'. While the pedal
The tandem circuit modulating treadle valve is a closed
is in this position the brakes are released.
centre controller which controls the level of hydraulic oil
pressure applied to the front and rear brakes and the
A microswitch (35), mounted on the brake treadle
maximum pressure available to these circuits. It is
valve, sends a signal to activate the rear brake lights
operated by a foot pedal in the operator's cab and with
and the engine brake when the treadle valve is
the engine running, is automatically applied by the park
depressed.
brake solenoid valve within the main hydraulic valve.
SM 2486 Rev 4 04-10 1
Braking System - Treadle Valve
Section 250-0070

SM - 2875 SM - 2876

9 9

PP PP

SUPPLY SUPPLY
FROM FROM FROM
TO FRONT P1 FRONT P1
A1 MAIN HYDRAULIC A1 MAIN HYDRAULIC
BRAKES VALVE, PORT ACC1 BRAKES VALVE, PORT ACC1
T1 T1

SUPPLY SUPPLY
TO MIDDLE FROM MIDDLE
FROM FROM
AND REAR P2 AND REAR P2
A2 MAIN HYDRAULIC A2 MAIN HYDRAULIC
BRAKES BRAKES
VALVE, PORT ACC2 VALVE, PORT ACC2
T2 T2

Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release

OPERATION Normal Service Brake Release

Numbers in parentheses refer to Figure 1. Refer to Figure 3. When the operator releases pedal (1)
assembly, spools (10 and 13) will become unbalanced
Normal Service Brake Application and move downwards, opening outlet ports 'A1' and
Refer to Figure 2. When the operator depresses pedal 'A2' to tank. At this point, oil in the 'A1' and 'A2' lines is
assembly (1), push rod (33) is moved up and pushes released to tank through tank ports 'T1' and 'T2',
on pistons (24 and 27), and in turn pushes spools (10 releasing the brakes.
and 13) up. As spools (10 and 13) move up, the
metering notches move out of the tank cavity and
close outlet ports 'A1' and 'A2' off to tank ports 'T1' and
Emergency Stop Brake Application/
'T2'. Spools (10 and 13) continue to move upwards until Release
the metering notches become exposed to the inlet Refer to Figure 4. Pushing in the park/emergency
pressure ports. This movement opens inlet ports 'P1' control results in the de-energization of the park brake
and 'P2' to outlet ports 'A1' and 'A2' respectively. As solenoid valve within the main hydraulic valve. This
hydraulic pressure builds in the brake, oil flows through allows full pressure to enter the 'PP' port in the treadle
the small orifice in spools (10 and 13) and into the valve simulating a full and immediate depression of
cavities above the spools. As pressure rises in the pedal (1) assembly, thus pushing the spools (10 and
brake it also rises in the cavities above the spools 13) upwards and thereby applying maximum braking
forcing spools (10 and 13) downwards closing outlet action.
ports 'A1' and 'A2'. Spools (10 and 13) are now
balanced between the brake pressure and the pressure Refer to Figure 5. Pulling out the park/emergency
of springs (20 - 22) generated by the operator's force control with park brake OFF Relay energised (i.e
on the pedal (1) assembly. Spools (10 and 13) have transmission in gear) will energize the park brake
closed off the inlet ports, outlet ports and the tank solenoid valve within the main hydraulic valve, allowing
ports and will remain in this position as long as pedal the pressure in the 'PP' line to fall via the return to tank
(1) assembly is not moved. If the operator further port opened within the park brake solenoid valve.
depresses pedal (1) assembly, spools (10 and 13) will Outlet ports 'A1' and 'A2' are opened to tank ports 'T1'
move up and build more pressure in the brake until it and 'T2' allowing oil in the 'A1' and 'A2' lines to return to
balances the pedal force. tank, releasing the brakes.

2 SM 2486 Rev 4 04-10

 Braking System - Treadle Valve
Section 250-0070

SM - 2877 SM - 2878

9 9
SUPPLY
PP FROM PP TO TANK VIA
MAIN HYDRAULIC MAIN HYDRAULIC
VALVE, PORT PBP VALVE, PORT PBP

SUPPLY FROM SUPPLY

TO FRONT P1 FRONT P1
A1 FROM A1 FROM
BRAKES MAIN HYDRAULIC BRAKES MAIN HYDRAULIC
T1 VALVE, PORT ACC1 T1 VALVE, PORT ACC1

SUPPLY SUPPLY
TO MIDDLE FROM MIDDLE
FROM FROM
AND REAR A2 P2 AND REAR A2 P2
MAIN HYDRAULIC MAIN HYDRAULIC
BRAKES BRAKES
VALVE, PORT ACC2 VALVE, PORT ACC2
T2 T2

Fig. 4 - Park/Emergency Brake Application Fig. 5 - Park/Emergency Brake Release

Advanced Engine Braking Note: Check all hydraulic lines and fittings to ensure
leakage is not coming from there.
Refer to Figure 1. The brake pedal microswitch (35)
sends a signal to activate the engine brake and the
2. Failure of the pedal to return to full upright position.
rear brake lamps. The brake pedal microswitch (35)
energizes the brake lamp relay K50, and the engine
3. Treadle valve holds pressure when in the neutral
brake select relay K32. Both relays are located in the
position.
operator cab fuse/relay box. Refer to Section 190-0000,
Circuit Diagrams. When these relays are energized, the
4. Varying output pressure with the pedal fully
electrical circuit is completed to energize the
depressed.
appropriate lamps and request signals.
5. Output pressure does not remain constant between
The first few degrees of movement of the pedal (1)
circuits.
engages the engine brake, providing that the
transmission is in 'lockup'. Further movement of the
pedal (1) applies the service brakes in addition to the
engine brake. The engine brake will disengage when
the pedal (1) is released, or when any of the operating
conditions become out of range.

REBUILD CRITERIA
Inspect the valve regularly for any signs of leakage or
damage and replace components if necessary.

The treadle valve should be rebuilt if one or more of the

following conditions exist:

1. Any sign of external leakage.

SM 2486 Rev 4 04-10 3

Braking System - Treadle Valve
Section 250-0070

REMOVAL SM - 2879

A
WARNINGS P2
P
To prevent personal injury and property T
A2 T2
damage, be sure wheel blocks are properly
secured and of adequate capacity to performthe P1
P
task safely. T
A1 T1
A
Hydraulic oil pressure will remain
within the system after engine shut down.
Operate the treadle pedal continuously until the PP
pressure has dissipated before carrying out any
work on the braking system or serious injury PP
could result.

1. Position the vehicle in a level work area, apply the

parking brake, switch off the engine and turn thhe
steering wheel in both directions several times to
relieve any pressure in the steering circuit.

2. Operate the treadle valve continuously to relieve

pressure in the braking system. Block all road wheels
and place the battery master switch in the 'Off'
position.

3. Pull on the handle to release the hood catch and lift

up the hood.

4. Remove the blanking cap from the remote drain line

at the bottom of the hydraulic tank. Install a length of
hose on remote drain fitting, open drain cock and drain
P1 - Pressure from main hydraulic valve, port ACC1
the hydraulic oil into a suitable container. Close the P2 - Pressure from main hydraulic valve, port ACC2
drain cock, remove the hose and reinstall the blanking A1 - Pressure to front brakes
cap. A2 - Pressure to rear brakes
T1 - Tank return, front brakes
T2 - Tank return, rear brakes
5. If necessary remove the engine air intake tube to
gain access to the treadle valve on the front of the cab. Fig. 6 - Treadle Valve Porting
Alternatively, tilt the cab to gain access. Refer to
Section 260-0010, Cab and Mounting. cab to a clean area for 'Disassembly'.

6. Clean the treadle valve assembly and the

surrounding area with a suitable solvent. Ensure that all DISASSEMBLY
hydraulic lines connected to the treadle valve are Numbers in parentheses refer to Figure 1.
identified for ease of installation and, with suitable
containers available to catch leakage, disconnect the 1. Remove the blanking caps from the treadle valve
hydraulic lines. Fit blanking caps to all open lines and ports and drain all oil from the valve body ports, by
treadle valve ports. rotating the valve over a suitable container.

7. Disconnect the electrical connection from the brake 2. Remove the treadle valve from the mounting plate
pedal microswitch (35). and secure the valve assembly upright in a table vice.

8. Remove the four bolts securing the treadle valve and 3. Remove the circlips to allow the cam assembly to
mounting plate to the cab. Remove the treadle valve be disassembled.
and mounting plate as an assembly from the front of

4 SM 2486 Rev 4 04-10

 Braking System - Treadle Valve
Section 250-0070
4. Remove the boot (34) from the push rod (33), then ASSEMBLY
remove the push rod (33) and spring (32) from the pilot
Numbers in parentheses refer to Figure 1.
housing (30) bore.
Lubricate all new rubber components with clean
5. Separate the pilot housing (30) and valve housing
hydraulic oil used in the braking system. Refer to
(16) by removing the screws (31). Remove the O-ring
Section 300-0020, Lubrication System.
(17) from the valve housing (16).
1. Clean all parts thoroughly before assembly.
6. Remove the piston (27) from the pilot housing (30).
2. Install a new cup (14) in the spacer (15) and one new
Note: Be careful not to scratch housing bore.
O-ring (11) on the spacer (15). Note the direction of the
cup.
7. Remove the O-rings (26 and 28) and back-up rings
(25 and 29) from the piston (27), being careful not to
3. Install other new O-rings (11) on the sleeve (12) and
damage the O-ring and piston grooves.
new O-rings (8) on the sleeve (9).
8. Remove the piston (24), springs (20, 21 and 22) and
4. Lubricate the spool (13) with clean hydraulic oil and
shims (19) from the valve housing bore.
carefully insert it into the sleeve (12). Note the direction
of the spool.
9. The bearing (23) should not be removed from the
housing bore.
5. Insert the spacer (15) into the housing bore through
the end plug (5) end. Note the direction of the spacer.
Note: Excessive wear in both the bearing (23) and the
piston (24) may require replacement.
6. Lubricate the sleeve (12) and the spool (13)
assembly with clean hydraulic oil and carefully insert it
10. Remove the retainer assembly (18) from the
into the housing bore using a wooden dowel. Note the
housing bore.
direction of the assembly.
Note: The ball is a press fit in the retainer.
7. Carefully insert the sleeve (9) into the housing until it
rests against the sleeve (12). Lubricate the spool (10)
11. Loosen the nut (2) and remove the end plug (5)
with clean hydraulic oil and carefully insert it into the
from the housing. Remove the spring (7), retainer (6),
sleeve (9). Note the direction of spools and sleeves.
nut (2), washer (3) and O-ring (4) from the end plug (5).
8. Install the spring (7) and retainer (6) in the housing
12. Remove the spacer (15), sleeves (9 and 12) and
bore.
spools (10 and 13) assembly from the housing bore.
This assembly must be removed through the end plug
9. Install the end plug (5) and torque it to 11 - 20 Nm
(5) end of the housing (16).
(96 - 180 lbf in) to the seat sleeves. Then turn back the
end plug a ¼ turn and torque it to 1 - 7 Nm
Note: Be careful not to scratch the housing bore.
(10 - 60 lbf in). Install a new O-ring (4), washer (3) and
nut (2). Hold the end plug and torque the nut to 68 - 81
13. Separate the spacer (15) and spools (10 and 13)
Nm (50 - 60 lbf ft).
from the sleeves (9 and 12).
10. Install a new O-ring (17) on the valve housing (16).
Note: Excessive wear on either the spools (10 and 13)
or the sleeves (9 and12) may require replacement.
11. Install the retainer assembly (18) in the housing.
Spool (10)/sleeve (9) and spool (13)/sleeve (12) are
matched sets and MUST be replaced as matched sets
Note: Depress the retainer (18) until it bottoms on the
- DO NOT intermix.
spacer (15). Spools (10 and 13) and retainer (18)
should return when released. If the spools and retainer
14. Remove the O-ring (11) and cup (14) from the
do not return when released, the bores of the sleeves
spacer (15). Remove the other O-rings (11) from the
(9 and 12) may have been damaged during installation.
sleeve (12) and the O-rings from the sleeve (8).
12. Install the shims (18), springs (20, 21 and 22) and
Note: Be careful not to damage the cup and O-ring
piston (24) in the valve housing bore.
grooves and bores.

SM 2486 Rev 4 04-10 5

Braking System - Treadle Valve
Section 250-0070

Note: For proper brake pressure setting, install the 4. If previously removed, install the engine air intake
same number of shims and spacer(s) that were tube, or if applicable, lower the cab. Refer to Section
removed during disassembly. If spools (10 and 13), 260-0010, Cab and Mounting.
sleeves (9 and 12), or spring (22) were replaced, shim
adjustment may be required. 5. Fill the hydraulic tank with oil specified in Section
300-0020, Lubrication System.
13. Install new O-rings (26 and 28) and new back-up
rings (25 and 29) on the piston (27). Note the order of 6. Place the battery master switch in the 'On' position,
the back-up rings and O-rings. start the engine and bring the hydraulic oil to operating
temperature.
14. Lubricate the piston (27) with clean hydraulic oil
and insert it into the pilot housing (30) through the 7. Apply the brakes and check for oil leaks. Tighten
valve housing (16) end. Be sure to install the piston line connections and fittings as necessary.
(27) as far as it will go into the pilot housing bore.
Note: When performing Step 8, make sure that parking
15. Carefully attach the pilot housing (30) to the valve brake applies and releases appropriately.
housing (16) using the screws (31). Torque the screws
to 24 - 30 Nm (18 - 22 lbf ft). 8. Check brake operations by actuating pedal and park/
emergency control and engaging transmission gear.
16. Install the spring (32) and push rod (33) into the Ensure that the pedal assembly is free to operate.
pilot housing (30) bore.
9. Shut off the engine and check the hydraulic tank oil
17. Install a new boot (34) on the push rod (33). level. Replenish as necessary.

18. Assemble the cam assembly and secure it with

circlips. CHECKING SYSTEM PRESSURES

19. Install the mounting plate to the treadle valve.

WARNINGS
To prevent personal injury and property
INSTALLATION damage, be sure wheel blocks and blocking
Numbers in parentheses refer to Figure 1. materials are properly secured and of adequate
capacity to perform the task safely.
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, Standard Bolt and Nut Torque Hydraulic fluid pressure will remain
Specifications. within the system after engine shut down.
Operate the brake treadle pedal continuously
Note: Tighten all hydraulic lines fitted with ORFS until the pressure has dissipated before
connections, as described in Section 250-0000, carrying out any work on the system or serious
Braking System Schematic. Renew all O-rings where injury could result.
used.
1. Position the vehicle in a level work area, apply the
1. Secure the treadle valve and mounting plate parking brake, switch off the engine and turn steering
assembly to the front of the cab using the four bolts wheel in both directions several times to relieve any
removed previously. pressure in the steering circuit.

2. Connect the electrical connection to the brake pedal 2. Operate the treadle valve continuously to relieve
potentiometer (35). pressure in the braking system. Block all road wheels,
place the steering lock bar in the 'Locked' position and
3. Remove the blanking caps and connect the the battery master switch in the 'Off' position.
hydraulic lines to the treadle valve assembly as noted
at 'Removal'. 3. Connect a hydraulic gauge, capable of recording a
pressure of 0 - 345 bar (0 - 5000 lbf/in²), to the front
brake diagnostic pressure point (point 3 on Figure 7),
inside the battery box.

6 SM 2486 Rev 4 04-10

 Braking System - Treadle Valve
Section 250-0070
Note: The actuating pressure for the front brake circuit
Truck Serial No. Pressure Tolerance is 60 ±5.1 bar (870 ±75 lbf/in²). The actuating pressure
A8891011 to for the rear brake circuit is specific to particular serial
55 bar ± 5.1 bar numbers, detailed on Page 7. However, the system
A8891214 (795 lbf/in²) (± 75 lbf/in²)
A8971011 to pressure is 240 bar (3500 lbf/in²) and can be checked
at the steering diagnostic pressure point (STR) inside
A8971149
the battery box (point 6 on Figure 7). Front and rear
A9201011 to
brake pressures are also tested at diagnostic points in
A9201033
the battery box (points 3 and 4 respectively on Figure
From:
7). System pressure is checked against steering
A8891215 57 bar ± 5.1 bar pressure as this is the highest pressure requirement in
A8971150 (825 lbf/in²) (± 75 lbf/in²) the hydraulic circuit. Refer to Section 230-0050, Main
A9201034
Hydraulic Pump.

SM 2849
6. If the pressures to the brake circuits have been
determined as high or low, refer to the Troubleshooting
table for the treadle valve and Section 250-0000,
Braking System Schematic.
1
2

P
3 MAINTENANCE
FB 4
RB 5 General
6
7
Check all hydraulic brake lines and fittings at the
8 treadle valve for leaks and damage. Tighten/replace as
9 required.
10

Every 1000 Hours

Check the front and rear brake pressures at remote
8 - Trans. Converter Press.
diagnostic test points. If the pressures are not within
1 - Diff-lockPressure
2 - Pump LS Pressure 9- Body System Press. the specified pressure range, refer to Troubleshooting
3 - Front Brake Pressure 10 - Trans. System Pressure table for treadle valve and Section 250-0000, Braking
4 - Rear Brake Pressure P- Primary Accumulator System Schematic.
5 - Park Brake Pressure FB - Front Brake Accumulator
6 - Steering Pressure RB - Rear Brake Accumulator
7 - Trans. Retarder Press. SPECIAL TOOLS
Fig. 7 - Diagnostic Pressure Check Points (Battery Box) There are no special tools required for the procedures
outlined in this section. Refer to Section 300-0070,
Service Tools, for part numbers of general service
4. Place the battery master switch in the 'On' position, tools and adhesives required. These tools and
start the engine and apply the park/emergency brake adhesives are available from your dealer.
(push button in), to apply the service brakes. Monitor
the system pressure gauge. The brake actuating
pressure for the front brake circuit is 60 ± 5.1 bar
(870 ± 75 lbf/in²).

Note: When brakes are released, a residual pressure of

0.5 bar (7 lbf/in²) should remain.

5. Repeat steps 1 through 4 at the rear brake

diagnostic pressure point (point 4 on Figure 7), inside
the battery box.

SM 2486 Rev 4 04-10 7

Braking System - Treadle Valve
Section 250-0070

TREADLE VALVE TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE REMEDY

Brakes slow to apply No or improper accumulator Check accumulator pre-charge pressure.

pre-charge pressure Refer to Section 250-0060,
Accumulator
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
Brake Parts
Inoperative brakes Check brakes. Refer to Section 165-0010,
Brake Parts
Hydraulic lines/fittings leaking Check for leaks and repair
Damaged hydraulic brake lines Check lines for restrictions
Air in system Bleed air from system. Refer to Section
165-0010, Brake Parts
Brakes will not release Pedal angle out of adjustment Check for proper pedal angle
Inoperative brakes Check brakes. Refer to Section 165-0010,
Brake Parts
Inoperative treadle valve. Replace treadle valve
Binding spools (10 and 13),
damaged sleeves (9 and 12),
piston (24) binding
Insufficient brakes Low hydraulic oil level Top up hydraulic oil
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
Brake Parts
Oil or grease on brake pads Clean or replace brake pads. Refer to
Section 165-0010, Brake Parts
Hydraulic lines damaged Check hydraulic lines
No or improper accumulator Check accumulator pre-charge pressure.
pre-charge pressure Refer to Section 250-0060,
Accumulator
Inoperative brakes Check brakes. Refer to Section 165-0010,
Brake Parts
Inoperative treadle valve. Replace treadle valve
Broken spring (21). Boot (34)
cut, allowing dirt under piston
(24) flange.
Excessive braking Inoperative brakes Check brakes. Refer to Section 165-0010,
Brake Parts
Inoperative treadle valve. Replace treadle valve
Excessive shims (19) fitted

8 SM 2486 Rev 4 04-10

 Braking System - Treadle Valve
Section 250-0070

TREADLE VALVE TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE REMEDY

Brakes will not release Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
completely Brake Parts
Inoperative brakes Check brakes. Refer to Section 165-0010,
Brake Parts
Pedal angle out of adjustment Check for proper pedal angle
Air in system Bleed air from system. Refer to Section
165-0010, Brake Parts
Inoperative treadle valve. Replace treadle valve
Piston (24) sticking, spring
(7) broken
Back pressure on return line Remove restriction
excessive
No brakes No oil in hydraulic system Add oil to tank
Broken/damaged hydraulic line Replace broken/damaged line
Brakes not properly adjusted Adjust brakes. Refer to Section 165-0010,
Brake Parts
No accumulator Check accumulator pre-charge pressure.
pre-charge pressure Refer to Section 250-0060,
Accumulator
No pump pressure Check pump operation
Worn brakes Replace brake pads and discs
Inoperative treadle valve. Replace treadle valve
Piston (24) binding, broken
spring (21)
Pedal kickback when brakes Air in system Bleed air from system. Refer to Section
are applied 165-0010, Brake Parts

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 5 End Plug 1-7 10 - 60 lbf in
1 2 Nut 68 - 81 50 - 60
1 31 Screw 24 - 30 18 - 22

* * * *

SM 2486 Rev 4 04-10 9

Braking System - Treadle Valve
Section 250-0070

THIS PAGE IS INTENTIONALLY BLANK

10 SM 2486 Rev 4 04-10

 OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010

SM - 3571

11 20,21
12

13

19
14,18 13
12
11
20,21
15
3, 35, 36, 37
16
17
CAB -
R.H.S.
23, 24
LH 25, 26 RH
31
R H - HINGED LH
32 22
34
38 1 6
33 4

5 40
27
41
29
5 28
2 39
10
LH
29
39 39
39 9
30 7 8
RH 30

1 - Locating Pin 12 - Mirror - Exterior 22 - Storage Box 30 - Locknut

2 - Hinge Pin 13 - Mirror - Wide Angle 23 - Mat (front floor) 31 - Mud flap (cab RHS)
3 - Nut 14 - Ball 24 - Mat (left rear) 32 - Bolt
4 - Bushing 15 - Washer 25 - Mat (right rear) 33 - Bolt
5 - Spring Pin 16 - Spring 26 - Mat (under seat) 34 - Washer
6 - Bolt 17 - Locknut 24 - Cab Pin 35 - Heat Shield
7 - Cab Safety Prop 18 - Grease 25 - Bolt 36 - Bolt
8 - Pin Assembly (EMS19014) 26 - Locknut 37 - Washer
9 - Bolt 19 - Window Guard 27 - Support Block 38 - Lockwasher
10 - Nut 20 - Bolt 28 - Isolation Mount 39 - Washer
11 - Mirror Arm 21 - Washer 29 - Bolt

Fig. 1 - Cab and Mounting

DESCRIPTION The cab assembly can be tilted to improve accessibilty

Numbers in parentheses refer to Fig. 1. to components below the cab, including transmission
and main hydraulic valve. A hydraulic hand pump (1,
The cab is fully insulated and mounted on cab supports Fig. 2), located inside the battery box on the left hand
(23) to damp structure-borne noise and vibration. It side of the tractor frame and a cab raise cylinder (7,
conforms with ISO/SAE, ROPS (Roll Over Protective Fig. 2) are used to raise the cab.
Structure) and FOPS (Falling Object Protective
Structure) requirements as standard.
WARNING
ROPS - ISO 3471, SAE J1040 APR 88 Never operate the machine while the cab is
FOPS - ISO 3449, SAE J231 tilted. Always ensure the cab is fully lowered
and properly secured before operating the
machine.
WARNING
The protection offered by the roll over and Cab assembly is spacious and offers outstanding
falling object protective structure may be visibility through large areas of tinted safety glass.
impaired if it has been subjected to any Access to cab assembly is from the left hand side with
modification or damage. open tread steps, platform and handrail.

SM 2493 02-07 1
Operators Compartment - Cab and Mounting
Section 260-0010

SM - 2882

11
9

8 CAB BRACKET

10 5

13
3 9 12

6
BRACKET IN 11
1 BATTERY BOX
FRAME BRACKET
12 13

16
2

15
14

1 - Hand Pump 6 - Lever 11 - Bolt

2 - Hydraulic Tank 7 - Cab Raise Cylinder 12 - Washer
3 - Elbow 8 - Hose Assy 13 - Nut
4 - Flow Control Valve 9 - Elbow 14 - Bolt
5 - Adaptor 10 - Clamp 15 - Washer
16 - Nut
Fig. 2 - Cab Tilt Mechanism

The cab interior, trimmed with noise-absorbent

material, is extensively thermally insulated and a WARNINGS
heater/filter/pressurizer and demisting unit keeps To prevent personal injury and property
internal air fresh and dust free. Sliding windows provide damage, be sure wheel chocks, blocking
additional ventilation. Air conditioning is fitted as materials and lifting equipment are properly
standard. Refer to Section 260-0130, AIR secured and of adequate capacity to do the job
CONDITIONING. safely.
Note: Access from the cab, in the case of an emergency, Hydraulic fluid pressure will remain within
can be gained by breaking any of the windows using the the system after engine shutdown. Operate the
hammer provided (mounted on back pillar). brake pedal continuously until the pressure has
dissipated before disconnecting any hoses.
REMOVAL
1. Position the vehicle in a level work area, apply the
Numbers in parentheses refer to Fig. 1. parking brake and switch off the engine.
Note: Identify and tag all cables, harnesses, lines and 2. Operate the brake pedal continuously to relieve
linkages disconnected from cab assembly during pressure in the system.
removal to aid in installation.
3. Block all road wheels, place the battery master
switch in the 'Off' position and lift the hood assembly.

2 SM 2493 02-07
 Operators Compartment - Cab and Mounting
Section 260-0010
4. Disconnect the electrical cables in the following Disconnect earth strap at rear right hand cab support
order to prevent damage to the electrical components: (40).

a. Battery earth cable. 11. Lower cab safety prop (7) and place in the stowed
b. Battery supply cable. position, then using lifting equipment, slowly lower cab
c. Alternator earth cables. until horizontal.
d. Alternator supply cables.
e. Electrical harnesses at cab bulkhead. 12. Remove spring pins (5) to allow right hand pins (2)
to be driven out using a suitable driver.

WARNING 13. Check to make certain that all necessary

Before disconnecting any air conditioner lines, disconnections have been made, before lifting cab
refer to Section 260-0130, AIR CONDITIONING. assembly. Taking care to prevent damaging the
Refrigerant will rapidly freeze all objects with insulating material, lift cab assembly from the frame
which it comes into contact. It can cause and place on suitable stands.
serious and permanent damage to the eyes and
skin.
INSTALLATION
5. Evacuate the refrigerant from the air conditioning Numbers in parentheses refer to Fig. 1.
system and disconnect the lines. Refer to Section
260-0130, AIR CONDITIONING. Fit blanking caps to all Note: Tighten all fasteners without special torques
open lines and fittings. specified to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
6. Ensure heater lines are identified for ease of TORQUE SPECIFICATIONS.
installation and with suitable containers available to
catch leakage, disconnect heater lines. Fit blanking
caps to open line ends and fittings. WARNING
To prevent personal injury and property
7. Remove the front right hand tyre and rim assembly damage, be sure blocking materials and lifting
for access. Refer to Section 160-0050, WHEEL RIM equipment are properly secured and of
AND TYRE. adequate capacity to do the job safely.

1. Inspect cab supports (27 & 40) for damage and

WARNINGS replace if necessary.
To prevent damage, always ensure hood is
raised before tilting or lowering the cab. 2. Attach suitable slings to the cab lifting points and
raise and position cab on frame.
Never work near or under an unblocked
or unsupported cab. Always use the cab safety 3. Secure cab assembly to right hand cab supports
prop. (23) with pins (2) and spring pins (5), as shown in Fig.
1.
8. Tilt cab to allow access to steering valve below cab,
and secure with cab safety prop (7). Ensure lines are 4. Using lifting equipment, raise cab and secure cab
identified for ease of installation and with suitable raise cylinder (7, Fig. 2) to bracket on cab floor using
containers available to catch leakage, disconnect and bolt (11, Fig. 2), washer (12, Fig. 2) and nut (13, Fig.
remove steering valve hoses. Fit blanking caps to open 2). Secure cab in raised position with cab safety prop
line ends and fittings. (7).

9. Attach suitable slings to the cab lifting points and 5. Install and connect steering valve hoses as noted on
raise lifting equipment to take up the slack. Disconnect removal. Connect earth strap at rear right hand cab
cab raise cylinder (7, Fig. 2) from cab floor by removing support.
bolt (11, Fig. 2), washer (12, Fig. 2) and nut (13, Fig.
2). 6. Connect and secure any other harnesses and hoses
that were previously removed.
10. Tag and disconnect any other harnesses and
hoses that may be affected by cab removal. 7. Place cab safety prop (7) in the stowed position.

SM 2493 02-07 3
Operators Compartment - Cab and Mounting
Section 260-0010
Using hand pump (1, Fig. 2) to control lowering of cab, SM - 3572
gently lower cab until cab brackets align with cab
supports (40). Install pins (1) and secure with bushes
(4) and bolts (6).

8. Install front right hand tyre and rim assembly. Refer

to Section 160-0050, WHEEL RIM AND TYRE.

9. Secure the heater hoses to the front of the cab as

identified at removal.

10. Connect air conditioning lines and charge air 1

conditioning system. Refer to Section 260-0130, AIR
CONDITIONING.
3
11. Connect electrical harnesses at cab bulkhead as
identified at removal.

12. Connect cables to alternator (earth cable last).

13. Connect cables to battery terminal posts (earth

cable last). 2
14. Place the battery master switch in the 'On' position,
start the engine and check for leaks. Tighten fittings if
necessary. Allow engine to warm up and recheck all
1 - Cab Safety Prop 3 - Cab Raise Cylinder
connections for leaks. Ensure electrical systems and 2 - Cab Support
gear shift are functioning properly.
Fig. 3 - Cab Secured In Raised Position
15. Ensure parking brake is applied and remove wheel
blocks from all road wheels. 4. Insert lever (6), located in the battery box on the left
hand side of the tractor frame, into cab hand pump (1).

TILTING THE CAB 5. Using hand pump (1), charge the cab raise cylinder
Numbers in parentheses refer to Fig. 2, unless (7) sufficiently to allow left hand pins (1, Fig. 1) to be
otherwise stated. removed. Hold cylinder (7) in this position by locking
hand valve on hand pump (1).

WARNINGS 6. Remove bolts and bushes (6 & 4 Fig. 1), then drive
To prevent damage, always ensure hood is out pins (1, Fig. 1). Carefully raise or lower the cab as
raised before tilting or lowering the cab. necessary to facilitate removal of pins (1, Fig. 1).

Never work near or under an unblocked 7. Once pins (1, Fig. 1) have been safely removed,
or unsupported cab. Always use the cab safety continue to raise the cab using hand pump (1) until the
prop. cab safety prop (1, Fig. 3) can be fitted.

1. Position the vehicle in a level work area, apply the 8. Remove pin assembly (8, Fig. 1) to allow cab safety
parking brake and switch off the engine. prop (1, Fig. 3) to swing down to a vertical position on
top of the front left hand cab leg.
2. Operate the brake pedal continuously to relieve
pressure in the hydraulic system. 9. Lock the cab safety prop (1, Fig. 3) in position using
pin assembly (8, Fig. 1), locating through holes on
3. Block all road wheels, place the battery master bracket at front left hand cab leg.
switch in the 'Off' position and lift the hood assembly.
10. Lock off hand valve on hand pump (1). Remove

4 SM 2493 02-07
 Operators Compartment - Cab and Mounting
Section 260-0010
lever (6) from pump (1) and place in the stowed (17), hardened washers (15) and springs (16) securing
position. mirror arm assembly to mounting brackets.

2. Remove mirror arm bracket (11) and ball bearings

LOWERING THE CAB (14) from mounting brackets.
Numbers in parentheses refer to Fig. 2, unless
otherwise stated. 3. Repeat steps 1 and 2 for other mirror arm bracket
(11).

WARNINGS
To prevent damage, always ensure hood is MIRROR ARMS
raised before tilting or lowering the cab.
Installation
Never work near or under an unblocked Numbers in parentheses refer to Fig. 1.
or unsupported cab. Always use the cab safety
prop. Note: Tighten all fasteners without special torques
specified to standard torques listed in
1. Remove pin assembly (8, Fig. 1) from bracket at Section 300-0080, STANDARD BOLT AND NUT
front left hand cab leg. Place cab safety prop (1, Fig. 3) TORQUE SPECIFICATIONS.
in stowed position by locating pin assembly (8, Fig. 1)
in bracket under cab.
WARNING
2. Slowly open hand valve on hand pump (1) to allow To prevent personal injury and property
cab to gently lower. Rate of descent is controlled by damage, be sure blocking materials and lifting
the hand valve on pump (1). equipment are properly secured and of
adequate capacity to do the job safely.
3. Lower cab until holes in cab brackets line up with
holes in cab supports (2, Fig. 3). Hold cylinder (7) in 1. Coat ball bearings (14) with grease (18) and locate in
this position by locking hand valve on hand pump (1). mounting brackets.

4. Install pins (1, Fig. 1) through cab brackets and cab 2. Locate mirror arm bracket (11) to mounting brackets
supports (2, Fig. 3). Secure pins in position with bush and install hardened washers (15), springs (16) and
(4, Fig. 1) and bolts (6, Fig. 1). locknuts (17) as shown in Fig. 1.

5. Lower the hood and place the battery master switch 3. Set mirror bracket spring (16) pressure as follows;
in the 'On' position before closing the battery box. a. rotate mirror arm (11) until ball bearings (14) are
out of their detent.
6. Ensure parking brake is applied and remove wheel b. tighten locknut (17) until spring (16) is almost
blocks from all road wheels. completely compressed (typical two places).
c. swing arm until it seats in detent.
d. check the other two detent positions
MIRROR ARMS
4. Repeat steps 1, 2 and 3 for other mirror arm bracket
Removal (11).
Numbers in parentheses refer to Fig. 1.

REPLACING GLASS
WARNING Note: When replacing broken glass, it is the user’s
To prevent personal injury and property responsibility to ensure that the replacement glass
damage, be sure blocking materials and lifting meets the required specifications. Replacement glass
equipment are properly secured and of can be purchased from your dealer.
adequate capacity to do the job safely.
The rear glass, left and right hand side glasses and
1. Support mirror arm bracket (11) and remove locknuts front windscreen are held in place by a bonding
adhesive.
To replace a glass assembly, proceed as follows:

SM 2493 02-07 5
Operators Compartment - Cab and Mounting
Section 260-0010
the sealing adhesive to set properly.
Note: Ensure the glass is supported adequately before
starting to cut the adhesive seal. 9. Clean off any excess adhesive using a suitable
solvent.
1. Using a pointed tool, pierce a hole in the adhesive
seal, it is advisable to start at the top edge of the
glass. Unscrew one handle of the special tool and feed Water Leaks
the wire through the opening. Pierce a second hole in Test for leaks by directing a stream of water along the
the adhesive on the side directly opposite the first. adhesive seal, while an assistant marks the spot of
leakage inside the cab. Care should be taken to note
2. From inside the cab pull the wire through and feed it whether the leak is between adhesive and glass. Then
back out through the second hole. apply a sealing compound from the outside. Start from
a point near the leak and continue applying the sealer
3. Re-fit the handle on the special tool. Pull both until well beyond the suspected point of entry.
handles outwards until wire is taut.
This should stop the leak immediately, but since some
4. Manoeuvre the special tool around the edge of the sealing compounds should be allowed to set before
glass, keeping the wire taut, to cut the adhesive seal. getting wet, wait a few minutes before testing.
Ensure the glass is supported adequately before
completing the cut.
MAINTENANCE
5. Clean the remains of the adhesive from the edge of
the panel opening using a suitable solvent.
General
Ensure that hand pump hydraulic tank (2, Fig. 2) is
6. Coat the edge of the replacement glass with primer filled with clean hydraulic oil as specified in Section
and apply adhesive around the lip of the window 300-0020, LUBRICATION SYSTEM. Capacity is 0.75
aperture, as per the manufacturers recommendations. litre (0.2 US gallon).

7. Position glass onto panel opening, pressing firmly

so that adhesive bonds sufficiently to allow the glass
SERVICE TOOLS
to be moved or straightened up as required. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the glass removal tool, adhesive bonding
8. Ensuring the glass is adequately supported, allow kit and other general service tools required. These
tools are available from your dealer.

* * * *

6 SM 2493 02-07
 OPERATORS COMPARTMENT - Driver Seat and Mounting
Section 260-0090
SM - 2884

1 - Seat Assembly 12 - Armrest LH 23 - Air Hose

2 - Backrest Cushion 13 - Armrest RH 24 - Lever
3 - Seat Cushion 14 - Suspension Assembly 25 - Cable
4 - Seat Belt 15 - Shock Absorber 26 - Shock Absorber - Vertical
5 - Headrest 16 - Locking Lever Kit 27 - Suspension Kit - Upper
6 - Cover LH 17 - Cable Assembly 28 - Level Controller
7 - Cover RH 18 - Operation Unit 29 - Swing Arm
8 - Backrest 19 - Operation Unit Handle 30 - Air Spring
9 - Bushing 20 - Horizontal Isolator 31 - Wear Kit
10 - Seat Pan 21 - Compressor 32 - Bolt
11 - Adjustment Rails 22 - Connecting Cable 33 - Lock Washer

Fig. 1 - Exploded View of Driver Seat

DESCRIPTION pan (10). Seat pan (10) is attached to a cab seat base
by means of a suspension assembly (14). The air seat
Numbers in parentheses refer to Fig. 1.
only reacts when the driver sits on the seat. When
WARNING unoccupied, the seat sinks to the lowest position to
allow easier access.
By Law, seat belts must be provided. Always
wear seat belts when travelling in the vehicle.
A retractable seat belt (4) is secured to the seat
assembly using nuts and spacers. A push button
The seat assembly consists of a seat cushion (3) and
allows quick release of seat belt (4).
backrest cushion (2) mounted to backrest (8) and seat

SM 2210 4-03 1
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
SM - 2885 the seat position in now engaged properly.
34 - Bolt (x4)
35 - Washer (x4)
36 - Lock Washer (x4)
6 3. Pull up horizontal adjustment handle (2) and move
37 - Nut (x4) seat forwards or backwards, release handle when
required position is achieved.

4. Pull up (or push down) height and weight adjustment

(1) handle and hold until the require height position is
10 achieved, release handle - 'bounce' lightly until a 'click'
is heard, the seat position in now engaged properly.

5. Pull handle (8) to adjust seat cushion fore and aft

4
11 position. Hold and pull handle (8) until desired position
5
is achieved.
8
9 6. Pull handle (9) to adjust seat cushion rake angle,
7
2 hold and pull until desired angle is achieved. Ensure
34 cushion is locked into position. This procedure is better
1 3 35 performed when operator is off seat.
36
37 7. Pull up handle (5) and adjust backrest to the required
angle, release handle when required position is
Fig. 2 - Operator Seat Controls
achieved.
Numbers in parentheses refer to Fig. 2.
The following is the list of controls to adjust the seat: 8. Pull up (or push down) backrest (6) to the required
1. Height and weight adjustment. height.
2. Horizontal adjustment (sliderails).
3. Fore/aft isolator (forward position - unlocked, 9. Turn lumber support adjustment (10) until desired
rearmost position - locked). pressure if felt on operators back.
4. Seat belt.
5. Backrest angle adjustment. 10. Set damper adjustment (7) position to suit driving
6. Backrest height adjustment. conditions, (4 positions; forward position - hardest
7. Damper adjustment (4 positions; forward position - setting, rearmost position - softest setting).
hardest setting, rearmost position - softest setting).
8. Seat cushion - Fore/aft adjustment. 11. Set fore/aft isolator (3) position to suit driving
9. Seat cushion - Rake adjustment conditions, (forward position - unlocked, rearmost
10.Lumber support adjustment position - locked).
11.Armrest adjustment.
12. Turning armrest adjustment (11) alters the height of
armrests.
WARNING
Do not attempt to adjust the seat or seat belt 13. Engage seat belt (4).
while the machine is moving. Loss of control
may result. Stop the machine; apply the brakes; NOTE: All controls should be set to operators own
then adjust. personal comfort.

OPERATION REMOVAL
To achieve the most comfortable driving position, Numbers in parentheses refer to Fig. 2.
adjust the seat as follows;
WARNINGS
1. Sit in seat. To prevent personal injury and property
damage, be sure wheel chocks, blocking
2. Pull up and release height and weight adjustment (1) materials and lifting equipment are properly
handle - this will reset the seat to the predetermined secured and of adequate capacity to do the job
height setting - 'bounce' lightly until a 'click' is heard, safely.

2 SM 2210 4-03
 Operator's Compartment - Driver Seat and Mounting
Section 260-0090
1. Position the vehicle in a level work area, apply the Horizontal Shock Absorber
parking brake and switch off the engine.
Numbers in parentheses refer to Fig. 3.
2. Block all road wheels and place the battery master
Note: Remove seat assembly as described in
switch in the 'Off' position.
'Disassembly'
3. Disconnect harness connector at the rear of the
1. Remove pop-out buttons (1) and remove access
seat.
cover (2) to allow access to suspension assembly.
4. Push down height and weight adjustment (1) handle
2. Unclip hooked end of shock absorber (4) from
to release the air from the seat air suspension system.
horizontal spring assembly.
5. Remove bolts (34), washers (35), lock washers (36)
3. Remove circlip (3) and lever out shock absorber (4)
and nuts (37) securing complete seat assembly to the
from rocker shaft and slide off of mounting pin.
cab seat base. Remove seat assembly from vehicle
using suitable lifting equipment.
4. Remove spacer (5) from mounting pin.

DISASSEMBLY 5. Reassembly is done in the reverse order.

Numbers in parentheses refer to Fig. 1. SM - 2487

Note: The disassembly and assembly procedures will

cover only basic sub-assemblies due to the multitude
of parts. If a sub-assembly must be disassembled, use
the exploded view in Fig. 1 for reference.

1. Remove covers (6 & 7) from seat assembly.

Remove nuts and spacers securing lap belt (4) to seat
assembly. Remove lap belt (4).

2. Pull up and remove headrest (5) from seat frame (1).

3. Remove screws securing backrest cushion (2) to

seat frame (1). Remove backrest cushion (2).

4. Remove screws securing seat cushion (3) to seat

Fig. 3 - Exploded View of Horizontal Shock Absorber
frame (1). Remove seat cushion (3).
Vertical Shock Absorber
5. Pull up horizontal adjustment (2, Fig. 2.) lever and
slide seat assembly rearwards. Hold captive nuts using Numbers in parentheses refer to Fig. 4.
a suitable spanner and remove front allen screws.
Note: Remove seat assembly as described in
6. Pull up horizontal adjustment (2, Fig. 2.) lever and 'Disassembly'
slide seat assembly forwards. Hold captive nuts using
a suitable spanner and remove rear allen screws. 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly.
7. Remove seat assembly from suspension base.
2. Unhook Bowden wire (5) and damper adjuster (6)
assembly from the top of shock absorber (7).

3. Remove circlips (3) and lever out shock absorber (7)

from mounting pins (4).

4. Remove spacers (8) from lower mounting pin (4).

5. Reassembly is done in the reverse order.

SM 2210 4-03 3
Operator's Compartment - Driver Seat and Mounting
Section 260-0090
Note: Inscription must face upwards when assembling 3. Remove pressurised airline (5) from compressor (6).
shock absorber (7).
4. Identify and tag and disconnect electrical plug
SM - 2488 connections (7 & 8). Unfasten cable tie on the rocker.

5. Pull suspension assembly up to its highest position

and block securely.

6. Unscrew lower nut (9) and remove micro

encapsulated cylinder screw (10) and retaining clamp
(11).

7. Remove compressor (6) and felt mat (12) from

suspension base.

8. Reassembly is done in the reverse order.

Note: Replace micro encapsulated cylinder screw (10).

Note: Centralise compressor (6) and felt mat (12)

Fig. 4 - Exploded View of Vertical Shock Absorber
between rocker arms.

SM - 2489 SM - 2490

Fig. 5 - Exploded View of Compressor and Mounting Fig. 6- Exploded View of Level Controller and Mounting

Compressor Level Controller

Numbers in parentheses refer to Fig. 5. Numbers in parentheses refer to Fig. 6.

Note: Remove seat assembly as described in Note: Remove seat assembly as described in
'Disassembly' 'Disassembly'

1. Remove pop-out buttons (1) and remove access 1. Remove pop-out buttons (1) and remove access
cover (2) to allow access to suspension assembly. cover (2) to allow access to suspension assembly.

2. Remove pop-out buttons (3) and push down 2. Remove pop-out buttons (3) and push down
suspension skirt (4) to allow further access to suspension skirt (4) to allow further access to
suspension assembly. suspension assembly.

4 SM 2210 4-03
 Operator's Compartment - Driver Seat and Mounting
Section 260-0090
3. Pull suspension assembly up to its highest position slide seat assembly rearwards. Hold captive nuts using
and block securely. a suitable spanner and install front allen screws.
Tighten allen screws to a torque of 25 Nm (18 lbf ft).
4. Unhook bowden wires (5 & 6) from level controller (7).
3. Install seat cushion (3) to seat frame (1) and secure
5. Identify and tag and disconnect electrical plug using screws.
connections (8 & 9).
4. Install backrest cushion (2) to seat frame (1) and
6. Identify and tag and disconnect pressurised airlines secure using screws.
(10) from air suspension unit (11). Unfasten cable tie on
the rocker. 5. Refit headrest (5) to seat frame (1).

7. Remove screw (12), push out pin (13) and release 6. Position lap belt (4) to seat assembly and secure
roll up belt (17). using nuts and spacers as removed at 'Disassembly'.
Tighten nuts to a torque of 50 Nm (36 lbf ft). Refit
8. Remove nuts (14) and manoeuvre level controller (7) covers (6 & 7).
until studs are free from mounting holes.

9. Remove screws (15) and remove bowden wire (16) INSTALLATION

retainer from level controller (7). Numbers in parentheses refer to Fig. 2.

10. Remove level controller (7) from suspension base. Note: Tighten all fasteners without special torques
specified to torques listed in Section 300-0080,
11. Reassembly is done in the reverse order. STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Note: Tighten nuts (14) to a torque of 25 Nm (18 lbf ft).

WARNINGS
INSPECTION To prevent personal injury and property
Numbers in parentheses refer to Fig. 1. damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
1. Inspect air lines, shock absorbers (15 & 26), secured and of adequate capacity to do the job
compressor (21), level controller (28) and air spring safely.
(30) for leaks and damage and replace if required.

2. Check all brackets and frame for cracks and/or 1. Using suitable lifting equipment, position seat
damage. Repair or replace as necessary. assembly on the cab seat base and secure using bolts
(34), washers (35), nuts (37) and lock washers (36).
3. Check springs for fatigue or damage and replace as
required. 2. Reconnect harness at the rear of the seat.

3. Place battery master switch in the 'On' position, start

ASSEMBLY the engine and charge the air system. Check seat for
Numbers in parentheses refer to Fig. 1. proper operation, refer to 'Operation'.

Note: Tighten all fasteners without special torques 4. Remove wheel chocks from road wheels.
specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.

1. Position seat assembly onto suspension base. Hold

captive nuts using a suitable spanner and install rear
allen screws. Tighten allen screws to a torque of 25
Nm (18 lbf ft).

2. Pull up horizontal adjustment (2, Fig. 2) lever and

SM 2210 4-03 5
Operator's Compartment - Driver Seat and Mounting
Section 260-0090

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 # Nut 50 36
1 # Allen Screw 25 18
5 14 Nut 25 18

MAINTENANCE
Numbers in parentheses refer to Fig. 1.

The care of the upholstery on seat cushion (3) and

backrest cushion (2) is a relatively simple, but
important matter. Accumulation of dirt on the surface
eventually turns into a hard gritty substance which cuts
into the surface of the upholstery.

To clean seat cushion (3) and backrest cushion (2),

use warm water and a mild soap, such as Castile.
Work up thin soap suds on a piece of soft cloth and
rub the upholstery briskly. Remove the suds with a
damp cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.

Lap belt (4) assembly should be inspected by the user

on a regular basis. Replace lap belt (9) immediately if
hardware is worn or damage, straps are nicked or
frayed, buckle is not functioning correctly, loose
stitching is found, or if the strap material has lost
strength due to the effects of ultraviolet rays.

Note: Regardless of appearance, lap belt (4) must be

removed and replaced at least once every three years.

* * * *

6 SM 2210 4-03
 OPERATOR'S COMPARTMENT - Instructor Seat and Mounting
Section 260-0110

SM3903

4
5
3 1

1 - Instructor Seat Assembly

2 - Seat Belt
3 - Bolt
4 - Washer
5 - Lockwasher

Fig. 1 - Exploded View of Instructor Seat

DESCRIPTION electrical harnesses, the transmission ECU, the

Hydraulic ECU, the wash/wipe relay, the CPU and the
Numbers in parentheses refer to Figure 1. busbar assembly, all of which are described elsewhere.
Access to the equipment below the seat requires
pivoting of the base cushion into a vertical attitude,
WARNING then securing it to the back rest by means of the strap
By Law, seat belts must be provided. Always provided, as shown on steps 1 and 2 on Figure 2
wear seat belts when travelling in the vehicle. below. The back rest can be pivoted to the horizontal
position when not in use, by first unlocking the release
The instructor seat is located adjacent to the left-hand catch on the right-hand side, then rotating it down as
side of the driver's seat, and is secured to tapped shown on steps 3 and 4 of Figure 2.
bosses on the rear wall of the cab with bolts (3),
washers (4) and lockwashers (5). The seat assembly The diagnostic interface socket and the hood control
(1) comprises a seat cushion and back cushion switch are both fitted adjacent to the right-hand side of
mounted to a seat frame. Seat frame (2) is attached to the instructor seat.
seat base (8) by means of a hinge (9) at the front end
and locked at the rear by a spring loaded latch A retractable lap seat belt (2) is secured to drilled lugs
arrangement. Located below the seat base is a storage on the rear wall of the cab. A release button allows
box, below which is a cavity containing a number of quick release of the seat belt (2).

SM3904

1 2 3 4

Fig. 2 - Instructor Seat, Hinged Back and Base Operations

SM2572 04-08 1
Operator's Compartment - Instructor Seat and Mounting
Section 260-0110
h. Disconnect the body control lever
REMOVAL AND DISASSEMBLY
i. Disconnect the Hydraulic ECU
Numbers in parentheses refer to Figure 1. j. Disconnect the instrument panel (VDU) ECU.

WARNINGS
To prevent personal injury and property ASSEMBLY AND INSTALLATION
damage, be sure wheel chocks, blocking Numbers in parentheses refer to Figure 1.
materials and lifting equipment are properly
secured and of adequate capacity to perform the Note: Tighten all fasteners without special torques
task safely. specified to torques listed in Section 300-0080,
Standard Bolt and Nut Torque Specifications.
WARNINGS
High electrical current. Turn the ignition key 1. Carry out the procedures itemized below in the order
switch 'Off' before disconnecting any electrical given to prevent damage to the electrical components.
components. Disconnect electrical connections
in the correct order given to prevent damage to a. Connect the instrument panel (VDU) ECU
the electrical components. b. Connect the Hydraulic ECU
c. Connect the body control lever
1. Position the vehicle in a level work area, apply the d. Connect the Transmission TCM
parking brake and shut down the engine. e. Connect the electrical connections at the engine
ECM
2. Turn the steering wheel in both directions several f. Connect the alternator supply cable
times to relieve any pressure in the steering system. g. Connect the alternator earth cable
Block all road wheels. h. Connect the battery supply cable
i. Connect the battery earth cable
3. Pivot the base cushion to the vetical position, then j. Switch on the battery master switch.
secure it to the back rest using the strap provided, thus
allowing access to the seat mounting hardware. 2. Position the instructor seat assembly (1) against the
internal rear wall of the cab, correctly orientated such
4. Undo and remove the bolts (3), lockwashers (5) and that the three holes in the rear of the seat frame align
washers (4) securing the seat assembly to the rear wall with the tapped holes in the bosses of the rear cab
of the cab. wall.

5. Lift the entire seat assembly (1) out of the cab and 3. Secure the instructor seat to the rear wall of the cab
remove it to a prepared area. using the bolts (3), lockwashers (5) and washers (4),
tightened evenly and securely.
6. If access is required to the electrical equipment in
the space underneath the seat mounting position, firstly 4. Support the base cushion, then undo the strap
undo and remove the screws securing the storage box, holding it in a vertical attitude. Carefully pivot the base
then remove the storage box and the screws to a cushion to the horizontal position.
prepared area.
5. Remove the wheel chocks from the road wheels.
7. Before working on any of the electrical items beneath
the instructor seat, carry out the procedures itemized
below in the order given to prevent damage to the
electrical components.

a. Turn off the battery master switch

b. Disconnect the battery earth cable
c. Disconnect the battery supply cable
d. Disconnect the alternator earth cable
e. Disconnect the alternator supply cable
f. Disconnect the electrical connections at the engine
ECM
g. Disconnect the Transmission TCM

2 SM2572 04-08
 Operator's Compartment - Instructor Seat and Mounting
Section 260-0110

MAINTENANCE strap material has lost strength due to the effects of

Numbers in parentheses refer to Fig. 1. ultraviolet rays.

The care of the upholstery on the base cushion and Note: Regardless of appearance, the seat belt (2) must
back rest is relatively simple, but an important matter. be removed and replaced at least once every three
Accumulation of dirt on the surface eventually turns years.
into a hard gritty substance which cuts into the surface
of the upholstery.

To clean the base cushion and back rest, use warm

water and a mild soap, such as Castile. Work up thin
soap suds on a piece of soft cloth and rub the
upholstery briskly. Remove the suds with a damp
cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.

The seat belt (2) assembly should be inspected by the

user on a regular basis. Replace the seat belt (2)
immediately if the hardware is worn or damage, straps
are nicked or frayed, release mechanism is not
functioning correctly, loose stitching is found, or if the

* * * *

SM2572 04-08 3
Operator's Compartment - Instructor Seat and Mounting
Section 260-0110

THIS PAGE IS INTENTIONALLY BLANK

4 SM2572 04-08
 OPERATORS COMPARTMENT - Air Conditioning
Section 260-0130

SM - 2430

1 3 IN
D

S OUT

4
5

1 - Compressor 3 - Receiver Drier 5 - Evaporator

2 - Condenser 4 - Expansion Valve

Fig. 1 - Typical Air Conditioning Flow Diagram

DESCRIPTION Compressor Drive Clutch

The R-134a compressor systems use an electronically
Temperature Control Switch actuated clutch to engage and disengage drive to the
A thermostat switch senses the temperature of the compressor. The drive belt pulley is mounted on a bearing
evaporator and engages or disengages the and is free to rotate without turning the compressor
compressor clutch. The control for this switch is crankshaft any time electrical power is disconnected. The
located in the cab. compressor is not operating when the pulley is
freewheeling. The field coil is energized by supplying
electrical current to the exposed wire. The other end of the
Compressor coil winding is grounded to the compressor and equipment
The compressor is designed to compress vapour and frame. Energizing the coil creates a magnetic force that
can be damaged by non-compressibles such as dirt, locks the driven disk to the pulley and drives the
moisture, liquid refrigerant (R-134a), etc. The compressor.
compressor draws vaporized R-134a from the
evaporator (which maintains the low pressure
necessary for proper evaporation) and compresses Condenser
the vapour to a high pressure, which is necessary for The purpose of the condenser is to radiate enough heat
condensation. The high pressure vapour then moves energy from the compressed high pressure vaporized
into the condenser where heat can be radiated to R-134a so that the R-134a changes from vapour to
change the R-134a back to liquid. liquid. During normal operation all the high pressure
section of the system will be warm or hot, but large
Note: R-134a designates the type of refrigerant used quantities of heat should be radiating from the
in heavy duty vehicle air conditioning systems. condenser. Nothing should be permitted to stop or slow
SM 2211 Rev1 10-04 1
Operators Compartment - Air Conditioning
Section 260-0130
down this radiation of heat. Cooling fins are located on Thermostatic Expansion Valve
the condenser tubes and fans are used to circulate
An expansion valve is installed in the system to lower
cool air around the condenser tubes. Keep all leaves,
the pressure before the R-134a enters the
paper, dirt, etc. clear from the condenser and
evaporator. The reduction in pressure is done by
condenser filter. The cooling fins should be straight to
passing the R-134a through a small hole (orifice).
permit free flow of air. The condenser is sometimes
The size of the orifice must be controlled to
located ahead of the engine radiator and blockage of air
compensate for changes in pressure and
flow through the radiator also affects the condenser.
temperature. The temperature of R-134a leaving the
Bent fan blades, slipping fan drive, inoperable
evaporator is sensed by a thermostatic sensor that
condenser fan motors, or any other fault that lessens
moves the valve seat via a diaphragm and actuating
the amount of cool air circulated through the
pin.
condenser, should be corrected. The oil, dirt, or
antifreeze will act as an insulator that will inhibit the
radiation of heat. Evaporator - Heat/Cool
The evaporator is the low pressure, low temperature
Since the purpose of the condenser is to radiate heat
component where liquid R-134a absorbs heat from
energy, anything that prevents or inhibits this action
surrounding air. The expansion valve bleeds high
may affect cooling, but the temperature and pressure
pressure R-134a into the low pressure evaporator.
of the R-134a raise and lower together. Heat energy
The R-134a expands rapidly in the evaporator and its
that has not been radiated will remain in the R-134a
temperature is quickly reduced. The R-134a absorbs
and the result will be pressure that is too high. The
heat from the air when the blower fan circulates air
condenser, hoses, connections and seals can be
over the evaporator coil fins. The exchange of heat
damaged by the high pressure. Pressure sensing
from the air to the R-134a depends upon the
safety switches may be activated by the high
difference in temperature. During high heat load, such
pressure caused by the condenser not radiating
as usually encountered when the system is first
enough heat.
turned on, the temperature difference is great and the
R-134a will absorb heat quickly. The blower fan can
Receiver Drier be set at its highest setting to circulate large
quantities of warm air around the evaporator. After
The high pressure liquid R-134a moves from the
the cab has cooled, the fan speed should be reduced
condenser to the receiver drier, where the R-134a is
so that the already cool air will have a longer time to
stored and filtered. Moisture is the major enemy of
yield heat to the R-134a as it passes the evaporator
the air conditioning system and the desiccant inside
coils. The heater circuits utilize engine coolant at
the receiver drier will absorb only a small amount.
approximately 82° C (180° F).
The container of desiccant inside the receiver drier
may break open and contaminate the system if any
attempt is made to dry the desiccant, or, if more High Pressure and Low Pressure Switches
moisture is inside the system than the desiccant can
The pressure switches are electric switches that
absorb.
monitor air conditioner operation. The high pressure
and low pressure switches are activated at preset
Every effort should be made to remove all moisture
pressures and engage and disengage the compressor
from the system and install a new receiver drier if its
clutch.
condition is questionable. Installation of a new
receiver drier is recommended each time any part of
the R-134a system is open to the atmosphere.
Bubbles are observed in the sight glass on top of the
receiver drier during the charging procedure.

A filter screen is located in the receiver drier to stop

solid contaminates from leaving the unit. Blockage of
the filter will result in a drop in pressure that will be
indicated by a drop in temperature. Connections of
the new receiver drier should be securely capped
before installation to prevent the entrance of moisture
(air) while in storage.

2 SM 2211 Rev1 10-04

 Operators Compartment - Air Conditioning
Section 260-0130

REMOVAL 5. When satisfied that the system is completely

discharged, tag refrigerant hoses (8 & 9) to aid in
Numbers in parentheses refer to Fig. 2, unless
installation and carefully disconnect hoses from cab
otherwise stated.
firewall. Cap fittings at front of cab and refrigerant
hoses (8 & 9) to prevent foreign matter from entering
the system.
WARNINGS
Always wear goggles or glasses to protect your
6. Remove fasteners securing front cover (36, Fig. 3)
eyes when working around R-134a.
and end plate (19, Fig. 3) to main weldment (18, Fig.
R-134a boils at sea level temperatures of
3).
-29.8° C (-21.6° F), which means that direct
contact with your skin will produce frostbite.
7. Remove heater hoses from front of cab, which
Exercise extreme care when handling R-134a. If
connect to water inlet hose (24, Fig. 3) and water outlet
R-134a contacts your skin, wash immediately
hose (23, Fig. 3). Cap open ports and hoses to prevent
with plenty of warm water. Remove any
foreign matter from entering the system.
contaminated clothing with caution as it may
adhere to the skin. If blistering or continued
8. Unhook control assembly cable (40, Fig. 3) at main
irritation occurs obtain immediate medical
weldment (18, Fig. 3).
attention.
9. If necessary to remove main weldment (18, Fig. 3)
If you get the slightest trace of R-134a in
from cab, be sure to disconnect any remaining
your eye, flood the eye immediately with cool
harnesses, hoses or ducting before withdrawing main
water; then treat with mineral oil or clear
weldment (18, Fig. 3) from cab.
petroleum jelly followed by boric acid rinse.
Report to a hospital or doctor as soon as
Note: The blower assembly mounting (35, Fig. 3),
possible.
thermostat (21, Fig. 3) and heat exchangers (31,32,
Fig. 3) can be accessed without removing the main
The chemicals of R-134a when burned
produce gases that will damage the respiratory weldment (18, Fig. 3) from cab.
system if inhaled. NEVER SMOKE in an area
where R-134a is used or stored. Use hot water 10. Tag refrigerant hoses (7 & 8) to aid in installation
or an approved heated charge cylinder as a heat and carefully disconnect hoses from receiver/drier (4).
source if required to force R-134a into the Cap receiver/drier (4) fittings and refrigerant hoses (7 &
system. If using water, do not exceed 52° C 8) to prevent foreign matter from entering the system.
(125° F). Never use direct flame or electric
heaters in direct contact with the R-134a 11. Support receiver/drier (4) and remove clamps
container. High temperatures may result in securing receiver/drier (4) to mounting bracket (14).
raising the pressure to a dangerous level.
12. Tag refrigerant hoses (6 & 7) to aid in installation
and carefully disconnect hoses at condenser (5). Cap
To prevent personal injury and property
condenser (5) fittings and refrigerant hoses to prevent
damage, be sure wheel blocks, blocking
ingress of foreign matter.
materials and lifting equipment are properly
secured and of adequate capacity to do the job
13. If required, support air conditioner condenser (5)
safely.
and remove bolts (15), lockwashers (16) and washers
(17) securing condenser (5) to radiator assembly.
1. Position the vehicle in a level work area, apply the
Remove condenser (5) from vehicle.
parking brake and switch off the engine.
14. Tag refrigerant hoses (6 & 9) to aid in installation
2. Block all road wheels and place the battery master
and carefully disconnect hoses from compressor (1).
switch in the 'Off' position.
Cap compressor (1) fittings and refrigerant hoses (6 &
9) to prevent foreign matter from entering the system.
3. Pull on handle (inside battery box) to release hood
catch and raise the hood.
15. Disconnect electrical connection from
compressor (1) clutch.
4. Discharge the air conditioning system as described
under 'Discharging The System'.

SM 2211 Rev1 10-04 3

Operators Compartment - Air Conditioning
Section 260-0130

SM - 2886

10
CAB 9
FIREWALL

12

11
12
1

26
5 8 6 26
25

11 27 20
3 22
26 23
24
21
28
18
2 13
19
10
10 10
7

17
16 4
15 14

1 - Compressor 8 - Refrigerant Hose 15 - Bolt 22 - Washer

2 - Compressor Bracket 9 - Refrigerant Hose 16 - Lockwasher 23 - Lockwasher
3 - Drive Belt 10 - 'O' Ring 17 - Washer 24 - Bolt
4 - Receiver/Drier 11 - 'O' Ring 18 - Lockwasher 25 - Bolt
5 - Condenser 12 - 'O' Ring 19 - Adjuster Bracket 26 - Washer
6 - Refrigerant Hose 13 - Washer 20 - Bolt 27 - Nut
7 - Refrigerant Hose 14 - Bracket 21 - Nut 28 - Bolt

Fig. 2 - Air Conditioner Lines and Mounting

16. Slacken nut (21) and bolt (20). Adjust bolt (20) to fan guard assembly to radiator assembly. Refer to
release tension on drive belt (3). Section 210-0040, RADIATOR AND MOUNTING.

17. Drive belt (3) should now be free to slide off the 20. If required, remove bolts (28), lockwashers (18),
groove in compressor (1). washers (13) and bracket (2) from engine.

18. Support compressor (1) and remove bolts (25), 21. If required, remove bolts (24), lockwashers (23),
washers (26) and nuts (27) securing compressor (1) to washers (22) and bracket (19).
bracket (2). Remove compressor (1) from the vehicle.
Note: If fitted, coolant filter will have to be removed.
Note: If drive belt (3) does not require replacement do
not remove from engine pulley. If drive belt (3) requires 22. If required, disconnect all clamps and clips
replacement, proceed with steps 19 and 20. securing refrigerant hoses and harnesses to the
vehicle. Remove hoses and harnesses from the
19. If required, remove mounting hardware securing vehicle.
4 SM 2211 Rev1 10-04
 Operators Compartment - Air Conditioning
Section 260-0130

SM - 3318

Fig. 3 - Air Conditioner Lines and Mounting

SM 2211 Rev1 10-04 5

Operators Compartment - Air Conditioning
Section 260-0130

LEGEND FOR FIG. 3

1 - Heater/Air-Con Assy 13 - Nut Insert 25 - Water Valve Assy 37 - Recirculation Filter
2 - Grommet 14 - Allen Screw 26 - Jubilee Clip 38 - Coil Seal
3 - Seal 15 - Allen Screw 27 - Demist Flap Assy 39 - Coil Seal
4 - Grommet 16 - Clamp Plate 28 - Cable Bracket 40 - Control Assy Cable
5 - Screw 17 - Clamp Plate 29 - Pivot Bracket 41 - Louver
6 - Grommet 18 - Main Weldment 30 - Fresh Air Flap Assy 42 - Drain Tube Assy
7 - 'O' Ring 19 - End Plate 31 - Evaporator 43 - Control Knob
8 - 'O' Ring 20 - Valve 32 - Heater Coil 44 - Potentiometer Assy
9 - Control Arm 21 - Thermostat 33 - Manifold 45 - Air Con Switch
10 - Control Arm 22 - Water Outlet Pipe 34 - Manifold 46 - Fan Speed Switch
11 - Nut Insert 23 - Water Outlet Hose 35 - Blower Assy Mounting 47 - Control Panel
12 - Binary Switch 24 - Water Inlet Hose 36 - Front Panel Assy

INSTALLATION 7. If removed, install receiver/drier (4) to mounting

Numbers in parentheses refer to Fig. 2, unless bracket (14) and secure with clamps.
otherwise stated.
8. Remove caps from end of refrigerant hoses (7 & 8)
Note: Tighten all fasteners to standard torques and ports on receiver/drier (4) and connect hoses to
specified in Section 300-0080, STANDARD BOLT AND ports as tagged at removal.
NUT TORQUE SPECIFICATIONS.
9. If removed, install condenser (5) to radiator
Note: Renew all 'O' rings where necessary (10, 11 & assembly and secure with bolts (15), lockwashers (16)
12). and washers (17).

10. Remove caps and connect refrigerant hoses

WARNING (6 & 7) to condenser (5) ports as tagged at removal.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 11. If removed, install bracket (19) to engine and
materials and lifting equipment are properly secure with bolts (24), lockwashers (23) and washers
secured and of adequate capacity to do the job (22). If applicable, install coolant filter to bracket (19).
safely.
12. If removed, install compressor bracket (2) to
1. If main weldment (18, Fig. 3) was removed, install in engine and secure using bolts (28), lockwashers (18)
cab and reconnect harnesses, hoses and air ducting as and washers (13) as shown in Fig. 2.
noted during removal.
13. Fit compressor (1) to compressor bracket (2) and
2. Attach control assembly cable (40, Fig. 3) as noted secure with bolts (25), washers (26) and locknuts (27).
during removal. Do not fully tighten at this stage.

3. Reconnect heater hoses to front of cab and connect Note: If fan guard and compressor drive belt (3) were
to water inlet hose (24, Fig. 3) and water outlet hose removed, proceed with steps 14 & 15.
(23, Fig. 3), as identified at removal.
14. Install new drive belt (3) onto engine pulley and fit
4. Once all necessary connections have been made, to groove on compressor (1).
secure front cover (36, Fig. 3) and end plate (19, Fig. 3)
to main weldment (18, Fig. 3) using fasteners 15. Adjust tension of compressor drive belt with nut
previously removed. (21) on adjuster bolt (20) until there is approximately an
inward deflection of 10 mm (0.4 in) at the centre of
5. Remove caps from end of refrigerant hoses (8 & 9) drive belt (3). Fully tighten all mounting hardware.
and ports at front of cab and connect hoses to ports as
tagged at removal. 16. Remove caps from end of refrigerant hoses (6 & 9)
and ports on compressor (1) and connect hoses to
6. Route refrigerant hoses (8 & 9) along the LH side of ports as tagged at removal.
the engine securing with clamps removed during
removal. 17. Connect electrical connection to compressor (1)
clutch.

6 SM 2211 Rev1 10-04

 Operators Compartment - Air Conditioning
Section 260-0130
18. Secure all lines with clips and clamps as removed 2. If the system has a heater in the same location as
during removal. Ensure no lines are chaffing on sharp the air conditioning evaporator core, heater valves
edges or resting against areas where heat will be should be closed.
evident.
3. To check the refrigerant level, run the engine at
19. Charge the air conditioning system as described 1 200 rev/min with fans on high speed and thermostat
under 'Charging Procedure'. fully open for a minimum of five minutes. If the clutch
is engaged in this situation, there should be very few
20. Switch the battery master switch to the 'On' bubbles visible in the receiver-drier sight glass.
position, start up the engine and check for correct
operation of the air conditioning system. Note: Unit can operate with some bubbles visible, but
not milky looking.
21. Lower hood and remove wheel blocks from all road
wheels. 4. Ensure all hoses and hose clamps are free from
contact with sharp metal, moving parts or near to
manifolds.
MAINTENANCE
5. Inspect condensation drain lines for debris, sharp
bends or breaks.
WARNINGS
Always wear goggles or glasses to protect your 6. Inspect the clutch wire from the thermostat for bare
eyes when working around R-134a. R-134a boils spots.
at sea level temperatures of -29.8° C (-21.6° F),
which means that direct contact with your skin 7. Inspect bolts and nuts on the compressor and
will produce frostbite. Exercise extreme care mounting bracket for proper tightness.
when handling R-134a. If R-134a contacts your
skin, wash immediately with plenty of warm 8. Check for any air blockages within the system.
water. Remove any contaminated clothing with Clean recirculation filter periodically, by shaking off
caution as it may adhere to the skin. If dust or by washing in soapy water.
blistering or continued irritation occurs obtain
immediate medical attention. 9. If the refrigerant system is broken into following gas
loss due to mechanical damage or there is any other
If you get the slightest trace of R-134a in reason to suspect foreign material ingress, then the
your eye, flood the eye immediately with cool receiver/drier should be replaced.
water; then treat with mineral oil or clear
petroleum jelly followed by boric acid rinse. 10. Every 4 000 hours, drain, flush and refill the
Report to a hospital or doctor as soon as compressor with refrigerant oil specified in Section 300-
possible. 0020, LUBRICATION SYSTEM. Also see 'Refrigerant
Oil'.
The chemicals of R-134a when burned
produce gases that will damage the respiratory
system if inhaled. NEVER SMOKE in an area Maintenance of drive belts
where R-134a is used or stored. Use hot water 1. Listen for 'ticking' sound - they mean interference
or an approved heated charge cylinder as a heat with the belts. Visually inspect for bent or damaged
source if required to force R-134a into the belt guards.
system. If using water, do not exceed 52° C
(125° F). Never use direct flame or electric 2. Replace all belts in a mismatched set at one time
heaters in direct contact with the R-134a to ensure even load distribution.
container. High temperatures may result in
raising the pressure to a dangerous level. 3. Periodically check tension and keep belts tight.

1. Periodically clean the condenser coil of debris and - The ideal tension is the lowest tension at which the
dirt using water or air pressure. A partially blocked belt will not slip under peak load conditions.
condenser coil can reduce the life of the compressor - Check belt tension frequently during the first 24 - 48
belt and/or clutch. hours of run-in operation.
- Initial belt tension should be 533 N (120 lbf)

SM 2211 Rev1 10-04 7

Operators Compartment - Air Conditioning
Section 260-0130
dropping to 422 N (95 lbf) after the first 48 hours. If any component is replaced the following amount of
- There should be a freeplay of 10 mm in the belt. oil should be added to the system;
- Do not over tension belts.
- Keep belts free from foreign material that may Condenser add 1 fl oz (28.4 ml)
cause slippage. Drier add 1 fl oz (28.4 ml)
- Inspect the drive periodically. Re-tension belts if Evaporator add 3 fl oz (85.2 ml)
they are slipping. Compressor add 4.4 fl oz (125 ml)
- Maintain sheave alignment with a strong straight
edge tool while tensioning belts. The oil should be added to the oil filling port of the
compressor before the evacuation procedure is started
4. Never attempt to correct belt slippage by using a or by using an oil injector when the system is being
belt dressing. The dressing may cause softening and charged, observing the following good practises:
deterioration.
a. Only pour the amount required from the container
5. If belt slips, even when properly tensioned, check for straight into a CLEAN measuring jug and
overload, worn sheave grooves or oil or grease on the immediately pour the oil into the compressor.
belts. b. Re-cap container tightly as soon as the required
amount has been taken (never leave an oil container
6. Never pry a drive belt or force it into the sheave open).
groove. Loosen the drive belt tightener prior to c. Do not mix different oils.
installation.
Only new oil should be used, because oil that has
7. A belt that has operated while rolled over in the been exposed to the air will have absorbed water
sheave groove may be damaged - replace it. (hygroscopic).

8. Store belts in a cool, dry place. If stored on a Use only refrigerant oil as specified in Section
machine, relieve all belt tension by loosening the 300-0020, LUBRICATION SYSTEM.
drive belt tightener.

9. Never attempt to check or adjust belts while they are System Leak Testing
running. Recommended Equipment Required:
Electronic Leak Detector

Refrigerant Oil Switch off the engine and check all connections
throughout the system for leaks. A large leak point will
have an oily or greasy appearance. The refrigerant
WARNINGS carries compressor oil with it and deposits it around the
To prevent personal injury always wear rubber leak area. Check all such points for loose connections
gloves when handling refrigerant oils. and tighten.

Too much refrigerant oil will dampen the Using a suitable leak detector, search for leaks around
cooling effect and too little refrigerant oil may all joints, connections, seals and control devices. If a
lead to compressor failure. If in doubt flush leak is located, purge the system of refrigerant and
the system. repair. Fully evacuate and charge the system to make
it operational.
Oil is required to lubricate the compressor. The oil
mixes with the refrigerant and is carried around the
system. The compressor is supplied with an oil DISCHARGING THE SYSTEM
charge. However, additional oil is required, the Note: Refer to all WARNINGS listed under
amount depending on the length of refrigerant hose 'Maintenance' prior to discharging the system.
being used. The quantity added should be calculated
using the following equation: Recommended Equipment Required:
Portable High Vacuum Charging Station
Amount of oil to add in fl oz. = Suitable Canister
(0.47 x total length of hoses in m) - 2.15 or Standard Service Manifold (Refer to Fig. 4)

8 SM 2211 Rev1 10-04

 Operators Compartment - Air Conditioning
Section 260-0130
To eliminate system contaminants from an air 9. After 10 - 15 minutes close vacuum pressure valve
conditioning system requires discharging the entire (1) and allow the system to settle, vacuum gauge (A)
system. This means removing all of the refrigerant should not alter. If the vacuum is held, no leaks or
and cleansing all contamination (air and moisture) from refrigerant contaminated oil is present. If not, open the
the system components. If any of the major system vacuum pressure valve (1) and continue pumping,
components are to be repaired or replaced, the system checking at regular intervals. If there is a leak, check
must also be completely discharged. all fittings and tighten if necessary.

10. Tighten down (turn clockwise) both high and low

WARNING side valves on the gauge manifold to the closed
The vehicle must not be running during this position, remove the service hose (yellow) from the
procedure. Be sure to have adequate ventilation vacuum connection (6) on vacuum pump and switch
during this operation. Do not discharge the pump 'Off'.
refrigerant near an open flame.
11. Connect the service hose (yellow) to the R-134a
Numbers and letters in parentheses refer to Fig. 4. cylinder. Open the cylinder valve and then purge air
from the hose at the manifold connection.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. 12. Open the low side hand valve on the manifold
slowly, until low pressure gauge (B) is at bottle
2. Block all road wheels and place the battery master pressure. Watch the high side manifold gauge (C) rise
switch in the 'Off' position. to ensure that no blockage is present. Close the
manifold valve and cylinder, then disconnect the hose
3. Pull on handle to release hood catch and raise the from the cylinder.
hood.
13. Connect the service hose (yellow) to the Nitrogen
4. Connect the service hose (yellow) to the centre cylinder. Open the neck valve on the cylinder and set
access port on the manifold gauge and to the vacuum the regulator pressure such that it is higher than the
connection (6) on vacuum pump. Ensure that the system pressure then purge the hose. Open the low
system is empty before connecting the vacuum so that side hand valve on the manifold, as the pressure
refrigerant does not enter the pump. rises open the high side hand valve on the manifold
and allow a system pressure of 10 bar (150 psig) to
5. Tighten down (turn clockwise) both high and low side be reached. Close all the valves. Using a suitable
valves on the gauge manifold to the closed position. electronic leak detector, check all joints in the air
Remove protective caps from the service ports on the conditioning system for leaks. Tighten any loose
compressor. joints and re-test if necessary.

6. Connect both service hoses from the two fittings (2 14. Vent the refrigerant mix to atmosphere by
& 3) in the bottom of the manifold to the two service removing the service hose (yellow) from the Nitrogen
ports on the compressor. High side (red) to compressor cylinder and opening the low side hand valve on the
discharge valve, low side (blue) to compressor suction manifold. Re-evacuate the system to below 6 mb
valve. (steps 7 to 10).

7. Switch vacuum pump on, open vacuum pressure 15. Lower hood assembly and remove wheel blocks.
valve (1) until less than 6 mb is reached on vacuum
gauge (A). The vacuum gauge (A) should remain at
this value when vacuum pressure valve (1) is closed CHARGING THE SYSTEM
to indicate that there are no leaks. Note: Refer to all WARNINGS listed under
'Maintenance' prior to charging the system.
8. Open the low side hand valve on the manifold and
vacuum pressure valve (1) and watch that the Recommended Equipment Required:
gauges start to register that a vacuum is being drawn. Portable High Vacuum Charging Station
If the gauges do not register the vacuum thena Electronic Leak Detector
blockage is present. Open the high side and pump or Standard Service Manifold (Refer to Fig. 4)
down until a vacuum of 10 mb is achieved.

SM 2211 Rev1 10-04 9

Operators Compartment - Air Conditioning
Section 260-0130

For New Or Completely Empty System 8. Start vacuum pump to evacuate the complete air
conditioning system.
Note: The charging procedure must be done in ambient
temperatures above 15.5° C (60° F) with the R-134a
9. Run vacuum pump for approximately 30 minutes.
canister temperature equal to the outside ambient
Ideal gauge readings should be 29.92 inches of
temperature.
mercury. The pressure will vary with altitude; it will be
approximately 0.03 bar (0.5 lbf/in²) less for each 305 m
1. Shut off engine and block all road wheels.
(1 000 ft) of elevation.
2. Pull on handle to release hood catch and raise the
10. Before disconnecting power supply from vacuum
hood.
pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
3. Remove protective caps from 'quick coupler' valves
R-134a source.
on rear of compressor.
11. Open R-134a source. Loosen, but do not remove,
4. Connect low pressure gauge hose (blue hose and
yellow supply hose at manifold on gauges to remove all
gauge) to suction side or low side fitting on
air in the yellow supply hose, replacing the air with R-
compressor. The suction side can be identified by the
134a. This is done in a few seconds. Tighten yellow
size of the hose connected to the fitting. This will be
supply hose.
the largest diameter hose of the system.
12. Open low side of R-134a gauges slowly. When
5. Connect the high pressure gauge hose (red hose and
gauge reads zero open both sides completely. Vacuum
gauge) to discharge or high side fitting on compressor.
in the system will draw R-134a gas into the system.
6. Connect yellow supply hose to suction port on
Hold until both gauge readings equalize.
vacuum pump.
Note: Never charge with liquid R-134a. Charge on
7. Open both sides of gauges, low and high, completely.
the low pressure side only.
SM - 2424

B C D Final Charging Of The System

1. Start the engine and run at engine idle speed.

4 2. Turn the air conditioning system on with the

2 3
thermostat set on maximum cooling and fan on high
SUC DIS R speed.
ACCESS E
F
PORT R 3. At this point a visual inspection must be made of
I the sight glass on top of the receiver-drier. Allow
G
E charging to continue until 1.1 kg (2.43 lbs) of refrigerant
A R has been added. The charging process can be speeded
A
N up by running the engine at a fast idle.
T
4. The sight glass on top of the receiver/drier will be
VACUUM PUMP
substantially free of bubbles.

Note: It is normal for bubbles to increase during clutch

6
1 5 cycling or system start-up.

Gauges: Valves: 5. With the system completely charged, shut off the
A - Vacuum Gauge 1 - Vacuum Pressure engine. Close the valve on the R-134a canister and
B - Low Pressure Gauge 2 - Suction Line remove the yellow supply hose. Remove both the low
C - High Pressure Gauge 3 - Discharge Line
D - Charging Cylinder 4 - Refrigerant Gas pressure (blue) hose and high pressure (red) hose from
Pressure Gauge 5 - Refrigerant Liquid the filling ports on the compressor.
Port:
6 - Vacuum Connection Note: Some R-134a will escape as the hoses are being
Fig. 4 - Standard Service Manifold removed.

10 SM 2211 Rev1 10-04

 Operators Compartment - Air Conditioning
Section 260-0130
The system is completely charged when; 4. Check the cab fresh air inlet filter for blockage.

a. the suction pressure on the gauge is approx. 5. Check that, with the ignition switch on (engine not
20 - 30 psig at 25° C ambient. running), the blower operates over whole speed range
b. the correct weight of refrigerant has been added i.e.
1.1 kg (2.43 lbs). 6. Check that, with the ignition switch on (engine not
c. the correct sub-cooling can be measured at the running), the blower and air conditioning switched on,
condenser, approx. 5 - 7° C. the compressor clutch engages.

6. Replace protective caps on hoses and valve fittings. Charge level:

Note: It is not possible to check refrigerant charge
7. Lower hood assembly and remove wheel blocks. level with R134a systems. Any bubbles seen at the
sight glass on the receiver drier may be bubbles of oil
and are perfectly normal.
TROUBLESHOOTING
Fault finding:
Preliminary Checks Refer to Troubleshooting table
Before any checks are carried out on the refrigerant Important: Refer to appropriate removal and installation
circuit the following checks should be made: procedures before working on any system component.

1. Check the compressor drive belt is serviceable and

correctly tensioned. SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
2. Check the condenser and engine radiator are not numbers of special tools referenced in this section and
blocked by debris. Clean with compressed air or water general service tools and sealants required. These
if necessary. tools and sealants are available from your dealer.

3. Check that the condenser fins are not flattened or

damaged, the fins must allow air to pass freely.

SM 2211 Rev1 10-04 11

Operators Compartment - Air Conditioning
Section 260-0130

AIR CONDITIONING TROUBLESHOOTING

CONDITION PROBLEM REMEDY
1. Belt Trouble

Slipping Loose Adjust belt to 10 mm (0.39 in)

depression

Overcharge Correct the charge

Air in system Evacuate and re-charge

Excessive wear Pulley not aligned Align pulley

Belt too tight Adjust or replace

Bad idler bearing Replace idler bearing

Belt wrong width Replace with correct belt

2. Vibration/Noise in Compressor
area

Vibration/noise Stuck compressor or clutch Replace

Vibration Overcharge Correct the charge

Air in system Evacuate system and re-charge

Compressor mounting or belts loose Tighten

Drive pulley loose Tighten

Belt tension incorrect Correct tension

Faulty compressor Replace compressor

Noise with clutch engaged Faulty clutch bearing Replace bearing

Noise with clutch engaged or Clutch loose Tighten

disengaged

Noise Clutch rubbing field coil Align clutch

Faulty belt Replace belt

Compressor oil level low Add oil

Chatter/Knock Valve plate broken Repair or replace

3. Noise - Evaporator

Rubbing/scraping Fan blade or blower Repair or replace

Hissing Low charge/leak Correct charge/repair leak

Chatter/Knocking Expansion valve Replace

Noisy case Loose brackets/screws Tighten

Motor squeal Dry bearings Replace

12 SM 2211 Rev1 10-04

 Operators Compartment - Air Conditioning
Section 260-0130

AIR CONDITIONING TROUBLESHOOTING (CONTINUED)

CONDITION PROBLEM REMEDY
4. Air Conditioning Inadequate
After Short Period Of Operation

Cooling quits Loss of refrigerant Charge system/check for leaks

Moisture in system Replace drier

Thermostat Replace thermostat

Clutch Check pull-in of clutch or replace

Cooling intermittent Moisture in system Replace drier

5. Electrical Trouble

Blower motor or condenser fan Defective circuit breaker or bad Replace. Clean and tighten
motor inoperable wiring connections connections

Tight motor bearing Repair or replace motor

Switch open or shorted Repair or replace switch

Blown fuse Check fuse, replace if necessary

Motor seized Check rotors are free to turn

Loose wire/connection Check connectors at blower. Check

there is power across terminals

Motor failure Remove and replace blower

Faulty control Check system with replacement

Module damaged Check system with replacement

module inside main weldment

Slow running blower Shaft binding Replace motor - worn bearings

Wheel misaligned Replace

Bad blower switch Replace blower

Insufficient current Install larger alternator

Clutch inoperable Defective relay Replace

Loose connection Clean and tighten connection

Broken wire - ground Repair wire

Shorted or open field Replace field

Blown fuse Check fuse, replace if necessary

Faulty freeze protection thermostat When temperature is above cut-off

temp, thermostat should be closed.
If faulty, replace thermostat

SM 2211 Rev1 10-04 13

Operators Compartment - Air Conditioning
Section 260-0130

AIR CONDITIONING TROUBLESHOOTING (CONTINUED)

CONDITION PROBLEM REMEDY
Clutch inoperable (continued) Faulty compressor If compressor clutch is being fed
power then it should be engaged. If
not, check wiring. Replace
compressor if faulty

Faulty pressure switch If the binary pressure switch

detects pressure within range,
circuit should be closed. If switch
is not closed circuit, indicates
incorrect pressure or faulty switch.

6. Air Conditioning System

Trouble - Gauges must be
connected

High head pressure Overcharge of refrigerant Purge system as necessary

Air in system Evacuate and re-charge

Condenser clogged Clean condenser

Low head pressure Undercharge of refrigerant Complete charge

Bad compressor valve plate or Repair or replace

gasket

Restriction in drier Replace drier

Low suction pressure Restriction in lines Clean lines

Restriction in expansion valve Replace expansion valve and drier

Improper expansion valve in charge Replace expansion valve

Refrigerant leak Inspect lines and fittings. Tighten,

repair or replace

* * * *

14 SM 2211 Rev1 10-04

 Body - Body and Mounting
Section 270-0010

SM - 2883

10
7
1
6
15
5
13
4
7 A A
8
A
14
BODY 17
18 1
19 3

21
16
8
17
18
11
20 2
22 12 9
L.H. FRAME RAIL

1 - Body 5 - Shim 9 - Shim 13 - Washer 18 - Washer

2 - Bushing 6 - Shim 10 - Locknut 14 - Lube Fitting 19 - Bolt
3 - Hinge Pin 7 - Washer 11 - Spacer 15 - Bolt 20 - Plate
4 - Body Pad 8 - Bolt 12 - Plate 16 - Proximity Switch 21 - Plate
17 - Locknut 22 - Bolt
Fig. 1 - Exploded View of Body and Mounting

DESCRIPTION OPERATION
The standard body is an all welded construction with all The body control lever, mounted on the right hand dash
wear plates fabricated from high hardness panel, controls the main hydraulic valve assembly.
(min. 360 BHN) 1000 MPa (145000 lbf/in2) yield
strength steel. Angled lower body sides reduce body When the body control lever is operated, a voltage is
impacts when loading and a tail chute angle of 25° sent to the hydraulic ECU, which converts voltage to
provides good retention when travelling without a current. This current controls the body raise and lower
tailgate. Refer to Section 000-0000, General proportional pressure control valves, producing a pilot
Information for body capacities. pressure to shift the control spool in the main hydraulic
valve. This allows the flow of oil to reach the body
The body is pivoted at the rear of the trailer frame and cylinders, to either raise or lower the body. Refer to
is operated by two single stage, double acting hoist Section 230-0000, Body System Schematic and
cylinders which are cushioned at both ends of the Section 215-0050, Main Hydraulic Valve.
stroke to reduce impact shocks. The hoist cylinders
raise the body to a tipping angle of 65° in 12 seconds The three operating positions of the joystick from front
and power down the body in 7.5 seconds. to rear are as follows:

Power Down - Pushing the lever forward provides

hydraulic force to power-down the body. Pushing the

SM 2212 Rev 1 05-08 1

Body - Body and Mounting
Section 270-0010
lever fully forward will engage the electric detent. When
the body reaches the body proximity switch, the lever WARNINGS
springs back to 'NEUTRAL' and power down is ramped To prevent personal injury and property
back to allow the body to float down on to the chassis. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
Neutral - If the body is above the body proximity secured and of adequate capacity to do the job
switch, the lever in this position will stop and hold the safely.
body at any desired height. If the body is below the
proximity switch, the hydraulic ECU defaults the Hydraulic fluid pressure will remain
control spool in the main hydraulic valve to the neutral
within the body hoist system after engine
position and energizes the float solenoid, allowing the
shutdown. To prevent personal injury and
body to float down on to the chassis. The body should
property damage, press and release the brake
be fully lowered and in the 'NEUTRAL' position while
treadle valve continuously to relieve pressure in
the machine is in motion. The lever will remain in the
the system.
'NEUTRAL' position when released.
WARNING
Raise - Pulling the lever back and holding it in this Exercise extreme caution when lowering
position directs oil to extend the body hoists and raise the cylinders from the body. The cylinders will
the body. When released, the lever will spring back to swing out sharply as they leave their
the 'NEUTRAL' position. mountings.
A Body Lower Emergency switch in the cab is
1. Position the vehicle in a level work area, ensure the
connected directly to the float solenoid, within the main
body is fully lowered, apply the parking brake and
hydraulic valve, to enable the lowering of the body in
switch off the engine.
the event of an engine, hydraulic or hydraulic ECU
failure. The cause of the failure must be investigated
2. Relieve stored hydraulic pressure in accumulators
and corrected.
(x3), by pressing and releasing brake treadle valve
continuously, until all accumulator pressure is relieved.
Note: The body must remain lowered with lever in the
'NEUTRAL' position until it is necessary to operate the
3. Block all road wheels, place the steering lock bar in
body again. Failure to comply with this could result in
the 'Locked' position and the battery master switch in
overheating the hydraulic oil and failure of the hydraulic
the 'Off' position.
system components.
4. Remove upper pins securing the body cylinders to
Note: A proximity sensor prevents the body being fully
body (1) assembly and secure body cylinders clear of
powered down on to the chassis. At a predetermined
the body. Refer to Section 230-0130, BODY
height, the sensor automatically energizes the float
CYLINDER.
solenoid on the main hydraulic valve assembly.
Note: Body lifting lugs can be fabricated as shown in
Note: If an electrical failure occurs, the main hydraulic
Fig. 2.
valve assembly will automatically default to the 'HOLD'
condition. The cause of the electrical fault must be
5. Secure lifting lugs to body (1) using suitable bolts.
investigated and corrected.
Using appropriate lifting equipment, sling body (1)
assembly at the four lifting points and take an initial
strain.
WARNING
Never work under or near an unblocked or Note: Approximate weight of body (1) assembly is
unsupported raised body. Always use the body 4 400 kg (9 700 lb).
safety prop. The body safety prop must only be
used when the body is empty.
6. Remove bolts (15) and washers (13) securing hinge
pins (3) in place. Remove hinge pins (3) and shims (9)
from body (1).
REMOVAL
Numbers in parentheses refer to Fig. 1. 7. Remove body (1) assembly from the vehicle.

8. Remove bushing (2) from body hinge bores.

2 SM 2212 Rev 1 05-08
 Body - Body and Mounting
Section 270-0010

INSTALLATION BODY SHIMMING PROCEDURE

Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners to standard torques listed in Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. TORQUE SPECIFICATIONS.

Note: When it becomes necessary, body pads (4)

WARNING should be replaced as a set to maintain load
To prevent personal injury and property distribution along the frame. Existing body pads will
damage, be sure wheel blocks, blocking have taken a compression 'set' and a new pad,
materials and lifting equipment are properly shimmed to match existing pads, will not carry its
secured and of adequate capacity to do the job share of the load, resulting in uneven load distribution
safely. along the frame.

1. Inspect bushing (2) for damage and replace if 1. Raise body (1) clear of the trailer frame and lay
necessary. Install bushing (2) in body hinge bores. body pads (4) (metal face down) roughly in position on
the frame.
Note: Body lifting lugs can be fabricated as shown in
Fig. 2. 2. Lower body (1) assembly onto body pads (4).

2. Secure lifting lugs to body (1) using suitable bolts. 3. Centralise body (1) assembly to the frame and
Using appropriate lifting equipment, sling body (1) place shims (5 & 6) under the front two body pads (4)
assembly and position over the trailer frame. until all other pads are clear of body (1) assembly.

Note: Approximate weight of body (1) assembly is 4. Slide shims (5 & 6) under remaining body pads (4)
4 400 kg (9 700 lb). until they just make contact with body (1) assembly.

3. Align hinge pin bores in body (1) assembly with bores 5. Raise body (1) assembly and install body pads (4)
in the trailer frame. Install hinge pins (3) and shims (9) and and shim packs (5 & 6) to their relative brackets on
secure with bolts (15) and washers (17). body (1) assembly securing with bolts (8), washers (7)
and locknuts (10).
4. Secure body cylinders to body (1) assembly with
pins and mounting hardware removed during removal. 6. Lower body (1) assembly to the frame and check the
Refer to Section 230-0130, BODY CYLINDER for shimming.
instructions.
7. Install body guide plates (12) with spacers (11) to
5. Lubricate hinge pins (3) through lube fitting (14) with mounting brackets on body (1) assembly. Set gap
lubricant specified in Section 300-0020, LUBRICATION between plates (12) and the frame at 5 - 10 mm
SYSTEM. Lubricate slowly until excess lube is seen. (0.2 - 0.4 in). Secure plates (12) and spacers (11) to
mounting brackets with bolts (8).
6. Install body pads (4) and body guide plates (12) on
body (1) assembly as described under 'Body
Shimming Procedure'.

7. Remove lifting equipment from body (1) assembly

and blocks from all road wheels.

8. Place the battery master switch in the 'On' position,

start the engine and check for correct operation of body
(1) assembly.

SM 2212 Rev 1 05-08 3

Body - Body and Mounting
Section 270-0010

SM - 1630
MAINTENANCE
64 DIA HOLE
Lubricate the body hinge pins and body cylinder pins at BURN
the intervals stated and with lubricant specified in 8
Section 300-0020, LUBRICATION SYSTEM. Lubricate R4
slowly until excess lube is seen.

SPECIAL TOOLS
Special tools can be fabricated as shown in Figure 2. 96
Refer to Section 300-0070, Service Tools, for part 6 6
19.5
numbers of the general service tools required. These

0
2 PLACES 2 PLACES

10
tools are available from your dealer. 40˚

CHAIN OPERATED TAILGATE OPTION

114
Numbers in parentheses refer to Figure 3.
R 20

The chain operated tailgate, when fitted features a rear

tail-gate (3), two tailgate side arms (1 and 2), trunnion 71
mounted to the stub shafts (5) on the sides of the 31
body, and side chain assemblies that connect the front
ends of the side arms (1 and 2) to outrigger assemblies 48 16
(23) bolted to the suspension equalization beams. As
the body is lifted, the chains rotate the side arms (1 1 HOLE DRILL THRO'
21 MM DIA
and 2) about the axes of the stub shafts (5), thus
maintaining the side arms in an approximately Fig. 2 - Body Lifting Lug
horizontal attitude, and opening up a gap between the
tailgate (3) and the rear end of the body. on assembly, and may not readily be separated from
the tailgate (3).
TAILGATE REMOVAL
5. Undo and remove the bolts (13) with nuts (14) and
WARNING washers (18) securing the locking plate (4), tailgate
To prevent personal injury and property side arm (2 or 1) and tailgate (3) together, and remove
damage, be sure wheel chocks and lifting the locking plate (4), if necessary.The side arm (2 or 1)
equipment are properly secured and of is applied with a retaining compound (Loctite™ 648) on
adequate capacity to perform the task safely. assembly, and may not readily be separated from the
tailgate (3).
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and 6. Remove the tailgate (3) to a prepared area.
switch off the engine. Turn steering wheel several
times to relieve any pressure in the steering circuit. 7. Transfer the lifting tackle to one of the tailgate side
arms (1 or 2) and take up the slack.
2. Block all road wheels and place the battery master
switch the 'Off' position. 8. Disconnect the shackle (15) at the lower end of the
respective chain (16) from the location on the
3. Attach lifting tackle to the attachment point on the respective outrigger (20).
top of the tailgate (3) and take up the slack.
9. Bend down the corners of the locking plate (28) to
4. Undo and remove the bolts (13) with nuts (14) and allow the bolts (11) and washers (12) to be removed.
washers (18) securing the locking plate (4), tailgate Undo and remove the bolts (11), washers (12), locking
side arm (1 or 2) and tailgate (3) together, and remove plate (28), thrust plate (10) and the shim (26), if fitted.
the locking plate (4), if necessary. The side arm (1 or
2) is applied with a retaining compound (Loctite™ 648) 10. Carefully manipulate the tailgate side arm (1 or 2)

4 SM 2212 Rev 1 05-08

 Body - Body and Mounting
Section 270-0010

SM 3905

6 7
22 23
12 11
25 21 22
17 10 26 1
9 15
20
23
27
4
27
16 BOLT-ON OUTRIGGERS 24

8 7 6 15
5 19
15
5
16,19
8

9 26
13 10 25
18 14 15
12 11
2
3
4 17

14
18 13

8 - Shim 15 - Shackle 22 - Washer

1 - Left-hand Tailgate Arm Assembly
9 - Bush 16 - Chain 23 - Nut
2 - Right-hand Tailgate Arm Assembly
10 - Thrust Plate 17 - Grease Fitting 24 - Bolt
3 - Tailgate
11 - Bolt 18 - Washer 25 - Locking Plate
4 - Locking Plate
12 - Washer 19 - Spiral Wrap 26 - Shim
5 - Stub Shaft
13 - Bolt 20 - Outrigger Assembly 27 - Washer
6 - Bolt
7 - Lockwasher 14 - Locknut 21 - Bolt

Fig. 3 - Chain Operated Tailgate Assembly (Option)

off the stub shaft (5), and remove it to a prepared area. off the stub shaft (5), and remove it to a prepared area.

11. Remove the bush (9) from the aperture of the 16. Remove the bush (9) from the aperture of the
tailgate side arm (1 or 2), if required. The bush is an tailgate side arm (2 or 1), if required. The bush is an
interference fit in the arm and therefore it will be interference fit in the arm and therefore it will be
necessary to use a bearing puller to assist in the necessary to use a bearing puller to assist in the
removal process. removal process.

12. Transfer the lifting tackle to the other tailgate side 17. Support the weight of one of the outrigger
arm (2 or 1) and take up the slack. assemblies (20), then undo and remove the bolt (24),
washers (27) and nut (23) securing the outrigger
13. Disconnect the shackle (15) at the lower end of the assembly lower arm to the respective equalization
respective chain (16) from the location on the beam lower lug. Similarly, undo and remove the bolts
respective outrigger (20). (21), washers (22) and nuts (23) securing the outrigger
assembly main beam to the body of the equalization
14. Bend down the corners of the locking plate (28) to beam. Remove the outrigger assembly to a prepared
allow the bolts (11) and washers (12) to be removed. area. Repeat this step for the other outrigger assembly.
Undo and remove the bolts (11), washers (12), locking
plate (25), thrust plate (10) and the shim (26), if fitted. 18. Undo and remove the four bolts (6) with
lockwashers (7) securing one of the stub shafts (5) to
15. Carefully manipulate the tailgate side arm (2 or 1) the side of the body. Remove the stub shaft to a
prepared area. Repeat this step for the stub shaft on
the other side arm (2 or 1 respectively).

SM 2212 Rev 1 05-08 5

Body - Body and Mounting
Section 270-0010

TAILGATE INSTALLATION SM 3906

Numbers in parentheses refer to Figure 2.

Note: Tighten all fasteners to standard torques listed in

Section 300-0080, Standard Bolt and Nut Torque
Specifications.

2 945 CHECK SIZE

WARNING
To prevent personal injury and property
damage, be sure wheel chocks and lifting
equipment are properly secured and of
adequate capacity to do the job safely.

1. Apply Loctite™ 243 (anaerobic threadlock) to bolts

(6), then secure both stub shafts (5) to the side walls of
the body using the bolts (6) and lockwashers (7).
Fig. 4 - Side Arm Check Size
Note: Ensure that the stub shaft is fitted with the radial
grease aperture uppermost. washers (12), locking plate (25) and thrust plate (10),
then fit a shim (26), and finally re-fit the thrust plate
2. Attach the outrigger assemblies (20) to the left-hand (10), locking plate (25), bolts (11) and washers (12).
and right-hand equalization beams by firstly bolting the There must be a clearancebetween each side arm (1
outrigger main beams to the bodies of the equalization and 2) and their respective thrust plate (10) of 0.3-1.3
beams using the bolts (21), washers (22) and nuts (23), mm. Bend up the corners of the locking plates (25)
then by securing the outrigger lower arms to the against the flats of the bolts (11) on completion.
equalization beam lower lugs using the bolts (24), SM 3909
washers (27) and nuts (23).

3. Install a bush (9) to each of the two tailgate side

arms (1 and 2 respectively).

Note: The bushes may be a tight fit in the side arms.

Take care not to damage the bushes if using
mechanical assistance during the installation process.
1
4. Lift both tailgate side arms (1 and 2) into position on 2
3
their respective stub shafts, correctly orientated.
LEFT-HAND RIGHT-HAND
Measure the linear distance between the two side arms
(1 and 2), which should be in accordance with the
reference dimension identified on Figure 4. If Fig. 5 - Orientation of Thrust Plates
necessary, remove the side arms (1 and 2) and insert
sufficient shims (8) over the stub shafts (5), in order to 6. Refer to Figure 5. Fit the two grease lubrication
achieve the reference dimension of 2945 mm, then re- hoses (3) complete with elbows (2) and adapters (1) to
fit the side arms (1 and 2) and check the dimension the stub shafts (5, Figure 3). Fit the couplings and
again. grease nipples (17, Figure 3) to the bottom of the
hoses (3).
5. Fit a thrust plate (10) to each stub shaft (5),
orientated as shown on Figure 5, securing them with 7. Apply retaining compound (Loctite™ 638) to the
the locking plates (25), bolts (11) and washers (12). areas of the tailgate (3) identified on Figure 6, at BOTH
Ensure that the thrust plates (10) are secured to the ENDS of the tailgate.
stub shafts (5) and NOT to the side arms (1 and 2
respectively). If a thrust plate (10) is impinging on a 8. Transfer the lifting tackle to the tailgate (3) and lift it
side arm, undo the bolts (11), remove the bolts (11), into position at the rear of the body. Loosely assemble

6 SM 2212 Rev 1 05-08

 Body - Body and Mounting
Section 270-0010

SM 3910 (17), until excess lubricant can be observed exiting the

pivot bushes (9).

12. Fit the two outrigger assemblies (20) to the

mm
suspension equalization beams using the bolts (21),
200 washers (22) and nuts (23) to secure each one to the
body of the respective beam, and the bolts (24),
washers (27) and nuts (23) to secure the lower leg of
each outrigger assembly (20) to the lug on the
underside of each respective beam.

m
13. Fit the chains (16) with shackles (15) to the drilled
m
200 lugs at the forward end of the side arms (1 and 2) and
to the correspponding drilled lugs on the top of the
outrigger assemblies (20).

Note: The tailgate (3) should begin to open when the

Fig. 6 - Retaining Compound Application Areas body has tilted 2° from the horizontal. If necessary,
remove chain links to achieve this action. DO NOT
remove sufficient chain lionks to allow the axis of
the tailgate (3), with the side arms (1 and 2) and the wither chain (16) to coincide with an imaginary axis
locking plates (4), using the bolts (13), washers (18) bbetween the respetive tailgate pivot point and the
and lock-nuts (14). chain location pint on the associated outrigger
assembly (20), whe the body is fully open.
9. Manipulate the tailgate (3) until it makes contact with
the rear lip of the body. Tighten the bolts (13) with 14. When the chains have been adjusted to their
washers (18) and lock-nuts (14), in accordance with required length, cut appropriate lengths of spiral wrap
Section 300-0080, Standard Bolt and Nut Torque (19) to cover as much of the chains (16) as possible.
Specifications.

10. Manually operate the side arms (1 and 2) to ensure

TAILGATE MAINTENANCE
that the tailgate (3) operates correctly, and does not Every 50 hours: Lubricate the tailgate stub shafts (5)
impinge on the top of the body in its lifted position. with lubricant specified in Section 300-0020,
Lubrication System. Lubricate slowly until excess
11. Lubricate the tailgate (3) via the grease nipples lubricant is observed.

* * * *

SM 2212 Rev 1 05-08 7

Body - Body and Mounting
Section 270-0010

THIS PAGE IS INTENTIONALLY BLANK

8 SM 2212 Rev 1 05-08

 MISCELLANEOUS - Lubrication System
Section 300-0020

LUBRICATION AND SERVICE

SAFETY PRECAUTIONS
Do not allow unauthorized personnel to service or
maintain this vehicle. Study the Operator's Handbook WARNING
and Maintenance Manual before starting, operating or These vehicles are equipped with engine and
servicing this vehicle. Always follow procedures and transmission oil pans which permit operation at
safety precautions detailed throughout this manual. maximum gradeability as designated in the
'Performance Data' section of the relevant Sales
Always attach a DO NOT OPERATE or similar warning Specification Sheet.
sign to the ignition switch or a prominent control before
cleaning, lubricating or servicing the vehicle. Lubrication is an essential part of preventive
maintenance. It is important that the instructions
Never allow anyone to work on the vehicle while it is regarding lubricant specifications, and the frequency of
moving. Make sure there is no one on the vehicle their application, be followed to prolong the useful life
before working on it. of the vehicle. Periodic lubrication of moving parts
reduces to a minimum the possibility of mechanical
Do not work under or near an unblocked or unsupported failures.
body. Always use the body prop. The body prop must only
be used when the body is empty. All change periods are recommendations based on average
operating conditions. Lubricants showing evidence of
Always install the steering lock bar before making excessive heat, oxidation or dirt should be changed more
adjustments or servicing the vehicle with the engine frequently to prevent these conditions.
running.
Lubricant change and service periods must be
Do not work under or near any unblocked or established on the basis of individual job conditions
unsupported linkage, part or vehicle. utilizing oil sampling and recommendations from
lubricant suppliers.
Always relieve pressure before servicing any
pressurized system. Follow the procedures and safety Thoroughly clean all fittings, caps and plugs, to prevent
precautions detailed in the relevant Maintenance dirt from entering any system while carrying out
Manual section. servicing procedures. Lubricants must be at normal
operating temperature when draining.
When changing oil in the engine, transmission and
hydraulic system, or removing hydraulic lines, Note: Do not operate any system unless oil level is
remember that the oil may be hot and can cause burns within the recommended operating levels as indicated
to unprotected skin. on oil level dipstick, sight gauge or level plug.

When working on or around exhaust components, Small circles on the following illustration represent
remember that the components may be hot and can points at which lubrication and/or servicing must take
cause burns to unprotected skin. place, at the intervals indicated on the left hand side of
the lubrication and service chart.
Always deflate the tyre before trying to remove any
embedded objects or removing the tyre and rim The numbered circles on the illustration contain
assembly from the vehicle. reference numbers which correspond to the reference
numbers in the 'Ref. Points' column of the lubrication
Always use a self-attaching chuck with a long airline, and service chart.
and stand to one side while inflating the tyre. Refer to
Section 160-0050, Wheel Rim and Tyre.

SM 2360 Rev 11 04-10 1

Miscellaneous - Lubrication System
Section 300-0020

SM2871

19 31 19 19
5 18 1 32 4 30 15 20 35 10 23 3 23 10 11 22 15 11 12 20 15 36 13

33 17 14 16 6 7 23 15 35 10 29 2 28 25 11 9 21 27 23 20 15 23 12 15 34 13
19 19 19

Lubrication and Servicing Points

LUBRICATION AND SERVICE CHART

Interval Ref. No. of
Hours Points Identification Service Instructions Points Lubricant Service/Quantities
1 Engine Check oil level. Add if low. 1 EO As Required
2 Transmission Check oil level. Add if low. 1 EO As Required
3 Hydraulic Tank Check oil level. Add if low. 1 HO As Required
4 Radiator Header Tank Check coolant level. Add if low. 1 - See Page 4
10 6 Fuel Filter/Water Separator Drain. 1 - -
(Daily) 7 Air Filter Restriction Gauge Check. Renew element if required. 1 - See Note 5
18 Drive Belts Check for damage. - - See Engine Manual
32 Fuel Tank Check fuel level. Add if low. 1 - As Required
- Engine Crankcase Breather Inspect and clean if required. 1 - -
- Cooling Fans Check for damage. - - -
- Hydraulic Filter Restriction Indicator Check. Replace element if required. 1 - -
- Tyres Check condition and pressure. 6 - Section 160-0050
- Hood Check air intake/vents for blockage. 3 - -
- General Check for debris, leaks and damage. - - -

9 Oscillation Bushes Lubricate 2 EP, NLGI See Note 1

12 Suspension Beam Bushings Lubricate 2 EP, NLGI See Note 1
15 Wheel Rim Nuts Check torque. (Torque Seal) 72 - 600 Nm (442 lbf ft)
50 14 Battery Electrolyte Check Level. Add if low 2 - As required
(Weekly) 30 Cab Ventilation Filter Inspect and clean if required. 1 - -
10 Steering Cylinder Pins Lubricate 4 EP, NLGI See Note 1
11 Body Cylinder Pins Lubricate 4 EP, NLGI See Note 1
13 Body Hinge Pins/Optional Tailgate Pins Lubricate 2 EP, NLGI See Note 1
36 Panhard Rod Bearings Lubricate 4 EP, NLGI See Note 1
- Engine Air Cleaner Inspect inlet screen. Renew if necessary - - -

- Differential Breathers Clean if required. 3 - -

35 Independent Front Suspension Lubricate 2 EP, NLGI See Note 6
250 21 Oscillation Pivot Check end float. Adjust if required. 1 - -
(Monthly) 25 Articulation Bearings Lubricate 2 EP LI COMP See Note 1
27 Parking Brake Pads Check wear. Renew if required. 2 - -
- Transmission Cooler Clean and inspect fins. 1 - See Note 3
- Radiator and Charge Air Cooler Clean and inspect fins. 1 - See Note 3
- Drive Belts Check tension. Tighten if required. - - -
19 Wheel Planetaries Check oil level. Add if low. 6 EPL See Page 5
20 Differentials Check oil level. Add if low. 3 EPL See Note 2

2 SM 2360 Rev 11 04-10

 Miscellaneous - Lubrication System
Section 300-0020

LUBRICATION AND SERVICE CHART (continued)

Interval Ref. No. of
Hours Points Identification Service Instructions Points Lubricant Service/Quantities

1 Engine Drain oil and refill with new oil 1 EO See Page 5
500 16 Engine Oil Filter Renew 1 - -
(3 Monthly) 32 Fuel Tank Clean filler neck, screen and cap. 1 - -

2 Transmission Drain oil and refill with new oil 1 EO See Page 5
2 Transmission Run AEB Starter 1 - -
2 Transmission Breather Clean if required 1 - -
6 Fuel Filter/Water Separator Renew 1 - See Note 7
22 Driveshaft Bearings Check oil level. Add if low. 1 EPL To fill plug. See Note 4.
28 Transmission Oil Filters Renew 2 - -
1000 29 Transmission Internal Oil Filter Clean 1 - -
(6 Monthly) 30 Cab Ventilation Filter Renew 1 - -
32 Fuel Tank Renew cap filter/cartridge. 1 - -
- Hydraulic Tank Breather Renew 1 - -
17 DCA4 Coolant Filter Renew 1 - See engine manual
- DCA4 Coolant Additive Check DCA4 Concentration - - See engine manual
3 Hydraulic Tank Drain oil and refill with new oil 1 HO See Page 5
19 Wheel Planetaries Drain oil and refill with new oil 6 EPL See Page 5
20 Differentials Drain oil and refill with new oil 3 EPL See Note 2
25 Articulation Pivot Nut Check torque. 1 - 1425 Nm (1050 lbf ft)
31 Hydraulic Oil Filter Renew 1 - See Page 5
2000 3 Hydraulic Tank Strainer Clean 1 -
(Annually) 23 Drivelines (Low Maintenance) Check for leaks and damage. - - See Page 5
- Engine Mounting Bolts Check torque. (Torque Seal) 4 - 298 Nm (220 lbf ft)
- Transmission Mounting Bolts Check torque. (Torque Seal) 3 - Section 120-0010
- Turbocharger Mounting Nuts Check torque. (Torque Seal) 4 - 65 Nm (50 lbf ft)
- Engine Water Pump Inspect drain hole. Clean if required. 1 -
19 Brake Packs Check brake wear 6 - Section 160-0030
34 Axle Mounting Bolts Check torque 24 - 671 Nm (495 lbf ft)
4000 33 Air Conditioning Compressor Drain, flush and refill with new 1 PAG Oil See Page 5
refrigerant oil
5 Cooling System Drain, flush and refill with new - - See Page 5
coolant

Note: Use 'Lubrication and Service Chart' in conjunction with 'Notes on Lubrication and Service Chart' and
'Miscellaneous Servicing' contained on the following pages.
Notes on Lubrication and Service Chart
Note - Capacities given are approximate - work to indicator moves from the yellow to the
dipstick, sight gauges or level plugs. orange section.
Note 1 - Lubricate slowly until excess lubricant is Note 6 - Independent Front Suspension (IFS) grease
observed. points (2). Remove excess grease from the
Note 2 - Capacity of front and rear differentials is grease holes in the pivot blocks (8 per side)
28 l (7.4 US gal). Capacity of centre and at the damper pins (2 per side).
differential is 31 l (8.2 US gal). Lubricate the left-hand IFS grease manifold
Note 3 - Clean the radiator and cooler fins more until excess is observed exiting through the
often when operating under extremely dusty grease holes in the pivot blocks (8) and at the
conditions. damper pins (2).
Note 4 - Remove plug from port on underside of
oscillation hub. Plug is removed to drain the Lubricate the right-hand IFS grease
cavity of any oil that enters the cavity when manifold until excess is observed exiting
filling. Remove grommet and level plug on through the grease holes in the pivot blocks (8)
side of oscillation hub. Add oil if required. and at the damper pins (2).
Refit all plugs. Note 7 - This service interval is dependant on fuel
Note 5 - Change safety element after every third quality. If a lesser grade of fuel is used than
primary element service.Check the air that specified within the Recommended
cleaner restriction gauge and operate the Lubricant, the service interval should be
vacuator valve. Renew the element if the reduced accordingly.

SM 2360 Rev 11 04-10 3

Miscellaneous - Lubrication System
Section 300-0020
EO - Engine Oil. Refer to 'Recommended obstructions from the vacuator valve lips which should
Lubricants' and 'Engine Oil Drain Intervals'. be open and pliable with the engine stopped.
HO - Hydraulic Transmission Oil. Refer to
'Recommended Lubricants'. Note: Service air cleaners more often when operating
EPL - Extreme Pressure Gear Lubricant spec. under extremely dusty conditions.
MIL-L-2105D.
EP, NLGI - Extreme Pressure Lithium No. 2 Grease Engine Crankcase - Check oil level and add oil if low.
(without 'Molybdenum').
With the engine off, the oil should be between the lower
EP LI COMP -Extreme Pressure Lithium
Complex Grease. Ref. EEMS19057 and upper marks on the dipstick, up to the upper mark
PAG Oil - Polyalklene Glycol (PAG) is preferable.
Compressor Lubricating Oil - Low
Viscosity (ISO46). Transmission - Check oil level and add oil if low.
Refer to Section 120-0010, Transmission and
Mounting, for correct oil level check procedure.
MISCELLANEOUS SERVICING
Hydraulic Tank - Check oil level and add oil if low.
WHEN REQUIRED With the engine off and the body down the oil should be
Seat Belts - Inspect for damage. Replace if required. visible in the sight gauge.

Windscreen Wipers And Washers - Replace wiper Radiator Header Tank - Check coolant level when cold
blades and top up reservoirs. and add if low. Fill the radiator header tank with coolant
until coolant reaches the bottom of the filler neck and
Wheel Rim Nuts - After first 10 hours (1 day) of holds that level.
operation re-torque nuts to 600 Nm (442 lbf ft). Check
torque every 50 hours thereafter. Note: Any time a significant amount of coolant is
added, the coolant concentration MUST be checked.
Engine - Steam clean the engine prior to performing Failure to use recommended coolant and to maintain
any repair or service work on it, and if heavily mixture at sufficient concentration levels can result in
contaminated due to prevailing site conditions. damage to the cooling system and its related
components. Always maintain concentrations at
CAUTION recommended levels. Refer to 'Recommended
Electrical and electronic connections, the Coolants', within Section 210-0000, Cooling System.
Engine ECM and harness connections should
AFTER FIRST 250 HOURS OF
be protected or not directly steam cleaned when
on or removed from the engine. OPERATING NEW OR REBUILT
COMPONENTS

Note: The engine and its components that are Wheel Planetaries - Drain oil and refill.
scheduled to be checked, serviced or replaced must be
cleaned in accordance with the manufacturer's Differentials - Drain oil and refill.
recommendations.

EVERY 10 HOURS OF OPERATION AFTER FIRST 500 HOURS OF

(DAILY) OPERATING NEW OR REBUILT
Walk Around Inspection - Inspect the vehicle as COMPONENTS
described in Section 4 of the Operator's Handbook.
Transmission - Drain oil, replace filter, clean internal
Engine - Visually check engine for damage, loose or filter and finger magnet. Refill transmission.
frayed belts and listen for any unusual noises.
Note: When refilling transmission ensure that the
Engine Air Cleaner - Change air cleaner element only transmission cooler is primed to prevent damage.
when air restriction gauge locks up in the red. Service
vacuator valves daily. Inspect and remove any

4 SM 2360 Rev 11 04-10

 Miscellaneous - Lubrication System
Section 300-0020

EVERY 250 HOURS OF OPERATION Note: Low Maintenance drivelines can be identified
(MONTHLY) by having plugs fitted to the spiders, not grease
nipples.
Oil Can Points - Oil working parts with engine oil. Multi Disc Brakes - Check operation and brake wear is
within the prescribed limit. Refer to Section 160-0030
General Inspection - Check entire dumptruck for Rear Axle Group - Axle Group Hub for details.
leaks, loose bolts and nuts or damaged parts. Examine
the vehicle, particularly the chassis, for cracks or Differentials - Drain oil and refill. Perform oil change
broken welds. Repair where necessary. when oil is warm. For specific details of oil fill and drain
plug locations, refer to the relevant differential section
Engine Air Intake - Check air intake system for wear contained within the service manual for details.
points or damage to piping, loose clamps and leaks.
Planetaries - Drain oil and refill. Perform oil change
Note: This service interval applies to normal driving. when oil is warm and simultaneously with the
check the pads more frequently under more severe differential. For specific details of oil fill and drain plug
conditions. Thickness of pad friction material should locations and steps, refer to the relevant planetary
never be allowed to wear below 3 mm (0.12 in). section contained within the service manual for details.
Parking Brake - Check pads and disc for wear. Adjust ENGINES AND TRANSMISSIONS
or replace if required. Test for proper function. Friction All information contained in the 'Lubrication and Service
material thickness should never be allowed to wear Chart' was extracted from the relevant manufacturers'
below 3 mm (0.12 in). Operators' Manuals and was correct at time of
publication. User should ensure that information
EVERY 500 HOURS OF OPERATION contained in this chart, regarding Engines and
Transmissions, reflects the information shown in the
(THREE MONTHS) relevant manufacturers' Operators' Manuals, supplied
Differentials - Check Oil level and add if low.The with the machine. Maintenance procedures should be
correct oil level is up to the rim of the oil filler and level- carried out in conjunction with any additional
check hole. Refer to relevant Differential section within procedures contained in the relevant manufacturers'
the service manual for specific details. 'Operation and Maintenance Manual', at the intervals
specified.
Planetaries - Check oil level and add if low.Oil level
should be at the lower bottom edge of the thread, with
the wheel hub orientated so that the oil drain plugs are
positioned horizontally in the middle of the axle. Refer
to relevant Planetary section within the service manual
for specific details.

EVERY 2000 HOURS OF OPERATION

(ANNUALLY)
Hydraulic Oil Tank - Drain oil, remove and clean filter
screen assemblies. Reinstall filter screens and refill
tank.

Hydraulic Oil Filter - Clean filter housing and install

new element when filter restriction gauge reads in red
zone, or after 2000 hours of operation, whichever
comes first.

Drivelines - Visually check Low Maintenance

drivelines for leaking or damaged seals.

SM 2360 Rev 11 04-10 5

Miscellaneous - Lubrication System
Section 300-0020

RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT *CAPACITY SPECIFICATIONS API CODE SAE GRADE
Engine Crankcase Engine Oil with 1.00% 41 l CH-4 15W-40
(Including Filters) sulphated ash limit is (10.8 US gal) (See Note 1)
recommended. Sulphated ash
must not exceed 1.85% limit
Transmission Engine Oil with 1.85% 63 l (See Note 2) CH-4 15W-40
(Including cooler) max. sulphated ash limit (16.6 US gal) See Trans.
Oil Table.
Transmission Engine Oil with 1.85% 8.25 l (See Note 2) CH-4 15W-40
Cooler max. sulphated ash limit (2.18 US gal) See Trans.
Oil Table.
Hydraulic System Hydraulic Transmission Oil 202 l See Hydraulic Oil Table
(Including Lines) (53.4 US gal) (See Note 3)
Cooling System Anti-freeze, Ethylene Glycol 54 l
(14.3 US gal)
Differential Extreme Pressure 28 l each MIL-L-2105 B GL-5 80W-90
(Front [non IFS] Gear Lubricant (7.4US gal)
and Rear)
Differential Extreme Pressure 26 l
(Front, IFS) Gear Lubricant (7 US gal)

Differential Extreme Pressure 31 l MIL-L-2105 B GL-5 80W-90

(Centre) Gear Lubricant (8.2 US gal)
Planetaries Extreme Pressure 11.0 l each MIL-L-2105 D GL-5 80W-90
(Front) Gear Lubricant (2.9 US gal) (See Notes 5 and 6)
Planetaries Extreme Pressure 7.5 l each MIL-L-2105 D GL-5 80W-90
(Centre & Rear) Gear Lubricant (2.0 US gal) (See Notes 5 and 6)
Fuel Tank Diesel Fuel Oil with 390 l DIN EN590
max. sulphur 0.5% (103 US gal)
Grease Nipples Extreme Pressure No.2
Lithium Grease Consistency
Driveshaft through Extreme Pressure (See Note 4 - Pag e 3) MIL-L-2105 D GL-5 80W-90
Bearings Gear Lubricant
Articulation Extreme Pressure EMS 19057
Bearings Lithium Complex
Air Conditioning Polyalklene Glycol (PAG) 0.125 l ISO46
Compressor Compressor Lubricating Oil - (0.033 US gal) SP 10
Low Viscosity

EMS19058 is suitable for use in the hydraulic system.

* - Capacities given are approximate, work to dipstick, sight
gauges or level plugs.
Note 4 - Automatic Transmission Fluids (ATF) may only be
used when the ambient temperature is less than -10° C
Note 1 - The use of low viscosity oils, such as 10W-30 or
(14° F). Should the temperature increase, it is necessary to
5W-30, can be used to aid in starting the engine and
switch to engine oil.
providing sufficient oil flow at low ambient temperatures.
Continuous use of low viscosity oils can decrease engine
Note 5 - 1.5% of Lubrizol (TEREX Part No. 15250489),
life due to wear.
must be added to planetary capacity to prevent brake
squeal.
Note 2 - Operation below the minimum temperatures listed
for the oil used without proper preheat or warm-up results
Warning
in greatly reduced transmission life. Proper warm-up
requires 20 minutes minimum operation in neutral (with Any increase in the stated volume of Lubrizol will
engine at part throttle) before operating the transmission in result in a decrease in brake performance.
gear.
Note 6 - Volume of Lubrizol to each planetary is as follows:
Note 3 - Hydraulic Transmission Oil meeting Specification
Front: 1.5% = 165 ml (5.57 oz)
Centre & Rear: 1.5% = 110ml (3.71 oz)

6 SM 2360 Rev 11 04-10

 Miscellaneous - Lubrication System
Section 300-0020

ENGINE OIL DRAIN INTERVALS

Engine oil drain intervals are dependant on working
environment and oil type used. Refer to table below for
engine manufacturer's recommended oil drain intervals.

ENGINE OIL DRAIN INTERVALS BY DUTY CYCLE (HOURS)

Severe Heavy Medium Light
Fuel Consumption > 13 gal/hr 10 to 13 gal/hr 8.5 to 10 gal/hr < 8.5 gal/hr
API CF-4 150 200 250 300
API CG-4 250 300 400 500
API CH-4 or ACEA E5 300 350 500 600
CES20076 or CES20077 350 400 550 700

LUBRICANT GRADE SELECTION GUIDE AT AMBIENT (START-UP) TEMPERATURE

SM637
HYDRAULIC OIL

API
SAE CODE MIL-SPEC
1 - - MIL-H-5606A
2 DEXRON Auto Trans. Fluid
3 10W CC/CD MIL-L-2104 B/C
4 20W/20 CC/CD MIL-L-2104 B/C
5 30 CC/CD MIL-L-2104 B/C

SM639
TRANSMISSION OIL

ENGINE OIL

(See Note 5)

Note - Consult your lubricant supplier for correct viscosity of lubricant when ambient temperatures are
consistently above or below those listed.

SM 2360 Rev 11 04-10 7

Miscellaneous - Lubrication System
Section 300-0020
TYRE PRESSURES
Tyre pressures on this pages apply to the truck serial number ranges specified only, Gross Vehicle Weight (GVW)
and axle weights may vary between truck derivatives. Tyre pressure should be recalculated if not shown for a
particular truck. Contact TEREX for assistance.

The tyre inflation pressures listed are manufacturers' recommendations for GVW travelling at maximum speed.
TEREX Advise that operators check tyre inflation pressures with tyre manufacturers to ensure the correct setting
for each particular application.

Front Centre Rear

Truck Brand Size Pattern b lbs/in2 b lbs/in2 b lbs/in2

TA27 Bridgestone 23.5 R25 VLT 4.4 64 4.4 64 4.4 64

A889 Bridgestone 23.5 R25 VMT 4.4 64 4.4 64 4.4 64
A892 Bridgestone 23.5 R25 VKT 4.4 64 4.4 64 4.4 64
Michelin 23.5 R25 XADT 3.8 55 3.4 50 3.8 55
Double Coin 23.5 R25 REM2 4.5 65 4.5 65 4.5 55
Triangle 23.5 R25 TB516 5.2 76 5.2 76 5.2 76
Triangle 23.5 R25 TM518 5.2 76 5.2 76 5.2 76
Triangle 23.5 R25 TL528 5.2 76 5.2 76 5.2 76
Bridgestone 30/65 R25 VLT 3 43 3 43 3 43
Michelin 30/65 R25 XADN 3.1 45 2.8 40 2.8 40
Michelin 750/65 R25 XAD 65 3.1 45 2.8 40 2.8 40

TA30 Bridgestone 23.5 R25 VLT 4.8 69 4.8 69 4.8 69

A894 Bridgestone 23.5 R25 VMT 4.8 69 4.8 69 4.8 69
A908 Bridgestone 23.5 R25 VKT 4.8 69 4.8 69 4.8 69
A897 Michelin 23.5 R25 XADT 4.1 60 4.1 60 4.1 60
A911 Double Coin 23.5 R25 REM2 4.5 65 4.5 65 4.5 65
Triangle 23.5 R25 TB516 5.2 76 7.2 76 5.2 76
Triangle 23.5 R25 TM518 5.2 76 5.2 76 5.2 76
Triangle 23.5 R25 TL528 5.2 76 5.2 76 5.2 76
Bridgestone 30/65 R25 VLT 3.2 46 3.2 46 3.2 46
Michelin 30/65 R25 XADN 3.1 45 3.1 45 3.1 45
Michelin 750/65 R25 XAD 65 3.1 45 3.1 45 3.1 45

* * * *

8 SM 2360 Rev 11 04-10

 Miscellaneous - Service Tools
Section 300-0070

INTRODUCTION 15500624 - Inline Connector (Individual Spare)

Contained in this section are recommended service 15500716 - Deutsch Cable (Individual Spare)
tools and equipment required for maintenance, 15500388 - QuickCheck II Kit (For use with palm top) -
overhaul and troubleshooting. In certain instances, Includes; Adaptors, Software and Cables.
both Metric and Imperial equivalents of the same
tools are listed. The following tools are recommended for Engine
Maintenance Procedures. These tools should be used
Note: A tool may be of one piece construction or in conjunction with procedures outlined in the engine
consist of a number of parts. manufacturers service manual.

General 15270076 - Vacuum Gauge

15270075 - Dial Depth Gauge
*15269784 - Multi-Gauge - Pressure range of 30 in of
15270006 - Connecting Rod Checking Fixture
vacuum to 5 000 lbf/in²
15269956 - Standard Puller
15269785 - Non-contact Infrared Thermometer
15269958 - Piston Ring Expander
15271082 - ORFS 'O' Ring Kit
15270078 - Manometer
15268968 - Strap Type Filter Wrench
15269959 - Main Bearing Cap Puller
15268969 - Socket Type Filter Wrench
15270081 - Pressure Gauge
15268970 - Universal Belt Tension Gauge
15269960 - Dial Gauge Attachment
15269858 - Digital Tachometer
15270009 - Threaded Insert Kit
15269859 - Multimeter
15269962 - Dial Bore Gauge Kit
15269813 - Water Manometer
15270079 - Manometer Tool
15269802 - Dial Indicator Gauge - Metric
15270042 - Pressure Gauge (0 - 160 lbf/in²)
15269803 - Dial Indicator Gauge - Imperial
15270010 - Crack Detection Kit
15269804 - Magnetic Base for Dial Indicator Gauge
15270082 - Pressure Gauge (0 - 300 lbf/in²)
15269805 - Micrometer - 0 to 25 mm
15269971 - Connecting Rod Guide Pins
15269806 - Micrometer - 0 to 1 in
15269966 - Cylinder Liner Puller Plate
15269860 - 92 Piece Heavy Equipment Tool Kit
15269961 - Dial Indicator Gauge
15269861 - Torque Wrench - 3/8 in drive,
15269973 - Oil Seal Guide
20 - 100 Nm (15 - 80 lbf ft) range
15269974 - Oil Seal Guide
15269862 - Torque Wrench - 1/2 in drive,
15269975 - Pulley Installation Tool
60 - 330 Nm (45 - 250 lbf ft) range
15269980 - Regulator Retainer Plug Driver
15269863 - Torque Wrench - 3/8 in drive,
15269981 - Oil Seal Guide
4 - 20 Nm (40 - 180 lbf in) range
15269982 - Torque Wrench - lb in
15269864 - Torque Wrench - 3/4 in drive,
15269985 - Flywheel Housing Alignment Plate
300 - 1 000 Nm (200 - 750 lbf ft) range
15270070 - Coupling Puller
15269865 - Torque Wrench - 3/4 in drive,
15270004 - Magnetic Base
700 - 1 500 Nm (500 - 1 000 lbf ft) range
15269994 - Cylinder Head Lifting Bracket
15269866 - Torque Multiplier - 1/2 in to 1 in drive,
15270084 - Blowby Check Tool
25:1 Ratio, 3 000 Nm (2 200 lbf ft) range
15269996 - Injector Puller
* - The following items should be added to the 15269997 - Piston Ring Compressor
multi-gauge to enable the gauge to be used on 15269999 - Gauge Block
diagnostic test points: 15270072 - Drive Gear Driver
15018226 - Diagnostic Coupling 15270020 - Needle Bearing Kit
00118748 - Connector (2 off) 15270021 - Bearing Installation Tool
15004085 - Hose Assembly (-4 HP, 84 in long) 15269984 - Engine Barring Tool
15270003 - Cylinder Liner Clamping Tool
Engine 15274125 - Cooling System Test Kit
15274126 - Refractometer
QSM - Electronic Diagnostic Tooling 15274129 - Hose Adaptor
15500622 - Insite Kit - Includes Insite program and 15274130 - Hose Adaptor
inline adaptor. Note; 15500716 Deutsch 15274127 - Belt Tension Gauge
Cable should be added to this kit. 15274128 - Hose Assembly Tools
15500623 - Insite Program (Individual Spare) 15274060 - Heavy Duty Cam Gear Puller Kit
15274131 - Wrench, Air Impact

SM 2468 Rev 1 05-07 1

Miscellaneous - Service Tools
Section 300-0070
15274138 - Installer, Valve Guide 15274098 - Kit, Counterbore Ledge Cutter
15274146 - Adaptor, Fuel Restriction 15274099 - Cutter Plate
15274141 - Lubriplate 105 Lubricant 15274100 - Clamp On Current Probe
15274136 - Kit, Torque Wrench 15274101 - Injector Puller/driver
15274139 - Pliers, Boot 15274102 - Kit, Hydraulic Actuator
15274142 - Lamp, 100W Black Light Kit 15274103 - Kit, Hydraulic Cylinder Support
15274143 - Charger Set International 15274104 - Kit, Cam Bushing I/R
15274135 - Kit, Guide Pin 15274105 - Kit, Rail Pressure Response
15274140 - Fixture, Pulley Alignment 15274106 - Kit, Pulley Installation Adaptor
15274134 - Kit, Inline II Datalink Adaptor 15274107 - Socket, Deep Flank Drive
15274059 - Liner Puller 15274108 - Template, Cylinder Head Capscrew
15274061 - Injector Protrusion Comparator 15274109 - Torque Angle Gauge
15274062 - Tube, Fuel Line Sight #12 15274110 - Small Bushing Driver Set
15274063 - Pilot, Oil Seal Puller Drills 15274111 - Kit,CNG Wastegate Test
15274064 - Kit, Turbo Rebuild 15274112 - Fixture, Cam Follower Assy R/I
15274065 - Digital Tachometer Kit 15274113 - Validator, Torque Wrench
15274066 - Bent Wrench 15274114 - Kit, Cylinder Head Leak Test
15274067 - Adaptor, Fuel Line Sight #16 Hose 15274115 - Kit, Charge Air Cooler Tester
15274068 - Gear Puller, Jaw 15274116 - Module, Vacuum Pressure
15274069 - Guide, Valve Installation 15274117 - Meter, Automotive
15274070 - Expander, Fan Hub Seal 15274118 - Puller, STC Injector
15274071 - Capscrew, Pulley Puller 15274119 - Driver, Thermostat Seal
15274072 - Driver, Regulator Valve Seat 15274120 - Sensor Break-out Kit
15274073 - Gauge, Cylinder Liner Ring 15274121 - Counterbore Salvage Kit
15274074 - Tube, Fuel Line Sight 15274122 - Installer, Oil Capacitor
15274075 - Cam Guide Expander - Large Dia 15274123 - Kit, Wiring Repair, Basic
15274076 - Fluorescent Tracer 15274133 - Cable, Throttle Breakout
15274077 - Expander, Accessory Drive Shaft Seal
15274078 - Fuel Pump S Wrench Transmission
15274079 - Kit, Torque Wrench
The following tools are recommended for Transmission
15274080 - Fitting Quick Connect
Maintenance Procedures. These tools should be used
15274081 - Fitting Quick Connect
in conjunction with procedures outlined in the
15274082 - Tube, Cooling System Sight
transmission manufacturers service manual.
15274083 - Tube, Cooling System Sight
15274084 - Tube, Cooling System Sight 15270087 - Straight Pin
15274148 - Wrench, Dial Type Torque 15270195 - Ring
15274144 - Wrench, Nylon Strap Filter 15270196 - Threaded Insert
15274145 - Gauge, Torque Angle
15270092 - Puller
15274147 - Wrench, Crows Foot 13 mm 15270093 - Puller
15274124 - Set, Torx Plus Driver 15270098 - Driver
15274137 - Bit, Screw Driver 15270197 - Driver
15274085 - Engine Parts Rack 15270198 - Driver
15274086 - Gauge, Belt Tension 15270199 - Driver
15274087 - Socket, Engine Position Sensor 15270200 - Driver
15274088 - Kit, Combustion Gas Leak Test
15270201 - Driver
15274132 - Test Fluid 15270104 - Driver
15274089 - Thermocouple Wire Kit 15270202 - Driver
15274090 - Engine Coolant Analyser 15270203 - Driver
15274091 - Gauge, Belt Tension 15270204 - Driver
15274092 - Wrench, CELECT Torque
15270112 - Measuring Pin
15274093 - Screwdriver, CELECT 15270115 - Set of Eye Bolts
15274094 - Puller, Water Pump Pulley 15270205 - Back-off Screws - M10
15274095 - Adjuster, STC Tappet 15270119 - Adjusting Screws - M10
15274096 - Super Chip Vacuum Kit 15270206 - Back-off Screws - M8
15274097 - Gauge, Cyl. Head Capscrew Length 15270116 - Adjusting Screws - M8

2 SM 2468 Rev 1 05-07

 Miscellaneous - Service Tools
Section 300-0070

15270207 - Back-off Screws - M12 Axles and Differentials

15270208 - Adjusting Screws - M5 15503031 - Grooved Socket Wrench
15270209 - Adjusting Screws - M12 15503032 - Lifting Device
15270210 - Adjusting Screws - M12 x 1.5 15503033 - Seal Punch
15269899 - Hot Air Blower 220 V 15503034 - Seal Punch
15269900 - Hot Air Blower 110 V 15503090 - Driver
15270211 - Backup Tool 15503093 - Lifting Device
15270120 - Clamping Yoke 15503094 - Bearing Tool
15269942 - Handle 15503095 - Bearing Tool
15270212 - Hoist 15503096 - Lifting Device
15270213 - Pulling Hook
15270214 - Ring Nut For Fabricated tools refer to Section 140-0020 AXLE
15270215 - Hoist GROUP HUB.
15270216 - Internal Puller
15270217 - Backup Tool
15270218 - Mounting Rail Front Suspension
15270127 - Guide Plate The following tools are recommended for any front
15270131 - Pry Bar suspension maintenence procedures. These tools
15270219 - Adjusting Spanner should be used in conjunction with the proecedures
15270220 - Hook Spanner outlined in Section 180-0020 SUSPENSION SYSTEM -
15270221 - Hook Spanner FRONT SUSPENSION.
15270222 - Insert for Torque Spanner
15270223 - Extension Those tools with an asterix* can be fabricated if
15270224 - Extension wished.
15270225 - Hook Spanner
15270226 - Hook Spanner 15503485 - Assembly rig* (Fig. 7)
15270227 - Pressing Sleeve 15503486 - Assembly support* (Fig. 8)
15270228 - Pressing Ring 15503487 - Assembly stand* (Fig. 9)
15270229 - Pressure Piece 15503488 - Locknut tool
15270230 - Backup Ring 15503489 - 3/8" x 17mm Crows Foot
15270231 - Test Cover 15503490 - 3/8" x 19mm Crows Foot
15270139 - Striker 15503491 - Puller Set
15270233 - Internal Snap Ring Pliers 15503492 - Puller set
15270145 - External Snap Ring Pliers 15503493 - 1/2 shaft Assy Removal Tool* (Fig. 10)
15270234 - Two Leg Puller 15503494 - 1/2 Shaft Seal Insertion Tool* (Fig. 11)
15270149 - Two Leg Puller 15503495 - 1/2 Shaft Seal Flinger Assy Tool* (Fig. 12)
15270150 - Three Leg Puller 15503496 - 1/2 Shaft Seal IBearing Assy Tool* (Fig.13)
15270151 - PR-78A Tester 15503497 - 1/2 Shaft Locknut Assy Tool* (Fig. 14)
15270311 - Harness 15503498 - Damper Extension Tool* (Fig. 15)
15270153 - Foil 15503499 - Pivot Block Seal Insertion Tool* (Fig. 16)
15270725 - PR-68 Tester 15503500 - Socket head tightening bolt* (Fig. 17)
15269943 - Spanner 15503501 - LWB Bush Insertion Tool 1* (Fig. 18)
15271103 - Hook Spanner 15503502 - LWB Bush Insertion Tool 2* (Fig. 19)
15271105 - Hook Spanner 15503503 - Knuckle dowel Removal Tool* (Fig. 20)
15272559 - Ring Clamp
15272560 - Bearing Puller
15272561 - Bearing Remover
15273664 - AEB Starter

SM 2468 Rev 1 05-07 3

Miscellaneous - Service Tools
Section 300-0070

Hydraulic Control System 15269111 - Loctite Prism 410

15500834 - IQAN Develop Change Interface 15269105 - Loctite 515
Contact Local Dealer - Hydraulic ECU Electronic 09007209 - Loctite 574 (50 ml)
Diagnostic Software. 09379518 - Loctite 574 (160 ml)
15269106 - Loctite 577 (Superflex)
Nitrogen Charging/Inflation 15270244 - Loctite 592 - Pipe Sealer with Teflon
15269121 - Nitrogen Tyre Inflation Kit
09359489 - Charging Assembly 15023696 - Loctite 635
09371048 - Loctite 638
Cooling and Air Conditioning 15269107 - Loctite 641
15269108 - Loctite Superclean Safety Solvent 706
15269814 - DCA4 Test Kit - Metric Version 15229541 - Loctite Activator 'N'
15269815 - DCA4 Test Kit - US Gallon Version 09243825 - Loctite Activator 'T'
15269816 - Refractometer - °C Scale 09175039 - General Adhesive
15269817 - Refractometer - °F Scale 15269114 - Tectyl 280 Wax Based Rust Preventive
15269844 - Portable High Vacuum Charging 09380475 - Hylosil RTV Silicone Compound
Station - R-134a Gas
15269845 - Halogen Leak Tester
Fabricated Tools
Cab The service tools shown in Figs. 1 through 6 can be
15271016 - Glass Removal Tool fabricated as shown.
15271017 - Bonding Kit (Quick Dry)
SM - 625

Adhesives and Sealants

15500552 - Torque Seal
15269103 - Loctite 221
09362529 - Loctite 225
09029849 - Loctite 243
15500690 - Loctite 262
09244598 - Loctite 270
09985300 - Loctite 271
15269104 - Loctite 275
15269245 - Loctite 277 Fig. 1 - Centring Spring Installation Tool
(Section 220-0090, STEERING VALVE)
15233715 - Loctite Prism 406

4 SM 2468 Rev 1 05-07

 Miscellaneous - Service Tools
Section 300-0070

SM - 407

DRILL
RAD
DEEP

RAD TYP
BURN OUT

SQUARE

SECURE ALUMINIUM DRILL AND REAM THROUGH

COLLAR WITH (3) M8 AND FIT 8 (0.31) Ø
CAP SCREWS HARDENED DOWEL
TORQUE PINS 2 PLACES

Dimensions in mm (inches)
Fig. 2 - End Cap Torque Tool (Section 220-0120, STEERING CYLINDER)

SM - 633

SILVER STEEL
SQUARE

OUTER SHIELD TO BE SECURED DOM TUBE

TO INNER BODY WITH 2BA CAPSCREWS

Dimensions in mm (inches)
Fig. 3 - Piston Torque Tool (Section 220-0120, STEERING CYLINDER)

SM 2468 Rev 1 05-07 5

Miscellaneous - Service Tools
Section 300-0070

SM - 2469

50 25
160 (6.299) (1.9680) (0.984)

10
90 (3.54) DRILL 13 (0.51) 11
(0.394)
RAD X 25 (0.984) (0.433)
DEEP

10 (0.394)
RAD TYP

150 (5.90) DIA

110 (4.33) DIA

120 (4.724)

(3.154 - 0.000 )

(4.724 - 0.005 )
+0.002

120.00 - 0.13
(1.9680)
80.10 - 0.00
+0.05
94 (3.7)

+
50

+
19 (0.75)
SQUARE

SECURE ALUMINIUM FIT 2 OFF B&T BUSH 12 (0.472) ID

COLLAR WITH (3) M8 25 65 18 (0.708) OD AND 2 OFF 12 DIA DOWEL
CAP SCREWS (0.984) (2.560) DRIVE FIT IN BUSH
110 (4.33)

Dimensions in mm (in)
Fig. 4 - End Cap Torque Tool (Section 230-0130, BODY CYLINDER)

SM - 2470

89 (3.5)
38.1 (1.5)

(0.375)
9.525

DIA
(0.470)
11.938
124.45 - 0.000 (4.899 - 0.000 )
+0.005

DIA
90 - 0.05 (3.543 - 0.002 )

SILVER STEEL
136 (5.35)
+
25.4 (1.0)
SQUARE

+0.13
+

(0.500)
12.7

EN3B
DIA

MILD STEEL

OUTER SHELL TO BE SECURED DOM TUBE

TO INNER BODY WITH 2BA CAP SCREWS 10.16 25.4
(0.4) (1.0)

Dimensions in mm (in)
Fig. 5 - Piston Torque Tool (Section 230-0130, BODY CYLINDER)

6 SM 2468 Rev 1 05-07

 Miscellaneous - Service Tools
Section 300-0070

SM - 1630
64 DIA HOLE
BURN
8
R4

96
19.5
6 6
2 PLACES 2 PLACES 0
10

40˚
114

R 20

71
31

48 16

1 HOLE DRILL THRO'

21 MM DIA
Fig. 6 - Body Lifting Lug Dimensions
(Section 270-0010, BODY AND MOUNTING)

SM - 3785

Fig. 7 - Assembly Rig Drawing (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM 2468 Rev 1 05-07 7

Miscellaneous - Service Tools
Section 300-0070

SM - 3786

15503485

Fig. 8 - Assembly Support Drawing (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM - 3787

15503485
15503486

Fig. 9- Assembly Stand Drawing (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

8 SM 2468 Rev 1 05-07

 Miscellaneous - Service Tools
Section 300-0070

SM - 3774

Fig. 10- 1/2 Shaft Assy Removal Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM - 3775

Fig. 11- 1/2 Shaft Seal Insertion Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM 2468 Rev 1 05-07 9

Miscellaneous - Service Tools
Section 300-0070

SM - 3776

Fig. 12- 1/2 Shaft Seal Insertion Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM - 3777

Fig. 13- 1/2 Shaft Seal FlingerTool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

10 SM 2468 Rev 1 05-07

 Miscellaneous - Service Tools
Section 300-0070

SM - 3778

Fig. 14- 1/2 Shaft Locknut Assembly Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM - 3779

Fig. 15- Damper Extention Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM 2468 Rev 1 05-07 11

Miscellaneous - Service Tools
Section 300-0070

SM - 3780

Fig. 16-Pivot Block Seal Insertion Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM - 3781

Fig. 17- Socket Head Bolt Tightening Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

12 SM 2468 Rev 1 05-07

 Miscellaneous - Service Tools
Section 300-0070

SM - 3782

Fig. 18- LWB Bush Insertion Tool 1(Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM - 3783

Fig. 19- LWB Bush Insertion tool 2(Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

SM 2468 Rev 1 05-07 13

Miscellaneous - Service Tools
Section 300-0070

SM - 3784

Fig. 20 - Knuckle Dowel Removal Tool (Section 180-0020, SUSPENSION SYSTEM- FRONT SUSPENSION)

14 SM 2468 Rev 1 05-07

 MISCELLANEOUS - Axle Bolt and Nut Torque Specifications
Section 300-0080

TORQUE LIMITS IN Nm (lbf ft)

Friction coefficient total 0.125 for screws and nuts
without after treatment as well as for phosphated
nuts.
Tighten by hand!

If nothing special is indicated, select correct Torque

Limits from the following tabulations -

Metric ISO Thread DIN 13 TABLE161

6.9 8.8 10.9 12.9

Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)

M6 8 (5.9) 9.5 (7) 13 (9.6) 16 (11.8)

M8 19 (14) 23 (16.9) 32 (23.6) 39 (28.8)
M 10 39 (28.8) 46 (33.9) 64 (47.2) 77 (56.8)
M 12 67 (49.4) 80 (59) 110 (81.1) 135 (99.6)
M 14 105 (77) 125 (92) 180 (133) 215 (159)
M 16 165 (122) 195 (144) 275 (203) 330 (243)
M 18 225 (166) 270 (199) 390 (288) 455 (336)
M 20 325 (240) 385 (284) 540 (398) 650 (479)
M 22 435 (321) 510 (376) 720 (531) 870 (642)
M 24 560 (413) 660 (487) 930 (686) 1 100 (812)
M 27 830 (612) 980 (723) 1 400 (1 033) 1 650 (1 217)
M 30 1 100 (811) 1 350 (996) 1 850 (1 365) 2 250 (1 660

Metric ISO Fine Thread DIN 13 TABLE162

6.9 8.8 10.9 12.9

Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)

M8x2 21 (15.5) 25 (18.4) 35 (25.8) 42 (31)
M 10 x 1.25 41 (30.3) 49 (36.1) 68 (50.2) 82 (60.5)
M 12 x 1.25 74 (54.6) 88 (64.9) 125 (92.2) 150 (110.6)
M 12 x 1.5 70 (51.6) 83 (61.2) 115 (84.8) 140 (103.3)
M 14 x 1.5 115 (85) 140 (103) 195 (144) 235 (173)
M 16 x 1.5 175 (129) 210 (155) 295 (218) 340 (251)
M 18 x 1.5 255 (188) 305 (225) 425 (314) 510 (376)
M 20 x 1.5 360 (266) 425 (314) 600 (443) 720 (531)
M 22 x 1.5 480 (354) 570 (420) 800 (590) 960 (708)
M 24 x 2 610 (450) 720 (531) 1 000 (738) 1 200 (885)
M 27 x 2 890 (656) 1 050 (774) 1 500 (1 106) 1 800 (1 328)
M 30 x 2 1 250 (922) 1 450 (1 070) 2 050 (1 512) 2 500 (1 844)

SM 1521 10-98 1
Miscellaneous - Axle Bolt and Nut Torque Specifications
Section 300-0080
Friction coefficient total 0.14 for screws and nuts
without after treatment as well as for phosphated
nuts.
Tighten by hand!

If nothing special is indicated, select correct Torque

Limits from the following tabulations -

Metric ISO Thread DIN 13 TABLE163

6.9 8.8 10.9 12.9

Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)

M6 8.5 (6.3) 10 (7.4) 14 (10.3) 17 (12.5)
M8 21 (15.5) 25 (18.4) 35 (25.8) 41 (30.2)
M 10 41 (30.2) 49 (36.1) 69 (50.9) 83 (61.2)
M 12 72 (53.1) 86 (63.4) 120 (88.5) 145 (106.9)
M 14 115 (85) 135 (100) 190 (140) 230 (170)
M 16 180 (133) 210 (155) 295 (218) 355 (262)
M 18 245 (181) 290 (214) 400 (295) 485 (358)
M 20 345 (255) 410 (302) 580 (428) 690 (509)
M 22 465 (343) 550 (406) 780 (575) 930 (686)
M 24 600 (443) 710 (524) 1 000 (738) 1 200 (885)
M 27 890 (656) 1 050 (774) 1 500 (1 106) 1 800 (1 328)
M 30 1 200 (885) 1 450 (1 070) 2 000 (1 475) 2 400 (1 770)

Metric ISO Fine Thread DIN 13 TABLE164

6.9 8.8 10.9 12.9

Size Nm (lbf ft) Nm (lbf ft) Nm (lbf ft) Nm (lbf ft)

M8x1 23 (17) 27 (19.9) 38 (28) 45 (33.2)
M 10 x 1.25 44 (32.5) 52 (38.4) 73 (53.8) 88 (65)
M 12 x 1.25 80 (59) 95 (70) 135 (99) 160 (118)
M 12 x 1.5 76 (56.1) 90 (66.4) 125 (92) 150 (111)
M 14 x 1.5 125 (92) 150 (111) 210 (155) 250 (184)
M 16 x 1.5 190 (140) 225 (166) 315 (232) 380 (280)
M 18 x 1.5 275 (203) 325 (240) 460 (339) 550 (406)
M 20 x 1.5 385 (284) 460 (339) 640 (472) 770 (568)
M 22 x 1.5 520 (384) 610 (450) 860 (634) 1 050 (774)
M 24 x 2 650 (479) 780 (575) 1 100 (811) 1 300 (959)
M 27 x 2 970 (715) 1 150 (848) 1 600 (1 180) 1 950 (1 438)
M 30 x 2 1 350 (997) 1 600 (1 180) 2 250 (1 660) 2 700 (1 991)

* * * *

2 SM 1521 10-98
 MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
Section 300-0080

fasteners can be safely tightened, the following torque

WARNING tables have been compiled.
Some fasteners are important attaching parts
which could affect the performance of vital The torque values listed in the tables have been
components and systems, and/or, could result established over a period of years and cover all
in major repair expense. Fasteners should be conditions of assembly. The maximum torque values
replaced with parts of the same part number, or for standard bolts and nuts are based on 75% of the
with equivalent parts, if replacement becomes specified minimum proof strength of the bolt steel in
necessary. Do not use replacement parts of order to provide a safety factor to compensate for the
lesser quality or substitute design. The torque variation in the accuracy of torque wrenches, skill of
values shown in the following tables should be the assembler, and variance in fractional conditions.
used in all cases, unless otherwise specified All torque values are for lubricated threads. The
elsewhere in this manual, in order to avoid term 'lubricated' includes the application of thread
possible personal injury or property damage. lubricants, cadmium plating or the use of hardened
washers.
The following torque specification tables are based on
GM Standard Materials for bolts, nuts, studs and self- To provide a quick method for determining the GM
locking fasteners based on SAE bolt steel material classification of a particular standard bolt
classifications, or, prevailing torque specifications for or nut, compare the bolt head markings to those in
self-locking fasteners. the appropriate tables, then locate the maximum
torque value for that bolt size in the column under
To prevent the threaded bolts and nuts used on this that marking.
equipment from being overstressed during assembly,
and to establish a uniform value to which these

RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ±10% TABLE 144

SAE Symbol SAE Symbol SAE Symbol SAE Symbol 12 Point

GM 260-M GM 280-M GM 290-M GM 300-M Cap Screws
Size Steel Steel Steel
Steel
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8)
Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
0.25 - 20 5 4 8 6 11 8 12 9 14 10
0.25 - 28 7 5 10 7 12 9 14 10 15 11
0.31 - 18 11 8 18 13 22 16 24 18 27 20
0.31 - 24 12 9 19 14 24 18 27 20 30 22
0.38 - 16 20 15 31 23 38 28 43 32 49 36
0.38 - 24 23 17 34 25 43 32 49 36 56 41
0.44 - 14 33 24 47 35 59 43 68 50 75 55
0.44 - 20 37 27 54 40 68 50 79 58 87 64
0.50 - 13 50 37 75 55 94 69 106 78 119 88
0.50 - 20 56 41 88 65 106 78 122 90 134 99
0.56 - 12 75 55 108 80 136 100 156 115 171 126
0.56 - 18 81 60 122 90 149 110 176 130 191 141
0.62 - 11 102 75 149 110 190 140 217 160 237 175
0.62 - 18 115 85 169 125 210 155 244 180 270 199
0.75 - 10 176 130 271 200 332 245 380 280 420 310
0.75 - 16 203 150 298 220 366 270 420 310 472 348
0.88 - 9 169 125 434 320 536 395 610 450 679 501
0.88 - 14 190 140 488 360 590 435 678 500 751 554
1.00 - 8 258 190 651 480 800 590 915 675 1021 753
1.00 - 12 285 210 719 530 881 650 1003 740 1119 825
1.00 - 14 285 210 732 540 902 665 1030 760 1148 847

SM 1238 Rev 1 06-08 1

Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080

RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ±10% TABLE 145

Size SAE Symbol SAE Symbol SAE Symbol SAE Symbol 12 Point Cap Screws
GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8)

Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft

1.12 - 7 366 270 800 590 1132 835 1302 960 1447 1067
1.12 - 12 407 300 902 665 1274 940 1451 1075 1624 1198
1.25 - 7 515 380 1132 835 1600 1180 1830 1350 2043 1507
1.25 - 12 569 420 1254 925 1776 1310 2034 1500 2267 1672
1.38 - 6 664 490 1478 1090 2095 1545 2400 1770 2676 1974
1.38 - 12 759 560 1688 1245 2393 1765 2739 2020 3056 2254
1.50 - 6 881 650 1966 1450 2786 2055 3186 2350 3556 2623
1.50 - 8 936 690 2088 1540 2962 2185 3390 2500 3781 2789
1.50 - 12 990 730 2217 1635 3145 2320 3593 2650 4010 2958
1.75 - 5 - - - - 4393 3240 5016 3700 5604 4133
1.75 - 12 - - - - 5091 3755 5830 4300 6497 4792
1.88 - 8 - - - - 6006 4430 6874 5070 7664 5653
1.88 - 12 - - - - 6304 4650 7213 5320 8048 5936
2.00 - 4.5 - - - - 6623 4885 7565 5580 8448 6231
2.00 - 8 - - - - 7342 5415 8406 6200 9367 6909
2.00 - 12 - - - - 7687 5670 8786 6480 9811 7236
2.25 - 4.5 - - - - 9701 7155 11090 8180 12377 9129
2.25 - 8 - - - - 10629 7840 12148 8960 13566 10006
2.25 - 12 - - - - 11050 8150 12636 9320 14102 10401
2.50 - 12 - - - - 15280 11270 17463 12880 19500 14383

Note: Where materials other than GM Standards are used, refer to the conversion table below.

Types of Steel Rockwell Hardness Applicable Torque SAE Bolt Head Symbols
Range Values

Plain Low Carbon Rockwell "B" 85-100 GM 260-M

(for example SAE 1018
or 1020)

Plain Medium Carbon Rockwell "C" 19-30 GM 280-M

(for example SAE 1035,
1038 and 1045)

Medium Carbon Alloy Rockwell "C" 28-34 GM 290-M

(for example SAE 4140,
8642 and 5157)

Medium Carbon Alloy Rockwell "C" 32-38 GM 300-M

(for example SAE 4140,
8642 and 5147)

2 SM 1238 Rev1 06-08

 Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080

RECOMMENDED MAXIMUM TORQUES (METRIC) ±10% TABLE 146

Class 8.8 Class 9.8 Class 10.9 Class 12.9
Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
M1.6 - 0.35 - - 0.20 0.15 - - 0.20 0.15
M1.6 - 0.20 - - 0.25 0.20 - - 0.40 0.30
M2.0 - 0.40 - - 0.25 0.20 - - 0.45 0.30
M2.0 - 0.25 - - 0.45 0.30 - - 0.45 0.30
M2.0 - 0.45 - - 0.25 0.20 - - 0.45 0.30
M2.5 - 0.35 - - 1 0.75 - - 1 0.75
M3.0 - 0.50 - - 1 0.75 - - 2 1.5
M3.0 - 0.35 - - 1 0.75 - - 2 1.5
M3.5 - 0.60 - - 2 1.5 - - 3 2
M4.0 - 0.70 - - 3 2 - - 4 3
M4.0 - 0.35 - - 3 2 - - 5 3
M5.0 - 0.80 - - 5 4 - - 8 6
M5.0 - 0.50 - - 6 4 - - 9 6
M6.0 - 1.00 - - 9 6 - - 13 10
M6.3 - 1.00 - - 10 8 13 10 16 11
M6.0 - 0.75 - - 10 7 12 9 14 10
M8.0 - 1.25 - - 21 15 27 20 32 23
M8.0 - 1.00 - - 23 17 29 21 34 25
M10.0 - 1.50 - - 42 31 54 39 63 46
M10.0 - 1.25 - - 45 32 57 41 67 48
M12.0 - 1.75 - - 74 53 94 68 110 80
M12.0 - 1.25 - - 81 58 103 74 121 87
M14.0 - 2.00 - - 118 85 151 109 176 127
M14.0 - 1.50 - - 128 92 163 118 190 137
M16.0 - 2.00 169 122 - - 234 169 274 197
M16.0 - 1.50 181 130 - - 250 180 292 211
M18.0 - 2.50 234 169 - - 323 234 378 273
M18.0 - 1.50 263 190 - - 363 262 425 307
M20.0 - 2.50 330 239 - - 457 330 531 386
M20.0 - 1.50 367 265 - - 507 366 593 423
M22.0 - 2.50 451 325 - - 623 450 728 526
M22.0 - 1.50 495 357 - - 684 494 800 577
M24.0 - 3.00 571 412 - - 790 570 923 667
M24.0 - 2.00 623 450 - - 861 622 1007 727
M27.0 - 3.00 837 605 - - 1158 836 1354 977
M27.0 - 2.00 903 652 - - 1250 902 1461 1055
M30.0 - 3.00 1135 820 - - 1570 1134 1835 1325
M30.0 - 2.00 1258 908 - - 1740 1256 2034 1468
M30.0 - 1.50 1300 939 - - 1799 1299 2102 1516
M36.0 - 4.00 1985 1433 - - 2745 1982 3208 2317
M36.0 - 3.00 2102 1517 - - 2907 2099 3398 2453

SM 1238 Rev 1 06-08 3

Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080

SELF-LOCKING FASTENERS has been used. Do not use a self-locking fastener

Self-locking fasteners develop a measured gripping more than five times.
action or torque and provide a renewed locking action
after being removed and reinstalled to their original The following table shows the minimum torque
mating part. The self-locking fasteners used on this specifications allowed to remove self-locking fasteners
equipment meet specifications necessary to allow the after the initial break-away torque has been achieved.
fasteners to be reused up to five times. Whenever a Any self locking fastener that can be removed with
self-locking fastener is removed, the head of the less than the prevailing torque value shown in the
fastener should be deeply scribed or otherwise table should be discarded, even if the fastener has not
marked to record the number of times the fastener yet been reused five times.

MINIMUM PREVAILING TORQUE - REMOVAL TABLE 537

Lock Screws Lock-nuts
SAE Grade 5 and 8, SAE Grade 5 SAE Grade 8
and ASTM A-574
Size Nm lbf in Nm lbf in Nm lbf in
0.25-20 0.3 3 0.4 3.5 0.5 4.5
0.25-28 0.3 3 0.4 3.5 0.5 4.5
0.31-18 0.6 5 0.6 5.5 0.9 7.5
0.31-24 0.6 5 0.6 5.5 0.9 7.5
0.38-16 1.0 9 1.0 8.5 1.3 11.5
0.38-24 1.0 9 1.0 8.5 1.3 11.5
0.44-14 1.4 12 1.4 12 1.8 16
0.44-20 1.4 12 1.4 12 1.8 16
0.50-13 1.8 16 1.7 15 2.3 20
0.50-20 1.8 16 1.7 15 2.3 20
0.56-12 2.5 22 2.4 21 3.2 28
0.56-18 2.5 22 2.4 21 3.2 28
0.62-11 3.4 30 3.1 27 4.1 36
0.62-18 3.4 30 3.1 27 4.1 36
0.75-10 5.1 45 4.6 41 6.1 54
0.75-16 5.1 45 4.6 41 6.1 54
0.88-9 7.3 65 7.0 62 9.3 82
0.88-14 7.3 65 7.0 62 9.3 82
1.00-8 9.6 85 9.5 84 12.7 112
1.00-12 9.6 85 9.5 84 12.7 112
1.00-14 - - 9.5 84 12.7 112

* * * *

4 SM 1238 Rev1 06-08

 MISCELLANEOUS - Unit Storage
Section 300-0090

GENERAL batteries where they will be protected from temperature

extremes. Coat the battery terminals and cable ends
The storage of machines for short periods of time or
with acid resistant petroleum jelly.
during the off-season is an important item if major
damage to components is to be avoided. Failure to take
9. TYRES - Remove all grease and oil. Inflate all tyres
the necessary steps to protect the various assemblies
to correct pressure. During storage, check inflation
while the machine is being stored can result in an
pressure approximately once every two weeks.
expensive overhaul job and delay in returning the
machine to work.
10. TRACKS - Check recoil cylinder pressure and track
adjustment. Remove all oil and grease (rubber tracks).
TEMPORARY STORAGE
11. EXHAUSTS - Cover exhaust stack openings with
When storing a machine for a period of 30 days or less,
plastic or waterproof paper and secure with adhesive
the following precautions must be taken:
tape.
1. INSPECTION AND REPAIR - Thoroughly inspect and
12. AIR INTAKES - Cover openings with plastic or
test the machine and make any necessary repairs or
waterproof paper and secure with adhesive tape.
adjustments which may be necessary to prepare the
machine for service. This will enable you to put the
13. SUSPENSION RIDE CYLINDERS - Release the
machine back into use immediately at the end of the
pressure in the cylinders to retract them for minimum
storage period.
piston rod exposure. Coat the remaining exposed
piston rod surface with a suitable oil or grease.
2. LUBRICATION - Lubricate the machine completely
according to the instructions given in Section
14. HYDRAULIC CONTROL VALVES - Where possible
300-0020, LUBRICATION SYSTEM of this manual.
position hydraulic controls for minimum exposure of
valve spools (spool inside valve body). Coat the
3. COOLING SYSTEM - Verify that the cooling system
remaining exposed spool surface with a suitable oil or
is adequately protected for the climatic conditions
grease.
expected at the storage locatin. Adjust if necessary.
15. HYDAULIC CYLINDERS - Where possible retract
4. PARKING - After thoroughly cleaning the entire
cylinders for minimum rod exposure. Coat the
machine, park it on a hard, dry, level surface that is free
remaining exposed piston rod surface with a suitable oil
from grease and oil. The oil and grease would cause
or grease.
tyre deterioration. Apply the parking brake.
16. AIR CYLINDERS - Coat the exposed piston rod
Note: If the machine is delivered from the Terex facility
surface with a suitable oil or grease.
with a wax coating to protect the paint-work, do not
remove it until the machine is removed from storage.
17. CONTROL CABLES & LINKAGE - All exposed
linkage, clevis ends, ball joints etc, wchich are not
5. FUEL TANK - Fill the fuel tank to prevent moisture
protected during "lubrication" should be protected by a
condensation within the tank. Coat filler neck and cap
suitable oil or grease.
threads with oil.
18. OPEN PORTS & HOSE ENDS - Plug or seal with
6. HYDRAULIC TANKS - Coat filler neck and cap
adhesive tape all open ports.
threads with oil. Fill the tank to operating level if
necessary.
19. MACHINED SURFACES - Coat any exposed
machined bores and surfaces with a suitable rust
7. AIR RESERVOIRS - Open all drain cocks at bottom
preventative.
of air tanks.
Note: Do not apply oil or grease to brake discs.
8. BATTERIES - Where moderate temperatures are
expected, the batteries may be left in the machine. Up
20. HINGES - Apply oil to all the hinges.
to 30 days, the batteries may require a boost at the
end of the storage period. Preferably place the batteries
21. SEAT SLIDE ADJUSTERS - Coat with grease.
in the shop where they can be inspected, brought up to
full charge and placed on a trickle charge to keep them
22. SEATS, ARMRESRTS & CUSHIONS - When
at full charge. In very cold or hot climates, store the

SM 2629 01-10 1
Miscellaneous - Unit Storage
Section 300-0090
machine is not equipped with a cab, cover these items Clean 8-19 mm (0.25-0.75 in) gravel under each tyre is
with plastic or waterproof barrier paper, and secure with desirable if the area is not paved. Storage should not be
adhesive tape. Provide an opening in the underside of permitted on blacktop or oil stabilised surfaces.
the protective materials to prevent condensation build
up. Except in very cold weather, stored machines should
be moved occasionally, at least once every six months,
23. CABS - All windows, doors and vents closed. so the same section of the tyre is not always under
strain from deflection.
24. HOODS, HOODSIDES, COVERS, PANELS, ETC -
Installed. Inflation in the tyres must be adjusted to the
recommended service pressure before shipping or
25. SECURITY PANELS AND SECURITY LOCKS - putting a stored machine into service.
Installed and locked.
EXTENDED STORAGE - Over Six Months
EXTENDED STORAGE - Under Six When a machine is to be stored for a period over SIX
Months MONTHS, the following procedure must be followed:
When storing a machine for periods of longer than 30
days, but less than six months, the following procedure Note: These steps are in addition to those given
must be followed, in addition to the procedure previously under 'Extended Storage - Under Six
described above: Months'.

1. ENGINE - Consult the relevant Engine Manual/Dealer 1. WHEEL BEARINGS - Remove, clean, inspect and
for storage procedure for periods longer than 30 days. repack all wheel bearings.

2. TRANSMISSION - Consult the relevant Transmission Note: The above steps must be repeated for every Six
Manual/Dealer for storage procedure for periods longer Month period the machine is in storage.
than 30 days.

3. BATTERIES - Remove the batteries from the REMOVAL FROM EXTENDED STORAGE
machine and store in shop. Protect batteries from
temperature extremes. Coat the terminals and cable The following procedure must be followed when a
ends with acid resistant petroleum jelly. machine is removed from storage.

4. VENTS AND BREATHERS - Remove all vents and 1. FUEL TANK - Drain off any condensation. Remove
breathers and plug all the openings with pipe plugs or covers from openings and re-install breather.
seal with adhesive waterproof tape.
2. HYDRAULIC TANKS - Remove covers from openings
5. BELTS - Release tension on all the belts. and re-install breathers. Fill tank to operating level if
necessary.
6. TYRES - When extended storage is anticipated, the
machines should be blocked up so weight does not 3. AIR RESERVOIRS - Close all drain cocks.
rest on the tyres, and inflation pressure reduced to 1
bar (15 lbf/in2). Storage of such machines should be 4. BATTERIES - Check batteries are fully charged and
under cover if possible; otherwise tyres should be re-install.
protected from the elements by an opaque waterproof
covering. 5. TYRES - Inflate to the recommended pressure.

If it is not possible to block up the machines, inflation 6. TRACKS - Check recoil cylinder pressure and track
pressure in the tyres should be increased to 25% above adjustment.
the rated pressure for the actual load on the tyre in
storage condition. 7. EXHAUSTS - Remove temporary storage covers from
exhaust stack openings.
The storage area surface should be firm, reasonably
level, well drained and free of all oil, fuel or grease. 8. AIR INTAKES - Remove temporary storage covers
from air intake openings.

2 SM 2629 01-10
 Section 300-0090

9. SUSPENSION RIDE CYLINDERS - Remove

protective coating from piston rod surface. Charge with
Nitrogen.

10. HYDRAULIC CYLINDERS - Remove protective

coating from piston rod surface.

11. VENTS AND BREATHERS - Remove seals and

plugs from all breather openings, then install all
breathers and vents.

12. BELTS - Adjust tension on all belts.

13. ENGINES - Consult the relevant Maintenance

Manual/Dealer for instructions on removing an engine
from storage.

14. TRANSMISSION - Consult the relevant

Maintenance Manual/Dealer for instructions on
removing a transmission from storage.

15. PAINT - Check machine for rust. Remove all rust

spots and repaint rusted areas.

16. DECALS - Check condition of decals and replace if

necessary.

17. LUBRICATION - Completely lubricate the machine

according to the instructions in the "Lubricatin System"
section of the relevant Manual.

18. GENERAL - Check for fuel, hydraulic oil, coolant

and air leaks. Replace all leaking seals.

Field rework should always be implemented in

accordance with the appropriate instructions in
the Maintenance Manuals.

* * * *

SM 2629 01-10 3
Miscellaneous - Unit Storage
Section 300-0090

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4 SM 2629 01-10