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TR70
Off-Highway Truck
Maintenance Manual

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TECHNICAL PUBLICATIONS DEPARTMENT

TEREX EQUIPMENT LIMITED,
PART No. 15273743 MOTHERWELL, SCOTLAND, ML1 5RY
REF. NO. SM789
SM 1909 Rev 8 03-06
 Service
The information contained within this
Alert must not be made available to
third parties not authorised to receive it. Information
Alert
DATE: April 1994 B168

MODEL: General

SUBJECT: VITON 'O' RINGS AND SEALS (FLUORO-ELASTOMERS) - SAFETY HAZARDS

PURPOSE:

To advise potentially hazardous condition.

DETAIL:

It has been brought to our attention that 'Viton' material used in manufacture of oil seals and 'O' rings, produces
a highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315° C.

The resulting contamination can have extreme consequences on human tissue since it is almost impossible to
remove after contact.

We therefore recommend the following procedure when it is necessary to inspect any equipment that has been
subjected to a high temperature i.e. fire.

a. Visually inspect for any gaskets or seals which have suffered from heat; they will appear black and sticky.

b. If this is affirmed - Do Not Touch

c. Make enquiries to ascertain the material composition. Any Fluoro-elastomer (Viton, Fluorel or Tecmoflon)
should be considered dangerous but natural rubber and nitrile are non-hazardous.

d. If Fluoro-elastomer seals have been used, then the affected area MUST be decontaminated before
undertaking further work.

e. Disposable Heavy Duty Gloves (Neoprene) MUST be worn and the affected area decontaminated by
washing thoroughly with Limewater (Calcium Hydroxide solution).

f. Any cloths, residue and gloves used MUST be safely discarded after use.

Note: Burning of the discarded items is NOT RECOMMENDED, except in an approved incineration process
where the gaseous products are treated by alkaline scrubbing.

TEREX SERVICE DEPARTMENT

TEREX Equipment Limited, Motherwell, Scotland ML1 5RY Tel. (0698) 732121 Tlx. 77141 Fax. (0698) 734046
TEREX Division, Tulsa, Oklahoma, 74107 USA Tel. (918) 446-5581 Fax. (918) 446-9752
 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.

Two types of heading are used in this manual to attract your attention.

1. WARNING - This symbol is used when an operating procedure, practice, etc., which, if not correctly
followed could result in personal injury or loss of life. Look for this symbol to point out important safety
precautions. It means - ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

2. Note - This is used when an operating procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.

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

SM 222 Rev 1 9-93

 TABLE OF CONTENTS
Section No. Description SM No.

000 GENERAL INFORMATION

0000 TR70 Off-Highway Truck 1911
0010 Welding Procedure 2172

100 CHASSIS
0010 Chassis, Hood and Fenders 1918 Rev 1

110 ENGINE
0030 Engine and Mounting 1923 Rev 2
0050 Air Cleaner 1925
0130 Power Takeoff 1914

120 TRANSMISSION
0010 Transmission and Mounting 1932
0070 Commercial Electronic Control (CEC) Shift System 1575 Rev 2
0070 Commercial Electronic Control 2 (CEC2) 2128 Rev 2
0090 Power Takeoff 1915
0100 Transmission Oil Filter 1931

130 DRIVELINE
0010 Front Driveline 1577
0020 Rear Driveline 1578

140 FRONT AXLE

0040 Wheel, Rim and Tyre 2042 Rev1

160 REAR AXLE

0020 Differential 2045
0030 Axle Group 1184
0050 Wheel, Rim and Tyre 2044 rev1

165 BRAKE PARTS

0020 Brake Parts - Front Axle 1916
0030 Brake Parts - Rear Axle 2038

180 SUSPENSION SYSTEM

0030 Ride Cylinder - Front 1912 Rev 1
0050 Ride Cylinder - Rear 2033 Rev 1

190 CIRCUIT DIAGRAMS

0000 Circuit Diagrams 1924
0000 Circuit Diagrams (C.E.C. 2, D.D.E.C. IV, Quantum Celect) 2425
0270 Switches and Sensors 2032 Rev 2

200 FUEL SYSTEM

0010 Fuel Tank, Lines and Mounting 1927
0051 Electronic Foot Pedal 2031

210 COOLING SYSTEM

0000 Cooling System 2278
0040 Radiator, Header Tank and Mounting 2034
0050 Disc Brake Oil Cooler 2035
0060 Transmission Oil Cooler 2036

SM 1910 Rev 14 03-06 1

 TABLE OF CONTENTS
Section No. Description SM No.

220 STEERING SYSTEM

0000 Steering System Schematic 1591
0040 Steering and Brake Control Tank 1592
0050 Steering Pump 2356
0080 Accumulator 1205
0090 Steering Valve 2027
0110 Double Relief Valve 1208
0120 Steering Cylinder and Linkage 2028 Rev 1
0130 Accumulator Valve 1209
0150 Steering Filter 1593

230 BODY SYSTEM

0000 Body System Schematic 1929 Rev 1
0040 Body and Disc Brake Cooling Tank 1928 Rev 1
0050 Tandem Pump 1213
0060 Body Control Valve 1659 Rev 2
0081 Body Control Joystick 1597
0110 Manifold Relief Valve 1645 Rev 1
0121 Pilot Supply Valve 1599 Rev 1
0130 Body Cylinder 1930

250 BRAKING SYSTEM

0000 Braking System Schematic 2039 Rev 1
0050 Brake Manifold Valve 2040 Rev 1
0060 Accumulator 1600
0070 Treadle Valve 1225 Rev 1
0090 Directional Control Valve 1226
0100 Monoblock Brake Valve 1227 Rev 2
0110 Pressure Reducing Valve (Optional) 2041
0130 Retarder Control Valve 1601 Rev 1
0140 Shuttle Valve 1229

260 OPERATORS COMPARTMENT

0010 Cab and Mounting 1602 Rev 1
0090 Driver Seat and Mounting 1901 Rev 1
0110 Passenger Seat and Mounting 1902
0130 Air Conditioning and Mounting 2043 Rev 1
270 BODY
0010 Body and Mounting 1917

300 MISCELLANEOUS
0020 Lubrication System 2030 Rev 3
0070 Service Tools 2037 Rev 2
0080 Standard Bolt and Nut Torque Specifications 1238
0090 Unit Storage 1239

* * * *

2 SM 1910 Rev 14 03-06

 GENERAL INFORMATION - TR70 Off-Highway Truck
Section 000-0000

SM - 2409

Max
1 536 4 270
Body (5-0)
(14-0)
Depth
3 940
(12-11)

1080 610
(3-6) (2-0) Vehicle Clearance Diameter (SAE) 22.4 m (73-6)
1 500 8 380
(4-11) (27-6)
2 995 (9-10)
4 445 (14-7)
8 380
(27-6)
5 290 (17-4) 6 580
4 940 (16-2) (21-7)
6 200
(20-4)
59˚

4 570 4 190 3 785

(15-0) (13-9) (12-5)
15˚

685 (2-3) 460 (1-6)

2 970 (9-9) 2 490 (8-2) 4 470 (14-8) 2 945 (9-8)
3 660 (12-0) 9 905 (32-6)
4 420 (14-6)
Dimensions in mm (ft-in)

Fig. 1 - Machine Dimensions

ENGINE TRANSMISSION
Make/Model .................................... Detroit Diesel 12V 2000 Make/Model .............................................. Allison M6600AR
Type ............................. 4 Cycle, Turbocharged/Aftercooled. automatic electronic control with soft shift feature.
Electronic Management Remote mounted in the frame. Integral TC 682 torque
Gross Power @ 2 100 rev/min .................................. 567 kW converter and planetary gearing. Six speeds forward, two
(760 hp, 770 PS) reverse. Automatic converter lockup action in all speed
Net Power @ 2 100 rev/min ..................................... 522 kW ranges. With body up, gear range is limited to 1st forward
(700 hp, 710 PS) only. Downshift inhibitor. Intregal hydraulic retarder.

Note: Power ratings to SAE J1995 Jun 95. Engine

emission meets USA EPA/CARB MOH 40 CFR 89 and Speeds With 24.00 R 35 Tyres
EU NRMM (non-road mobile machinery directive). Forward
Gear 1 2 3 4 5 6
Maximum Torque ... 3 118 Nm (2 300 lbf ft) @ 1 200 rev/min
Number of Cylinders/Configuration .............................. 12, V Ratio 4.00 2.68 2.01 1.35 1.00 0.67
Bore x Stroke ........................ 130 x 150 mm (5.11 x 5.91 in) km/h 9.5 14.2 18.9 28.2 38.1 57.0
Total Displacement ................................. 24 litres (1 464 in³) mile/h 5.9 8.8 11.8 17.5 23.7 35.5
Starting ...................................................................... Electric
Maximum Speed, Full Load ............................ 2 100 rev/min Reverse
Maximum Speed, No Load ............................. 2 250 rev/min Gear 1 2
Idle Speed .......................................................... 750 rev/min
Ratio 5.12 3.46
Safe Operating Angle .................................. 30°/60% Grade
km/h 7.4 11.0
mile/h 4.6 6.8

SM 1911 7-00 1
General Information - TR70 Off Highway Truck
Section 000-0000
DRIVE AXLE Parking
Heavy duty axle with single reduction spiral bevel gear Application of rear brakes by springs in brake disc pack.
differential, full floating axle shafts, and planetary reduction Hydraulically released.
at each wheel. Hold-off Pressure .................................. 83 bar (1 200 lbf/in²)

Ratios: Standard Optional Retardation

Differential ....................................... 3.73:1 3.15:1 Modulated lever control of rear disc pack. . 670 kW (900 hp)
Planetary ......................................... 5.80:1 5.80:1 continuous.
Total Reduction ............................. 21.63:1 18.27:1 Retarder Actuation Pressure ......... up to 33 bar (480 lbf/in²)

Emergency
SUSPENSION
Push button solenoid control applies service and parking
Front: King pin strut type independent front wheel brakes. Automatically applies when engine is switched off.
suspension by self-contained, variable rate, nitrogen/oil Parking brake applies should system pressure fall below a
cylinders. predetermined level.
Rear: Variable rate nitrogen/oil cylinders with A-frame Brakes conform to ISO 3450, SAE J1473 OCT 90.
linkage and lateral stabilizer bar.

Maximum Strut Stroke STEERING SYSTEM

Front ....................................................... 235 mm (9.25 in)
Rear .......................................................... 193 mm (7.6 in) Independent hydrostatic steering with closed-centre
Maximum Rear Axle Oscillation ..................... ± 7.5 Degrees steering valve, accumulator and pressure compensating
piston pump.

WHEELS AND TYRES Accumulator provides uniform steering regardless of engine

speed. In the event of loss of engine power it provides
Wheel Rim Width .......................................................... 17 in steering of approximately two lock-to-lock turns.
Standard Tyres (Front & Rear) .............. 24.00 R 35** Radial A low pressure indicator light warns of system pressure
Optional Tyres (Front & Rear) ............ 24.00-35 (48 PR) E-3 below 83 bar (1 200 lbf/in²). Steering meets SAE J53.
Note: It is recommended that for tyres both listed and Relief Pressure ................................... 210 bar (3 000 lbf/in²)
unlisted, the user should consult the tyre manufacturer and Steering Cylinders ................... Double Acting, Single Stage
evaluate all job conditions in order to make the proper Accumulator:
selection. Nitrogen Precharge Pressure ............... 55 bar (800 lbf/in²)
Steering Angle (Left and Right) ....................................... 42°
Pump:
BRAKES Type ......................................................................... Piston
Service Capacity at 2 100 rev/min ..... 1.75 litres/s (32 US gal/min)
All hydraulic brake system. Transmission mounted pressure
compensating pump provides hydraulic pressure for brakes
and steering. Independent circuits front and rear. Each BODY HYDRAULICS
circuit incorporates a nitrogen accumulator which stores Two body hoist cylinders are mounted between the frame
energy to provide consistent braking response. rails. Cylinders are two-stage with power down in the
second stage.
Front Brake Circuit Pressure ............. 110 bar (1 600 lbf/in²)
Rear Brake Circuit Pressure .................... 52 bar (750 lbf/in²) System Relief Pressure ..................... 190 bar (2 750 lbf/in²)
Accumulators: Pump:
Nitrogen Precharge Pressure ............... 55 bar (800 lbf/in²) Type ........................................................................... Gear
Capacity at 2 100 rev/min .................................. 6.1 litres/s
Front: (97 US gal/min)
Type ............................ Dry Disc with 2 callipers per wheel Control Valve ...................... Servo Controlled, Open Centre
Disc Diameter ............................................ 710 mm (28 in) Body Raise Time ................................................ 13 Seconds
Pad Area, Total .................................... 2 788 cm² (432 in²) Body Lower Time ............................................ 11.5 Seconds

Rear:
Type ............................... Oil cooled, multiple friction discs, ELECTRICAL
completely sealed from dirt and water. Type ............................................. 24 Volt, Negative Ground
Braking Surface, Total .................. 67 390 cm² (10 445 in²) Battery ......... Two, 12 Volt, 165 Ah each, Maintenance Free
Accessories ................................................................ 24 Volt
Alternator .................................................................. 70 Amp
Starter ........................................................................... 9 kW

2 SM 1911 7-00
 General Information - TR70 Off-Highway Truck
Section 000-0000
BODY Typical Noise Levels
Longitudinal 'V' type floor with integral transverse box- Operator Ear (ISO 6394) ............................................ 81 dbA
section stiffeners. The body is exhaust heated and rests on
resilient impact absorption pads. *Exterior Sound Rating (SAE J88 JUN 86) ................ 91 dbA
* - The above result is for the mode giving the highest
Body floor wear surfaces are high hardness (450 BHN) exterior sound level when measured and operated as per
abrasion resistant steel. Yield strength of plates 1 200 MPa the prescribed procedures of the standard. Results shown
(174 000 lbf/in²). All other wear surfaces are high hardness are for the vehicle in base configuration.
(360-440 BHN) abrasion resistant steel. Yield strength of
plates 1 000 MPa (145 000 lbf/in²). Note: Noise Level Exposure to the operator and bystander
personnel may be higher depending upon proximity to
Plate Thicknesses: buildings, rock piles, machinery etc.. The actual job site
Floor ......................................................... 19 mm (0.75 in) Noise Level Exposure must be measured and applicable
Side .......................................................... 10 mm (0.39 in) regulations complied with in respect to Employee Hearing
Front, lower ............................................... 10 mm (0.39 in) Protection.

ROPS Cabguard SAE J1040 Feb 86. ISO 3471

Vehicle Weights (Mass)
Volumes: kg lb
Struck (SAE) ............................................... 29 m³ (38 yd³) Chassis, with hoists 36 190 79 780
Heaped 2:1 (SAE) ................................ 41.5 m³ (54.3 yd³)
Body, standard 11 500 25 350
SERVICE CAPACITIES Net Weight 47 690 105 140
Engine Crankcase and Filters ............... 94 litres (25 US gal) PAYLOAD, maximum 65 000 143 300
Transmission and Filters .................... 85 litres (22.5 US gal) Maximum Gross Weight* 112 690 248 440
Cooling System ................................ 236 litres (62.3 US gal)
Fuel Tank .......................................... 938 litres (248 US gal) FOR UNIT EQIPPED WITH OPTIONAL HARD ROCK
Steering Hydraulic Tank ....................... 61 litres (16 US gal) BODY:
Steering System ................................. 92 litres (24.3 US gal) Chassis, with hoists 36 190 79 780
Body and Brake Cooling Tank ............ 258 litres (68 US gal) Body, with wear plates 16 450 36 270
Body and Brake Cooling System ...... 432 litres (114 US gal)
Net Weight 52 640 116 050
Planetaries (Total) ............................. 43 litres (11.4 US gal)
Differential .......................................... 52 litres (13.7 US gal) PAYLOAD, maximum 60 050 132 390
Front Ride Strut (Each) ........................ 25 litres (6.6 US gal) Maximum Gross Weight* 112 690 248 440
Rear Ride Strut (Each) ......................... 21 litres (5.5 US gal) * Maximum permissable gross vehicle weight with options,
Power Takeoff ........................................... 4 litres (1 US gal) attachments, full tank and payload.
Air Conditioning Compressor ...... 0.135 litres (0.036 US gal)
WEIGHT DISTRIBUTION Front Axle Rear Axle
Empty % 48 52
Loaded % 34 66

* * * *

SM 1911 7-00 3
 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 - Chassis, Hood and Fenders
Section 100-0010

SM - 2511

1
2

11
10
14
12
13

5
9 8
8 7
7 6
3
6
1 - Frame Assembly 11 - Bolt
2 - Bushing 5 - Bolt 8 - Washer 12 - Hardened Washer
3 - Engine Guard 6 - Nut 9 - Bolt 13 - Locknut
4 - Transmission Guard 7 - Lockwasher 10 - Washer 14 - Spring Disc
Fig. 1 - Exploded View of Chassis and Guards

REMOVAL 3. Attach a suitable lifting device to the component and

remove mounting hardware. Remove the component
from the vehicle.
WARNING
To prevent personal injury and property
damage, be sure wheel chocks, blocking INSTALLATION
materials and lifting equipment are properly Note: Tighten all fasteners to standard torques listed
secured and of adequate capacity to do the job in Section 300-0080, STANDARD BOLT AND NUT
safely. TORQUE SPECIFICATIONS.

To remove any of the components shown in

Figs. 1 to 7 (or similar components) the following WARNING
procedures should be carried out. To prevent personal injury and property
damage, be sure wheel chocks, blocking
1. Position the vehicle in a level work area, apply the materials and lifting equipment are properly
parking brake and switch off the engine. secured and of adequate capacity to do the job
safely.
2. Turn steering wheel in both directions several times
to relieve pressure in the steering circuit. Block all road Using a suitable lifting device, align the component to
wheels. be installed in position on the chassis. Secure the
component securely to the chassis with mounting
hardware removed during removal.

SM 1918 R1 08-03 1
Chassis - Chassis, Hood and Fenders
Section 100-0010

MAINTENANCE SM - 2554

2 4
Inspection 5

Inspect the frame and attached parts at intervals not 1

exceeding 250 hours for cracked or broken welds and
bending/twisting of the frame. Any defects found
should be repaired before they progress into major
failures. Contact your dealer for recommended weld
and repair instructions.

WARNINGS
Before any welding is done on a machine
equipped with the Detroit Diesel DDEC IV
system, disconnect the following in this order:
5
Battery earth cable, battery supply cable, 3
alternator earth cables, alternator supply
cables, electrical connections at the engine
ECMs and transmission ECU to avoid damage
to electrical components. Turn off ignition key 1 - Hood Assembly 4 - Bolt
switch to isolate the batteries before 2 - Plate 5 - Hardened Washer
3 - Bolt
disconnecting any components.
After welding connect all of the above in the Fig. 2 - Exploded View of Hood and Mounting
reverse order.
frame is bent or twisted, no welding should be done
until the parts are straightened or realigned.

Before any welding is done ensure all paint has Successfully welded repairs will depend to a great
been removed from the area to be welded. extent upon the use of the proper equipment, materials
Failure to do so may result in hazardous fumes and the ability of the welder. The Service Department
being given off from the paint. can be consulted regarding the feasibility of welding
repairs.
WARNING
Welding and flame cutting cadmium plated Painting
metals produce odourless fumes which are A check of the condition of the paint should be made
toxic. Recommended industrial hygiene approximately twice a year and chassis repainted if
practice for protection of the welding operator necessary.
from the cadmium fumes and metallic oxides
requires enclosure ventilation specifically
designed for the welding process. A WARNING
respiratory protective device such as the Welding, burning, heating or dressing surfaces
M.S.A. 'Gasfoe' respirator with G.M.A. cartridge previously painted using polyurethane paint
will provide protection against cadmium, produces fumes which are toxic. Surfaces
fumes and metallic oxides. The 'Gasfoe' must be prepared using paint stripper prior to
respirator has been approved by the U.S. area being reworked. Recommended Industrial
Bureau of Mines: Approval number 23B-10, Hygiene and Safety Rules should be be
and is designed to protect against gases, followed for protection of the welding operator
vapours, and/or metal fumes. from fumes.
Electric arc welding is recommended for all chassis If painting of the actual frame of the unit is required,
welding. Since the nature and extent of damage to the thoroughly clean the areas to be painted. Apply a
frame cannot be predetermined, no definite repair primer coat of red oxide and then a finish coat of
procedure can be established. As a general rule polyurethane enamel.
however, if parts are twisted, bent or pulled apart, or a

2 SM 1918 R1 08-03
 Chassis - Chassis, Hood and Fenders
Section 100-0010

SM - 2555

23 22
15
21
11
11 7
18 12

6
7

24

1918 12
11
20 2 7
4 8 12
3
13
14 16 11
10 5 18

11
12 7
19
7 4
12 3
1
9

12 7 11 17
12 1819

1 - Front Crossmember Assembly 9 - Fender Assembly LH 17 - Kickstrip

2 - Rear Crossmember Assembly 10 - Fender Assembly RH 18 - Hardened Washer
3 - Bolt 11 - Bolt 19 - Bolt
4 - Hardened Washer 12 - Locknut 20 - Platform Extension
5 - Platform & Cover Assembly 13 - Bolt 21 - Bolt
6 - Bolt 14 - Snubbing Washer 22 - Hardened Washer
7 - Hardened Washer 15 - Handrail & Kickstrip Assembly 23 - Mirror
8 - Platform LHS 16 - Handrail Assembly LH 24 - Mirror Wide Angle

Fig. 3 - Exploded View of Fenders and Mounting

To keep rust and corrosion to a minimum, periodic SM - 2942

painting of abrasions and other exposed metal areas
on the frame is highly recommended.
14.75

67˚

POSITION ON DELIVERY

Fig. 4 - Right Hand Mirror Bracket Position

SM 1918 R1 08-03 3
Chassis - Chassis, Hood and Fenders
Section 100-0010

SM - 2513

3
4
4
5

3
4
4
5

3
4
4
5
3
4
4
5
6

6
9
8
8
7 9
8
8
7

1 - LH Step Assembly 4 - Washer 7 - Bolt

2 - RH Step Assembly 5 - Nut 8 - Washer
3 - Bolt 6 - Step 9 - Locknut

Fig. 5 - Exploded View of Ladders and Handrails

4 SM 1918 R1 08-03
 Chassis - Chassis, Hood and Fenders
Section 100-0010

SM - 2556

5
3
3
4

6
1
3
7
3
4
9
8

2
5
3
3
4

1 - Radiator Guard 4 - Locknut 7 - Washer

2 - Grille 5 - Bolt 8 - Bolt
3 - Hardened Washer 6 - Bolt 9 - Hardened Washer

Fig. 6 - Radiator Guard and Mounting

SM 1918 R1 08-03 5
Chassis - Chassis, Hood and Fenders
Section 100-0010

SM - 2557

11
10 10 6 12 11
25 11
27 12
4
3 10 12
7
11
2 9
8
11 10 10
11 12
10 29 5
12
13 11

11
4 10 10
10 11 12 21 28
14 23 26
1
22
11 12
23 22
24 24
19 23
21 23
17 30 11
20 10
9 16
8
10 18
19 19 15 21
22 23
10 10
11 11
19 19
11 21
10 19
19 22

1 - Mudflap Front 9 - Clamp Plate

2 - Angle Bracket 10 - Bolt 17 - Backing Strip 24 - Bolt
3 - Angle Bracket 11 - Lockwasher 18 - Mudflap RH Rear 25 - Plate Assembly LH
4 - Plate 12 - Nut 19 - Backing Strip 26 - Plate Assembly RH
5 - Mudflap 13 - Plate 20 - Bracket Assembly 27 - Mudguard Plate LH
6 - Angle Bracket 14 - Plate 21 - Bolt 28 - Mudguard Plate RH
7 - Clamp Plate 15 - Mudflap RH Front 22 - Locknut 29 - Mudflap LH
8 - Mudflap 16 - Bracket Assembly 23 - Hardened Washer 30 - Mudflap RH
Fig. 7 - Exploded View of Mudflaps and Mounting

* * * *

6 SM 1918 R1 08-03
 ENGINE - Engine and Mounting
Section 110-0030

SM - 2465

6
6
8
8
7
5
LIFTING POINTS

1
9

14
15 12
4 10

9
3

13
12
21 12 16
10 19
24

23 18
17
22
2 20
12
11 21 25

1 - Engine 9 - Front Mounting Bracket 17 - Isolation Mount

2 - Oil Filter 10 - Bolt 18 - Snubbing Washer
3 - Primary Fuel Filter 11 - Bolt 19 - Bolt
4 - Secondary Fuel Filter 12 - Lockwasher 20 - Locknut
5 - Fan Belt 13 - Mounting Crossmember 21 - Rear Mounting Bracket
6 - Thermostat 14 - Bolt 22 - Isolation Mount
7 - Thermostat Seal 15 - Washer 23 - Snubbing Washer
8 - Gasket 16 - Nut 24 - Bolt
25 - Locknut

Fig. 1 - Engine and Mounting

DESCRIPTION Rubber isolation mounts (17 & 22) through engine

Numbers in parentheses refer to Fig. 1. mounts provide sufficient flexibility to absorb varying
engine vibration and torsional loads.
For engine make, model and specification, refer to
Section 000-0000, GENERAL INFORMATION. For There are three full-flow oil filters (2) mounted on the
engine servicing and repair data refer to the engine right hand side of engine (1) in a downward position.
manufacturers service manual. The filters are of the throw away, spin-on type. Oil
supplied by the engine oil pump passes through oil
The engine is mounted to the frame by mounting filters (2) before reaching the various moving parts of
crossmember (13) and two mounting brackets (9) at engine (1). The oil is forced by pump pressure
the front of engine (1) and two rear mounts (21). through a passage in the filter adaptor and into the

SM 1923 R2 03-04 1
Engine - Engine and Mounting
Section 110-0030
elements. Impurities are filtered out as the oil passes 2. Programmable Read Only Memory (PROM) -
through the elements and out through another Located in the ECM and encoded with the operating
passage in the filter adaptor. software. Additional information is programmed into
the EEPROM. This information controls the
There are four spin-on type fuel filters mounted on horsepower rating, torque curve, maximum engine
the right hand side of engine (1), two primary fuel speed and engine protection devices. The ECM
filters (3) and two secondary fuel filters (4). Primary processes this information and sends electronic
fuel filters (3) are in the fuel flow and act as strainers signals to the Electronic Unit Injectors (EUI) where the
and secondary fuel filters (4) filter the fuel after precise amount of fuel is injected into the engine.
having passed through primary fuel filters (3).
3. Electronic Unit Injectors (EUI) - The EUI is a
lightweight, compact unit that injects diesel fuel directly
DETROIT DIESEL ELECTRONIC into the combustion chamber. The amount of fuel
CONTROL (DDEC) injected and the beginning of injection timing is
determined by the ECM. The ECM sends a command
Description pulse which activates the injector solenoid.
Refer to Fig. 2.
The EUI performs four functions:

WARNING a - Creates the high fuel pressure required for efficient

Before any welding is done on a machine injection.
equipped with the DDEC IV system, b - Meters and injects the exact amount of fuel
disconnect the following in this order: required to handle the load.
Battery earth cable, battery supply cable, c - Atomizes the fuel for mixing with the air in the
alternator earth cables, alternator supply combustion chamber.
cables, transmission connector, ECM interface d - Permits continuous fuel flow for component cooling.
harness connectors (30 pin RHS), ECM
powerharness connectors (5 pin RHS), ECM Electronic unit injectors are self compensating and
engine to transmission datalink connectors (6 virtually eliminate engine tune-ups.
pin RHS), ECM sensor harness connectors (30
pin LHS) and ECM injector harness connectors Note: Never apply 12 V directly to terminals on the
(5 pin LHS - 2 connectors) (Note: this engine injector or engine sensors as they will burn out. Before
is equipped with 2 ECMs). Turn off ignition removing injectors, the fuel passages must be blown
key switch to isolate the batteries before out to prevent fuel flow from entering the cylinder
disconnecting any components. head.

After welding connect all of the above in the 4. Electronic Foot Pedal - The electronic foot pedal
reverse order. provides an electrical signal to the engine's fuel
control system in proportion to the degree of pedal
The engine is equipped with DDEC IV which which actuation.
continually monitors the engine and warns the
operator when a problem develops. The DDEC IV Note: The engine MUST be started with foot 'OFF'
system also takes action to prevent damage to the the electronic foot pedal.
engine and, provides the serviceman with diagnostic
capabilities so that problems can be corrected 5. Stop Engine Light - When the 'Stop Engine' light
quickly and easily. comes on, the computer has detected a major
malfunction in the engine that requires immediate
1. Electronic Control Module (ECM) - Receives attention. It is the operators responsibility to shut
electronic inputs from the driver as well as from down the engine to avoid serious damage.
mounted sensors that provide information
electronically, such as oil pressure and temperature 6. Check Engine Light - When the 'Check Engine'
and intake manifold pressure. This information is light comes on, the computer has detected a fault in
used to control both the quantity of fuel injected and the engine. The fault should be diagnosed and
injection timing. corrected at the earliest opportunity.

2 SM 1923 R2 03-04
 Engine - Engine and Mounting
Section 110-0030

SM - 2529

STOP

5
7

1,2
6

TEST TEST

8 9

1 - Electronic Control Module (ECM) 6 - Check Engine Light

2 - Programmable Read Only Memory (PROM) 7 - Diagnostic Test Point
3 - Electronic Unit Injectors (EUI) 8 - Master ECM Diagnostic Request/Stop
4 - Electronic Foot Pedal Engine Override Switch
5 - Stop Engine Light 9 - Receiver ECM Diagnostic Request Switch

Fig. 2 - DDEC IV Components

7. Diagnostic Test Point - Plug in connector for 9. Receiver ECM Diagnostic Request Switch -
diagnostic data reader (DDR). Operates as a diagnostic request switch when:
a - the engine is not running and ignition is 'On'.
8. Master ECM Diagnostic Request/Stop Engine b - the engine is idling and not in an engine protection
Override Switch - Operates as a diagnostic request condition.
switch when: Pressing and releasing the switch will flash out the
a - the engine is not running and ignition is 'On'. engine codes. Pressing the switch a second time will
b - the engine is idling and not in an engine protection stop the engine codes flashing.
condition. Note: Inactive codes are displayed on Check Engine
Pressing and releasing the switch will flash out the Light and active codes are displayed on Stop Engine
engine codes. Pressing the switch a second time will Light. Code 25 means no codes present.
stop the engine codes flashing.
Note: Inactive codes are displayed on Check Engine
Light and active codes are displayed on Stop Engine Operation
Light. Code 25 means no codes present. Numbers in parentheses refer to Fig. 2.
Operates as a Stop Engine Override Switch when the
engine is in a rampdown protection mode for any of The DDEC system operates from a 24 volt supply.
the following: However, in the event of a loss of power supply, the
Low Coolant Level system will operate at reduced voltage. At reduced
High Coolant Temperature voltage the electronic control system will detect a
Low Oil Pressure malfunction and the check engine light on the dash
High Oil Temperature panel will illuminate.

At this point the ECM (1) will go into backup control

SM 1923 R2 03-04 3
Engine - Engine and Mounting
Section 110-0030
and a change in engine operation will be noticed. The Whenever check engine light (6) or stop engine light
engine will operate only at reduced rev/min until the (5) comes on, the DDEC computer will determine
battery voltage reaches a point where it will no longer where the problem is and will store this information in
function and the engine will shut down. The machine its memory. If the malfunction is intermittent, the
can still be operated when the check engine light is lights will come on and go off as the computer
illuminated, however, the fault should be diagnosed senses the changing engine condition.
and corrected at the earliest possible opportunity.
A special diagnostic data reader (DDR) is available
Note: When the stop engine light on the dash panel that can be plugged into the engine computer memory
illuminates, the computer has detected a major to extract information related to the cause of the
malfunction in the engine that requires immediate problem. Once the malfunction has been corrected,
attention. It is the operators responsibility to shut the DDEC system will return the engine to normal
down the engine to avoid serious damage. operation. The DDR can now distinguish between
active codes and those stored in the historic code
The machine is equipped with the DDEC engine memory. The malfunction code recorded in ECM (1)
protection system, which records the stop engine memory will remain until it is erased by a technician.
malfunction in ECM (1). The stop engine and check
engine lights illuminate when the engine protection
system is initiated. The engine will immediately WARNINGS
reduce to 70% of the available torque. Rampdown The operator of a DDEC-equipped vehicle
then commences over a 30 second period and must not attempt to use or read a DDR of any
reduces the engine to 40% of the available torque. kind while the vehicle is operating. Doing so
can result in loss of control, which may cause
To allow for the possibility of the engine protection vehicle damage and may result in personal
system being activated while the machine is injury.
operating in a critical situation, a stop engine override
switch (8) is provided. If the switch is pressed and When engine or electronics system
released during rampdown, the 30 second timer will diagnosis is required on a DDEC-equipped
reset, restoring torque to the level immediately vehicle, this must be done by a person other
following illumination of stop engine (5) and check than the operator. The operator must maintain
engine (6) lights. The switch must be pressed and control of the moving vehicle while the
released again to obtain a subsequent override. assistant performs the diagnosis.

Note: The operator must continue to reset the When the engine is not running and the ignition is on,
automatic engine protection system by pressing and or, the engine is idling and not in an engine protection
releasing stop engine override switch (8) at intervals of condition, engine faults can be diagnosed by the
approximately 15 to 20 seconds. operator. Pressing and releasing diagnostic request
switch (8) will cause check engine light (6) or stop
Note: ECM (1) will record the number of times the engine light (5) to flash a code number indicating the
override is activated after the fault occurs. Available fault, e.g. flash twice - pause - flash five times -
Torque is the actual torque available from the engine pause indicates a code 25. Code 25 indicates all
when the fault occurred based on the actual rev/min systems are operating correctly. Pressing the switch
when the fault occurred. a second time will stop the engine codes flashing.
Refer to 'DDEC IV Diagnostic Codes' table for other
The engine should not be restarted after it has been code descriptions.
shut down after activation of the engine protection
system unless the problem has been diagnosed and Note: Only one light will be flashing at any one time.
corrected. When code flashing is initiated, the active codes (or
code 25) will be flashed on stop engine light (5), then
Conditions that will cause the Stop Engine Light to the inactive codes (or code 25) will be flashed on
come on are; Low Coolant Level, High Coolant check engine light (6). When all of the inactive codes
Temperature, Low Oil Pressure and High Oil have been flashed, the process of flashing the codes
Temperature. will repeat until the conditions for code flashing are
no longer satisfied.

4 SM 1923 R2 03-04
 Engine - Engine and Mounting
Section 110-0030

DDEC IV DIAGNOSTIC CODES

DDEC Code #
(Flashed) PID SID FMI DDEC Description
- 240 - 2 Fram checksum incorrect
- 251 - 10 Clock module abnormal rate
- 251 - 13 Clock module fault/failure
- - 253 13 Incompatible calibration version
- - 254 0 External failed RAM
- - 254 1 Internal failed RAM
- - 254 6 Entered boot via switches
11 187 - 4 VSG sensor voltage low
11 187 - 7 VSG switch system not responding
12 187 - 3 VSG sensor high
13 111 - 4 Coolant level sensor input voltage low
13 111 - 6 Add coolant level sensor input voltage low
14 52 - 3 Intercooler coolant temperature sensor input voltage high
14 110 - 3 Coolant temperature sensor input voltage high
14 175 - 3 Oil temperature sensor input voltage high
15 52 - 4 Intercooler coolant temperature sensor input voltage low
15 110 - 4 Coolant temperature sensor input voltage low
15 175 - 4 Oil temperature sensor input voltage low
16 111 - 3 Coolant level sensor input voltage high
16 111 - 5 Add coolant level sensor input voltage high
17 72 - 3 Throttle plate position sensor input voltage high
17 51 - 3 Throttle position sensor input voltage high
18 72 - 4 Bypass position sensor input voltage low
18 51 - 4 Throttle plate position sensor input voltage low
21 91 - 3 TPS input voltage high
22 91 - 4 TPS input voltage low
23 174 - 3 Fuel temperature sensor input voltage high
23 - 65 3 Oxygen content circuit input voltage high
24 174 - 4 Fuel temperature sensor input voltage low
24 - 65 4 Oxygen content circuit input voltage low
25 - - - Reserved for 'No Codes'
26 - 25 1 Auxiliary shutdown #1 active
26 - 61 11 Auxiliary shutdown #2 active
27 171 - 3 Ambient air temperature sensor input voltage high
(Release 2.00 or later only)
27 172 - 3 Air temperature sensor input voltage high
27 105 - 3 Intake manifold temperature sensor input voltage high
28 171 - 4 Ambient air temperature circuit failed low (Release 2.00
or later only)
28 172 - 4 Air temperature sensor input voltage low
28 105 - 4 Intake manifold temperature sensor input voltage low
31 - 51 3 Aux. output #3 open circuit (high side) - S3
31 - 51 4 Aux. output #3 short to ground (high side) - S3
31 - 51 7 Aux. output #3 mechanical system fail - S3
31 - 52 3 Aux. output #4 open circuit (high side) - T3
31 - 52 4 Aux. output #4 short to ground (high side) - T3
31 - 52 7 Aux. output #4 mechanical system fail - T3
32 - 238 4 SEL open circuit
32 - 238 3 SEL short to battery (+)
32 - 239 3 CEL short to battery (+)
32 - 239 4 CEL open circuit

SM 1923 R2 03-04 5
Engine - Engine and Mounting
Section 110-0030

DDEC IV DIAGNOSTIC CODES

DDEC Code #
(Flashed) PID SID FMI DDEC Description
33 102 - 3 Turbo boost pressure sensor input voltage high
34 102 - 4 Turbo boost pressure sensor input voltage low
35 100 - 3 Oil pressure sensor input voltage high
35 19 - 3 High range oil pressure sensor input voltage high
36 100 - 4 Oil pressure sensor input voltage low
36 19 - 4 High range oil pressure sensor input voltage low
37 94 - 3 Fuel pressure sensor input voltage high
37 18 - 3 High range fuel pressure sensor input voltage high
37 95 - 3 Fuel restriction sensor input voltage high
38 94 4 Fuel pressure sensor input voltage low
38 18 - 4 High range fuel pressure sensor input voltage low
38 95 - 4 Fuel restriction sensor input voltage low
41 - 21 0 Too many SRS (missing TRS)
42 - 21 1 Too few SRS (missing SRS)
43 111 - 1 Coolant level low
44 52 - 0 Intercooler coolant temperature high
44 110 - 0 Coolant temperature high
44 172 - 0 Air inlet temperature high
44 175 - 0 Oil temperature high
44 105 - 0 Intake manifold temperature high
45 100 - 1 Oil pressure low
45 19 - 1 High range oil pressure low
46 168 - 1 ECM battery voltage low
46 - 232 1 Sensor supply voltage low
47 94 - 0 Fuel pressure high
47 102 - 0 Turbo boost pressure high
47 106 - 0 Air inlet pressure high
47 164 - 0 Injection control pressure high
47 18 - 0 High range fuel pressure high
48 18 - 1 High range fuel pressure low
48 94 - 1 Fuel pressure low
48 106 - 1 Air inlet pressure low
48 164 - 1 Injection control pressure low
52 - 254 12 A/D conversion fail
53 - 253 2 Non-voilatile checksum incorrect
53 - 253 12 EEPROM write error
53 - 253 13 Out of calibration
54 84 - 12 Vehicle speed sensor fault
55 - 231 12 J1939 data link fault
55 - 248 8 Proprietary datad link fault (Master)
55 - 248 9 Proprietary datad link fault (Receiver)
56 - 250 12 J1587 data link fault
57 - 249 12 J1922 data link fault
58 92 - 0 Torque overload
61 - xxx 0 Injector xxx response time long
62 - 26 3 Aux. output #1 short to battery (+) - F3
62 - 26 4 Aux. output #1 open circuit - F3
62 - 40 3 Aux. output #2 short to battery (+) - A2
62 - 40 4 Aux. output #2 open circuit - A2
62 - 53 3 Aux. output #5 short to battery (+) - W3
62 - 53 4 Aux. output #5 open circuit - W3

6 SM 1923 R2 03-04
 Engine - Engine and Mounting
Section 110-0030

DDEC IV DIAGNOSTIC CODES

DDEC Code #
(Flashed) PID SID FMI DDEC Description
62 - 54 3 Aux. output #6 short to battery (+) - X3
62 - 54 4 Aux. output #6 open circuit - X3
62 - 55 3 Aux. output #7 short to battery (+) - Y3
62 - 55 4 Aux. output #7 open circuit - Y3
62 - 56 3 Aux. output #8 short to battery (+) - A1
62 - 56 4 Aux. output #8 open circuit - A1
62 - 26 7 Aux. output #1 mechanical system not responding
properly - F3
62 - 40 7 Aux. output #2 mechanical system not responding
properly - A2
62 - 53 7 Aux. output #5 mechanical system not responding
properly - W3
62 - 54 7 Aux. output #6 mechanical system not responding
properly - X3
62 - 55 7 Aux. output #7 mechanical system not responding
properly - Y3
62 - 56 7 Aux. output #8 mechanical system not responding
properly - A1
63 - 57 3 PWM #1 short to battery (+)
63 - 57 4 PWM #1 open circuit
63 - 58 3 PWM #2 short to battery (+)
63 - 58 4 PWM #2 open circuit
63 - 59 3 PWM #3 short to battery (+)
63 - 59 4 PWM #3 open circuit
63 - 60 3 PWM #4 short to battery (+)
63 - 60 4 PWM #4 open circuit
63 - 57 0 PWM #1 above normal range
63 - 57 1 PWM #1 below normal range
63 - 58 0 PWM #2 above normal range
63 - 58 1 PWM #2 below normal range
63 - 59 0 PWM #3 above normal range
63 - 59 1 PWM #3 below normal range
63 - 60 0 PWM #4 above normal range
63 - 60 1 PWM #4 below normal range
64 103 - 8 Turbo speed sensor input failure
64 103 - 0 Turbo overspeed
65 51 - 0 Throttle plate position above normal range
65 51 - 1 Throttle plate position below normal range
65 51 - 2 Throttle plate position erratic
65 51 - 7 Throttle plate not responding
65 107 - 3 Air filter restriction sensor voltage high
65 107 - 4 Air filter restriction sensor voltage low
66 - 76 0 Engine knock level above normal range
66 - 76 3 Engine knock level sensor input voltage high
66 - 76 4 Engine knock level sensor input voltage low
66 - 76 7 Engine knock level sensor not responding
66 - 99 3 Oil filter restriction sensor voltage high
66 - 99 4 Oil filter restriction sensor voltage low
67 109 - 3 Coolant pressure sensor input voltage high
67 109 - 4 Coolant pressure sensor input voltage low
67 106 - 3 Air inlet pressure sensor input voltage high
67 106 - 4 Air inlet pressure sensor input voltage low

SM 1923 R2 03-04 7
Engine - Engine and Mounting
Section 110-0030

DDEC IV DIAGNOSTIC CODES

DDEC Code #
(Flashed) PID SID FMI DDEC Description
67 20 - 3 High range coolant pressure sensor input voltage high
67 20 - 4 High range coolant pressure sensor input voltage low
68 - 230 6 TPS idle validation circuit fault (short to ground)
68 - 230 5 TPS idle validation circuit fault (open circuit)
71 - xxx 1 Injector xxx response time short
72 84 - 0 Vehicle overspeed
72 84 - 11 Vehicle overspeed (absolute)
72 - 65 0 Oxygen content too high
72 - 65 1 Oxygen content too low
73 - 151 14 ESS transmission stuck in gear
73 - 226 11 Transmission neutral switch failure (ESS Transmission)
73 - 227 2 Aux. analog input data erratic, intermittent, or incorrect
(ESS transmission)
73 - 227 3 Aux. analog input #1 voltage high (ESS transmission)
73 - 77 0 Gas valve position above normal range
73 - 77 1 Gas valve position below normal range
73 - 77 3 Gas valve position input voltage high
73 - 77 4 Gas valve position input voltage low
73 - 77 7 Gas metering valve not responding
73 107 - 0 Air filter restriction high
74 99 - 0 Oil filter restriction high
74 70 - 4 Optimized idle safety loop short to ground
75 168 - 0 ECM battery voltage high
75 - 232 0 Sensor supply voltage high
76 121 - 0 Engine overspeed with engine brake
81 - 20 3 Timing actuator (dual fuel) input voltage high
81 98 - 3 Oil level sensor input voltage high
81 101 - 3 Crankcase pressure sensor input voltage high
81 164 - 3 Injection control pressure circuit voltage high
81 173 - 3 Exhaust temperature sensor input voltage high
82 - 20 4 Timing actuator (dual fuel) input voltage low
82 98 - 4 Oil level sensor input voltage low
82 101 - 4 Crankcase pressure sensor input voltage low
82 164 - 4 Injection control pressure circuit voltage low
82 173 - 4 Exhaust temperature sensor input voltage low
83 98 - 0 Oil level high
83 101 - 0 Crankcase pressure high
83 173 - 0 Exhaust temperature high
83 173 - 4 Exhaust temperature sensor input voltage low
83 73 - 0 Pump pressure high
84 98 - 1 Oil level low
84 101 - 1 Crankcase pressure low
85 190 - 0 Engine overspeed
86 73 - 3 Pump pressure sensor input voltage high
86 108 - 3 Barometric pressure sensor input voltage high
87 73 - 4 Pump pressure sensor input voltage low
87 108 - 4 Barometric pressure sensor input voltage low
88 109 - 1 Coolant pressure low
88 20 - 1 High range coolant pressure low
89 95 - 0 Fuel restriction high
89 111 - 12 Maintenance alert coolant level fault

8 SM 1923 R2 03-04
 Engine - Engine and Mounting
Section 110-0030

REMOVAL 7. Evacuate air conditioning system and disconnect

Numbers in parentheses refer to Fig. 1. air conditioner lines at the engine compressor. Refer
to Section 260-0130, AIR CONDITIONING.
Note: Tag all cables, harnesses, lines and pipes
disconnected during removal to aid in installation. 8. With suitable containers in position, open drain cocks
and drain coolant from the radiator and engine (1)
assembly. Close all drain cocks after draining.
WARNINGS
To prevent personal injury and property 9. Identify cooling lines for ease of installation and
damage, be sure wheel blocks, blocking with suitable containers in position, disconnect
materials and lifting equipment are properly cooling lines from engine (1). Cap open line ends and
secured and of adequate capacity to do the job fittings.
safely.
10. Using suitable lifting equipment, carefully remove
High electrical current can cause sparks the radiator assembly from the vehicle. Refer to
and personal injury from burns. Turn ignition Section 210-0040, RADIATOR AND MOUNTING.
key switch to the 'Off' position before
removing any components. Remove battery 11. Disconnect and remove air cleaner intake pipe
ground cable first, and reconnect last, to avoid from the engine turbocharger and air cleaner.
damaging electrical components.
12. Disconnect and remove exhaust tube from the
1. Position the vehicle in a level work area, ensure engine turbocharger.
the body is fully lowered, apply the parking brake and
switch off the engine. 13. Identify heater lines for ease of installation and,
with a suitable container in position, disconnect
2. Turn steering wheel several times to relieve heater lines from engine (1). Cap open line ends and
pressure in the steering circuit. Block all road fittings.
wheels.
14. Close fuel shutoff valve at filter head, identify fuel
3. Disconnect battery cables from battery terminal lines for ease of installation and, with a suitable
ports before starting removal procedures. Disconnect container in position, disconnect fuel lines from
ground cable first. engine (1). Cap open line ends and fittings.

4. Remove mounting hardware securing the hood on 15. Identify all electrical harnesses and cables
the vehicle. Remove hood assembly from the vehicle. attached to engine (1) for ease of installation and
disconnect from engine (1).
5. Disconnect electrical connections from the radiator
guard and remove mounting hardware securing the 16. Disconnect driveline from engine coupling and
radiator guard on the vehicle. Remove radiator guard secure clear of engine (1). Refer to Section
from the vehicle. 130-0010, FRONT DRIVELINE.

6. Place a suitable container under the engine drain 17. Remove tandem pump from the engine power
port, remove drain plug and drain the oil. After takeoff. Refer to Section 230-0050, TANDEM PUMP.
draining, reinstall drain plug in the engine sump and
tighten securely. Note: The hydraulic lines can be left attached to the
tandem pump.

WARNING
Harmful gas. Before disconnecting any air WARNING
conditioner lines refer to Section 260-0130, Heavy assembly. To prevent personal injury
AIR CONDITIONING. Refrigerant will rapidly and property damage, be sure lifting device is
freeze all objects with which it comes into of adequate capacity and properly secured to
contact, and it can cause serious damage to do the job safely.
the skin and eyes.

SM 1923 R2 03-04 9
Engine - Engine and Mounting
Section 110-0030
18. Attach suitable lifting equipment to the lifting 7. Loosen air conditioner compressor drive belt and
points on engine (1) assembly and raise lifting remove compressor from engine (1). Refer to Section
equipment to take up the slack. Refer to Fig. 1. 260-0130, AIR CONDITIONING.

19. Remove locknuts (16), lockwashers (12), bolts 8. Remove mounting hardware securing alternator
(14) and hardened washers (15) securing front guard to engine (1). Remove alternator guard.
mounting brackets (9) to mounting crossmember
(13). Remove locknuts (25), snubbing washers (23) 9. Loosen alternator mounting bolt to allow slack in 'V'
and bolts (24) securing rear mounting brackets (21) belts. Remove 'V' belts.
to the frame.
Note: Adjuster screw and link assembly will have
20. Check to make certain that all necessary line and been released when removing radiator assembly from
electrical disconnections have been made before the vehicle.
lifting engine (1).
10. Remove bolt and lockwasher securing screw and
21. Carefully lift engine (1) assembly clear of the link assembly to alternator. Support alternator and
frame and move to a clean work area. Securely remove mounting hardware. Remove alternator from
mount engine (1) assembly to a work stand. engine (1).

22. If required, attach suitable lifting equipment to the 11. If necessary, damper can be removed from the
front mounting crossmember (13) assembly and raise flywheel after the power takeoff assembly is
lifting equipment to take up the slack. removed. Refer to Section 110-0130, POWER
TAKEOFF.
23. Remove locknuts (20), bolts (19) and snubbing
washers (18) securing mounting crossmember (13) 12. With power takeoff assembly removed, remove
to the frame. mounting hardware and damper from engine (1). If
necessary, remove mounting hardware from flange
24. Carefully lift mounting crossmember (13) clear of coupling and remove flange coupling from damper.
the frame and move to a clean work area for further
disassembly. 13. Remove and discard filters (2, 3 & 4) from engine
(1), as described in 'Maintenance'. Cover engine inlet
ports to prevent entry of dirt.
DISASSEMBLY
Numbers in parentheses refer to Fig. 1. 14. Refer to 'Engine Manufacturers Service Manual' if
engine service or repair is required.
1. Remove bolts (10) and lockwashers (12) securing
front mounting brackets (9) to engine (1). Remove
front mounting brackets (9). INSPECTION
Numbers in parentheses refer to Fig. 1.
2. Remove bolts (10 & 11) and lockwashers (12)
securing rear mounting brackets (21) to engine (1). 1. Inspect rubber isolation mounts (17 & 22) for
Remove rear mounting brackets (21). damage and replace if required.

3. If required, remove rubber isolation mounts (22) 2. Check rear mounting brackets (21), front mounting
from rear mounting brackets (21). brackets (9), mounting crossmember (13) and
brackets on the frame for cracks and/or damage.
4. If required, remove rubber isolation mounts (17) Repair or replace as necessary.
from mounting crossmember (13).
3. Inspect engine damper and flange coupling for
5. Remove mounting hardware securing fan to engine damage and repair or replace as required.
(1) then remove fan.

6. Loosen the fan hub mounting bolts and turn the

adjusting rod anticlockwise enough to allow slack in
poly 'V' belts. Remove poly 'V' belts.

10 SM 1923 R2 03-04
 Engine - Engine and Mounting
Section 110-0030

ASSEMBLY Note: Position rubber isolation mounts (17 & 22) to

Numbers in parentheses refer to Fig. 1. their mounts as shown in Fig. 1.

Note: Tighten all fasteners without special torques 10. If removed, install rubber isolation mounts (17) to
specified to standard torques listed in Section front mounting crossmember (13).
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 11. If removed, install rubber isolation mounts (22) in
rear mounting brackets (21). Secure rear mounting
1. Remove covers from engine filter ports and install brackets (21) to engine (1) with bolts (10 & 11) and
new filters (2, 3 & 4) on engine (1), as described in lockwashers (12). Tighten bolts (10 & 11) to a torque
'Maintenance'. of 230 Nm (170 lbf ft) lubed.

2. Install damper to rear of engine (1) and secure 12. If removed, secure front mounting brackets (9) to
with mounting hardware as removed at 'Removal'. engine (1) with bolts (10) and lockwashers (12).
Install flange coupling to damper and secure with Tighten bolts (10) to a torque of 230 Nm (170 lbf ft)
mounting hardware as removed at 'Removal'. lubed.

3. Position alternator on engine mounting bracket and

align the holes in the alternator mounting flanges with INSTALLATION
the tube in the bracket. Secure alternator in position Numbers in parentheses refer to Fig. 1.
with mounting hardware as removed at 'Removal'.
Tighten bolt finger tight at this stage. Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
4. Install adjuster screw and link assembly to 300-0080, STANDARD BOLT AND NUT TORQUE
alternator and secure with mounting hardware as SPECIFICATIONS.
removed at 'Removal'. Tighten bolt finger tight at this
stage.
WARNING
Note: Replace all belts in a set when one is broken To prevent personal injury and property
or replaced. damage, be sure lifting device is properly
secured and of adequate capacity to do the job
5. Install 'V' belts in the grooves of alternator and safely.
accessory drive pulley.
1. Attach suitable lifting equipment to front mounting
Note: Alternator belt tension adjustment is made crossmember (13) and carefully position assembly in
after installation of engine (1) and the radiator the frame.
assembly.
2. Secure mounting crossmember (13) to frame
6. Install air conditioner compressor and drive belt to mounting brackets with bolts (19), snubbing washers
engine (1). Refer to Section 260-0130, AIR (18) and locknuts (20) as shown in Fig. 1. Tighten
CONDITIONING. bolts (19) to a torque of 434 Nm (320 lbf ft) lubed.

7. Install poly 'V' belts to the fan pulley and 3. Attach suitable lifting equipment to engine (1) lifting
crankshaft pulley. points and carefully position engine (1) in the frame.

8. Adjust poly 'V' belts by turning the adjusting screw 4. Secure rear mounting brackets (21) to the frame
clockwise until the correct tension is obtained. Refer with bolts (24), snubbing washers (23) and locknuts
to 'Drive Belt Adjustments'. When correct tension is (25) as shown in Fig. 1. Tighten bolts (24) to a torque
obtained tighten fan hub mounting bolts to a torque of of 915 Nm (675 lbf ft) lubed.
100 Nm (74 lbf ft).
5. Secure front mounting brackets (9) to mounting
9. Position fan to fan pulley on engine (1) and secure crossmember (13) with bolts (14), hardened washers
with mounting hardware. Tighten bolts in a star (15), lockwashers (12) and and locknuts (16) as
shaped pattern to a torque of 34 Nm (25 lbf ft). shown in Fig. 1. Tighten bolts (14) to a torque of
170 Nm (230 lbf ft) lubed.

SM 1923 R2 03-04 11
Engine - Engine and Mounting
Section 110-0030
6. Connect driveline to the engine coupling. Refer to 19. Connect battery positive connections to battery
Section 130-0010, FRONT DRIVELINES. terminal posts. Connect battery earth connections to
battery terminal posts.
7. Install tandem pump on power takeoff assembly
and secure with mounting hardware. Refer to Section 20. Ensure all lines, harnesses and cables are
230-0050, TANDEM PUMP. secured with clips and clamps as removed during
removal. Ensure no lines are chaffing on sharp edges
8. Using suitable lifting equipment, install the radiator or resting against areas where heat will be evident.
assembly to the frame and secure with mounting Ensure all drain plugs and cocks are secured tightly.
hardware. Refer to Section 210-0040, RADIATOR
AND MOUNTING. 21. Fill the cooling system with coolant specified in
Section 300-0020, LUBRICATION SYSTEM. Check
9. Adjust 'V' belts by loosening locknut and turning the coolant level as described in Section 210-0000,
screw assembly clockwise until the correct tension is COOLING SYSTEM.
obtained (refer to 'Drive Belt Adjustments'). When
correct tension is obtained tighten locknut. 22. Fill the engine with lube oil specified in Section
300-0020, LUBRICATION SYSTEM. Check oil level
10. Tighten bolt securing alternator to engine as described under 'Maintenance'.
mounting bracket and bolt securing link assembly to
alternator to a torque of 81 - 95 Nm (60 - 70 lbf ft). 23. Check all line and pipe connections for leaks prior
to starting the vehicle. Tighten as required.
11. Remove caps from all cooling lines and connect
lines to the radiator assembly and engine (1) 24. Start up the engine and bring the engine oil to
assembly as identified at removal. operating temperature. Check all lines and fittings for
leaks and tighten as required.
12. Install air cleaner intake pipe and exhaust piping
to engine turbocharger. Tighten mounting clamps 25. Ensure parking brake is applied and remove
securely. wheel blocks from all road wheels.

13. Remove caps from heater lines and fittings and

connect heater lines to engine (1) as identified at MAINTENANCE
removal. Numbers in parentheses refer to Fig. 1.

14. Remove caps from fuel lines and fittings and Note: Carry out the following maintenance
connect fuel lines to engine (1) as identified at removal. procedures in conjunction with additional procedures
listed in Section 300-0020, LUBRICATION SYSTEM.
15. Connect all electrical harnesses and cables to
engine (1) (with the exception of battery connections)
as identified at removal. Every 10 Hours (Daily)
Engine (1): Visually check engine for damage, loose
16. Connect air conditioning lines to the compressor or frayed belts and listen for any unusual noises.
as identified at removal. On completion of engine Check the turbocharger for leaks.
installation the air conditioning system will require to
be charged. Refer to Section 260-0130, AIR Engine (1) Oil Level: Check engine oil level and add
CONDITIONING. oil if low.

17. Using suitable lifting equipment, install radiator 1. Cold Level - Before starting up after a major shut
guard assembly to the frame. Secure with the down period the oil level should be up to the
required mounting hardware and connect electrical MAXIMUM mark.
connections as identified at removal.
2. Hot Level - Shut down the engine and wait 5
18. Using suitable lifting equipment, install hood minutes. The oil level should be up to, but not over,
assembly into position on the vehicle. Secure hood the MAXIMUM mark (hot level).
assembly with mounting hardware removed at
removal.

12 SM 1923 R2 03-04
 Engine - Engine and Mounting
Section 110-0030

After First 150 Hours of Operation 3. Start new primary fuel filter (4) on the filter adaptor
Engine (1): Drain engine oil and refill. Refer to and tighten it by hand until the gasket contacts the
Section 300-0020, LUBRICATION SYSTEM for oil adaptor fully with no side movement of the filter
specification. evident. Tighten an additional 1/2 of a turn.

Engine Oil Filters (2): Replace oil filters as follows: Note: Mechanical tightening of fuel filters (4 & 5) is
not recommended, and may result in seal and/or
1. Using filter wrench, remove and discard all oil cartridge damage. Tighten fuel filters by hand only.
filters (2) from engine (1). Inspect the sealing surface
of the filter to ensure that the seal ring stayed with 4. Repeat step 3 for remaining primary fuel filter (4)
the filter. If not, remove it from the filter adaptor. and both secondary fuel filters (5).

2. Clean the filter adaptor with a clean, lint free cloth. 5. Start the engine and check for leaks. If any leaks
are noted, have them corrected.
3. Lightly coat new oil filter (2) seal with clean engine
oil as specified in Section 300-0020, LUBRICATION
SYSTEM. After First 200 Hours of Operation
Coolant: Check coolant level and condition of
4. Start a new oil filter (2) on the filter adaptor and coolant inhibitor as described in Section 210-0000,
tighten it by hand until the seal touches the adaptor COOLING SYSTEM.
filter head. Tighten an additional 2/3 of a turn after
contact.
Every 500 Hours
Note: Mechanical tightening of oil filters (2) is not Engine (1): Drain engine oil and refill. Refer to
necessary and will distort or crack the adaptor. Section 300-0020, LUBRICATION SYSTEM for oil
Tighten oil filters by hand only. specification.

5. Repeat steps 3 and 4 for remaining oil filters (2). Engine Water Pump: Inspect water pump drain hole
and clean if required.
6. Start and run the engine for a short period and
check for oil leaks. If any leaks are noted, have them Engine Oil Filters (2): Replace oil filters (2) as
corrected. described in 'After first 150 hours of operation'.

7. After the engine has been stopped long enough Fuel Filters (4 & 5): Replace primary fuel filters (4)
(approximately 20 minutes) for the oil from various and secondary fuel filters (5) as described in 'After
parts of engine (1) to drain back to the crankcase, first 150 hours of operation'.
check oil level and add oil to bring it to the proper
level on the dipstick. Refer to Section 300-0020, Coolant: Check coolant level and condition of
LUBRICATION SYSTEM for oil specification. coolant inhibitor as described in Section 210-0000,
COOLING SYSTEM.
Fuel Filters (4 & 5): Replace primary fuel filters (4)
and secondary fuel filters (5) as follows:
Drive Belt Adjustments
Note: There is a fuel system shut off valve on the Every 100 Hours: Check all drive belt tensions and
discharge side of secondary fuel filter (5). Closing adjust if required. Check and adjust air conditioning
this valve will prevent loss of fuel prime at time of compressor belts as described in Section 260-0130,
filter replacement. AIR CONDITIONING.

1. Close shut off valve at secondary fuel filters (5) Every 2 000 Hours: Replace all drive belts.
and, using filter wrench, remove and discard all fuel
filters (4 & 5) from engine (1). Note: Replace all belts in a set when one is worn.
Single belts of similar size should not be used as a
2. Fill the replacement filters and coat the gaskets substitute for a matched belt set as premature belt
slightly with clean fuel oil as specified in Section wear can result due to belt length variation. All belts
300-0020, LUBRICATION SYSTEM. in a matched belt set are within 0.81 mm (0.032 in) of
their specified centre distances.
SM 1923 R2 03-04 13
Engine - Engine and Mounting
Section 110-0030
Using belt tension gauge, adjust the belt tension to the Belts should be neither too tight nor too loose. Belts
following values: that are too tight impose excess loads on the
crankshaft, fan and alternator bearings, shortening both
Fan - Poly 'V' Belt belt and bearing life. Excessively overtightened belts
'New' Belt Tension - 2670 - 2935 N (600 - 660 lbf) can result in crankshaft breakage. A loose belt will slip
'Used' Belt Tension - 2295N (515 Ibf) and may cause damage to accessory components.

Alternator - 'V' Belt

Belt Tension - 623 - 734 N (140 - 165 lbf) SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of service tools which should be used in
Note: A belt is considered 'Used' if it has been in conjunction with procedures outlined in the engine
service for 10 minutes or longer. If the used belt manufacturers service manual, and, general service
tension is less than the minimum value, tighten the belt tools required. These tools are available from your
to the maximum value. dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Bolt 230 170
1 11 Bolt 230 170
1 14 Bolt 230 170
1 19 Bolt 434 320
1 24 Bolt 915 675
- - Fan Hub Mounting Bolts 100 74

* * * *

14 SM 1923 R2 03-04
 ENGINE - Air Cleaner
Section 110-0050

SM - 1532

1 - Air Cleaner Body 3

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

DESCRIPTION SM - 1898

Numbers in parentheses refer to Fig. 1, unless

otherwise specified.

There are two, dual dry element type air cleaner

assemblies mounted on the platform to the right hand STOP

side of the cab. Air cleaner assemblies prolong engine

life by removing grit, dust and water from the air as it
enters the engine. Grit and dust combined with engine
oil, forms a highly abrasive compound which can destroy
the engine in a comparatively short period of time.

A rubber vacuator valve (6) attached to cover

assembly (4) in a downward position, ejects grit, dust
Fig. 2 - Air Cleaner Restriction Indicator Light
and water while the engine is running. Vacuator valve
(6) minimizes the need for daily servicing. Even
though vacuator valve (6) is normally under a slight the circuit closes and a restriction indicator light in the
vacuum when the engine is running, pulsing of the dash panel (Fig. 2) illuminates. This light shows at a
vacuum opens and closes vacuator valve (6) expelling glance when the system air flow is being restricted
grit, dust and water as they collect. When the engine is indicating that primary element (2) should be serviced.
stopped, vacuator valve (6) opens and expels any Air restriction gauge (15, Fig. 3) automatically resets
accumulated grit, dust or water. after each air cleaner assembly is serviced.

An electrical air restriction gauge (15, Fig. 3) indicates While the indicator light indicates the need for
when air restriction levels reach the maximum servicing, it does not give as precise a measurement
allowable limit. When air restriction levels are reached, as a water manometer or vacuum gauge. Refer to

SM 1925 7-00 1
Engine - Air Cleaner
Section 110-0050

SM - 2434
7

8
9
8,9

6 15
5
14
4 13
3
12

4
16
4
1 6
5
2 4
10

4
16 11
4

1 - Bolt 5 - Hump Hose 9 - Clamp 13 - Nipple

2 - Hardened Washer 6 - Clamp 10 - Tube Assembly 14 - Elbow
3 - Mounting Band 7 - Cap Assembly 11 - Tube Assembly 15 - Air Restriction Gauge
4 - Clamp 8 - Tube Extension 12 - Reducer 16 - Hump Hose

Fig. 3 - Exploded View of Air Cleaner Mounting

'Measuring Air Restriction'. over service. When restriction readings finally indicate
a change, remove primary element (2) carefully and
Safety element (3) is installed in each air cleaner clean/replace as required. Refer to 'Primary Element'.
assembly inside of primary element (2). This element
increases the reliability of the air cleaner’s protection Never attempt to clean safety element (3). Change
of the engine from airborne dirt. It protects the engine safety element (3) after every third primary element (2)
from dirt admitted by a damaged primary element (2), service.
or dirt that might be dropped into the air cleaner
assembly while servicing primary element (2). Make sure vacuator valve (6) is not damaged or
plugged and that the joint with cover assembly (4) is
not broken. If vacuator valve (6) is lost or damaged,
MAINTENANCE replace it to maintain pre-cleaner efficiency and normal
Numbers in parentheses refer to Fig. 1, unless filter element service life.
otherwise specified.
Check condition of clamps (4 & 6, Fig. 3), hump hoses
(5 & 16, Fig. 3) and tube assemblies (10 & 11, Fig. 3).
WARNING Tighten/replace as necessary.
Always shutdown the engine before servicing
air cleaner.
Air Cleaner Assembly
The air cleaner elements should be serviced only Numbers in parentheses refer to Fig. 1, unless
when the maximum allowable restriction has been otherwise specified.
reached, as indicated by air cleaner restriction
indicator light. The elements should not be serviced on Note: Air cleaner body (1) should be thoroughly
the basis of visual observation as this would lead to cleaned twice a year. Do not apply heat in any form to

2 SM 1925 7-00
 Engine - Air Cleaner
Section 110-0050
air cleaner body (1). 2. Remove primary element (2) from air cleaner body (1).

1. Release latches (5) on cover assembly (4) and 3. Using a damp cloth and a suitable solvent, wipe out
remove cover assembly from air cleaner body (1). all excess dust from air cleaner body (1) and allow to
dry.
2. Remove primary element (2) and safety element (3)
from air cleaner body (1). 4. If the major contaminant on primary element (2) is
light dust, direct a jet of compressed air, not exceeding
3. Slacken clamp (6, Fig. 3) and disconnect hump 6.9 bar (100 lbf/in2), against the pleats of the element.
hose (5, Fig. 3) from air cleaner body (1). The air jet should be directed in the opposite direction
of normal operating air flow. Move the air jet up and
4. Remove bolts (1, Fig. 3) and hardened washers down the pleats, holding the air nozzle 25 mm (1.0 in)
(2, Fig. 3) securing the air cleaner assembly to the away from the pleats, to prevent rupturing the element
platform. with either the nozzle or air jet.

5. Remove the air cleaner assembly from the platform 5. In cases where the dust cake on primary element
for cleaning. (2) contains oil or carbon, air will not clean effectively.
Using manufacturers recommended solution and
6. Open mounting bands (3, Fig. 3) and remove from warm water, not exceeding 48° C (120° F), soak
air cleaner body (1). Open clamp (9, Fig. 3) and primary element (2) for fifteen minutes. Element
remove cap assembly (7, Fig. 3) and tube extension should be gently agitated to assist cleaning process.
(8, Fig. 3) from air cleaner body (1).
Note: It is possible to modify an old agitator type
7. Blank off air cleaner body (1) outlets with tape or washing machine for primary element (2) cleaning. Do
cardboard. Reach inside body with a compressed air not soak or agitate primary element (2) in the solution
nozzle or brush and remove dust from the body. for more than fifteen minutes. Prolonged exposure
softens vertical seams in the element.
8. Remove all loose dust from air cleaner body (1) and
remove tape or cardboard from body outlets. 6. Rinse washed element thoroughly with a low
pressure stream of water, not exceeding 0.7 bar
Note: Assembly and installation of the air cleaner (10 lbf/in2), opposite from the normal air flow, until
assembly is the reverse of disassembly and removal. rinse water runs clear.

7. Air dry primary element (2) thoroughly before

Primary Element returning it to service. Drying is a slow process which
Numbers in parentheses refer to Fig. 1. may be hastened by exposing element to slowly
circulating heated air. Heated air temperature should
Although a paper primary element (2) is used, it is not exceed 46o C (115o F). Drying time can be reduced
possible to clean it so that it can be reused. The to about three hours with heated air. DO NOT use a
number of times one element can be reused depends light bulb for drying. DO NOT use compressed air on a
on the type of dirt on the element and the care wet element.
exercised in cleaning.
Note: Replace paper elements after six cleanings or
The life of a properly cleaned element will be two years in service, whichever comes first. Mark each
approximately as long as that of a new element for the cleaned element to show total cleanings to date.
first one or two cleanings. After that, the life of the
element will gradually decrease with each cleaning; 8. After primary element (2) is thoroughly dried,
however, it should perform satisfactorily through inspect for damage or ruptures, especially close to the
approximately six cleanings, providing it does not rupture. end caps. To detect paper ruptures, place a bright light
bulb inside the element and rotate element slowly.
Visually determine the condition of primary element (2) Inspection of element on the outside will disclose any
and choose either the compressed air or washing holes where concentrated light shines through. Even
method. the smallest hole will pass dust to the engine and may
result in costly engine repairs.
1. Release latches (5) on cover assembly (4) and
remove cover assembly from air cleaner body (1). 9. Install primary element (2) in air cleaner body (1).

SM 1925 7-00 3
Engine - Air Cleaner
Section 110-0050
10. Install cover assembly (4) on air cleaner body (1) (air cleaner outlet) increases. This vacuum is generally
and secure with latches (5). 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 (15), elbow (14) and
outlet and, using a damp cloth and a suitable solvent, nipple (13) from reducer (12).
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 reducer (12) by means of a flexible
element (2) in air cleaner body (1) hose.

4. Install cover assembly (4) on air cleaner body (1) c. With the manometer held vertically and the engine
and secure with latches (5). drawing maximum air, the difference in height of the
water columns in the two legs is measured as the air
cleaner restriction.
Recommendations
Numbers in parentheses refer to Fig. 3. d. If the restriction exceeds the levels indicated,
engine performance will be affected. Primary filter
1. Under no condition should the vehicle be operated element should be cleaned or replaced.
without both filter elements in each air cleaner
assembly. Vacuum Gauge
a. Remove air restriction gauge (15), elbow (14) and
2. It is very important that hump hoses (5 & 16) and nipple (13) from reducer (12).
tube assemblies (10 & 11) from the air cleaner
assembly to the engine be airtight or the purpose of b. Connect the hose from the vacuum gauge to
the air cleaner will be completely defeated. All clamps reducer (12) and, with the engine drawing maximum
(4 & 6) should be checked frequently and tightened to air, take a note of the reading on the gauge.
prevent leaks.
c. If the restriction exceeds the levels indicated, engine
3. Keep new or cleaned filter elements on hand for performance will be affected. Primary filter element
replacement to prevent unnecessary downtime of the should be cleaned or replaced.
vehicle.

SERVICE TOOLS
MEASURING AIR RESTRICTION Refer to Section 300-0070, SERVICE TOOLS for part
Numbers in parentheses refer to Fig. 3. numbers of service tools referenced in this section and
general service tools required. These tools are
As a dry air cleaner element becomes loaded with available from your dealer.
dust, the vacuum on the engine side of the air cleaner

* * * *
4 SM 1925 7-00
 ENGINE - Power Takeoff
Section 110-0130

DESCRIPTION AND OPERATION SM - 1361

Numbers in parentheses refer to Fig. 1.

The function of the power takeoff (PTO), as the name

implies, is to provide the means of mounting and
driving an auxiliary component. The tandem pump for
the body hoist system and disc brake cooling system
is mounted to PTO cover (26) and its input shaft is
meshed with the internal splines in the hub of driven
gear (12). Refer to Section 230-0050, TANDEM
PUMP.

The major components of the PTO assembly are;

flywheel cover case (1), PTO cover (26), driveshaft (15),
drive gear (14) and driven gear (12).

As driveshaft (15) is driven by the engine crankcase,

drive gear (14) turns to drive driven gear (12). The
tandem pump driveshaft, meshed in the hub of driven
gear (12), turns with driven gear (12) to operate the
tandem pump which, in turn, supplies hydraulic oil to
the body hoist system and cooling oil to the disc brake
assemblies. Refer to Section 230-0050, TANDEM
PUMP.

1 - Flywheel Cover Case 12 - Driven Gear

REMOVAL 5 - Oil Seal 14 - Drive Gear
Numbers in parentheses refer to Fig. 2. 6 - Plug 15 - Driveshaft
9 - Oil Seal 17 - Snap Ring
10 - Bearing 18 - Gasket
11 - Bearing 26 - PTO Cover
WARNING
Fig. 1 - Cutaway View of Power Takeoff Assembly
To prevent personal injury and property damage,
be sure wheel blocks, blocking materials and
lifting equipment are properly secured and of 6. With suitable blocking or lifting equipment, support
adequate capacity to do the job safely. the pump before loosening attaching nuts. Remove
nuts and lockwashers from pump mounting studs and
1. Position the vehicle in a level work area, apply the secure pump clear of the PTO assembly.
parking brake and switch off the engine.
7. Match mark engine flywheel housing and flywheel
2. Turn the steering wheel in both directions to relieve cover case (1) so that the PTO assembly can be
pressure in the steering system. Block all road wheels. installed in the same position at 'Installation'.

3. Disconnect driveline from yoke (22) at the PTO 8. Attach a suitable lifting device to the PTO assembly
assembly. Refer to Section 130-0010, FRONT and remove bolts (23 & 25) and lockwashers (24)
DRIVELINE. securing PTO assembly to the engine flywheel
housing. Carefully lower PTO assembly from the
4. Drain oil from power takeoff housing by removing flywheel housing and move to a clean work area for
drain plug (6) from flywheel cover case (1). Reinstall disassembly.
drain plug (6) securely.

5. Match mark tandem pump mounting flange and DISASSEMBLY

PTO cover (26) so that the pump can be installed in Numbers in parentheses refer to Fig. 2.
the same position at installation.
1. Remove locknut (16) and hardened washer (19)
from driveshaft (15). Pull yoke (22) from driveshaft (15).

SM 1914 7-00 1
Engine - Power Takeoff
Section 110-0130

SM - 2421

26 29
2
18
4 3
6

17
12 11
1 6 16
13 19
11 9
6 22

2
17
10
15

14 8 7
10

21
27
5 20
28

23,25
6 24

22 - Yoke
1 - Flywheel Cover Case 8 - Lockwasher 15 - Driveshaft 23 - Bolt
2 - Dowel Pin 9 - Oil Seal 16 - Locknut 24 - Lockwasher
3 - Bolt 10 - Bearing 17 - Snap Ring 25 - Bolt
4 - Lockwasher 11 - Bearing 18 - Gasket 26 - PTO Cover
5 - Oil Seal 12 - Driven Gear 19 - Hardened Washer 27 - Coupling
6 - Plug 13 - Plug 20 - Breather 28 - Adaptor
7 - Bolt 14 - Drive Gear 21 - Breather Cap 29 - Plug
Fig. 2 - Exploded View of Power Takeoff Assembly

2. Remove bolts (3 & 7) and lockwashers (4 & 8) from 8. If necessary, note locations and remove dowel pins
PTO cover (26). Pull PTO cover (26) and gasket (18) (2) from flywheel cover case (1) and breather
from flywheel cover case (1). Discard gasket (18). assembly (20, 21, 27 & 28) from PTO cover (26).

3. Place PTO cover (26) yoke side up on a work

bench. Pry oil seal (9) from PTO cover (26) and INSPECTION
discard. Numbers in parentheses refer to Fig. 2.

4. Remove snap rings (17) from pump and driveshaft 1. Wash all parts thoroughly in a suitable solvent and
bores. Drive bearings (10 & 11) from PTO cover (26) dry all but bearings (10 & 11) with compressed air. Dry
with a sleeve or soft steel drift. Drive on the outer race bearings (10 & 11) with a clean lint free cloth.
of bearings (10 & 11) taking care not to damage the
bearings. 2. Check the condition of splines and teeth on gears
(12 & 14), driveshaft (15) and yoke (22) for burrs or
5. Slide drive gear (14) from driveshaft (15) and pull signs of wear.
driven gear (12) from flywheel cover case (1).
3. Lubricate bearings (10 & 11) with oil and check
6. Pull driveshaft (15) from flywheel cover case (1). operation by spinning bearings by hand. DO NOT spin
Pry oil seal (5) from flywheel cover case (1). bearings with compressed air. Inspect bearing bores
for out of roundness. Replace bearings, if required.
7. Pull bearings (10 & 11) from flywheel cover case (1)
with a suitable bearing puller. 4. Inspect flywheel cover case (1) and PTO cover (26)
for cracks. If either flywheel cover case (1) or PTO

2 SM 1914 7-00
 Engine - Power Takeoff
Section 110-0130
cover (26) are damaged, both parts must be replaced 6. Install driven gear (12) and driveshaft (15) into
as an assembly. flywheel cover case (1). Slide drive gear (14) over
driveshaft (15) to its proper location.
5. Visually check oil seal lip contact surfaces on
driveshaft (15) and yoke (22) for nicks, dents, 7. Install new gasket (18) on PTO cover (26) and
scratches, wear, or corrosion. Replace as necessary. assemble PTO cover (26) to flywheel cover case (1).
Secure PTO cover (26) to flywheel cover case (1) with
bolts (3 & 7) and lockwashers (4 & 8).
ASSEMBLY
Numbers in parentheses refer to Figs. 2. 8. Install yoke (22), hardened washer (19) and locknut
(16) on driveshaft (15) end. Tighten locknut (16) to a
Note: Prior to assembly, lubricate all seal lips and torque of 950 - 1 085 Nm (700 - 800 lbf ft).
surfaces with lubricant specified in Section 300-0020,
LUBRICATION SYSTEM.
INSTALLATION
Note: Tighten all fasteners without special torques Numbers in parentheses refer to Figs. 1 & 2.
specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE Note: When reassembling PTO assembly to engine
SPECIFICATIONS. flywheel housing, and tandem pump to PTO assembly,
be sure to align match marks inscribed during
disassembly.
WARNING
To prevent personal injury and property Note: Tighten all fasteners without special torques
damage, be sure lifting device is properly specified to standard torques listed in Section
secured and of adequate capacity to do the job 300-0080, STANDARD BOLT AND NUT TORQUE
safely. SPECIFICATIONS.

1. If removed, install dowel pins (2) in flywheel cover 1. Using suitable lifting equipment, position PTO
case (1) and breather assembly (20, 21, 27 & 28) in assembly on engine flywheel housing. Secure the
PTO cover (26), as noted at disassembly. PTO assembly to the engine flywheel housing with
bolts (23 & 25) and lockwashers (24).
2. Install new oil seal (5) in centre bore of flywheel
cover case (1) so that it is flush with flywheel cover 2. Using suitable lifting equipment, position tandem
case (1) face. See Fig. 1. pump over its mounting studs and secure with nuts
and lockwashers removed during removal.
Note: When installing new oil seals, install them with
the oil lip (larger of the two lips with the spring behind 3. Reconnect driveline to yoke (22). Refer to Section
it) facing inward. Care should be taken to prevent 130-0010, FRONT DRIVELINE.
damage to seal lips during assembly.
4. Remove oil level plug (6) from the front of PTO
3. Press bearings (10 & 11) into their bores in flywheel cover (26) and fill PTO assembly with lubricant
cover case (1). specified in Section 300-0020, LUBRICATION
SYSTEM, until oil flows from the oil level port. Install oil
4. Press bearings (10 & 11) into their respective bores level plug (6) in PTO cover (26) and tighten securely.
in PTO cover (26). Turn PTO cover (26) over and
install snap rings (17). 5. Start the engine and bring oil to correct operating
temperature. Check for leaks and correct as necessary.
5. Install new oil seal (9) into centre bore in PTO cover
(26) so that it is flush with PTO cover (26) face. See 6. Remove wheel blocks from all road wheels.
Fig. 1.

SM 1914 7-00 3
Engine - Power Takeoff
Section 110-0130

MAINTENANCE case (1) and drain oil into a suitable container.

Numbers in parentheses refer to Fig. 1. Reinstall drain plug (6) securely when draining is
complete.
Note: Refer to Section 300-0020, LUBRICATION
SYSTEM for recommended check and drain intervals To refill: Remove oil level plug (6) from the front of
and lubricant specifications. PTO cover (26) and fill PTO assembly with lubricant
specified in Section 300-0020, LUBRICATION
SYSTEM, until oil flows from the oil level port. Install oil
Oil Level Check level plug (6) in PTO cover (26) and tighten securely.
Remove oil level plug (6) from the front of PTO cover
(6) and, if oil level is below the bottom of the filler hole,
add lubricant until it flows from the filler hole. Reinstall SPECIAL TOOLS
oil level plug (6) and tighten securely. 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
Drain and Refill tools required. These tools are available from your
To drain: Remove drain plug (6) from flywheel cover dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
2 16 Locknut 950 - 1 085 700 - 800

* * * *

4 SM 1914 7-00
 TRANSMISSION - Transmission and Mounting
Section 120-0010

SM - 2443
20 21 24
32
23 33
22 34
37 35,36
3
49
20 4
47
21 53
46 19
48
44 29
28
13 54
14
27 2 53
26 30 5
31

25
6
15 7
10
11
50 12
47
51 46
52 48 45
44
1 12
16 42
9 11 10 43
39
41 8
38 15 17 40
18
40 - Drain Cock
26 - Key 41 - Adaptor
1 - Transmission 27 - Padlock 42 - Adaptor
2 - Trunnion 14 - Gasket 28 - Bolt 43 - Snubbing Washer
3 - Bolt 15 - Clamp 29 - Cover Plate 44 - P-clip
4 - Washer 16 - Filler Hose 30 - Level Gauge 45 - Bracket
5 - Locknut 17 - Filler Tube 31 - Ring 46 - Lockwasher
6 - Bolt 18 - Elbow 32 - Bolt 47 - Nut
7 - Hardened Washer 19 - Connector 33 - Strip 48 - Bolt
8 - Nut 20 - Nut 34 - Retainer 49 - P-clip
9 - Mounting Bracket - RH 21 - Sleeve 35 - Shim 50 - Bolt
10 - Bolt 22 - Nylon Tube 36 - Shim 51 - Hardened Washer
11 - Lockwasher 23 - Elbow 37 - Input Yoke 52 - Nut
12 - Isolation Mount 24 - Breather 38 - Nut 53 - Isolation Mount
13 - Filler Cap 25 - Adaptor 39 - Output Yoke 54 - Mounting Bracket - LH
Fig. 1 - Exploded View of Transmission and Mounting

DESCRIPTION (previously known as ATEC).

For transmission make, model and specification, refer
to Section 000-0000, GENERAL INFORMATION. For A brief description and operation of the main
transmission switches, sensors and instruments, refer transmission components are as follows:
to Section 190-0270, SWITCHES AND SENSORS. For
transmission servicing and repair data, refer to the CEC Shift System
transmission manufacturers service manual. Refer to Section 120-0070, CEC SHIFT SYSTEM for
description and operation, wiring diagrams and
The transmission is remote mounted in the frame and electrical troubleshooting of the CEC System.
is supported by trunnion (2) assembly at the front and
mounting brackets (9 & 54) at the rear. Torque Converter
The torque converter consists of three elements -
Integral with transmission (1) assembly are torque pump, turbine, and stator. The pump is the input
converter and planetary gearing. There are six forward element and is driven directly by the engine. The
gears and two reverse gears with automatic lockup in turbine is the output element and is hydraulically
all speed ranges. Operation of the transmission is by driven by the pump. The stator is the reaction (torque
the Commercial Electronic Control (CEC) Shift System, multiplying) element.

SM 1932 7-00 1
Transmission - Transmission and Mounting
Section 120-0010
When the pump turns faster than the turbine, the Transmission Oil Cooler
torque converter is multiplying torque. When the The transmission oil is cooled by a separate oil cooler
turbine approaches the speed of the pump the stator mounted between the radiator and transmission to
starts to rotate with the pump and turbine. When this maintain transmission oil within its required operating
occurs, torque multiplication stops and the torque temperature range. Refer to Section 210-0060,
converter functions as a fluid coupling. TRANSMISSION OIL COOLER.

Lockup Clutch Transmission Oil Filter

The lockup clutch is located inside the torque The transmission oil filter is mounted off the frame at
converter and consists of three elements - piston, the front right hand side of the transmission. It is
clutch plate, and backplate. The piston and backplate installed in the transmission oil lines to remove dirt and
are driven by the engine and the clutch plate, located other contaminants from the transmission oil to
between the piston and backplate, is splined to the minimise wear and provide maximum service life for
converter turbine. the transmission. Refer to Section 120-0100,
TRANSMISSION OIL FILTER.
The lockup clutch is hydraulically engaged and
released in response to electronic signals from the
ECU. It engages when the vehicle reaches a REMOVAL
predetermined speed. Engagement of the lockup Numbers in parentheses refer to Fig. 1.
clutch provides a direct drive from the engine to the
transmission gearing. This eliminates converter Note: Tag all lines, pipes, electrical connections and
slippage to provide maximum fuel economy. The mechanical linkages disconnected during removal to
lockup clutch releases at lower speeds (and aid in installation.
momentarily during shifts). When the lockup clutch is
released, drive from the engine is transmitted
hydraulically through the converter to the transmission WARNINGS
gearing. The lockup clutch also releases when the To prevent personal injury and property
ECU detects certain undesirable conditions. damage, be sure wheel chocks, blocking
materials and lifting equipment are properly
Planetary Gears and Clutches secured and of adequate capacity to do the job
A series of planetary gears and shafts provide the gear safely.
ratios and directions of travel for the vehicle. Power flow
through the planetaries is controlled by multiple clutch High electrical current can cause sparks
packs. The clutches are applied and released hydraulically and personal injury from burns. Switch circuit
in response to electronic signals from the ECU. breakers to the 'Off' position before removing
any electrical components. Remove battery
Hydraulic Retarder ground cable first, and reconnect last, to
A vaned rotor and two vaned stators are the basic prevent damaging electrical components.
components of the retarder. Application of the retarder
control valve fills the cavity around the rotor with oil Any time the battery equalizer is
when the vehicle must be slowed on steep disconnected from the batteries, remove
downgrades. When the cavity is emptied, the rotor is ground cable first, and reconnect last, to
free of drag. Refer to Section 250-0130, RETARDER prevent damaging the component.
CONTROL VALVE.
1. Position the vehicle in a level work area, raise the
Maximum retarder effect occurs in the lowest gear body and install the body prop pins. Refer to
range with foot off of the accelerator pedal. Long Section 270-0010, BODY AND MOUNTING.
continuous use of the retarder will raise transmission
oil temperature. Short periods of full release, to interrupt 2. Apply the parking brake and switch off the engine.
continuous application, will help prevent overheating. Turn steering wheel several times to relieve pressure
in the steering circuit. Depress and release brake
During normal operation the dash mounted pedal continuously to relieve pressure in the braking
transmission oil temperature gauge should read in the system (pressure in accumulator hydraulic line should
green zone. However, during transmission retarder be zero).
operation oil temperature can enter the yellow
'Retarder On' zone but should not enter the red zone. 3. Block all road wheels.

2 SM 1932 7-00
 Transmission - Transmission and Mounting
Section 120-0010
Note: It is important that the electrical connections are transmission (1) and move bracket and valve clear of
removed in the order listed in step 4 to prevent the transmission (1).
damage to the electrical components.
17. Remove mounting hardware supporting mounting
4. Disconnect battery equalizer ground connection brackets for body hoist lines to the top of
from the batteries. Disconnect battery cables from transmission (1).
terminal posts (ground cable first). Disconnect battery
equalizer positive connection. Disconnect electrical 18. Remove mounting hardware securing kick-over
connections at the ECU. valve mounting bracket to the top of transmission (1).

5. Using suitable lifting equipment, support 19. Slacken nut (20) and move nut (20) and nylon tube
transmission guard and remove mounting hardware (22) assembly free from connector (19) in the top of
securing the guard to the frame. Remove transmission transmission (1).
guard.
20. Detach clamps (15) and remove filler hose (16)
6. Disconnect driveline from input yoke (37) at the from filler tube (17) and adaptor (25).
front of transmission (1). Refer to Section 130-0010,
FRONT DRIVELINE. 21. Install suitable lifting eyes into the holes provided
at the top of transmission (1) housing and secure a
7. Disconnect driveline from output yoke (39) at the suitable lifting device to the eyes. Take up slack in the
rear of transmission (1). Refer to Section 130-0020, chain or cable.
REAR DRIVELINE.
22. Remove locknuts (5), bolts (3) and washers (4)
8. Place a suitable container under drain cock (40), securing trunnion (2) to the frame.
loosen drain cock and drain oil from transmission (1).
After draining, tighten drain cock (40) securely. 23. Remove bolts (6), hardened washers (7), snubbing
washers (43) and nuts (8) securing mounting brackets
9. Disconnect the transmission retarder linkage at (9 & 54) to frame.
transmission (1).
24. Check to make certain that all hydraulic lines and
10. Place a suitable container under the steering tank electrical connections fitted to transmission (1) have
drain plug, remove drain plug and drain the oil from the been disconnected before moving transmission (1).
steering tank. After draining, reinstall drain plug.
25. Carefully manoeuvre transmission (1) out of the
11. Disconnect steering lines from the steering pump frame mounting and lower onto a suitable dolly or pallet.
and remove mounting hardware securing steering
lines to transmission (1). Cap all open line ends and 26. Move transmission (1) assembly to a suitable work
steering pump fittings to prevent entry of dirt. area or onto a work stand for further disassembly, if
necessary.
12. Disconnect transmission oil cooler lines and oil
filter lines from transmission (1). Cap all open lines
and fittings to prevent entry of dirt. DISASSEMBLY
Numbers in parentheses refer to Fig. 1.
13. Disconnect hydraulic line from lockup drop out
valve at the front right hand side of transmission (1). Note: Refer to the transmission manufacturers
Service Manual if transmission service or repair is
14. Disconnect all remaining hydraulic lines attached required.
to transmission (1). Cap all open lines and fittings to
prevent entry of dirt. 1. Remove bolts (32), strip (33), retainer (34) and
shims (35 & 36) securing input yoke (37) on
15. Disconnect all electrical connections and cables transmission (1). Pull input yoke (37) from
attached to transmission (1). transmission (1).

16. Remove mounting hardware securing accumulator 2. Pull trunnion (2) assembly from transmission (1)
valve mounting bracket to the front left hand side of and remove ring (31) from trunnion (2), if required. If
necessary, remove isolation mounts (53) from

SM 1932 7-00 3
Transmission - Transmission and Mounting
Section 120-0010
trunnion (2). 6. Coat output shaft splines and threads, and lip of oil
seal with a thin layer of EP, NLGI molybdenum
3. Remove nut (38) securing output yoke (39) on grease. Install output yoke (39) on output shaft by
transmission (1). Pull output yoke (39) from tapping lightly until the yoke is seated. If output yoke
transmission (1). (39) is a tight fit, heat output yoke (39) to 121° C
(250° F) maximum prior to assembly, using either of
4. Remove bolts (10) and lockwashers (11) securing the methods described in step 3.
mounting brackets (9 & 54) to transmission (1).
Remove mounting brackets (9 & 54). 7. Secure output yoke (39) on output shaft with nut
(38). Tighten nut (38) to a torque of 950 - 1 355 Nm
5. If necessary, remove isolation mounts (12) from (700 - 1 000 lbf ft).
mounting brackets (9 & 54).
8. After assembly has cooled, check torque of bolts
(32) and nut (38) and retighten to their required
ASSEMBLY torques.
Numbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners without special torques INSTALLATION

specified to standard torques listed in Section Numbers in parentheses refer to Fig. 1.
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
1. Secure mounting brackets (9 & 54) to transmission 300-0080, STANDARD BOLT AND NUT TORQUE
(1) assembly with bolts (10) and lockwashers (11). SPECIFICATIONS.
Tighten bolts (10) to a torque of 156 Nm (115 lbf ft). If
removed, install isolation mounts (12) to mounting
brackets (9 & 54). WARNING
To prevent personal injury and property
2. If removed, install isolation mounts (53) to trunnion damage, be sure wheel chocks, blocking
(2). If removed, fit new ring (31) to trunnion (2) and materials and lifting equipment are properly
mount trunnion (2) to the front of transmission (1) with secured and of adequate capacity to do the job
small leg to the top and facing away from transmission safely.
(1).
1. Position transmission (1) assembly under the
3. Make sure that transmission input shaft is in its vehicle and attach a suitable lifting device to the eye
most outward position and the bearing is seated bolts on top of transmission (1).
against the shaft shoulder.
2. Carefully lift transmission (1) assembly into its
4. Coat input shaft splines and lip of oil seal with a thin mounting position and lightly secure trunnion (2) to the
layer of EP, NLGI molybdenum grease. Install input frame (mounting face to the front of the frame
yoke (37) on input shaft by tapping lightly until the mounting brackets) with bolts (3), washers (4) and
yoke is seated. If input yoke (37) is a tight fit, heat locknuts (5). Install bolts (3) from the rear of the
input flange (37) to 121° C (250° F) maximum prior to assembly.
assembly. Two methods which may be employed are:
3. Install bolts (6), hardened washers (7), snubbing
a. Heat in controlled temperature furnace for a washers (43) and nuts (8) securing mounting brackets
minimum period of 45 minutes. (9 & 54) to frame mounting brackets. Securely tighten
bolts (6) to a torque of 278 Nm (205 lbf ft).
b. Submerge flange in heated oil for 15 minutes.
4. Securely tighten bolts (3), securing trunnion (2) to
5. Use proper combination of shims (35 & 36) to obtain frame mounting brackets, to a torque of 156 Nm
a 0.2 - 0.3 mm (0.008 - 0.012 in) gap between retainer (115 lbf ft).
face of input yoke (37) and end of input shaft. Fit
retainer (34) and secure with bolts (32) and strip (33). 5. Remove lifting device and lifting eye bolts from top
Tighten bolts (32) to a torque of 130 - 156 Nm of transmission (1).
(96 - 115 lbf ft).

4 SM 1932 7-00
 Transmission - Transmission and Mounting
Section 120-0010
6. Install filler hose (16) to filler tube (17) and adaptor level as described in Section 220-0040, STEERING
(25) and secure with clamps (15). AND BRAKE CONTROL TANK.

7. Secure accumulator valve mounting bracket to the Note: It is important that the electrical connections are
front left hand side of transmission (1) assembly with made in the order listed in step 21 to prevent damage
mounting hardware removed during removal. to the electrical components.

8. Secure kick-over valve mounting bracket to top of 21. Connect electrical connections at the ECU.
transmission (1) assembly with mounting hardware Connect battery equalizer positive connection.
removed during removal. Connect battery cables to battery terminal posts
(ground cable last). Connect battery equalizer ground
9. Secure body hoist lines mounting brackets to the connection.
top of transmission (1) assembly with mounting
hardware removed during removal. 22. Start the engine and make an operational check
while the engine is running of all lines and connections
10. Connect all electrical connections and cables to disconnected during removal of transmission (1).
transmission (1) as tagged at removal. Check for leaks and tighten lines and fittings as
required.
11. Connect transmission oil cooler lines to
transmission (1) and oil filter lines to transmission oil 23. Ensure parking brake is applied, remove the body
filter as tagged at removal. prop pins and lower the body. Refer to Section
270-0010, BODY AND MOUNTING. Remove wheel
12. Connect steering pump hydraulic lines as tagged chocks from all road wheels.
at removal and secure lines to transmission (1) with
mounting hardware removed during removal.
MAINTENANCE
13. Connect hydraulic line from lockup drop out valve
to front right hand side of transmission (1). Periodic Inspections
For easier inspection, the transmission should be kept
14. Connect any remaining hydraulic lines which were clean. Make periodic checks for loose bolts and
removed during removal. Ensure all hydraulic lines are leaking oil lines. Check the condition of electrical
securely tightened. harnesses and connections regularly.

15. Connect transmission retarder linkage at The transmission breather should be checked
transmission (1). regularly and as frequently as necessary, depending
on the operating conditions of the vehicle. A badly
16. Install rear driveline to output yoke (39) at the rear corroded or plugged breather restricts proper
of transmission (1) and secure with mounting breathing and causes a buildup of condensation and
hardware removed during removal. Refer to Section subsequent oil deterioration.
130-0020, REAR DRIVELINE.

17. Install front driveline to input yoke (37) at the front Oil Level Check
of transmission (1) and secure with mounting
hardware removed during removal. Refer to Section
130-0010, FRONT DRIVELINE. WARNING
When checking the oil level, be sure that the
18. Using suitable lifting equipment, support parking brake is applied and all road wheels
transmission guard and secure guard to the frame with are securely blocked.
mounting hardware removed during removal.
Check the transmission oil level and add oil if low,
19. Fill transmission (1) assembly with oil specified in every 10 hours/daily. Use only oil of the type specified
Section 300-0020, LUBRICATION SYSTEM, and check in Section 300-0020, LUBRICATION SYSTEM.
the oil level as described under 'Oil Level Check'.
Because the transmission oil cools, lubricates and
20. Fill steering tank with oil specified in Section transmits hydraulic power it is important that the
300-0020, LUBRICATION SYSTEM, and check the oil proper oil level be maintained at all times. If the oil

SM 1932 7-00 5
Transmission - Transmission and Mounting
Section 120-0010
level is too low, the converter and clutches will not SM - 1250
receive an adequate supply of oil. If the oil level is too
high, the oil will aerate and the transmission will
overheat. It is absolutely necessary that the oil put into
the transmission be clean.

Oil must be handled in clean containers to prevent

foreign material from entering the system.
RED LINE
Note: Containers or fillers that have been used for
NO RED
antifreeze or engine coolant solution must not be used LINE VISIBLE
for transmission oil. (OVERFILL)

Visual Level Indicator

A visual level indicator is mounted on the lower left SAFE
FULL MARK
side of the transmission main housing and provides a OPERATIONAL
(CENTRE)
LEVEL AREA
method of checking the oil level. Refer to Fig. 2.

Cold Oil Level Check

Before starting the engine, check the visual level NO OIL VISIBLE
(UNDERFILL)
indicator or remove the ADD (lower) plug. If oil is
present in the indicator or if oil flows from the plug
opening, the transmission has sufficient oil to permit
safe starting of the engine. If no oil is present, add
sufficient oil to bring the level within the indicator or to
cause a flow from the plug opening. Replace the plug.
Fig. 2 - Visual Level Indicator
Hot Oil Level Check
Note: Observe the condition of the oil in the visual The transmission oil and filters should be changed at
level indicator or the type of flow from the plug the intervals specified in Section 300-0020,
opening. Foaming or spurting may indicate a false LUBRICATION SYSTEM, or sooner, depending on
level. operating conditions. Also, the oil must be changed
whenever there are traces of dirt or evidence of high
A hot oil level check is made to determine if there is temperature indicated by discoloration or strong odour.
sufficient oil for working operation of the transmission.
Select neutral on the transmission range selector and The screen and magnet assembly in the sump should
start the engine. Operate the vehicle until the be removed and cleaned with mineral spirits at each
transmission reaches a normal operating temperature oil change. Metal particles in the oil (except for the
of 82 - 103° C (180 - 220° F). Idle the engine, apply minute particles normally trapped in the oil filters)
the parking brake and block all road wheels. indicate damage has occurred in the transmission
When these particles are found in the filters, the cause
Check the visual level indicator or remove the FULL must be established and rectified immediately to
(upper) oil level check plug. The oil should be within prevent damage to the transmission.
the indicator limits shown in Fig. 2 or at or near the
level of the plug opening. Add or drain oil as necessary At each oil change, examine the used oil for evidence
to bring the oil level within these limits. of dirt or water. A normal amount of condensation will
emulsify in the oil during operation of the transmission.
Note: The transmission may be operated safely as However, if there is evidence of water or engine
long as the oil level is above the ADD (lower) plug. coolant in the oil, the cause must be established and
rectified immediately to prevent damage to the
transmission.
Oil and Filter Change
After the first 150 hours of operating a new or rebuilt
transmission, the transmission oil and filters should be
changed.

6 SM 1932 7-00
 Transmission - Transmission and Mounting
Section 120-0010

Welding on Vehicles Equipped With CEC

WARNING
When conducting a stall test, the vehicle must
WARNINGS be positively prevented from moving. The
The ECU can be damaged by improper welding parking brake must be applied and the vehicle
procedures. should be blocked to prevent movement
forward or reverse. Keep people safely away
Any time the battery equalizer is from the vehicle path. Do not maintain the
disconnected from the batteries, remove stalled condition longer than 30 seconds due
ground cable first, and reconnect last, to to rapid heating of the transmission oil. With
prevent damaging the component. the transmission in neutral, run the engine at
1 200 - 1 500 rev/min for two minutes to cool
When frame or other welding is required, the following the oil between tests. Do not allow the
precautions are to be taken to protect the electronic converter-out temperature to exceed 135° C
components. (275° F). Keep a close check to prevent
overheating of the engine cooling system.
a. Disconnect battery equalizer ground connection
from the batteries. Disconnect battery cables from 1. Position the vehicle on a level area with room for
terminal posts (ground cable first). Disconnect battery movement all round.
equalizer positive connection. Disconnect electrical
connections at the ECU. 2. Apply the parking brake and block all road wheels.
Turn the manual mode key switch to the 'On' position
b. If additional system ground wires are connected to and the mode selection switch to the 'Power' mode.
the frame, they must be disconnected also.
3. Apply the service brake, release the parking brake
c. Cover electronic components and wiring to protect and select fifth gear on the transmission shift selector.
from damage. The transmission will shift to fifth gear and deactivate
the lockup clutch. Apply the parking brake and release
d. Do not connect welding cables to electronic the foot pedal.
components. Do not weld on electronic components. If
welding is to be done close to electronic components, 4. Accelerate the engine to full throttle and, using a
the components should be removed prior to the tachometer of known accuracy, note the maximum
welding process. rev/min the engine will attain. Converter-out pressure
should be 2 bar (30 lbf/in²).
e. On completion of all welding reconnect electrical
connections in the reverse order to step a. Note: The stall speed of each vehicle is noted on the
final inspection records prior to the vehicle leaving the
factory. This can be used as a guide when checking
TROUBLESHOOTING the stall speed. It is recommended to keep a record of
the stall speed after each major service and use the
Converter Stall Test previous recorded value as a guide.
A stall test should be conducted when the power
package (engine and transmission) is not performing 5. When the stall check is complete, return the
satisfactorily. The purpose of the test is to determine accelerator to the idle position and move the shift
the engine power output and establish if the selector to the neutral position.
transmission is the malfunctioning component.
Note: Engine power will decrease with an increase in
elevation (altitude), becoming more pronounced at
greater elevation. This will result in a lower engine
speed under converter stall conditions.

SM 1932 7-00 7
Transmission - Transmission and Mounting
Section 120-0010
6. During the stall check the transmission oil for mechanical troubleshooting, as outlined in the
temperature should rise while the engine is under load 'Mechanical Trouble Shooting' charts, before carrying
and drop when the transmission is returned to neutral. out electrical troubleshooting procedures.
Should the temperature fail to drop it indicates that
there is a problem with the converter.
WARNING
7. After making allowances for elevation, a low engine Be sure to apply the parking brake, switch off
speed may indicate the engine is not delivering full the engine and block all road wheels before
power. Refer to engine service manual for engine troubleshooting the vehicle. Should it be
repair information. necessary to run the engine, it is imperative
that an operator be present in the cab at all
times, even at idle.
Electronic Troubleshooting
Refer to Section 120-0070, CEC SHIFT SYSTEM for
general electrical troubleshooting. For more detailed SPECIAL TOOLS
electrical troubleshooting refer to the Allison There are no special tools required for the procedures
Transmission Commercial Electronic Control (CEC) outlined in this section. Refer to Section 300-0070,
Troubleshooting Manual SA2712A. SERVICE TOOLS for part numbers of service tools
which should be used in conjunction with procedures
outlined in the transmission manufacturers service
Mechanical Troubleshooting manual, and general service tools required. These
It is recommended to follow the procedures laid down tools are available from your dealer.

MECHANICAL TROUBLESHOOTING CHART

CONDITION REASON REMEDY
A - Transmission overheats High or low oil level Restore proper oil level
Aerated (foaming) oil Refer to condition 'B'
Vehicle overloaded Reduce load
Engine coolant overheated Correct engine overheating
Transmission oil cooler or Clean or replace oil cooler or lines
lines kinked or clogged
Low coolant level Add coolant, check for leaks
Oil leaking Check transmission and lines for leaks
Low main pressure Refer to condition 'V'
Low converter-out pressure Refer to condition 'U'
Vehicle brakes dragging Check parking and service brakes
Torque converter stator locked Check for low top speed of vehicle. Check
torque converter components.
Clutch slipping Overhaul transmission. Replace worn piston
seal rings or clutch plates.
B - Oil is aerated (foaming) Incorrect type of oil used Change oil. Use only oil specified in Section
300-0020, LUBRICATION SYSTEM.
High or low oil level Restore proper oil level
Air entering suction side of Check oil pump bolts and gasket
oil pump
Water in oil Check for source, clean system

8 SM 1932 7-00
 Transmission - Transmission and Mounting
Section 120-0010

MECHANICAL TROUBLESHOOTING CHART

CONDITION REASON REMEDY
C - Heavy metal debris found Transmission internal failure Completely disassemble, clean and repair
in oil transmission. Replace filters and clean lines
and oil cooler.
D - Coolant found in oil Transmission oil cooler leaking Completely disassemble and thoroughly clean
transmission. Replace all friction faced clutch
plates. Repair or replace oil cooler. Replace
filters and clean external lines.
E - Transmission will not Loss of electrical power Refer to Electronic Troubleshooting
operate in any range
Internal mechanical failure Overhaul transmission
regardless of selector position
Driveline failure Check transmission input and output
Low oil level Restore proper oil level
Low main pressure Refer to condition 'V'
F - Transmission continues in Loss of electrical power Refer to Electronic Troubleshooting
the same forward gear
regardless of selector position
G - Shifting is erratic Refer to Electronic Troubleshooting
H - Transmission operates only Refer to Electronic Troubleshooting
in first, neutral and reverse
I - Transmission shifts to Refer to Electronic Troubleshooting
neutral during reverse
operation, but will operate
normally in all other ranges
J - Vehicle operates in reverse Reverse clutch has failed Overhaul transmission
and moves backwards in (won't release)
neutral when engine is
accelerated, but stalls in all
other gears when engine is
accelerated - Electronic
Troubleshooting OK
K - Vehicle operates in first First and second gear clutch Overhaul transmission
and second gears and moves failed (won't release)
forward in neutral when engine
is accelerated, but stalls in all
other gears when engine is
accelerated - Electronic
Troubleshooting OK
L - Vehicle operates in third Third and fourth gear clutch Overhaul transmission
and fourth gears and moves failed (won't release)
forward in neutral when engine
is accelerated, but stalls in all
other gears when engine is
accelerated - Electronic
Troubleshooting OK

SM 1932 7-00 9
Transmission - Transmission and Mounting
Section 120-0010

MECHANICAL TROUBLESHOOTING CHART

CONDITION REASON REMEDY
M - Vehicle operates in fifth Fifth and sixth gear clutch Overhaul transmission
and sixth gears and moves failed (won't release)
forward in neutral when engine
is accelerated, but stalls in all
other gears when engine is
accelerated - Electronic
Troubleshooting OK
N - No power is transmitted in Range clutch failed (won't Overhaul transmission. Check for worn piston
any one range - Electronic apply, slipping) seals, broken piston housing, or worn clutch
Troubleshooting OK plates in that range.
O - Vehicle will operate in Splitter-overdrive clutch won't Overhaul transmission. Check splitter clutches
second, fourth, sixth and release or splitter-direct clutch for worn components.
reverse gears but will not won't apply, slipping
operate in all other gears -
Electronic Troubleshooting OK
P - Vehicle will operate in first, Splitter-direct clutch won't Overhaul transmission. Check splitter clutches
third and fifth gears but will not release or splitter-overdrive for worn components.
operate in all other gears - clutch won't apply, slipping
Electronic Troubleshooting OK
Q - Slow clutch engagement Low oil level Add oil to proper level
Foaming oil Refer to condition 'B'
Worn piston seals Overhaul transmission
Low main pressure Refer to condition 'V'
R - Vehicle lacks power and Engine malfunction Check engine. Refer to engine service manual.
acceleration
Aerated oil Refer to condition 'B'
Low engine speed at converter Refer to condition 'T'
stall
High engine speed at Refer to condition 'S'
converter stall
Hydraulic retarder partially Check retarder linkage
applied
Vehicle brakes dragging Check parking and service brakes
Stator freewheel clutch failed Overhaul transmission
S - High engine speed at Low oil level Add oil to proper level
converter stall
Low converter-out pressure Refer to condition 'U'
High oil temperature (above Refer to condition 'A'
135° C; 275° F)
Clutch slipping, main pressure Overhaul transmission. Replace clutch piston
normal seal rings or clutch plates.
Foaming oil Refer to condition 'B'

10 SM 1932 7-00
 Transmission - Transmission and Mounting
Section 120-0010

MECHANICAL TROUBLESHOOTING CHART

CONDITION REASON REMEDY
T - Low engine speed at Low engine output torque Tune engine and check output
converter stall
Converter element Check for noise at stall; overhaul converter if
interference necessary
Transmission oil not up to Warm up transmission to 82 - 103° C
operating temperature (180 - 220° F)
U - Low converter-out Low oil level Add oil to proper level
pressure
Oil line leakage (oil cooler or Check for leaks, correct as required
filter)
Plugged oil strainer Clean oil strainer
Defective oil pump Rebuild/replace oil pump assembly
High oil temperature Refer to condition 'A'
Foaming oil Refer to condition 'B'
V - Low main pressure Low oil level Add oil to proper level
Leaks in hydraulic system Check all external points for leaks; check each
range for localizing internal leaks
Failure in pressure regulator Overhaul valve assembly
Worn input oil pump assembly Rebuild/replace pump assembly
Clogged oil strainer Clean oil strainer
Air leaks at suction side of Check input pump, correct as required
input pump
W - Downshift of transmission Refer to Electronic Troubleshooting
is permitted during lockup
operation
X - Shift quadrant not Failed light bulb Replace the light bulb
illuminated
Y - Reverse signal not Refer to Electronic Troubleshooting
energized

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 3 Bolt 156 115
1 6 Bolt 278 205
1 10 Bolt 156 115
1 32 Bolt 130 - 156 96 - 115
1 38 Nut 950 - 1 355 700 - 1 000

* * * *
SM 1932 7-00 11
 TRANSMISSION - CEC Plus II Shift System
Section 120-0070

DESCRIPTION seconds and then, if the condition fails to correct itself,

The CEC (Commercial Electronic Control) shift system locks in gear and prevents any further shifting. The
continually monitors the transmission and shift system Check Trans and Do Not Shift lights will both come on.
electrical components and warns the operator when a If this occurs, the ECU must be reset before normal
problem develops. It also takes action to prevent operation may be resumed.
damage to the transmission, and provides the
serviceman with diagnostic capabilities so that To reset the ECU if the transmission has locked in
problems can be corrected quickly and easily. gear because of wheel spinning or a panic stop, stop
the vehicle, select neutral 'N', apply the parking brake,
The CEC Plus II shift system used on this vehicle and turn the ignition key switch to position '0' to shut
consists of a gear shift selector, an electronic control down the engine. Wait ten seconds, then turn the
unit (ECU), throttle position sensor, transmission output ignition key switch to restart engine. Select reverse 'R',
shaft speed sensor (magnetic pick-up), oil temperature then neutral 'N'. The Check Trans and Do Not Shift
sensor, solenoids, switches, relays, circuit breakers, lights should go off.
fuses, indicator lights and wiring harnesses.
Cold Weather Starts - During cold weather, if the
In addition, CEC provides the following systems transmission temperature is below -24° C (-10° F) the
designed to protect the operator and mechanical Do Not Shift and Check Trans lights will illuminate and
components: the ECU will prevent the transmission from being
shifted out of Neutral. Between -24° C (-10° F) and
Reverse Inhibit - Prevents gear selection if engine is -7° C (19° F) the lights will go out and the ECU will
operating at more than 20% throttle. only permit operation in first or reverse gears. Above
-7° C (19° F), normal operation will be permitted.
Hoist Interlock Pressure Switch - The ECU will shift
the transmission from reverse to neutral if the body
control joystick is moved to the 'Raise' position. When CEC PLUS II COMPONENTS
this circuit has been activated, moving the transmission
shift lever to neutral, then re-selecting reverse, will Description and Operation
engage reverse gear whilst the body is held in the Refer to Fig. 1.
'Raise' position. This feature is only operational in the
normal automatic driving mode, either Power or 1. Electronic Control Unit (ECU) - Contains an
Economy. It is not activated during the manual mode. electronic microcomputer. The ECU receives
information in the form of electronic signals from
switches and sensors, processes the information
WARNING according to shift schedule programs stored on a
The standard procedure for raising the body programmable read only memory (PROM) chip, and
must still be adhered to. sends electronic signals to the appropriate solenoids
which control the transmission.
Body Up Interlock - When the body is raised, the CEC
system will only allow the transmission to operate in The ECU is programmed to take corrective action to
first gear. This feature is only operational in the normal prevent damage to the transmission if a failure occurs
automatic driving mode, either Power or Economy. It is in the CEC system and has diagnostic capabilities
not activated during the manual mode. which allow the serviceman to quickly find and repair
or replace a failed component.
Parking Brake Interlock - If the parking brake is
applied while the transmission is in neutral, the CEC 2. Battery Equalizer - Since the ECU continually
system will prevent a shift out of neutral to protect the draws 12 volts from one of the vehicles batteries, the
brake components. If the parking brake is applied while battery equalizer is provided to continually monitor and
the transmission is in gear, the parking brake interlock balance the charge on the batteries.
will not function and normal shifts will occur.

Lock-in-gear - The lock-in-gear feature is designed to WARNING

protect the transmission from damage should wheel Any time the battery equalizer is disconnected
spinning or lockup occur due to poor traction or panic from batteries, remove ground wire first and
braking. The ECU will delay making a shift for several reconnect last to avoid damaging component.

SM 1575 Rev 2 11-00 1

Transmission - CEC Plus II Shift System
Section 120-0070

SM - 1966

4 7

11

TEST

10
DO NOT
SHIFT

4
5D
3
2
1
N
R1
9
R2

12
DO NOT
SHIFT

6 5
2
10 13 1 MANUAL AUTO POWER ECONOMY

14
17
15

BODY
16

18
HYD CONTROL VALVE

1 - Electronic Control Unit (ECU) 7 - Manual Mode Warning Light 13 - Circuit Breakers
2 - Battery Equalizer 8 - Check Trans Warning Light 14 - Lockup Valve & Temp Control
3 - CEC Interface Box 9 - Check Trans Switch 15 - Main Control Valve
4 - Gear Shift Selector 10 - Do Not Shift Warning Light 16 - Speed Sensor
5 - Mode Selection Switch 11 - In-converter Indicator Light 17 - Reverse Hoist Press Switch
6 - Manual Mode Switch 12 - Digital Data Line 18 - Body Up Proximity Switch

Fig. 1 - CEC Plus II Components

3. CEC Interface Box - Provides the electrical link

between the vehicle harnesses and the CEC WARNING
harnesses. The interface box contains fuses and Do not allow the vehicle to coast in Neutral.
relays. This practice can result in severe transmission
damage.
4. Gear Shift Selectors - When any one of the
forward drive ranges is chosen, detents will hold the The transmission provides six forward ranges, two
lever in the selected position. A two-finger latch reverse ranges and a neutral position. The
release must be pulled up to permit movement of the transmission upshifts and downshifts automatically
lever into and out of neutral 'N' and reverse 'R'. between first range and the highest range selected on

2 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070

the range selector in direct response to throttle

position and transmission output speed. WARNING
Always select Neutral and apply the parking
When Reverse is selected the reverse alarm sounds and brake before leaving the operator’s seat.
the reverse light illuminates at the rear of the vehicle. This
feature warns personnel to the immediate rear of the 5. Mode Selection Switch - Gives the option to select
vehicle that the operator has shifted to reverse. between transmission Power and Economy shift
schedules. The transmission must be in Neutral before
When drive 'D' is selected, the transmission the switch will function.
automatically upshifts and downshifts through all six
forward ranges as required by loads and travel The transmission torque converter is equipped with a
speeds. Selecting a lower range (4th, 3rd etc.) limits lockup clutch which, when engaged by the ECU, locks
the highest range to which the transmission will the converter pump and turbine together as a single
automatically upshift. unit and allows power to be transmitted mechanically
from the engine directly to the transmission gearing on
If a lower range is selected while moving forward, the a 1:1 ratio. When the lockup clutch is disengaged, the
transmission automatically downshifts sequentially to torque converter acts as a fluid coupling, multiplying
the selected lower range at maximum controlled torque when engine speed is significantly higher than
engine speeds. Downshifts will not occur until vehicle transmission output shaft speed.
is slowed by use of the service brakes and/or retarder.
When the mode selection switch is in the Power
When shifting from neutral to start from a standstill, or position, the ECU controls operation of the lockup
to reverse direction, decelerate the engine to idle clutch according to signals received by the throttle
speed. To move forward, select drive 'D' and position sensor (giving engine speed as a percent of
accelerate the engine to the vehicle load and speed throttle), the transmission output shaft speed sensor,
requirements. The transmission will automatically and range selector. The ECU may delay application of
upshift from 1st through 6th ranges as travel speed the lockup clutch and allow torque multiplication by the
increases. torque converter to take place until a balance is
achieved between engine speed and transmission
With the throttle fully depressed, and the mode output shaft speed before activating the lockup clutch.
selection switch in the Power position, the
transmission upshifts to the next higher range when Power versus Economy Mode
the engine attains maximum rated speed, since The Power mode is designed for applications involving
maximum power train output is needed under this heavy loads and hilly duty cycles where performance
condition. At lower throttle settings where minimum rather than fuel economy is of prime importance.
power train performance is required, the transmission
will upshift to the next higher range at less than The Economy mode is designed for applications
maximum rated engine speed. involving lighter loads and level duty cycles or where
fuel economy is more important than performance.
Upgrades or soft spots might slow travel speed, even
at full throttle, requiring transmission downshifts to In the Economy mode, the ECU controls operation of
maintain maximum powertrain performance. When this the lockup clutch with a timed, preprogrammed
occurs, the transmission downshifts automatically. schedule where in second through sixth gears the
lockup clutch is disengaged only long enough to allow
Shift the transmission to the next lowest range if the torque converter’s fluid coupling to absorb shift
transmission 'Hunting' or 'Shift Cycling' occurs. shock. Otherwise, the lockup clutch is engaged and no
torque multiplication takes place in second through
When temporarily stopped, such as for yielding the sixth gears.
right-of-way to a loaded vehicle, the transmission can
be left in the selected range and the vehicle held 6. Manual Mode Switch - The manual mode facility is
stationary with the service brakes. designed as a Service Technician facility to allow stall
checks and clutch pressure checks to be implemented
However, when stopped for a more extended period by Service Personnel, and permit movement of the
with the engine left running, shift the transmission to vehicle, if necessary, to a repair area. With the manual
neutral to avoid unnecessary heat buildup and apply mode switch in the 'On' position, the body up interlock
the parking brake.

SM 1575 Rev 2 11-00 3

Transmission - CEC Plus II Shift System
Section 120-0070
and hoist interlock pressure switch mechanisms are 9. Check Trans Switch - Is used in conjunction with
disengaged! This allows unauthorised selection of the check trans warning light to obtain trouble codes
reverse or any forward gear with the body raised, which will indicate shift system malfunctions. Refer to
constituting a safety hazard. Operators must not use 'Troubleshooting' covered in this section, or, Allison
the manual mode facility when working the vehicle! It Commercial Electronic Control (CEC) Troubleshooting
is recommended that the mode selection key is Manual SA2712A, for instructions on finding and
removed from the unit and retained in a safe place clearing trouble codes and diagnostic procedures.
until required by Service personnel.
10. Do Not Shift Warning Light - This warning light is
Note: The manual mode can only be used if the mode incorporated in the gear shift selector. The light will
selection switch is in the Power position and the illuminate when the ignition key switch is turned to
transmission is in neutral. position '1' to provide a bulb and system check. It
should go 'Off' a few seconds after the ignition is
switched on.
WARNINGS
Do not operate the engine for more than 30 If the do not shift warning light starts to flash and the
seconds at full throttle with transmission in buzzer sounds along with the Check Trans Warning
gear and output stalled as this will result in Light, the ECU has detected a serious problem in the
severe overheat damage to the transmission. shift system and will disengage the lockup clutch, if
applied, preventing a shift out of the gear the
The manual mode is not intended to be transmission is in (Lock-in gear). Any time the do not
used for normal operations. The vehicle should shift warning light starts flashing and the buzzer
only be driven at very low speeds in first or sounds, bring the vehicle to a stop at the first safe
reverse gears if the manual mode is activated, opportunity and shut down the engine until the
or damage to the transmission may result. problem is corrected.

7. Manual Mode Warning Light - Illuminates to alert 11. In-convertor Indicator Light - Illuminates when
the operator when the transmission has been switched the transmission is in torque converter drive. It goes
to operate in the manual mode. The light should be 'Off' when Lockup is engaged. In order to avoid
'Off' during normal operation. unnecessary waste of fuel, if traffic or other road
conditions permit, the operator should modify throttle
8. Check Trans Warning Light - Illuminates to alert of position, or gear held, to achieve a steady road speed
a minor fault in the transmission shift system or with the torque converter lockup engaged (light 'Off').
abnormal transmission temperature. The light will
come 'On' when the ignition key switch is turned to 12. Digital Data Line - Located in the right hand side
position '1' to provide a bulb and system check and of the transmission control tower. Plug in connector for
should go 'Off' a few seconds after the engine is diagnostic data reader (DDR).
started and the transmission oil pressure rises.

The check trans warning light will come 'On' during CEC PLUS II ELECTRICAL CIRCUITS
operation, if the ECU has detected a minor fault in an Note: The following circuits refer to both colour coded
electrical component or abnormal transmission oil wires (vehicle harnesses) and number coded wires
temperature. If transmission oil temperature is too (Allison harnesses). For ease of explanation, the
high, stop the vehicle, select neutral 'N', and increase number codes are used in the text.
engine speed to allow a greater flow of oil to the cooler
until oil temperature drops to normal operating range. Note: Where wire colours are indicated in the circuits
In most cases, a minor fault triggering the check trans followed by the Allison number in brackets, this
warning light will not prevent normal operation from indicates which Allison wire the vehicle harness wire
continuing but, depending on the nature of the will connect to.
problem, the ECU could take action to protect the
transmission from damage, such as preventing Note: Refer to Section 190-0000, CIRCUIT
operating in high gear ranges. If the check trans light DIAGRAMS, for vehicle electrical circuits. Refer to
comes 'On', have the problem diagnosed and Section 190-0270, SWITCHES AND SENSORS, for
corrected at the earliest opportunity. location and description of transmission switches and
sensors.

4 SM 1575 Rev 2 11-00

 CEC COMPONENT DESIGNATIONS
F7 - 10 Amp Fuse - CEC (in fuse box)

F
H27 - Check Trans W/L W/B

SM 1575 Rev 2 11-00

R R R
G G 313 G
311 B
B B B W W
K1 - Starter Relay W/B W/B 309 W/B U/G
K17 - Reverse Relay W/B W/B

S53
R/W R/W
1

P1 205
W

Z
B
N2 - Voltage Regulator

S52

F7

B
U/G

R
G
W/B

W/B
E
S4 - Test Switch W/B B B
W/B 330A W/B W
S7 - Park/Emergency Brake Switch R 308 R W/U
H27 U/P 87A U/P U/P
S19 - Dipswitch G/U G/U
2

S4 B
216A B
S22 - Body Up W/light Switch 306

R
S51 - Reverse Hoist Pressure Switch

W/B
R R

G/U

D
F7
S52 - Manual Mode Keyswitch W/R R/U
W/B 330 R/W
U/R U/R U/R
U/G

S53 - Power/Economy Keyswitch

W/R
W/U

322
F2 W/R 341 R/P R/P
S62 - Retarder On Switch Y Y
S62 211
R

F4
3

S19 R/Y 230 R/Y

B

U/W 75 U/W
K17
U/P
R/U

U W/Y 45 U
B
TO S22 K1
INTERFACE BOX RELAYS TO S22

W/B
R

C
F3
1 - ECU Initial Start R R G/W

p
S7 222

S51
W/P 203 W/P
F6

2 - ECU Supply N2
B
B

B N2 W 87 W U/P
R/P
R

W/B R
G/W
U/W

3 - Retarder (Not Used) 308

B/O B/O
4

W N2 306
F1

4 - Transmission Check

R
U
G
W
B
Y
R

5 - Reverse Warning
B
DDL
R/Y
G/U

W/P

6 - Neutral Start CONNECTOR 205 R/W

F2
R

222 U/R
235 G

G
R/P U/W

315
313
311
310
309
305
INTERFACE BOX FUSES 203 Y
215 R/Y
1 - 8 Amp 5 - 5 Amp 213
5

211 U/W
F5

U
B
U
G

2 - 5 Amp 6 - 8 Amp
R/P

B/O
B/O

3 - 8 Amp 7 - 5 Amp
A

R/P
4 - 5 Amp G
214 G/U
R

G/R
201

216A B/O
208 U
B/O
WIRE COLOURS 209 B/W
W

234
6

G/R
B - Black O - Orange 231 W/U
202 U/G
N - Brown Y - Yellow 223 R/Y
J3 230

TRANSMISSION
J1A

U - Blue P - Purple
R - Red W - White

J1B
G - Green S - Slate
E.C.U.

L - Light Green
SM - 1967

Fig. 2 - CEC Plus II and Interface Box Circuit Diagram

Section 120-0070
Transmission - CEC Plus II Shift System

5
Transmission - CEC Plus II Shift System
Section 120-0070

SM - 1968

WARNINGS
The ECU can be damaged by improper welding
B(306)
procedures. GRD

VANNER
W/P(203)
12V
Any time the battery equalizer is
24V 208
disconnected from the batteries, remove W/P(203)
W ECU
ground cable first, and reconnect last, to FUSE 3 209
+ 381
prevent damaging the component.
-
Note: When frame or other welding is required, the +
-
following procedure must be followed to protect the
electronic components:
B(306)
Turn ignition keyswitch to position '0' to shut down the
engine and disconnect the batteries.
Fig. 3 - ECU Memory Power (12 volts)
Disconnect battery equalizer ground connections from
the batteries. Disconnect battery cables from terminal
Refer to Fig. 3. Current flows from the battery through
posts (ground cable first). Disconnect battery equalizer
lines 381, 203, Fuse 3 and line 203 to the ECU. The
positive connections. Disconnect electrical
circuit is completed to ground through lines 208 or 209
connections at the ECU. On completion of all welding
and line 306.
reconnect electrical connections in the reverse order
to disconnections.
Circuit Breakers
Note: Both 12 and 24 volt circuits are present in the
Refer to Fig. 4. When circuit breakers are switched
CEC interface box. Extreme care must be taken, when
'ON' current (24 volts) flows through Fuse 1 and Line
making repairs to the system, to avoid damaging the
308 to Relays 3, 5 & 6 and Check Trans indicator light.
ECU by introducing 24 volts into a 12 volt circuit.
Current also flows through Fuse 2 and Line 235 to
provide operating power for the shift selector. Circuits
Ecu Memory Power are completed to ground through ECU and Lines 208,
209 and 306.
The ECU draws 12 volts at a maximum of 10
milliamps (mA) continuously to store trouble codes
and throttle position sensor calibration values. The Ignition Keyswitch
ECU stores two trouble codes at a time in its memory.
Refer to Fig. 5. When ignition keyswitch is turned to
If the memory power is disconnected trouble codes
position '1', current (24 volts) flows through Cable
and throttle position calibration values will be lost.
330A to Relay 1 and back to ground through Line 306,
Memory power must be reconnected, the engine
energising the solenoid. Solenoid in relay 1 closes
started, and the vehicle may have to be put into
switch, allowing current (12 volts) to flow through Line
operation, to restore trouble codes. Throttle position
87, Fuse 6, Switch and Lines 202A and 223A to the
calibration values will be recalculated by the ECU
ECU. Circuit is completed to ground through Lines
when power is restored and engine started.
208, 209 and 306.

6 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070

SM - 1969

BATTERIES

R
+

+
-
-

FUSE 1
B(306)
R/G
GRD FUSE 2
VANNER

(235) R R R(308)
12V
CHECK
24V R R R TRANS
SHIFT 3 5 6 LIGHT
SELECTOR

B(306)
B(306) R4
U/P
208 (87A)
ECU
209

Fig. 4 - Circuit Breakers

SM - 1970

FROM
IGN. SW. W/B(330A) U/G(223)
W/U(202A)

RELAY 1
(N.O.)
W(87) FUSE 6 W
+
BATTERIES

- B(306)
W(381)
+
-
GRD
24V

12V

208
ECU
209
VANNER

Fig. 5 - ECU Operating Power - Ignition Switch

SM 1575 Rev 2 11-00 7

Transmission - CEC Plus II Shift System
Section 120-0070

ECU Operating Power Circuit is completed to ground through line 306.

Refer to Fig. 6. When the engine is started, current Solenoid in Relay 2 closes Switch allowing current
(24 volts) flows through Line 330 and Fuse 7 to Relay (12 volts) to flow through Fuse 6, Line 87, Switch and
2, energizing solenoid. Lines 202A or 223A to the ECU. Circuit is completed
to ground through Lines 208 or 209 and Line 306.

SM - 1971

W/B(330) FUSE 7 W
RELAY 2 B(306)

FUSE 6 202 208

W(87)
ECU
223 209

B(306)
GRD
24V

12V

VANNER

Fig. 6 - ECU Operating Power

Neutral Start Circuit to ground when selector is in Neutral through Line 210,
Refer to Fig. 7. The Neutral Start circuit prevents the ECU, Lines 208 or 209 and Line 306. Solenoid in
engine from being started unless the shift selector is in Relay 6 closes Switch, allowing current (24 volts) to
Neutral position. When ignition keyswitch is turned to flow through Line 308, Switch and Line 45 to start
position '1', current (24 volts) flows through Line 341 solenoid. Refer to SECTION 190-0000, CIRCUIT
and Fuse 4 to Relay 6, energizing solenoid. Current DIAGRAMS for continuation of starter circuitry.
continues through Line 231 to shift selector, and goes

SM - 1972
VANNER
GRD

12V

24V

B(306)
+
BATTERIES

-
+ SHIFT
- SELECTOR
B(306)

G/R 210
(231)
RELAY 6 208
IGN. W/R W/R R/P(341) FUSE 4
SW. ECU
209

SOLENOID
TERMINAL TO CAB TO START
R(308) U(45)
WIRING SOLENOID

Fig. 7 - Neutral Start Circuit

8 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070

Check Trans Light When the engine is started, a switch in the ECU
The Check Trans light has two functions: to warn the closes, allowing current (24 volts) to flow through the
operator of a system failure and to flash trouble codes circuit made by Fuse 7, Lines 330, 215, 208 or 209
when the test switch is activated. and 306. Relay 4 solenoid is energized, opening relay
switch and turning 'Off' the Check Trans light.
Normal Operation And Warning Should the ECU detect a system failure, it will open
Refer to Fig. 8. When the ignition keyswitch is turned internal switch, deactivating relay 4 solenoid. Relay
to position '1', current (24 volts) flows through the switch closes, turning 'On' the Check Trans light to
circuit made by Fuse 1, Lines 308 and 87A, turning warn operator of failure.
'On' the Check Trans light.

SM - 1973
FUSE 7
R/W
24V
VANNER

12V
B(306) W/R
GRD ECU
(330)
B(306) 208

G/W 209
(215)

R
B(306)
+

+
-
-

BATTERY CHECK RELAY 4

DISCONNECT TRANS N.C.
RELAY LIGHT
BATTERIES FUSE 1 U/P(87A)
R(308) B(308)
B(306)
Fig. 8 - Check Trans Light

Obtaining Trouble Codes With Test Switch depressed, ECU closes internal switch, energizing
Refer to Fig. 9. When the test switch is depressed, relay solenoid which opens relay switch, turning Check
circuit to ground from ECU through line 216A and 306 Trans light off. ECU opens and closes internal switch
is completed, signalling ECU to supply diagnostic to flash trouble codes with Check Trans light. The
codes to Check Trans light. When test switch is engine must be running.

FUSE 7 SM - 1974
R/W
24V
VANNER

12V
B(306) W/R
GRD ECU
(330)
B(306) 208

G/W 209
(215)

R
B(306)
+

+
-
-

BATTERY CHECK RELAY 4 G/U(216A)

DISCONNECT TRANS N.C. TEST
RELAY LIGHT SW.
BATTERIES FUSE 1 U/P(87A)
R(308) B(308) B(306)
B(306)
Fig. 9 - Obtaining Trouble Codes With Test Switch (Engine Running)

SM 1575 Rev 2 11-00 9

Transmission - CEC Plus II Shift System
Section 120-0070

Reverse Alarm ECU and back to ground through Lines 208 or 209 and
Refer to Fig. 10. When the shift selector is placed in Line 306. Solenoid closes Switch, allowing current to
Reverse, ECU closes circuit allowing current (24 volts) flow through Line 308, Switch and Line 75 to reverse
to flow through Line 308 and Fuse 1 to Relay 5, alarm. Refer to SECTION 190-0000, CIRCUIT
energizing solenoid. Current flows through Line 214 to DIAGRAMS for continuation of Reverse Alarm circuitry.

SM - 1975
RELAY 5
R(308)
U/W(75)
FUSE 1 TO REVERSE RELAY
R(308) R(308)
ECU
208
G(214)
209
BATTERY
DISCONNECT
RELAY B(306) B(306)
R
GRD
24V

12V
+

+
-
-

BATTERIES VANNER
Fig. 10 - Reverse Alarm

Reverse Hoist Pressure Switch being moved to the 'Raise' position, current is
Refer to Fig. 11. The Reverse Hoist Pressure switch is interrupted and ECU will shift transmission to Neutral.
a safety feature to prevent the vehicle from backing up To obtain Reverse again, switch must be opened and
while the body is being raised. Current from the ECU shift selector must first be placed in Neutral or a
flows through line 305, microswitch and line 309. If forward range. This interlock will not prohibit shifts to a
pressure switch is opened by the body control valve forward range while body is being raised.

SM - 1976

SHIFT
SELECTOR
B(309)
ECU W(305)

Fig. 11 - Reverse Hoist Pressure Switch

Parking Brake Interlock prevents a shift out of Neutral. This interlock will not
Refer to Fig. 12. The Parking Brake Interlock prevents inhibit shifting if the parking brake is applied while the
a shift out of Neutral when the parking brake is transmission is operating in reverse or any forward
applied. When the parking brake is applied, switch range.
opens, breaking the circuit to ground. The ECU then

10 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070

SM - 1977
VANNER

GRD

12V

24V
208
B(306) R(222) N.C. B(309)
ECU
209 N.O.
EMERGENCY
+

+
-
-

PARK BRAKE SW.

N.C. - RUN POSITION
BATTERIES N.O. - PARK POSITION
Fig. 12 - Parking Brake Interlock

Body Up Interlock proximity switch closes.

Refer to Fig. 13. When the body is raised off the
chassis, the proximity switch opens to complete the Note: CEC wires B (309) and U (310) are 12 volt and
circuit through Lines 309 and 310 to the ECU. The P/G and P/R wires for the body up circuit are
ECU then prevents the transmission from shifting 24 V. Improper connection of wires could lead to CEC
above 1st gear until the body is lowered and the damage.

SM - 1978
BODY-UP
VANNER PROXIMITY SW.

P/R
GRD

24V
12V

24V

P/G
B(306)
208 B(309)
B(306)
ECU U(310)
209
+

+
-
-

BATTERIES Fig. 13 - Body-up Interlock

Shift Selector Illumination one bulb burns out, both lamps will cease functioning.
Refer to Fig. 14. When the panel light switch is closed, Circuit is completed to ground through lines 234 and
current (24 volts) flows through Line 230 to the shift 147 to the panel ground.
selector. Lamps are 12 volts, wired in series, so that if

SM - 1979
BATTERIES
+

SHIFT
-

SELECTOR
R/Y(230) B/W(234) B(306) B(306)
TO PANEL
LIGHT SW.
LAMPS
24V

12V

GRD

VANNER

Fig. 14 - Shift Selector Illumination

SM 1575 Rev 2 11-00 11

Transmission - CEC Plus II Shift System
Section 120-0070

ECU Electromagnetic Shield - Ground SM - 426

Refer to Fig. 15. Must be grounded to protect ECU.

GROUND TO
PASSENGER
SEAT BOX

Fig. 15 - ECU Electromagnetic Shield - Ground

Mode Selection Switch 2. With mode selection switch in Power (closed)

Refer to Fig. 16. position, Lines 313 and 315 are connected to Line 309
1. With mode selection switch in Economy (open) and the ECU will then control the transmission as per
position, ECU will control transmission as per the the Power mode shift schedule.
Economy mode shift schedule.

SM - 429

MODE
SELECTION
SECONDARY MODE
SWITCH
HARNESS - J3

Fig. 16 - Mode Selection Switch

Manual Mode Switch connected to Line 309 and ECU will change operation
Refer to Fig. 17. of transmission from automatic to manual.
1. With ignition keyswitch at position '2' and manual
mode switch 'On' (closed) indicator light on console Note: Both switches must be closed and transmission
will illuminate. in neutral to obtain manual mode.

2. When mode selection switch is in the Power Note: CEC wires B (309) and 311 are 12 volt and
(closed) position and manual mode switch is in the W/B wires at manual mode switch are 24 V. Improper
'On' (closed) position, Lines 311, 313 and 315 are all connection of wires could lead to CEC damage.

SM - 430
IND. LIGHT

MANUAL MODE
MODE SELECTION SECONDARY MODE
SWITCH SWITCH HARNESS - J3

24V SUPPLY
FROM IGN. SWITCH

Fig. 17 - Manual Mode Switch

12 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070

SM - 1980

1
3

ENGINE

C B A
1 - Throttle Pedal Assembly
2 - Sensor and Harness - Engine
3 - Sensor and Harness - Transmission TRANSMISSION

Fig. 18 - Throttle Sensor

VALVE BODY SOLENOIDS grades. When the oil temperature falls below 121° C
The hydraulic circuits and valves within the electro- (250° F) the Check Trans light will go off. Refer to
hydraulic valve bodies are controlled by continuous Section 190-0270, SWITCHES AND SENSORS.
power solenoids. The solenoids are located in
separate valve bodies and they shift the valve spools
to direct hydraulic oil to the various clutch packs within
ELECTRONIC FOOT PEDAL
the transmission. Refer to Fig. 18. The dual control electronic foot pedal
provides an electronic signal to the engine's fuel
control system in proportion to the degree of pedal
TEMPERATURE SENSOR actuation, an electronic signal is also sent to the
Temperature Sensor is mounted in the lockup valve transmission ECU.
body cover. The ECU constantly monitors
transmission oil temperature and will not permit shifts Note: The electronic controlled engine will override the
to occur when the oil temperature is -24° C (-10° F) or electronic foot pedal position until the engine is
below. At this temperature, operation is restricted to warmed up to the correct operating temperature. The
Neutral and both the Do Not Shift and Check Trans engine MUST be started with the foot 'OFF' the
lights will be on. From -22° C (-9° F) to -7° C (+19° F) electronic foot pedal.
operation will be restricted to Neutral, First and
Reverse. Once transmission oil temperature reaches The control system continually monitors the engine
121° C (250° F) the Check Trans light will come on and warns the operator when a problem develops. The
and the ECU will restrict operation to Reverse, Neutral system also takes action to prevent damage to the
and First through Fourth gears. Temperatures can engine and provides the serviceman with diagnostic
easily exceed 121° C (250° F) when the retarder is capabilities. Refer to Section 110-0030, ENGINE AND
being used to help slow the vehicle while descending MOUNTING.

SM 1575 Rev 2 11-00 13

Transmission - CEC Plus II Shift System
Section 120-0070

SM - 1981

SPEEDOMETER
WIRE 205
20 30

10 40
ECU 0 50

TRANSMISSION CALIBRATION BUTTON

OUTPUT SPEED
SENSOR

Fig. 19 - Electronic Speedometer Output

Speedometer/Odometer Transmission Output Speed Sensor

Refer to Fig. 19. Driven by a signal from the CEC, the This is installed in the transmission rear cover. The
speedometer indicates travel speed in kilometers per sensor should be screwed in until it makes contact with
hour and miles per hour. A digital odometer is the output gear and then backed out 3/4 turn and locked
incorporated in the speedometer to record the into place with the jam nut. Tighten the jam nut to
distance travelled by the vehicle at any given time. 17 - 21 Nm (13 - 16 lbf ft). Refer to Section 190-0270,
SWITCHES AND SENSORS.
Speedometer Calibration Table -
All units with standard tyres Hoist Interlock Pressure Switch
Unit Transmission Pulses
Located in a tee installed in body hoist control valve.
TR35 CBLT-754 20200 The hoist interlock is a safety feature to prevent the
TR40 M5600A 188600 vehicle from backing up while the body is being raised.
TR45 M5600A 188600 If the pressure switch is opened by the body control
TR60 M6600AR 208580 joystick being moved to the 'Raise' position, current is
TR70 M6600AR 208580 interrupted and the ECU will shift the transmission to
TR100 DP-8963 249120 Neutral. To obtain reverse gear whilst the body is held
in the raise position, move the transmission shift lever
Speedometer Calibration to Neutral, then re-select reverse gear. This interlock
will not prohibit shifts to a forward range while the body
1. Determine the impulses/mile required. Reference
is being raised. Refer to Section 190-0270,
speedometer calibration table.
SWITCHES AND SENSORS.
2. Depress and hold calibration button on the
speedometer and turn the ignition keyswitch to TROUBLESHOOTING
position '1'.
The ECU is a small computer with operating limits
programmed into its memory. Whenever the ECU
3. Release button when PULSE is displayed. The
detects a condition which falls outside those limits, or a
second digit will flash. Depress the button until the
malfunctioning component, the Check Trans light, or
desired number is displayed the release the button
Do Not Shift lights will be activated and a trouble code
for a few seconds until the next digit flashes.
stored in the ECU’s memory. Two soft codes
(indicating problems which may inhibit but not prevent
4. Repeat step 3 to obtain the desired impulses/mile.
operation) or two hard codes (indicating problems
After a few seconds only two digits will be displayed.
which will limit or prevent operation), or one of each,
The speedometer is now calibrated.
can be stored in the memory at one time. The trouble
codes identify which circuit the problem is in. The
circuits consist of a component such as a solenoid, the
applicable wiring harness and the ECU.

Both the Check Trans and Do Not Shift lights will come
'On' when the ignition keyswitch is turned to position
'1'. The Check Trans light will stay on until the engine

14 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070
is started. The 'Do Not Shift' lights will go 'Off' when turned to position '0', then back to position '1 and shift
the ignition is switched on, unless the ECU has into Reverse and back to Neutral. If the codes are still
detected a failure in the system. Depressing the test present, the problem has not been corrected.
button when the engine is running, will turn 'Off' the
Check Trans light and call up a trouble code, if one is Note: After clearing a Code 21 (Throttle Position
present. In the case of an intermittent problem, such Sensor) the ignition keyswitch may have to be turned
as a line which shorts to ground occasionally due to 'On' and 'Off' as many as five times to reset the self
vehicle movement, the lights may go on and off, but a calibration feature of the throttle position sensor.
trouble code will remain stored in the memory.
The following diagnostic procedures are a summary of
In an electronic system such as the CEC system, it is troubleshooting procedures given in the Allison
extremely important that connections at terminal Commercial Electronic Control (CEC) Troubleshooting
blocks, grounds to vehicle frames, and all connectors Manual SA 2712A. This manual contains detailed step
be clean and secure. Connectors may be cleaned with by step procedures for diagnosing and correcting
a good quality solvent which does not conduct problems indicated by the trouble codes.
electricity and evaporates quickly (See Special Tools).
Excess solvent should be shaken out or gently blown It is essential that the serviceman has an accurate
out with compressed air after cleaning. Volt-Ohm Meter (VOM) in order to correctly diagnose
problems in the CEC system.

FINDING TROUBLE CODES Fig. 20 is an electrical circuit view showing the terminal
numbers and wire numbers for the CEC J1A, J1B and
Check Trans Light J3 harnesses connecting the various components of
Running the engine and depressing the test switch will the system.
cause the ECU to enter the diagnostic mode. The
ECU will cause the Check Trans light to flash a trouble Fig. 21 shows the locations of the terminals in Fig. 20
code, if present. in their connectors. Check for intermittent shorts or
open circuits by moving harnesses with VOM probes
For example: FLASH - PAUSE - FLASH - FLASH - connected to the applicable terminals. For step-by-
FLASH - LONG PAUSE denotes a Code 13. step procedures for finding shorts or open circuits in
harnesses or components, refer to Allison Commercial
If more than one trouble code is stored in the memory, Electronic Control (CEC) Troubleshooting Manual
the most important code will be flashed first. The SA 2712A.
problem indicated by the first code must be corrected
and the code cleared from the memory before another Note: Both 12 and 24 volt circuits are present in the
code can be found. control box interface. Extreme care must be taken,
when making any repairs to the system, to avoid
damaging the ECU by introducing 24 volts into a 12
Diagnostic Data Reader volt circuit.
Using a diagnostic data reader, both codes can be
found at the same time. Plugging the diagnostic data When troubleshooting leads to replacement of the
reader into the Digital Data Line (DDL) connector ECU, always check for an over voltage condition. If too
(12, Fig. 1) under the dash panel, on the steering high a voltage damaged the ECU and the condition is
column mounting bracket, will automatically cause the not corrected the replacement ECU may also be
ECU to enter the diagnostic mode. Ignition keyswitch damaged.
must be turned to position '1'.
Voltage limits for the ECU are:
CLEARING TROUBLE CODES 9 volts - minimum
Trouble codes should always be cleared from the ECU 16 volts - continuous
memory after repairs are made. To clear the trouble 18 volts - 10 minutes
codes, make sure the ignition keyswitch is turned to 24 volts - 2 minutes
position '1', depress the test switch, shift into Reverse
and wait a few seconds, then shift back to Neutral. If
the codes do not clear, turn the ignition keyswitch is

SM 1575 Rev 2 11-00 15

Transmission - CEC Plus II Shift System
Section 120-0070

Probable Cause:
WARNINGS a. Throttle sensor failure.
To prevent any unexpected shift during b. Shorts or open circuits in harness wiring.
removal of wiring harnesses, shut down
engine and switch 'OFF' both circuit breakers. Remedy:
1. Check cable for binding.
Be sure to apply the parking brake, shut
off the engine and block all road wheels before 2. Connect VOM probes to sensor terminals A & C
any troubleshooting of the main valve body (L, Fig. 21). If reading is not between 9 000 and
solenoids. Accidental activation of a solenoid 15 000 ohms replace sensor.
while the engine is running could cause the
vehicle to run away. 3. Connect VOM probes to sensor terminals A & B
(L, Fig. 21). Stroke sensor slowly from closed to full
throttle position and back. If VOM reading does not
Code 13 - Low Battery Voltage increase smoothly from at least 500 ohms to
System Response: 15 000 ohms, replace sensor.
1. If transmission is in neutral, Check Trans and Do
Not Shift lights will come on. If forward or reverse is 4. Connect one VOM probe to vehicle ground, other to
selected, shift will not occur. sensor terminals A, B & C. VOM meter should not
record continuity.
2. If transmission is in forward or reverse and a shift is
made, the code will be set in memory and no lights will 5. Check J1B harness wiring for shorts or open circuits.
come on. Shifts may be erratic or not made.
6. If fault cannot be located, replace ECU.
Probable Cause:
a. Insufficient voltage supplied to ECU.
b. Intermittent open circuit on power to ECU.
Code 22 - Transmission Output Shaft
c. Intermittent or partial short to ground on power to ECU. Speed Sensor
System Response:
Remedy: The Check Trans and Do Not Shift lights will come on.
1. Check battery voltage with VOM. Fully charged All shifts will be prevented and lockup clutch
batteries should measure 28 ± 1 volt. disengaged. If this happens due to wheel lockup
(panic braking) or wheel spinning, the engine must be
2. Check vehicle charging system. With engine shut down, ignition keyswitch turned to position '0' and
running, voltage regulator should put out 28 volts. then back to position '1', engine restarted, and Neutral,
Charge and recheck batteries. Reverse and Neutral selected to reset ECU.

3. Refer to Fig. 2. Check circuits supplying power to Probable Cause:

ECU through interface. a. Sensor failure.
b. Open circuit or short in harness wiring.
4. Input voltage to ECU can be checked with a digital c. Dirty or loose connections.
analyser. Input voltage should be 10.5 - 16 volts. Place d. Sensor not adjusted properly in rear cover.
load on batteries by turning on all vehicle accessories e. Unusually rapid deceleration, or wheel spinning.
and recheck input voltage. If input voltage is within
limits and Code 13 recurs, replace ECU. If input Remedy:
voltage is not within limits check all connections 1. Check speed sensor to ensure that it is properly
between battery and ECU. threaded into rear cover, adjusted, and locked into
place with jam nut.
Code 21 - Throttle Position Sensor 2. Connect VOM probes to sensor terminals A & B (M,
System Response: Fig. 21). If VOM reading is less than 50 ohms or
When sensor is stroked into error zone, the Check greater than 200 ohms, replace sensor.
Trans light will come on. ECU will assume 100%
throttle. Shift will occur at either closed throttle or full 3. Connect one VOM probe to transmission housing,
throttle points. other to terminal A, then B. VOM meter should not
record continuity.

16 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070

SM - 432

MAIN VALVE
J1A HARNESS J1B HARNESS BODY HARNESS

CONNECTORS
TO ECU CONNECTORS AT
CONNECTOR TO MAIN VALVE
SHIFT SELECTOR BODY COVER

TO
CONTROL
BOX
INTERFACE
MAIN
CONTROL
VALVE
SOLENOID
CONNECTORS
DIGITAL DATA
LINE CONNECTOR

LOCKUP VALVE
SOLENOID
AND TEMP
SENSOR
TO CONTROL
BOX INTERFACE TO P/BRAKE SW
CONNECTORS
AT LOCKUP
VALVE BODY COVER
LOCKUP VALVE BODY HARNESS

TO CHASSIS GRD TRIM BOOST

SOLENOID

CONNECTORS AT
TRANSMISSION
OUTPUT SHAFT
SPEED SENSOR

TO SECONDARY
MODE SWITCHES CONNECTORS AT
THROTTLE
POSITION SENSOR

CONNECTORS AT
TRIM BOOST
VALVE
SELECTION MODE
HARNESS CONNECTOR
TO ECU

Fig. 20 - Electrical Circuit - J1A, J1B and J3 Harnesses

SM 1575 Rev 2 11-00 17

Transmission - CEC Plus II Shift System
Section 120-0070

SM - 433

A - J1A HARNESS CONNECTOR TO ECU B - J1B HARNESS CONNECTOR TO ECU

D - J1A HARNESS
C - J3 HARNESS CONNECTOR TO ECU CONNECTOR TO
SHIFT SELECTOR

E - J1B HARNESS F - J1B HARNESS

D - J1A HARNESS CONNECTOR TO CONNECTOR TO CONNECTOR TO G - J1B HARNESS
SHIFT SELECTOR MAIN VALVE BODY LOCKUP VALVE BODY CONNECTOR TO
THROTTLE POSITION
SENSOR

H - J1B HARNESS CONNECTOR J - MAIN VALVE BODY

TO TRANS OUTPUT SHAFT HARNESS CONNECTOR
SPEED SENSOR K - LOCKUP VALVE L - THROTTLE POSITION
BODY CONNECTOR SENSOR CONNECTOR

M - SPEED SENSOR N - DIGITAL DATA LINE 1/2 SHIFT/TRIM BOOST J1B HARNESS
CONNECTOR CONNECTOR - J1A HARNESS VALVE BODY CONNECTOR CONNECTOR TO
1/2 SHIFT/TRIM
BOOST VALVE

Fig. 21 - Harness Connectors

18 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070
4. Check J1B harness wiring for shorts or open circuits. 2. Check engine coolant temperature.

5. If fault cannot be located, replace ECU. 3. Check oil cooler and lines for blockage.

4. Stop vehicle, run engine at high idle until

Code 23 - Shift Selector temperature drops.
System Response:
The Check Trans light will come on. Last good
command from the shift selector will be used. Shifting Code 33 - Temperature Sensor
may still occur up to and including the range selected. System Response:
If oil temperature is above 204° C (350° F) or below
Probable Cause: -73° C (-100° F), the Check Trans light will come on
a. Shift selector failure and code set in memory.
b. Shorts or open circuits in harness wiring.
Probable Cause:
Remedy: a. Sensor failure.
1. Check J1A harness connectors at the shift selector b. Oil temperature too hot or too cold.
and ECU. c. Short or open circuit in harness wiring.

2. Check for shorts or open circuits in J1A harness Note: A CODE 33 may erase a previously diagnosed
wiring. Refer to Fig. 20 for applicable terminals and CODE 24.
wire numbers.
Remedy:
3. If fault cannot be found using steps 1 & 2, install a 1. Check transmission oil level.
new shift selector and reconnect all harness
connectors. Test drive the vehicle and check for 2. Check cooling system.
presence of trouble code. If trouble code recurs,
replace new shift selector with old, check connectors 3. Connect VOM probes to pins C & D on lockup valve
and wiring again. If trouble code is still present, body connector (K, Fig. 21). VOM reading should be
replace ECU. 5 000 to 130 000 ohms.

4. Connect one VOM probe to pin C, other to lockup

Code 24 - Oil Temperature valve body. VOM meter should not record continuity.
System Response:
1. Below -23° C (-10° F), Check Trans and Do Not 5. Check J1B and lockup valve body harness wiring for
Shift lights will come on. Transmission will not shift out shorts or open circuits.
of Neutral. Code will NOT be set in memory. Warming
oil to above -23° C (-10° F) will turn off lights. 6. If fault cannot be located, replace ECU.

2. Between -23° C (-10° F) and -7° C (20° F),

operation is limited to Reverse, Neutral and First Code 34 - PROM Check
gears. No lights will come on. No code is set in System Response:
memory. Warming oil above -7° C (20° F) will allow If the ECU detects a CODE 34 condition, the Check
normal shifting. Trans and Do Not Shift lights will come on, all shifts will
be prevented, and the lockup clutch will be disengaged.
3. Above 121° C (250° F), Check Trans light will come
on and shifts to Fifth or Sixth gear will not be Probable Cause:
permitted. Code will be set in memory. Light will go off PROM not in socket, installed incorrectly, or wrong or
when oil temperature falls below 121° C (250° F). faulty PROM installed.

Probable Cause:
a. Transmission oil temperature too high. WARNING
Only authorised warranty outlets are permitted
Remedy: to open the PROM access cover. Warranty may
1. Check transmission oil level with engine at idle. be void if opened by unauthorized personnel.

SM 1575 Rev 2 11-00 19

Transmission - CEC Plus II Shift System
Section 120-0070
Remedy: When a CODE 52 is present, the trim boost solenoid
Install new ECU, send old ECU to authorized service will either not function at all or only intermittently,
centre for repair or replacement of PROM. resulting in a loss of power in Reverse or lower
forward gear range.

Codes 41 Thru 45 - Solenoids A Thru E Probable Cause:

System Response: a. Failed solenoid.
1. If output shaft speed is over 500 rev/min, the Check
Trans and Do Not Shift lights will come on, all shifts b. Shorts or open circuits in J1B or main valve body
will be prevented and lockup clutch will be disengaged. harnesses.

2. If output shaft speed is under 500 rev/min, the Remedy:

Check Trans light only will come on. Shifts will not be 1. Disconnect J1B harness from lockup valve body
blocked unless speed is increased above 500 rev/min connector or trim boost valve body connector. Connect
and condition is still present. VOM probes to pins in valve body connector to which
K or J solenoid is connected. Refer to Figs. 20 & 21.
Probable Cause: VOM should read 12 - 24 ohms.
a. Failed solenoid.
2. Check J1B harness if correct reading was obtained
b. Shorts or open circuits in J1B or main valve body in Step 1 for shorts or open circuits in circuits
harness. applicable to K solenoid.

Note: Solenoids in main valve body are lettered A, B, 3. If in Step 1 VOM reading was not within limits,
C, D, E, F and G from left to right. remove lockup valve body cover or trim boost valve
body cover and remove connector from solenoid.
Remedy: Connect VOM probes to solenoid terminals. If VOM
1. Disconnect J1B harness from main valve body probes to solenoid terminals reading is not 12 - 24
connector. Connect VOM probes to pins in main valve ohms, replace solenoid.
body connector corresponding to solenoid indicated by
trouble code. Refer to Figs. 20 & 21. VOM should read 4. If in Step 3 VOM reading was within limits, check
12 - 24 ohms. lockup valve body or trim boost valve body harnesses
for shorts or open circuits.
2. Check J1B harness for shorts or open circuits in
circuits corresponding to solenoids indicated by
trouble code if correct reading was obtained in Step 1. Code 54 - Solenoid Chain (A, B, C, D & E))
System Response:
3. If in Step 1 VOM reading was not within limits, The Check Trans and Do Not Shift lights will come on,
remove main valve body cover and disconnect all shifts will be prevented and the lockup clutch will be
harness from solenoid indicated by trouble code. disengaged.
Connect VOM probes to solenoid terminals. If VOM
reading is not 12 - 24 ohms, replace solenoid. Probable Cause:
a. Failed solenoid.
4. If in Step 3 VOM reading was within limits, check main
valve body harness for shorts or open circuits in circuits b. J1B harness not properly connected to main valve
corresponding to solenoid indicated by trouble code. body harness connector.

c. Short or open circuit in J1B or main valve body

Code 51 - Lockup (K) Solenoid and, harness.
Code 52 - 1-2 Shift Solenoid (H) or Trim
Boost (J) Solenoid Remedy:
1. Check to ensure J1B harness is properly connected
System Response: to main valve body harness connector and that
Either code will cause the Check Trans light to come connectors are clean.
on. When a CODE 51 is present the lockup clutch will
either not function at all or only intermittently,
depending on the problem.

20 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070
2. Remove J1B harness from main valve body 2. Above 500 rev/min, the Check Trans and Do Not
harness connector. Connect VOM probes to pins Shift lights will come on and all shifts will be prevented.
corresponding to Solenoids A thru E in turn. Refer to
Figs. 20 & 21 for correct pins. VOM should read Probable Cause:
12 - 24 ohms for each solenoid. a. Failed solenoid.

3. If correct reading was obtained from all solenoids in b. Short or open circuit in J1B or main valve body
Step 2, check J1B harness circuits for shorts or open harness.
circuits.
Remedy:
4. If incorrect reading was obtained for one or more Use same procedure for checking 'F' solenoid as
solenoids in Step 2, remove valve body cover and shown for Codes 41 thru 45 (A thru E Solenoids).
disconnect harness from solenoids in question.
Connect VOM probes to solenoid terminals and check
for correct reading of 12 - 24 ohms. If problem is not in Code 69 - ECU Test (Software Error)
solenoid check main valve body harness for shorts or System Response:
open circuits. ECU will turn itself off. The Check Trans and Do Not
Shift lights will come on, all shifts will be prevented,
Note: Solenoids in main valve body are lettered A, B, and the lockup clutch disengaged.
C, D, E, F and G from left to right.
Probable Cause:
Error in software (programming) inside ECU
Code 61/63 - Splitter High Solenoid (G) which prevents normal operation of shift system.
System Response:
1. Below 500 rev/min, the Check Trans light only will Remedy:
come on. Shifts may not occur. 1. Replace ECU.

2. Above 500 rev/min, the Check Trans and Do Not

Shift lights will come on, all shifts will be prevented and DETERMINING PROM PART NUMBER
the lockup clutch will be disengaged. The PROM is located inside the ECU and the part
number is printed on the PROM itself. On the ECU is a
Probable Cause: label with the ECU/PROM assembly number. The
a. Failed solenoid. ECU/PROM assembly number is also programmed
into the PROM and can be read with the diagnostic
b. Short or open circuit in J1B or main valve body data reader. A DDAD distributor or your dealer can
solenoid. use the ECU/PROM assembly number to determine
the PROM part number.
Remedy:
Use same procedure for checking 'G' solenoid as
shown for Codes 41 thru 45 (A thru E Solenoids). WARNING
Only authorized warranty outlets are permitted
to open the PROM access cover. Warranty may
Code 62 - Splitter Low Solenoid (F) be void if opened by unauthorized personnel.
System Response:
1. Below 500 rev/min, the Check Trans light only will
come on. Shifts may not occur.

SM 1575 Rev 2 11-00 21

Transmission - CEC Plus II Shift System
Section 120-0070

ELECTRICAL TROUBLESHOOTING - No Codes

CONDITION REASON REMEDY
No Check Trans light when Faulty light bulb Replace light bulb
ignition keyswitch is turned to Faulty Relay 4 Replace Relay 4
position '1'
Incorrect power to Relay 4 Check circuit from batteries to Relay 4
Faulty wiring to ECU Check J1A harness wiring, interface in control
box and wiring from circuit breakers and
ignition keyswitch to ECU
Faulty ECU Replace ECU
Check Trans light will not go Faulty Relay 4. Note 2. Replace Relay 4
out when engine is started Faulty wiring in cab. Note 2. Check J1A harness and interface in control box
Light wired incorrectly . Note 2. Check wiring
Oil temperature too low. Run engine until oil warms above -23° C
Note 1. (-10° F). Refer to Codes 24 and 33
troubleshooting procedures.
Faulty ECU. Notes 1 and 2. Replace ECU
Check Trans light goes out Percent throttle is incorrect Refer to Code 21 troubleshooting procedure
only when drive 'D' is selected
Shift selector not illuminated Light bulb burned out. Note 3. Replace light bulbs
Shift selector lamp power or Check wiring from interface to panel
ground wiring faulty
Instrument panel circuit Check reason for circuit breaker being open.
breaker open. Note 4. Reset when corrected.
Transmission stays in Neutral Extremely low oil level Check transmission oil level, add if low
(will not shift), or will not make Oil temperature too low Run engine until oil warms above -23° C
a selected shift (-10° F). Refer to Codes 24 and 33
troubleshooting procedures.
Voltage to ECU too low Refer to Code 13 troubleshooting procedure
Throttle sensor not functioning Refer to Code 21 troubleshooting procedure
properly
Shift selector not functioning Refer to Code 23 troubleshooting procedure
properly

Note 1 - Transmission will not shift. Note 3 - Other instrument panel lights operate.
Note 2 - Shift system operates normally. Note 4 - Other instrument panel lights do not operate.

22 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070

ELECTRICAL TROUBLESHOOTING - No Codes

CONDITION REASON REMEDY
Transmission stays in Neutral Disconnected or dirty Check and clean harness connectors
(will not shift), or will not make
connectors
a selected shift Faulty wiring harness Check and repair harness
Transmission output shaft Refer to Code 22 troubleshooting procedure
speed sensor not functioning
properly
Faulty F solenoid or circuitry Refer to Code 62 troubleshooting procedure
Faulty A, B or C solenoids or Refer to Codes 41 - 45 troubleshooting
circuitry procedures
Internal hydraulic problem in Refer to Transmission Service Manual
transmission
Faulty ECU Replace ECU
Faulty parking brake interlock Check wiring. Replace microswitch if
switch or circuitry necessary
Faulty body up interlock Check wiring. Replace microswitch if
switch or circuitry necessary
Transmission will not shift into Faulty hoist interlock pressure Check wiring. Replace pressure switch if
Reverse, but will shift into switch or circuitry necessary
forward range
Vehicle will not start Dead batteries Charge batteries, replace if necessary
Voltage to shift selector is too Refer to Code 23 troubleshooting procedure
low
Faulty start circuit Repair circuit
Faulty Relay 6 Replace Relay 6
Faulty neutral start circuit Repair circuit
Faulty shift selector Refer to Code 23 troubleshooting procedure
Transmission does not shift Faulty throttle position sensor Refer to Code 21 troubleshooting procedure
properly (e.g. rough shifts, or circuitry
shifts at wrong speeds) Faulty transmission output Refer to Code 22 troubleshooting procedure
shaft speed sensor or circuitry
Wrong PROM installed Check PROM part number. Replace if
necessary
Intermittent shorts or open Check wiring and repair if necessary
circuits in wiring
Crossed wires in harness Check harness and repair
Faulty temperature sensor Refer to Code 22 troubleshooting procedure
circuitry

SM 1575 Rev 2 11-00 23

Transmission - CEC Plus II Shift System
Section 120-0070

ELECTRICAL TROUBLESHOOTING - No Codes

CONDITION REASON REMEDY
Transmission will not make a Extremely low oil level Check oil level and add if low
specific shift Extreme oil temperature Refer to Codes 24 and 33 troubleshooting
procedures
Faulty solenoid circuitry Refer to Codes 41 - 45, 54, 61, 62 or 63
troubleshooting procedure
Faulty transmission output Refer to Code 22 troubleshooting procedures
shaft speed sensor or circuitry
Faulty shift selector Refer to Code 23 troubleshooting procedures
Internal hydraulic problem Refer to Transmission Service Manual
Faulty ECU Replace ECU
Check Trans light flashes but Intermittent power to the ECU Check power to ECU. Correct if necessary.
no code present Faulty Relay 4 Replace Relay 4
Faulty wiring to 'Check Trans' Check wiring and repair if necessary
light
No reverse alarm signal Reverse alarm not working Repair or replace reverse alarm
Faulty Relay 5 Replace Relay 5
Faulty reverse alarm circuitry Repair wiring and repair if necessary

SPECIAL TOOLS
The Special Tools listed in the following tables are
required for servicing the CEC Plus II Shift System
and are available from your dealer.

SPECIAL TOOLS
TOOL NUMBER TOOL NAME
15268971 PRO-LINK Diagnostic Data Reader (DDR)
15268973 CEC I and II Cartridge for DDR
15268975 DDR and CEC I and II Cartridge Assembly
15269231 CEC Off-Highway Diagnostic Service Kit
15269038 Portable Printer for use with DDR, complete with 110 V AC Adaptor
15269039 Portable Printer for use with DDR, complete with 220 V AC Adaptor
15269040 Printer Paper for use in above printer - 5 Rolls
15270344 NoFlash Electro Contact Cleaner

24 SM 1575 Rev 2 11-00

 Transmission - CEC Plus II Shift System
Section 120-0070

SPECIAL TOOLS
The following tools are contained in CEC Off-Highway Diagnostic Service Kit - 15269231
TOOL NUMBER TOOL NAME
15269232 Wire Cutter, Stripper and Terminal Crimper
15269233 Jumper Wire Set
15269234 Terminal Crimper
15269235 Terminal Remover - Metri Pack (J1A, J1B, J3 and Shift Selector Connector Terminals)
15269236 Terminal Remover - Speed Sensor and Throttle Position Sensor Terminals
15269237 Terminal Remover - Depress holding prong on ECU and DDL Connector Terminals
15269238 PROM Remover
15269239 High Impedance Digital Multimeter Kit
15269240 AMP Pin Remover - Remove terminal pins from Interface and Shift Selector Connectors
15269241 Terminal Crimper - Weatherpac

* * * *

SM 1575 Rev 2 11-00 25

 Transmission - C.E.C. 2
Section 120-0070
SM2657

10 11
3 9

CONNECTOR TO
TERMINATION
RESISTOR
EARTH
2
SHIFT
4 E.C.U. SELECTOR
TRANS. HARNESS

12 5
INTERFACE MODULE

GHJ
KLM
7
DIAGNOSTIC
8 REF. CONSOLE HARNESS CONNECTOR

1. Gear Shift Selector 5. Shift Control Harness 9. Bolt

2. E.C.U. 6. Mounting Plate 10. Lock Washer
3. Transmission Harness 7. Bolt 11. Washer
4. Transmission Harness 8. Washer 12. Interface Box

Fig. 1 - C.E.C. 2 General Layout

DESCRIPTION uses this information to control the transmission

The CEC–2 (Commercial Electronic Control, Version 2) solenoids and valves, supply system status and
continually monitors the transmission and shift system provide diagnostic information.
electrical components and warns the operator when a
problem develops. It also takes action to prevent The ECU is programmed to take corrective action to
damage to the transmission, and provides the prevent damage to the transmission if a failure occurs
serviceman with diagnostic capabilities so that in the CEC–2 system and has diagnostic capabilities
problems can be corrected quickly and easily. which allow the serviceman to quickly find and repair or
replace a failed component. The ECU has 3
The CEC–2 system used on this vehicle consists of a connectors; Blue - Transmission Connector (T), Gray -
gear shift selector, an electronic control unit (ECU), Vehicle Connector (V), Black - Shifter Connector (S).
SM2924
throttle position sensor, transmission speed sensors (3
off), oil temperature sensor, solenoids, switches,
relays, circuit breakers, fuses, indicator lights and
wiring harnesses.
Y
A
R
G

VEHICLE
CONNECTION
(V)
CEC–2 COMPONENTS
K
C

UE
A

BL
L
B

Description and Operation

Electronic Control Unit (ECU) - Contains an TRANSMISSION
CONNECTION
electronic microcomputer. The ECU receives and BL
UE
SHIFTER (T)

processes information defining: shift selector position, CONNECTION

(S)
throttle position, sump temperature, input speed,
turbine speed and transmission output speed. The ECU Fig.2 - ECU

SM2128 R2 07-03 1
Transmission - C.E.C. 2
Section 120-0070
Power Module - The Power Module is located on the 1 2 3 8 9
SM2940
side of the battery box (Fig.3). The Power Module
contains ignition run fuses and relays, and a timer relay
for the shutdown function of the ECU. The ignition
fuses and relays open power to the ECU. On power
shut down the timer relay remains open for a 30 4
second period to allow the ECU to down load
5
information and close down properly (Fig. 4).
SM2680 6
1 2 3 4 5 6 7
10 7

A C B
1. Check Trans. Relay 7. Converter Drive Relay
2. Neutral Start Relay 8. On Board Weighing Relay
3. Reverse Relay 9. Rear View Camera Relay
4. Body Up Relay 10. Ignition Signal Fuse
5. Delta P Relay A. Manual/Automatic Key
6. Lock Up Off Relay B. Power/Economy Key
C. Manual Mode Light
Fig. 5- Interface Box

A B C D Gear Shift Selector - The shift selector is a remote

mounted lever type (Fig. 6). The gear shift selector is
1. Control Fuse 6. Transmission ECU Fuse
connected to the ECU by a wiring harness. The shift
2. Engine Master ECM Fuse 7. Transmission ECU Fuse
3. Engine Receiver ECM Fuse A. Ignition Sense Relay lever has 6 forward ranges and 2 reverse ranges, as
4. Engine Master ECM Fuse B. Engine ECM Power Relay 1 well as a neutral position. The shift selector has a
5. Engine Receiver ECM Fuse C. Engine ECM Power Relay 2 single digit LED display, that during normal operation
D. Trans. ECU Power Relay
will display the gear selected (Not gear attained).
Fig. 3 - Power Module Diagnostic information can be displayed on the single
digit LED display by pressing the diagnostic display
SM2679
button. There is a hold override button that must be
pressed when shifting between R, N and D. The hold
override button is released when desired selector
position is reached. The selector lever can move freely
between D and the number ranges without pressing the
L. E. D.
hold override button.
Release delay
On-off pulse
On-pulse
Off-pulse SET DIAL TO 'Release delay' WARNING
Do not allow the vehicle to coast in Neutral. This
0.6 - 6 sec
6 - 60 sec practice can result in severe transmission damage.
0.6 - 6 min
6 - 60 min SET DIAL TO '6 - 60 sec'
4
5
3
6
The transmission upshifts and downshifts
SET DIAL TO '3'
LOCK IN POSITION
2 automatically between first range and the highest range
USING ARALDITE OR
SIMILAR
1 selected on the range selector in direct response to
throttle position and transmission output speed.

When Reverse is selected the reverse alarm sounds

Fig. 4 - Timer Relay Setting and the reverse light illuminates at the rear of the
vehicle. This feature warns personnel to the immediate
CEC–2 Interface Box - Provides the electrical link rear of the vehicle that the operator has shifted
between the vehicle harnesses and the CEC–2 to reverse.
harnesses. The interface box contains an ignition
signal fuse and function relays.(Ref. Fig. 5)

2 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070
SM2667 SM2669
SPEED SENSOR ENGINE SPEED SENSOR

MODE LIGHT
1
MODE BUTTON MODE
2
3
TURBINE SPEED SENSOR
4
DISPLAY
5
D
N

DIAGNOSTIC R1
BUTTON R2

OUTPUT SPEED SENSOR

Fig. 6 - Gear Shift Selector Fig. 7 - Speed Sensors Locations

When drive 'D' is selected, the transmission right-of-way to a loaded vehicle, the transmission can
automatically upshifts and downshifts through all six be left in the selected range and the vehicle held
forward ranges as required by loads and travel speeds. stationary with the service brakes.
Selecting a lower range (4th, 3rd etc.) limits the highest
range to which the transmission will automatically upshift. However, when stopped for a more extended period
with the engine left running, shift the transmission to
If a lower range is selected while moving forward, the neutral to avoid unnecessary heat buildup and apply
transmission automatically downshifts sequential to the parking brake.
the selected lower range at maximum controlled engine
speeds. Downshifts will not occur until vehicle is
slowed by use of the service brakes and/or retarder. WARNING
Always select Neutral and apply the parking brake
When shifting from neutral to start from a standstill, before leaving the operator’s seat.
or to reverse direction, decelerate the engine to idle
speed. To move forward, select drive 'D' and
accelerate the engine to the vehicle load and speed Speed Sensors - 3 off speed sensors (Fig. 7); Input,
requirements. The transmission will automatically Turbine and Output Speed, provide information to the
upshift from 1st through 6th ranges as travel speed ECU. The input speed signal is generated by the gear
increases. teeth on the top PTO gear. The turbine speed signal is
generated by the serrations on the tone wheel. The
With the throttle fully depressed, and the mode output speed sensor signal is generated by a toothed
selection switch in the Power position, the member attached to the output shaft. The speed ratios
transmission upshifts to the next higher range when between the various speed sensors allow the ECU to
the engine attains maximum rated speed, since determine if the transmission is in the selected range.
maximum power train output is needed under this Hydraulic problems are detected by comparing the
condition. speed sensor information for the current range to that
At lower throttle settings where minimum power train ranges speed sensor information programmed in the
performance is required, the transmission will upshift ECU memory.
to the next higher range at less than maximum
rated engine speed. Mode Selection Switch - Gives the option to select
between transmission Power and Economy shift
Upgrades or soft spots might slow travel speed, even schedules. The transmission must be in Neutral before
at full throttle, requiring transmission downshifts to the switch will function.
maintain maximum powertrain performance. When this
occurs, the transmission downshifts automatically. The transmission torque converter is equipped with a
lockup clutch which, when engaged by the ECU, locks
Shift the transmission to the next lowest range if the converter pump and turbine together as a single
transmission 'Hunting' or 'Shift Cycling' occurs. unit and allows power to be transmitted mechanically
from the engine directly to the transmission gearing on
When temporarily stopped, such as for yielding the a 1:1 ratio. When the lockup clutch is disengaged, the

SM2128 R2 07-03 3
Transmission - C.E.C. 2
Section 120-0070
torque converter acts as a fluid coupling, multiplying SM2670
5 1
torque when engine speed is significantly higher than
transmission output shaft speed.

When the mode selection switch is in the Power

position, the ECU controls operation of the lockup
clutch according to signals received by the throttle 6 2
position sensor (giving engine speed as a percent of
throttle), the transmission output shaft speed sensor, 4 3
and range selector. The ECU may delay application of
the lockup clutch and allow torque multiplication by the
torque converter to take place until a balance is
achieved between engine speed and transmission 1. Transmission Check Light 4. Converter Mode Light
output shaft speed before activating the lockup clutch. 2. Delta P Filter Restriction 5. Transmission Oil Temperature
3. Transmission Overspeed 6. Retarder Apply Light
Power versus Economy Mode Fig. 8 - Warning Lights
The Power mode is designed for applications involving
heavy loads and hilly duty cycles where performance the manual mode. The light should be 'Off' during
rather than fuel economy is of prime importance. normal operation.

The Economy mode is designed for applications Check Trans Warning Light (Fig. 8) - Illuminates to
involving lighter loads and level duty cycles or where alert of a minor fault in the transmission control system
fuel economy is more important than performance. or abnormal transmission temperature. The light will
come 'On' when the ignition key switch is turned to
In the Economy mode, the ECU controls operation of position '1' to provide a bulb and system check and
the lockup clutch with a timed, preprogrammed should go 'Off' a few seconds after the engine is
schedule where in second through sixth gears the started and the transmission oil pressure rises.
lockup clutch is disengaged only long enough to allow The check trans warning light will come 'On' during
the torque converter’s fluid coupling to absorb shift operation, if the ECU has detected a minor fault in an
shock. Otherwise, the lockup clutch is engaged and no electrical component or abnormal transmission oil
torque multiplication takes place in second through temperature. If transmission oil temperature is too high,
sixth gears. stop the vehicle, select neutral 'N', and increase engine
speed to allow a greater flow of oil to the cooler until oil
Manual Mode Switch - The manual mode facility is temperature drops to normal operating range. In most
designed as a Service Technician facility to allow stall cases, a minor fault triggering the check trans warning
checks and clutch pressure checks to be implemented light will not prevent normal operation from continuing
by Service Personnel, and permit movement of the but, depending on the nature of the problem, the ECU
vehicle, if necessary, to a repair area. With the manual could take action to protect the transmission from damage,
mode switch in the 'On' position, the body up interlock such as preventing operating in high gear ranges. If the
and hoist interlock pressure switch mechanisms are check trans light comes 'On', have the problem
disengaged! This allows unauthorised selection of diagnosed and corrected at the earliest opportunity.
reverse or any forward gear with the body raised,
constituting a safety hazard. Operators must not use Converter Mode Light - Illuminates when the
the manual mode facility when working the vehicle! It is transmission is in torque converter drive. It goes 'Off'
recommended that the mode selection key is removed when Lockup is engaged. In order to avoid
from the unit and retained in a safe place until required unnecessary waste of fuel, if traffic or other road
by Service personnel. conditions permit, the operator should modify throttle
position, or gear held, to achieve a steady road speed
Note: The manual mode can only be used if the mode with the torque converter lockup engaged (light 'Off').
selection switch is in the Power position and the The Lockup relay in the interface box (Fig. 5) is also
transmission is in neutral. activated by the 20 bar (290 psi) pressure switch on
the foot brake pedal. When this switch is activated the
Manual Mode Warning Light - This light is located on converter in light will be illuminated due to the
the front face of the CEC–2 interface box. The Manual transmission dropping out of converter lock up,
Mode Warning Light illuminates to alert the operator avoiding engine stall. (Ref. Fig. 24)
when the transmission has been switched to operate in

4 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070
SM2666
MAIN CONNECTOR - ALL MODELS MAIN VALVE BODY
(Solenoids A - G)

PLATE & COVER CONNECTOR

(Solenoids H, I, & J) LOCKUP VALVE BODY
8610, 9610, 9810

LOCKUP CONNECTOR
ALL MODELS
TRIM BOOST CONNECTOR (K Solenoid and sump
(Solenoid J) temperature sensor)
5610, 6610

Fig. 9 - Solenoid Positions

GEAR ATTAINED SOLENOIDS ACTIVATED CLUTCHES ENGAGED

6 E, G 5/6 - High Splitter
5 E, F 5/6 - Low Splitter
4 D, G 3/4 - High Splitter
3 D, F 3/4 - Low Splitter
2 C, G 1/2 - High Splitter
1 C, F 1/2 - Low Splitter
N A, F Low Splitter
R1 A, B, F Reverse - Low Splitter
R2 A, B, G Reverse - High Splitter
Fig. 10 - Solenoid Activation (5010/6010 Series Only)
Transmission Overspeed Light - Illuminates when 3. Hold in Range - This is a body raise function. The
the transmission ECU senses transmission RPM ECU prevents any up-shifts when the body is raised
exceeds 2350 RPM. while in a forward gear. The ECU receives a signal
from the body up magnetic switch. (Ref. Fig. 11)
Electro-Hydraulic Valve Components: The CEC–2 SM2932
electro-hydraulic valve bodies contain various solenoids
to control hydraulic pressure (Fig. 9). The solenoid
pressure, or lack of pressure, positions shift valves that
apply transmission clutches to produce the range selected
by the ECU inputs (Fig. 10). The ECU is connected to
the solenoids by a wiring harness, with multi-pin twist-
lock connectors at the valve bodies (Ref. Fig. 25).

C.E.C.2 FUNCTIONS
1. Check Transmission - Relay within the Interface
Box triggers the Transmission Check Light on the dash
panel, when the transmission ECU senses a fault.
Fig. 11 - Hold in Range (Body Mag-Pick Up Switch)
2. Neutral Start - Neutral start relay inside the interface
box will not close unless the Transmission Shift 4. Bed Hoist Interlock (Reverse Hoist Interlock) - The
Selector is in the neutral position, thus preventing the ECU shifts the transmission to neutral (N) if the body is
engine ignition circuit being energised. raised when the transmission is in a selected reverse
gear (R). To over-ride this function, stop the truck, shift

SM2128 R2 07-03 5
Transmission - C.E.C. 2
Section 120-0070
gear shift selector to neutral, than back to reverse. The
ECU receives a signal from a pressure switch located 6. Lock in Gear - The Lock in gear feature is designed
on the raise circuit on the body control valve. (Ref. Fig. to protect the transmission from damage should wheel
12). spinning or lock-up occur due to poor traction or panic
SM2932
braking. The ECU will delay making a shift for several
seconds and then, if the condition fails to correct itself,
locks the gear to prevent any further shifting. The
check transmission light will illuminate. If this occurs,
the ECU must be reset before normal operation may
be resumed.
To reset the ECU if the transmission is locked in gear,
stop the truck, select neutral gear (N), apply the park
brake and turn the ignition key to '0' position. Wait 10
seconds, then turn the ignition key to restart engine.
Select Reverse gear (R) then neutral (N). The check
transmission light should go off.

7. Cold Weather Starts - During cold weather, if the

transmission temperature is below -24°C (-10°F) the
Check Transmission light will illuminate and the ECU
will prevent the transmission being shifted out of
neutral (N). Between -24°C (-10°F) and -7°C (19°F) the
light will go out and the ECU will only permit operation
on first and reverse gear. Above -7°C (19°F) normal
operation will be permitted.

Fig. 12 - Bed Hoist Interlock (Body Raise Pressure Sw)

5. Delta P Hold - The ECU prevents any up-shifts

should the transmission filter switch sense a pressure
differential of 2.5 bar (35 psi). This function is only
active when oil temperature is >40°C (104°F). (Ref. Fig.
13)
SM2934

Fig. 13 - Delta P Hold Pressure Switch

6 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070

ELECTRICAL DIAGRAMS
Transmission ECU Power Diagrams
SM2921

Fig. 14 -

Transmission ECU Power via the power module mounted on the trucks battery
box (Ref. Fig. 15, 16 & 18). Inside the power module
Refer to Fig. 14
there are 4 relays, 1 timer relay and 7 power fuses.
With the ignition key (S2) in the off position - The
Battery Disconnect Relay (K2), Ignition Run Relay
After the ignition run relay (K23) has been energised,
(K23), Neutral Start Relay and Starter Relay (K1) are all
24 Volts is permitted to access the Power Module.
de-energised.
Inside the power module the 4 relays (A through D) are
energised allowing 24 Volt power to access the
Turning the ignition key (S2) to position 'R' energises
transmission and engine ECUs via the 7 power fuses.
the battery disconnect relay (K2). This allows 24 Volts
The timer relay (Fig. 19) allows the transmission and
to access the bus-bar from the batteries (G2). 24 Volts
engine ECUs to remain powered for at least 30
power is also on stand-by at the alternator (G1) and
seconds after the ignition key has been switched off
starter relay (K1).
(position '0'). This allows all operating data to be
downloaded into the ECU memory.
Turning the ignition key (S2) to position '1' energises
ignition run relay (K23). By energising ignition run relay
The truck will not be able to start up unless the
(K23), 24 Volts power from the bus-bar is directed to
transmission gear shift selector is in the neutral (N)
the power module (Ref. Fig. 18), via engine ECU fuse
position. An electrical signal via wire number 123 (Ref.
(F3) and transmission ECU fuse (F7).
Fig. 14), from the transmission ECU will energise the
neutral start relay, Only if the gear shift selector is in
Both the transmission and engine ECUs are powered

SM2128 R2 07-03 7
Transmission - C.E.C. 2
Section 120-0070
SM2922

Fig. 15 -

SM2923

Fig. 16 -

8 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070
neutral (N). When the key switch is turned to position SM2679

'2', Starter relay (K1) will be energised via the neutral

start relay (Fig. 17). The engine cranking procedure will
begin.
SM2940
1 2 3 8 9
L. E. D.

Release delay
On-off pulse
On-pulse
Off-pulse SET DIAL TO 'Release delay'

0.6 - 6 sec
4 6 - 60 sec
0.6 - 6 min
6 - 60 min SET DIAL TO '6 - 60 sec'
5 4
5
3
6 SET DIAL TO '3'
6
2
LOCK IN POSITION
10 7 USING ARALDITE OR
1
SIMILAR

Fig.19 - Timer Relay Setting

1. Check Trans. Relay

A C B
7. Converter Drive Relay
C.E.C.2 FUNCTION DIAGRAMS
2. Neutral Start Relay 8. On Board Weighing Relay Refer. Fig. 21 & 22
3. Reverse Relay 9. Rear View Camera Relay 1. Check Transmission - Relay (1) within the Interface
4. Body Up Relay 10. Ignition Signal Fuse
5. Delta P Relay A. Manual/Automatic Key Box (Ref. Fig. 17) triggers the Transmission Check
6. Lock Up Off Relay B. Power/Economy Key Light on the dash panel (Ref. Fig. 20), via wire 115,
C. Manual Mode Light from the ECU shifter connector, pin 31, when the
Fig. 17 - Interface Box transmission ECU senses a fault.
SM2670
SM2680
5 1
1 2 3 4 5 6 7

6 2

4 3

1. Transmission Check Light 4. Converter Mode Light

2. Delta P Filter Restriction 5. Transmission Oil Temperature
3. Transmission Overspeed 6. Retarder Apply Light
Fig. 20 - Warning Lights

2. Neutral Start - The Neutral Start Circuit prevents the

A B C D engine being started unless the shift selector is in the
1. Control Fuse 6. Transmission ECU Fuse neutral (N) position. Neutral start relay (2) inside the
2. Engine Master ECM Fuse 7. Transmission ECU Fuse interface box (Ref. Fig. 17) will not close unless the
3. Engine Receiver ECM Fuse A. Ignition Sense Relay Transmission Shift Selector is in the neutral position,
4. Engine Master ECM Fuse B. Engine ECM Power Relay 1
this signal is received via the ECU vehicle connector
5. Engine Receiver ECM Fuse C. Engine ECM Power Relay 2
D. Trans. ECU Power Relay (V), pin 6, wire 123.

Fig.18- Power Module 3. Hold in Range - This is a body raise function. The
ECU prevents any up-shifts when the body is raised
while in a forward gear. When the body is raised the
body up magnetic switch (S22) signals the body up
relay (4) within the interface box (Ref. Fig. 17). The

SM2128 R2 07-03 9
Transmission - C.E.C. 2
Section 120-0070
SM2930

Fig. 21 -

SM2929

Fig. 22 -

10 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070
SM2933
body up relay (4) completes the hold in range signal via
wire 163 back to the ECU shifter connector (S), pin 27.

4. Bed Hoist Interlock (Reverse Hoist Interlock) - The

ECU shifts the transmission to neutral (N) if the body is
raised when the transmission is in a selected reverse
gear (R). To over-ride this function, stop the truck, shift
gear shift selector to neutral, than back to reverse. The
ECU receives a signal from pressure switch (S51)
located on the raise circuit on the body control valve
(Fig. 23). This signal request the interlock function via
wire 177 to the ECU vehicle connector (V), pin 14.
SM2932
1

1. Lock Up Drop Out Pressure Sw.

2. Stop Lamp Pressure Sw.

Fig. 24 - Lock Up Drop Out Pressure Switch

7. Parking Brake Interlock - If the park brake is
applied while the transmission is in neutral, the ECU
will prevent a shift out of neutral to protect the brake
components. To select a gear, hold the truck on the
service brakes, disengage the park brake then select
gear. The park brake switch (S7) sends a signal to the
Fig. 23 - Bed Hoist Interlock Pressure Switch (S51)
ECU vehicle connector (V), pin 29, wire 137. This
5. Delta P Hold - The ECU prevents any up-shifts signal prevents any shift out of neutral when the park
should the transmission filter switch sense a pressure brake is applied.
differential of 2.5 bar (35 psi). This function is only
active when oil temperature is >40°C (104°F). The 8. Reverse Relay Signal - The signal to the reverse
pressure differential is sensed by pressure switch alarm is made by energising reverse relay (3), inside
(S36). Pressure switch (S36) grounds out wire 161 to the interface box (Ref. Fig. 17). When a reverse gear
illuminate the Delta P Filter Restriction Lamp in the has been selected, the signal from ECU vehicle
dashboard.The pressure switch (S36) also breaks the connector (V) pin 4, wire 113, energises the reverse
signal to the Delta P Relay (5) inside the interface box relay (3), completing the reverse alarm circuit.
(Ref. Fig. 17), the signal to the ECU is via the vehicle
connector (V), pin30, wire 117. 9. Engine Overspeed Lamp - Overspeed lamp will
illuminate, (Ref. Fig. 20), when a speed greater that
6. Lock Up Drop Out - Pressure switch (S16) mounted 2350 RPM is sensed. The speed sense signal
on the brake treadle valve will dis-engage the originates from the ECU vehicle connector (V), pin 22,
transmission lock up mechanism when it senses a wire 112.
pressure greater than 20 bar (290lbf/in2)(Fig. 24). When
pressure switch (S16) senses the activating pressure it 10. Speedometer Output - The signal to the
will energise Lock Up Drop Out Relay (6) inside the speedometer mounted on the operators dashboard is
interface box (Ref. Fig. 17). This signal is sensed by received from the ECU shifter harness (S), pin 30, wire
the ECU vehicle connector (V) pin 27, wire 154. 157. Should the speedometer be changed, a calibration
procedure should be executed prior to the truck being
The converter drive lamp, located on the dash (Ref. put back to work. Please refer to general
Fig. 20) will illuminate when the lock up clutch is troubleshooting for procedure.
disengaged. Converter drive relay (7) inside the
interface box (Ref. Fig.17) is energised via the signal
from ECU vehicle connector (V), pin 3, wire 132.
SM2128 R2 07-03 11
Transmission - C.E.C. 2
Section 120-0070
11. Manual Mode Key - The manual mode key, For all transmission solenoid locations please refer to
mounted on the interface box, is defined as (S52) - Fig. 9. All transmission solenoid inputs/outputs are
Ref. Fig. 21. The signal to switch from automatic mode received at the ECU transmission connector (T). Refer
to manual mode is received at ECU shifter connector to Fig. 25.
(S), pin 11, wire 119. For manual/automatic mode
functions, please refer to CEC-2 COMPONENTS, Three transmission speed sensors send their required
Descriptions and Operation. signals back to the ECU via ECU transmission
connector (T) - Ref. Fig. 25.
12. Power/Economy Key - The power/economy key,
mounted on the interface box, is defined as (S53) -
Ref. Fig. 21. The signal to switch between power and TRANSMISSION RETARDER
economy mode is received at ECU shifter connector Refer to Fig 26, 27 & 28
SM2936
(S), pin 28, wire 126. For power/economy mode
functions, please refer to CEC-2 COMPONENTS,
Descriptions and Operation.

SOLENOID WIRING HARNESS 1

SM2681
ECU
T MAIN
BLUE
BODY SOLENOID
3
7 B -
17 A + A
C + B REVERSE/ 2
5 D - SHIFT LOCK
24 P - LOW
19 E + C RANGE
N + D INTER
23 M - RANGE 1. Retarder Solenoid Valve (K32)
13 R 2. Retarder Pressure Switch (S69)
3. Hi-Retard Relay
L + E HIGH
6 K - RANGE
4 F - F SPLITTER Fig. 26 - Transmission Retarder Valves (Centre Console)
1 J + LOW Transmission retarder can be selected by pressing
G + G SPLITTER transmission retarder switch (S59) - Ref. Fig. 27. -
21 H - HIGH
S located on the operators dashboard. The selection of
TRIM BOOST switch (S59) will default retarder solenoid (K32) from
3 A - rear brake retarder mode to transmission retarder
22 B + J/H mode.
8 C -
D + I
E Transmission retardation pressure can be controlled by
pulling back on the retarder lever located on the centre
LOCKUP BODY
console next to the gear shift selector. When
2 A + K retardation pressure begins to rise, pressure switch
20 B -
27 C + TEMP (S62) will close, illuminating the retarder lamp on the
D - SENSOR operator dashboard, Ref. Fig. 20.

25 A A temperature switch (S46) is located on the rear brake

10 B TPS
9 C
cooling oil return pipe mounted below the main
hydraulic tank. Ref. Fig. 28. This Allows the
14 A transmission to operate in a pre-selected downshift
30 B SS - ENGINE
schedule (Hi-Retard). When (S46) senses 100°C
15 A (212°F) OCDB temperature. The pre-select downshift
31 B SS - TURBINE
mode will make downshifts quicker, keeping engine
16 A
32 B SS - OUTPUT speed high as possible. When 100°C (212°F) OCDB oil
temperature is sensed by temperature switch (S46),
Fig. 25- Solenoid Wiring Harness to ECU

12 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070
the Hi-Retard Relay, located inside the centre console
(Ref. Fig. 26), is energised completing the Hi-Retard
request back to ECU vehicle connector (V), pin 28,
wire 178.
SM2935

Fig. 27 -

SM2937

1. Hi-Retard Temperature Switch (S46)

2. OCDB Temperature Switch (Warning)

Fig. 28 - Hi-Retard Temperature Switch (S46)

SM2128 R2 07-03 13
Transmission - C.E.C. 2
Section 120-0070

TRANSMISSION ECU CONNECTIONS SM2924

Refer to Fig. 29.

The transmission ECU has 3 conections that provide

Y
A
R
G
inputs and out puts for transmission functions. The 3
VEHICLE
connections are; CONNECTION
(V)

K
(V) Vehicle Connector - Gray Colour

C
UE

A
BL

L
B
(S) Shifter Connector - Black Colour TRANSMISSION
E CONNECTION
U
BL (T)
SHIFTER
(T) Transmission Connector - Blue Colour CONNECTION
(S)

Refer to Fig. 30, 31 & 32 for generic connecor pin Fig.29 - ECU
identifications.

WARNING
Before any welding is done on a machine equipped with an C.E.C. 2 system, disconnect the following
in this order: Battery earth cable, battery supply cable, alternator earth cables, alternator supply cables
and electrical connections at the engine ECM, transmission ECU and cab bulkhead to avoid damage to
electrical components. Turn off ignition key switch to isolate the batteries before disconnecting any
components. After welding connect all of the above in the reverse order.

SM2927

GRAY

16

32

17
No. COLOUR WIRE# DESCRIPTION
1 R 136-V1 Main Power to ECU
3 O 132-V3 Converter Drive Warning Light
4 W 113-V4 Reverse Alarm
6 N 123-V6 Neutral Start
14 N 177-V14 Reverse Hoist Interlock
16 R 136-V16 Battery Power
17 B 143-V17 ECU Earth
22 N 112-V22 Overspeed Warning Light
26 K 146-V26 Engine Run Signal
27 W 154-V27 Lock Up Off Signal
28 O 178-V28 Retarder Apply
29 O 137-V29 Park Brake Interlock
30 G 117-V30 Delta P Switch
31 Y 161-V31 Isolated Return
32 B 143-V32 ECU Earth
Fig.30 - ECU Vehicle Connector (V)

14 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070
SM2926

BLACK

16

32

17
No. COLOUR WIRE# DESCRIPTION
1 W 142-S1 Diagnostic connector (High)
3 K 124-S3 Shift Selector Power
4 Y 146-S4 Ignition Sense (Diagnostic Connector)
5 O 170-S5 PSS, Data Bit 1
6 G 171-S6 PSS, Data Bit 2
7 U 172-S7 PSS, Data Bit 4
8 Y 173-S8 PSS, Data Bit 8
9 N 174-S9 PSS, Parity
10 G 175-S10 PSS Mode Input
11 Y 119-S11 ECU To Manual Mode Switch
12 G 182-S12 CAN Controller Shield (J1939)
13 R 183-S13 CAN Controller, High (+) (J1939)
14 U 180-S14 PSS Display
16 R 136-S16 Battery Power
17 U 151-S17 Diagnostic Connector (Low)
27 U 163-S27 Range Inhibit Signal
28 Y 126-S28 Secondary Mode Switch
29 B 184-S29 CAN Controller, Low (-) (J1939)
30 N 157-S30 Speedometer Drive
31 G 115-S31 Check Transmission
32 B 143-S32 Battery Return

Fig.31 - ECU Shifter Connector (S)

SM2128 R2 07-03 15
Transmission - C.E.C. 2
Section 120-0070
SM2925

BLUE

16

32

17
No. COLOUR WIRE# DESCRIPTION
1 O 102-T1 Solenoid Power, Solenoids F, G & I
2 N 121-T2 Solenoid Power, Solenoid K
3 G 107-T3 Solenoid Power, Solenoid J or H
4 W 120-T4 F Solenoid, Low
5 G 103-T5 B Solenoid, Low
6 N 129-T6 E Solenoid, Low
7 W 104-T7 A Solenoid, Low
8 G 111-T8 I Solenoid, Low
9 K 124-T9 TPS Power
10 U 156-T10 TPS Input
13 Y 195-T13 Transmission Identification
14 N 141-T14 Engine Speed Sensor, High
15 O 149-T15 Turbine Speed Sensor, High
16 Y 139-T16 Output Speed Sensor, High
17 Y 130-T17 Solenoid Power, Solenoids A & B
19 Y 116-T19 Solenoid Power, Solenoids E, D & C
20 O 128-T20 K Solenoid, Low
21 U 131-T21 G Solenoid, Low
22 W 110-T22 J or H Solenoid, Low
23 W 127-T23 D Solenoid, Low
24 U 101-T24 C Solenoid, Low
25 G 135-T25 Analog Return
27 N 147-T27 Sump Temperature Sensor Input
30 O 150-T30 Engine Speed Sensor, Low
31 U 140-T31 Turbine Speed Sensor, Low
32 G 148-T32 Output Speed Sensor, Low

Fig.32 - ECU Transmission Connector (T)

16 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070

TROUBLE-SHOOTING 2. For Inactive Codes - Press and hold the mode

button for 8 to 10 seconds.
Begin troubleshooting by checking the transmission
fluid level and ECU input voltage. Remember that
Exit Diagnostic Mode
some problems may be temperature related. Do
troubleshooting at the temperature level where the 1. Press diagnostic button.
problem occurs. You can check diagnostic codes by;
DDR PROCEDURE
1. Using gear shift selector display.
2. Diagnostic Data Reader (DDR) - Ref. Special Tools The Digital Data Line (DDL) is located on the right hand
side of the centre console. The DDR should be
SM2667
connected at this point to access troubleshooting
codes. Diagnostic codes are listed and stored in the
ECU memory, listing the most recently occurring code
MODE LIGHT first and logging upto 5 codes. The DDR will display
1
MODE BUTTON MODE
2
the code list position, main code, sub code and active
3
indicator. The DDR also has the capability of
4
DISPLAY
5 displaying an ignition signal counter and event counter.
D
N
The following defines the different parts of the code list
DIAGNOSTIC
BUTTON
R1 displayed by the DDR;
R2

(A) Code List Position - The position which the code

occupies in the code list. Positions are displayed as
Fig. 33 - Gear Shift Display 'd1' through to 'd5'.

Using Gear Shift Display

(B) Main Code - The general condition or area of the
Reference Fig. 33 fault detected by the ECU.
Gear Shift Selector Procedure
1. Transmission check light will illuminate when the
(C) Sub-Code - The specific area or condition related to
ECU detects a fault.
the main code in which the fault is detected.

2. Stop the truck and shift gear selector to neutral (N).

(D) Active Indicator - Indicates when a diagnostic code
is active. The DDR will indicate 'YES'.
3. Press the diagnostic button on the gear
shift selector.
(E) Ignition Cycle Counter - Determines the number
of times the ignition has been cycled since the code
4. Display will illuminate one digit at a time. was detected.

5. Display starts with the code position, which will be (F) Event Counter - Determines how many times
d1, d2 etc. This is followed by the two digit main the code has occurred without being cleared from
code, then the two digit sub-code. the memory.

6. To move to the next code, press the Mode Button to

display the next diagnostic code. Up to 5 codes can
be stored at one time.

7. Active codes are indicated by illumination of the

Mode Light.

Clearing Codes
1. For Active Codes - Press and hold the mode button
for 3 to 5 seconds.

SM2128 R2 07-03 17
Transmission - C.E.C. 2
Section 120-0070

TROUBLE-SHOOTING DIAGNOSTIC CODES

Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated.
SOL OFF - All Solenoids Off.
GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode.

18 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070

TROUBLE-SHOOTING DIAGNOSTIC CODES (CONT.)

Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated.
SOL OFF - All Solenoids Off.
GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode.

SM2128 R2 07-03 19
Transmission - C.E.C. 2
Section 120-0070

TROUBLE-SHOOTING DIAGNOSTIC CODES (CONT.)

Abbreviations; DNS - Do Not Shift, Transmission will not respond to the shift selector when the transmission check light is illuminated.
SOL OFF - All Solenoids Off.
GPO - General Purpose Output, Output signal from ECU to control vehicle components to allow special operating mode.

20 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070

GENERAL TROUBLESHOOTING Speedometer/Odometer

Driven by a signal from the CEC, the speedometer
Performance Complaints indicates travel speed in kilometers per hour and miles
Make the following general checks before beginning per hour. A digital odometer is incorporated in the
specific troubleshooting. speedometer to record the distance travelled by the
vehicle at any given time.
• Are there active diagnostic codes?
• Is the shift lever in N to allow engine start? Speedometer Calibration Table -
• Is the battery properly connected and charged? All units with standard tyres
• Are all fluid levels correct? Unit Transmission Pulses
• Is the voltage to the ECU correct? TR40 M5610A 96720
• Is engine properly tuned? TR45 M5610A 96720
• Is fuel flow to the engine correct? TR45* M5610A 91950
TR60 M6610A 106960
• Is air flow to the cooler and radiator unrestricted?
TR70 M6610A 106960
• Is the driveline properly connected? TR100 M8610A 121520
• Are there signs of fluid leakage under the vehicle?
• What is the origination point of this leak? * - (If Optional Tyres 21*35 fitted)
• Are all hydraulic connections leak free?
• Are all electrical connections correct? Speedometer Calibration
1. Determine the impulses/mile required. Reference
After making these checks, Some complaints involve speedometer calibration table.
diagnostic codes, so all troubleshooting checks should
involve checking the system for diagnostic codes. 2. Depress and hold calibration button on the
speedometer and turn the ignition keyswitch to
Solenoid Ratings position '1'.
Each pressure solenoid that controls the functions on 3. Release button when PULSE is displayed. The
the transmission via the CEC2 commands have second digit will flash. Depress the button until the
electrical resistance ratings. (Ref. Fig 9) These desired number is displayed the release the button
electrical resistance ratings can be checked through for a few seconds until the next digit flashes.
the CEC2 harnesses and connectors to the ECU.
4. Repeat step 3 to obtain the desired impulses/mile.
All solenoids should be checked at normal operating After a few seconds only two digits will be
temperature. displayed. The speedometer is now calibrated.
A through G solenoid 12 to 24 ohms
K solenoid 12 to 24 ohms
J solenoid 10 to 13 ohms

Speed Sensor Ratings

The 3 speed sensors have electrical resistances and
can be checked at various transmission temperatures.
These resistances can be checked via the CEC2
harnesses and connectors to the ECU (Fig. 9).

Temperature Resistance
-40°C (-40°F) 200 ohms
20°C (68°F) 300 ohms
110°C (230°F) 400 ohms

SM2128 R2 07-03 21
Transmission - C.E.C. 2
Section 120-0070

SPECIAL TOOLS
The Special Tools listed in the following tables are
required for servicing the CEC 2 Shift System and are
available from your dealer.

SPECIAL TOOLS
TOOL NUMBER TOOL NAME
15275098 Diagnostic Data Reader (DDR) Multikit (Includes Reader, Cartridge, Cables)
15275180 CEC 2 Diagnostic Card
15269038 Portable Printer for use with DDR, complete with 110 V AC Adaptor
15269039 Portable Printer for use with DDR, complete with 220 V AC Adaptor
15269040 Printer Paper for use in above printer - 5 Rolls
15270344 NoFlash Electro Contact Cleaner

SPECIAL TOOLS
The following list of tools are required to service CEC 2
wiring harnesses.

SPECIAL TOOLS
TOOL NUMBER TOOL NAME
15275719 Sealed Splice (14-16 AWG)
15275720 Sealed Splice (18-22 AWG)
15275721 Crimper - Deutsch Connector, Transmission Harness Bulkhead, J1939 Connector
15269234 Crimper (Alternate) - Delphi Packard (DDL connector)
15275722 Crimper (Alternate) - Throttle Position Sensor
15275723 Wire Stripper
15275724 Remover - Delphi Packard (DDL Connector), Sump Temperature Sensor
15275725 Remover - Throttle Position Sensor
15275726 Remover - Deutsch Connector
15275727 Crimper - Throttle Position Sensor, Delphi Packard (DDL Connector)
15275728 Crimper - Speed Sensors, Throttle Position Sensor,
15275729 Crimper - Repair of broken cable using appropriate Sealed Splice
15275730 Remover - Deutsch Connector (Optional DDL)
15269241 Crimper (Alternate) - Throttle Position Sensor
15275731 Remover - ECU Connectors, Shift Selector Connection
15275732 Connector Repair Kit - Transmission Harness Bulkhead Connector
15275733 Guide Pin - Transmission Harness Bulkhead Connector
15275734 Insertion Tool - Transmission Harness Bulkhead Connector
15275735 Terminal Remover - Transmission Harness Bulkhead Connector
15275736 Crimper - ECU Connectors, Shift Selector Connection

22 SM2128 R2 07-03
 Transmission - C.E.C. 2
Section 120-0070

GLOSSARY
Detailed below is a glossary of abbreviation used
withing the C.E.C. 2 descriptions.
Abbreviation Termination Point
AGND Analog Return (Ground)
ASOL Solenoid A - Main Valve Body Cover
BSOL Solenoid B - Main Valve Body Cover
CSOL Solenoid C - Main Valve Body Cover
DDRD Diagnostic Data Reader - Deutsch
DDRP Diagnostic Data Reader - Packard
DSOL Solenoid D - Main Valve Body Cover
ECU-S Electronic Control Unit - Selector (S) Connector
ECU-T Electronic Control Unit - Transmission (T) Connector
ECU-V Electronic Control Unit - Vehicle (V) Connector
ESOL Solenoid E - Main Valve Body Cover
FSOL Solenoid F - Main Valve Body Cover
GSOL Solenoid G - Main Valve Body Cover
H/JSOL Solenoid H/J - Trim Boost or 1-2 Cover
ISOL Solenoid I - Solenoid I - 1-2 Cover
J1939 J1939 Data-link From ECU Selector (S) Harness
KSOL Solenoid K - Lockup Cover
LOW Low or 1-2 Cover
LU Lockup Cover
MNVB Main Valve Body Cover
NE Input (Engine) Speed Sensor
NO Output Speed Sensor
NT Turbine Speed Sensor
PSS Primary Shift Selector
RNGTRM Chassis Ground Ring Terminal
SCI Serial Communication Interface
TB Trim Boost Cover
TEMP Sump Temperature Sensor - Lockup cover
TPS Throttle Position Sensor
VIM Vehicle Interface Module
VIW Vehicle Interface Wiring

* * * *

SM2128 R2 07-03 23
Transmission - C.E.C. 2
Section 120-0070

* * * *

24 SM2128 R2 07-03
 TRANSMISSION - Power Takeoff
Section 120-0090

SM - 2422

22

25
24
27
28 9

10
6

23
26
18
19

13
15,16,17

9 21

11

20

8
7

12
2

3 5
14
4
1

1 - Snap Ring 8 - Pinion Shaft 15 - Shim 0.07 mm (0.003 in) 22 - Hose Assembly
2 - Bearing 9 - Bearing 16 - Shim 0.20 mm (0.008 in) 23 - Elbow
3 - Snap Ring 10 - Pinion Gear 17 - Shim 0.50 mm (0.020 in) 24 - Bushing
4 - Output Shaft 11 - Set Screw 18 - Bolt 25 - Connector
5 - Driven Gear 12 - Housing 19 - Lockwasher 26 - Adaptor
6 - Pipe Plug 13 - Pipe Plug 20 - Pipe Plug 27 - Coupling
7 - 'O' Ring 14 - Bearing 21 - Elbow 28 - Adaptor

Fig. 1 - Exploded View of Power Takeoff Assembly

DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1.

The power takeoff is mounted off a machined pad at

the lower right hand side of the torque converter WARNING
housing. Pinion gear (10) meshes with the oil pump To prevent personal injury and property
drive gear and provides the drive through driven damage, be sure wheel chocks and lifting
gear (5) to output shaft (4). Mounted off power takeoff equipment are properly secured and of
housing (12) is the steering pump which is driven by adequate capacity to do the job safely.
output shaft (4). Refer to Section 220-0050,
STEERING PUMP. 1. Position the vehicle in a level work area, apply the

SM 1915 7-00 1
Transmission - Power Takeoff
Section 120-0090
parking brake and switch off the engine. suitable puller tool into the internally splined output
shaft (4) and pull output shaft, together with bearing
2. Turn steering wheel in both directions several times (14) from driven gear (5).
to relieve pressure in the steering circuit. Block all road
wheels. 6. Remove snap rings (1 & 3) and bearing (14) from
output shaft (4) if necessary.
3. Match mark the steering pump housing and power
takeoff housing (12) to facilitate assembly. Remove 7. Remove driven gear (5) and bearing (2) from
steering pump from power takeoff housing (12) housing (12). Remove bearing (2) from driven gear (5).
following procedures outlined in Section 220-0050,
STEERING PUMP.
INSPECTION
4. Disconnect hose assembly (22) from elbow (21) and Numbers in parentheses refer to Fig. 1.
cap hose assembly and adaptor to prevent entry of
dirt. 1. Clean all parts, except bearings (2, 9 & 14), in a
suitable solvent and dry with compressed air.
5. Attach suitable lifting equipment to the power takeoff
assembly and remove bolts (18) and lockwashers 2. Clean bearings (2, 9 & 14) in volatile mineral spirits,
(19). Lift the power takeoff assembly and shims (15, and wipe dry with clean, lint-free cloth. Lubricate with
16 & 17) from the torque converter housing. Keep light oil, and spin by hand to check for wear and
shims (15, 16 & 17) with power takeoff housing (12) to roughness. Replace with new bearings if excessively
assure correct installation. Cover torque converter worn, or if operation is rough or noisy.
housing to prevent entry of dirt.
3. Check the condition of splines and teeth on all gears
Note: Identify or mark the number and thickness of and shafts for burrs or signs of excessive wear.
shims (15, 16 & 17) removed. This procedure is
necessary so as not to alter the backlash of the gears 4. Pinion shaft (8) and output shaft (4) should not be
during assembly. rough, worn, cracked or damaged. If either shaft is
distorted, it should be replaced.
Note: The gasket used at the steering pump mounting
face should be discarded and replaced at installation. 5. Check all threaded parts and tapped holes for
stripped or battered condition.

DISASSEMBLY 6. Inspect housing (12) for cracks or bearing bores

Numbers in parentheses refer to Fig. 1. out-of-roundness.

1. Remove the 'stake' mark from set screw (11), then 7. Gear teeth should not be worn, cracked or broken.
remove set screw (11).
8. Any small nicks, scratches or burrs should be
2. Place housing (12) on the bed of an arbor press smoothed up with a fine stone or crocus cloth, and
with the steering pump mounting flange facing part cleaned in solvent and dried with lint-free cloth.
downward. Remove pipe plug (13) and press pinion
shaft (8) out of housing (12).
ASSEMBLY
Note: If an arbor press is unavailable, the pinion shaft Numbers in parentheses refer to Fig. 1. Refer to
can be driven out of the housing using a soft drift and Fig. 2 for location of parts within housing (12).
hammer.
1. With housing (12) in position with steering pump
3. Remove and discard 'O' ring (7) from pinion shaft (8). mounting face up, press bearing (2) into bearing bore
in housing (12).
4. With housing (12) positioned mounting flange face up,
lift out pinion gear (10) and bearings (9) as an assembly. Note: Be sure bearing is seated by tapping outer race
Remove bearings (9) from pinion gear (10). with a soft drift and hammer.

5. Remove snap ring (1) from housing (12). Insert a 2. Install snap ring (3) onto output shaft (4).

2 SM 1915 7-00
 Transmission - Power Takeoff
Section 120-0090

SM - 272 8. Install and stake set screw (11) in housing (12).

9. Install pipe plug (13) in the end of pinion shaft (8).

INSTALLATION
Numbers in parentheses refer to Fig. 1.

Note: Tighten all fasteners to standard torques listed in

Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.

Note: Tighten all hydraulic lines fitted with ORFS

connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
where used.

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. Using suitable lifting equipment, position power

takeoff assembly to torque converter housing and
1 - Snap Ring
2 - Bearing 9 - Bearing secure with bolts (18) and lockwashers (19), using the
3 - Snap Ring 10 - Pinion Gear same quantity and thickness of shims (15, 16 & 17)
4 - Output Shaft 11 - Set Screw removed during removal.
5 - Driven Gear 12 - Housing
7 - 'O' Ring 13 - Pipe Plug
8 - Pinion Shaft 14 - Bearing 2. Remove pipe plug (6) from housing (12).
Fig. 2 - Cutaway View of Power Takeoff Assembly Note: Pipe plug (6) hole serves as an access for
checking the backlash.
3. Position driven gear (5) in housing (12) and slide
output shaft (4) through driven gear (5). Press output 3. Position a dial indicator on housing (12) so that the
shaft (4) into bearing (2), if necessary. plunger rests against a tooth of pinion gear (10).

4. Press bearing (14) onto opposite end of output shaft 4. Hold or block either the power takeoff drive gear, or
(4) and install snap ring (1). Be sure bearing (14) is the converter charging pump driven gear, whichever is
seated against output shaft (4) shoulder, with shielded the case, so that it cannot revolve.
side of bearing facing toward snap ring (1) (facing out).
5. Set the dial indicator to a zero reading then, with a
5. Rotate driven gear (5) and check for any visible screwdriver, turn pinion gear (10) back and forth as far
signs of drag. as possible. The maximum allowable backlash is from
0.381 - 0.635 mm (0.015 - 0.025 in).
6. Press bearings (9) into bearing bores of pinion gear
(10). Be sure bearings are seated against shoulder in 6. If the dial indicator reading is less than 0.381 mm
pinion gear. (0.015 in) additional shims (15, 16 & 17) will have to be
installed. A greater reading than 0.635 mm (0.025 in)
7. Position pinion gear (10) and bearings (9) assembly means that some shims (15,16 & 17) will have to be
in housing (12). Install a new 'O' ring (7) on pinion removed.
shaft (8). Insert pinion shaft (8) through pinion gear
(10) and bearings (9), lining up set screw hole in pinion 7. After the correct backlash is obtained, remove the
shaft (8) with set screw hole in housing (12). block preventing the gear from revolving. Install pipe
plug (6) in housing (12) and secure the power takeoff

SM 1915 7-00 3
Transmission - Power Takeoff
Section 120-0090
assembly in position with bolts (18) and tighten lines and fittings as required.
lockwashers (19).
11. Ensure parking brake is applied and remove wheel
8. Remove blanking caps from elbow (21) and hose chocks from all road wheels.
assembly (22) and install hose assembly (22).

9. Install steering pump on power takeoff assembly SERVICE TOOLS

following procedures outlined in Section 220-0050, Refer to Section 300-0070, SERVICE TOOLS for part
STEERING PUMP. numbers of tools referenced in this section and
general service tools required. These tools are
10. Start the engine and make an operational check available from your dealer.
while the engine is running. Check for leaks and

* * * *

4 SM 1915 7-00
 TRANSMISSION - Transmission Oil Filter
Section 120-0100

SM - 2442

5
3
4

OUT
IN 2 INSIDE R.H.
OUT FRAME RAIL
IN
TOP FRONT R.H.S.
TRANSMISSION

7
6

1 - Filter Assembly 4 - Adaptor 6 - Bolt

2 - Filter Inlet Line 5 - Elbow - 45° 7 - Lockwasher
3 - Filter Outlet Line

Fig. 1 - Transmission Oil Filter and Lines

DESCRIPTION sends a signal to a filter restriction indicator warning

Numbers in parentheses refer to Fig. 2, unless light (mounted on the dash panel) to warn the operator
otherwise specified. when element (2) becomes sufficiently clogged to
restrict oil flow. This indicates that element (2) should
Transmission oil filter assembly (1, Fig. 1) is installed be changed.
in the transmission oil lines to remove dirt and other
contaminants from the transmission oil to minimise Oil flows from the transmission to the inlet side of filter
wear and provide maximum service life for the head (1) where the oil will then take one of two paths:
transmission.
a. If the oil is cold and thick, or element (2) is clogged, oil
A bypass valve in filter head (1) ensures an adequate pressure increases and opens the bypass valve allowing
flow of oil to the transmission if element (2) becomes the oil to bypass the filter and flow through filter head (1)
clogged and cannot pass oil through quickly enough to and exit at the outlet port to the transmission.
satisfy demand. The bypass valve opens at 3.5 bar
(50 lbf/in²). b. If the oil is warm and element (2) is not clogged, oil
will flow through element (2) before returning to the
Installed in filter head (1) is pressure switch (4) which transmission.

SM 1931 7-00 1
Transmission - Transmission Oil Filter
Section 120-0100

REMOVAL INSTALLATION
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless
otherwise specified. otherwise specified.

Note: Tighten all fasteners to standard torques listed

WARNING in Section 300-0080, STANDARD BOLT AND NUT
To prevent personal injury and property TORQUE SPECIFICATIONS.
damage, be sure wheel chocks are properly
secured and of adequate capacity to do the job Note: Tighten all hydraulic lines fitted with ORFS
safely. connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
1. Position the vehicle in a level work area, raise the where used.
body and install the body prop pins. Refer to Section
270-0010, BODY AND MOUNTING. 1. If new filter assembly (1) is being fitted, install
adaptors (4) in filter head (1, Fig. 2).
2. Apply the parking brake and switch off the engine.
2. Position filter assembly (1) to mounting bracket on
3. Turn steering wheel in both directions several times the right hand frame rail and secure with bolts (6) and
to relieve pressure in the steering circuit. Block all road lockwashers (7).
wheels.
3. If filter inlet line (2) and filter outlet line (3) were
4. Tag filter inlet line (2) and filter outlet line (3) to aid removed, remove blanking caps and install lines on
in installation and disconnect from filter assembly (1). elbows (5) in the transmission, as tagged during
Cap open line ends and fittings to prevent entry of dirt. removal.

5. Support filter assembly (1) and remove bolts (6) and 4. Remove blanking caps and connect filter inlet line
lockwashers (7) securing filter assembly (1) to (2) and filter outlet line (3) on adaptors (4) on filter
mounting bracket on the right hand frame rail. Remove assembly (1), as tagged during removal.
filter assembly (1) and drain oil from assembly into a
suitable container. 5. Start the engine and check for leaks. Tighten lines,
fittings and filter locking collar as required.
6. If filter assembly (1) is being replaced, remove
adaptors (4) to use on new filter assembly (1). 6. Check transmission oil level and add oil if required.
Refer to Section 120-0010, TRANSMISSION AND
7. If filter element (2, Fig. 2) is only being replaced, MOUNTING for correct fill level, and, use only oil as
disassemble filter assembly (1) and replace element specified in Section 300-0020, LUBRICATION
(2, Fig. 2) as described under 'Changing Filter SYSTEM.
Element'.
7. Ensure parking brake is applied, remove the body
8. If required, remove filter inlet line (2) and filter outlet prop pins and lower the body. Refer to Section
line (3) from the transmission. Cap open line ends and 270-0010, BODY AND MOUNTING.
fittings to prevent entry of dirt.
8. Remove wheel chocks from all road wheels.

2 SM 1931 7-00
 Transmission - Transmission Oil Filter
Section 120-0100

SM - 1251 1. Position the vehicle in a level work area, raise the

body and install the body prop pins. Refer to Section
270-0010, BODY AND MOUNTING.

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

3. Turn steering wheel in both directions several times

to relieve pressure in the steering circuit. Block all road
wheels.

4. With a suitable container under the filter assembly

to catch draining oil, unscrew locking collar on housing
(5) and remove housing (5) and element (2). Discard
element (2).

5. Remove and discard 'O' ring (3) from filter head (1).

6. Clean housing (5) with clean fuel oil and dry with a
clean lint free cloth. Lubricate new 'O' ring (3) and
install on filter head (1).

1 - Filter Head 7. Install new element (2) on filter head (1), making
2 - Element sure plastic insert in element centre contacts spiral
3 - 'O' Ring snap ring on filter head (1).
4 - Pressure Switch
5 - Housing
8. Install housing (5) over element (2) and secure
Fig. 2 - Exploded View of Transmission Oil Filter tightly with locking collar.

9. Start the engine and check the filter assembly for

CHANGING FILTER ELEMENT leaks. If leaks are present around locking collar on
Numbers in parentheses refer to Fig. 2. housing (5), tighten locking collar as required. If leaks
persist, remove and install new 'O' ring (3) on filter
Change filter element (2) at intervals specified in head (1).
Section 300-0020, LUBRICATION SYSTEM. Element
(2) should also be changed whenever a transmission 10. Check transmission oil level and add oil if required.
overhaul is performed, or other internal servicing is Refer to Section 120-0010, TRANSMISSION AND
carried out. MOUNTING for correct fill level, and, use only oil as
specified in Section 300-0020, LUBRICATION
SYSTEM.
WARNING
To prevent personal injury and property 11. Ensure parking brake is applied, remove the body
damage, be sure wheel chocks are properly prop pins and lower the body. Refer to Section
secured and of adequate capacity to do the job 270-0010, BODY AND MOUNTING.
safely.
12. Remove wheel chocks from all road wheels.

* * * *

SM 1931 7-00 3
 DRIVELINE - Front Driveline
Section 130-0010

SM - 1982

ENGINE 2
2
1

TRANSMISSION

3
3
4 4

1 - Driveline Assembly
2 - Universal joint
3 - Capscrew
4 - Capscrew

Fig. 1 - Exploded View of Front Driveline Installation

DESCRIPTION REMOVAL
The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig. 1.
power from one point to another in a smooth and
continuous action while allowing a degree of
movement or misalignment of the components it WARNINGS
connects. To prevent personal injury and property
damage, be sure wheel blocks, blocking
The drivelines must operate through constantly materials and lifting equipment are properly
changing relative angles between the components secured and of adequate capacity to do the job
they are mounted to and must also be capable of safely.
changing length while transmitting torque.
Rotating shafts can be dangerous. You
A typical driveline consists of universal joints which can snag clothes, skin, hair, hands, etc. This
allow some misalignment and permit the driveline to can cause serious injury or death. Do not go
pivot in any direction, and, a light rigid hollow slip under a vehicle when the engine is running.
yoke and splined shaft assembly forming a slip joint.
Note: Extra care should be taken when handling
The slip joint accommodates length variations drivelines since carelessness can result in premature
generated during operation, preventing tension or failure of the components. Chips, dents, burrs, or any
compression loads from causing serious damage to other deformity of universal joints will prevent accurate
the components. mating. This will cause misalignment, which is
accompanied by vibration and excessive wear.
Note: Extra care should be taken when handling the
driveline since chips, dents, burrs or deformity on 1. Position the vehicle in a level work area, apply the
any rotating mass creates vibration and excessive parking brake and switch off the engine.
wear during any operation.

SM 1577 12-98 1
Driveline - Front Driveline
Section 130-0010
2. Turn steering wheel in both directions several SM - 088
times to relieve pressure in the steering circuit. Block
all road wheels. APPLY PRESSURE MAXIMUM PERMISSABLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
3. Match mark universal joints (2) and their mating
surfaces to ensure correct mating alignment when
installing driveline assembly (1). STRAIGHTEDGE

4. Support driveline (1) with suitable lifting equipment

and remove capscrews (4) securing universal joints (2)
to their mating components. Remove driveline
assembly (1). If necessary tap driveline assembly (1) REMOVE ALL
from its mating components with a soft faced hammer. BURRS AND
PAINT FROM
THESE SURFACES
Note: Access to driveline assembly (1) can be
obtained from underneath the vehicle.

DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Fig. 2 - Checking Parallelism

Universal Joint
1. Place the yoke end of driveline assembly (1) in a ASSEMBLY
soft jawed vice, clamping on the tube of shaft. Numbers in parentheses refer to Fig. 1.

Note: Do not distort the tube withn excessive grip. Universal Joint
1. Place the yoke end of driveline assembly (1) in a
2. Remove capscrews (3) and universal joints (2) from soft jawed vice, clamping on the tube of shaft.
driveline assembly (1).
Note: Do not distort the tube withn excessive grip.
3. Place the shaft end of driveline assembly (1) in a
soft jawed vice. 2. Install universal joints (2) to yoke end of driveline
assembly (1) and secure with capscrews (3). Tighten
4. Remove capscrews (3) and universal joint (2) from capscrews (3) to a torque of 128 - 142 Nm
driveline assembly (1). (95 - 105 lbf ft).

3. Place the shaft end of driveline assembly (1) in a

INSPECTION soft jawed vice.
1. Clean all metal parts in a suitable solvent and dry all
parts with compressed air. 4. Install universal joint (2) to shaft end of driveline
assembly (1) and secure with capscrews (3)
2. Inspect splines of shaft and yoke for nicks, burrs
and excessive wear. Replace if wear is excessive or
splines are nicked. Burrs may be removed with a fine INSTALLATION
file or medium India stone. Numbers in parentheses refer to Fig. 1.

3. Check the surfaces of the components that Note: Tighten all fasteners without special torques
universal joints mate against for parallelism. Refer to specified to standard torques listed in Section
Fig 2. 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Check the condition of mounting capscrews and
replace if required. Note: Extra care should be taken when handling
drivelines since carelessness can result in premature
failure of the components. Chips, dents, burrs, or any

2 SM 1577 12-98
 Driveline - Front Driveline
Section 130-0010

other deformity of universal joints will prevent MAINTENANCE

accurate mating with the crosses and bearings. This
will cause misalignment, which is accompanied by Lubrication
vibration and excessive wear. Lubricate driveline with either a hand-operated or a
pressure grease gun. Refer to Section 300-0020,
LUBRICATION SYSTEM, for recommended lubricant
WARNINGS and service intervals.
To prevent personnel injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Periodic Inspection
secured and of adequate capacity to do the job Use a small pry bar to check companion flange
safely. yokes for looseness. If loose, drop one end of the
driveline and twist the yoke to check backlash
To prevent serious injury or death, DO between splines and yokes. Replace any yoke that
NOT go under vehicle when the engine is does not fit snugly.
running. Rotating shafts can be dangerous.
You can snag clothes, skin, hair, hands, etc. Using a small pry bar, check the universal joints for
play. If loose, replace the universal joints. Check
1. Using suitable lifting equipment, position driveline splines at slip joint and replace universal joints, if
assembly (1) on the vehicle and align match marks excessively worn.
on universal joints (2) with those on its mating
surfaces. Note: In the event of a failed or worn bearing, a new
universal joint with a new set of bearings must be
2. Apply Loctite 242 to the threads of capscrews (4) installed.
and secure universal joints (2) to their mating
surfaces with capscrews (4). Tighten capscrews (4)
to a torque of 135 Nm (100 lbf ft). SPECIAL TOOLS
There are no special tools required for procedures
3. Ensure the parking brake is applied and start the outlined in this section. Refer to Section 300-0070,
engine. Remove wheel blocks from all road wheels. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.

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 balance.
universal joints and/or run-out 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.

SM 1577 12-98 3
Driveline - Front Driveline
Section 130-0010

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 3 Capscrew 128 - 142 95 - 105
1 4 Capscrew 135 100

* * * *

4 SM 1577 12-98
 DRIVELINE - Rear Driveline
Section 130-0020

SM - 1983

TRANSMISSION
2

1 4
DIFFERENTIAL

4
2

1 - Driveline Assembly
2 - Universal joint
3 - Capscrew
4 - Capscrew

Fig. 1 - Exploded View of Rear Driveline Installation

DESCRIPTION REMOVAL
The function of the driveline is to transmit rotating Numbers in parentheses refer to Fig. 1.
power from one point to another in a smooth and
continuous action while allowing a degree of
movement or misalignment of the components it WARNINGS
connects. To prevent personal injury and property
damage, be sure wheel blocks, blocking
The drivelines must operate through constantly materials and lifting equipment are properly
changing relative angles between the components secured and of adequate capacity to do the job
they are mounted to and must also be capable of safely.
changing length while transmitting torque.
Rotating shafts can be dangerous. You
A typical driveline consists of universal joints which can snag clothes, skin, hair, hands, etc. This
allow some misalignment and permit the driveline to can cause serious injury or death. Do not go
pivot in any direction, and, a light rigid hollow slip under a vehicle when the engine is running.
yoke and splined shaft assembly forming a slip joint.
Note: Extra care should be taken when handling
The slip joint accommodates length variations drivelines since carelessness can result in premature
generated during operation, preventing tension or failure of the components. Chips, dents, burrs, or any
compression loads from causing serious damage to other deformity of universal joints will prevent accurate
the components. mating. This will cause misalignment, which is
accompanied by vibration and excessive wear.
Note: Extra care should be taken when handling the
driveline since chips, dents, burrs or deformity on 1. Position the vehicle in a level work area, apply the
any rotating mass creates vibration and excessive parking brake and switch off the engine.
wear during any operation.

SM 1578 12-98 1
Driveline - Rear Driveline
Section 130-0020
2. Turn steering wheel in both directions several SM - 088
times to relieve pressure in the steering circuit. Block
all road wheels. APPLY PRESSURE MAXIMUM PERMISSABLE
HERE BY HAND GAP IS 0.2 mm (0.008 in)
3. Match mark universal joints (2) and their mating
surfaces to ensure correct mating alignment when
installing driveline assembly (1). STRAIGHTEDGE

4. Support driveline (1) with suitable lifting equipment

and remove capscrews (4) securing universal joints (2)
to their mating components. Remove driveline
assembly (1). If necessary tap driveline assembly (1) REMOVE ALL
from its mating components with a soft faced hammer. BURRS AND
PAINT FROM
Note: Access to driveline assembly (1) can be THESE SURFACES
obtained from underneath the vehicle.

DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Fig. 2 - Checking Parallelism

Universal Joint
1. Place the yoke end of driveline assembly (1) in a ASSEMBLY
soft jawed vice, clamping on the tube of shaft. Numbers in parentheses refer to Fig. 1.

Note: Do not distort the tube withn excessive grip. Universal Joint
1. Place the yoke end of driveline assembly (1) in a
2. Remove capscrews (3) and universal joints (2) from soft jawed vice, clamping on the tube of shaft.
driveline assembly (1).
Note: Do not distort the tube withn excessive grip.
3. Place the shaft end of driveline assembly (1) in a
soft jawed vice. 2. Install universal joints (2) to yoke end of driveline
assembly (1) and secure with capscrews (3). Tighten
4. Remove capscrews (3) and universal joint (2) from capscrews (3) to a torque of 312 - 325 Nm
driveline assembly (1). (230 - 240 lbf ft).

3. Place the shaft end of driveline assembly (1) in a

INSPECTION soft jawed vice.
1. Clean all metal parts in a suitable solvent and dry all
parts with compressed air. 4. Install universal joint (2) to shaft end of driveline
assembly (1) and secure with capscrews (3)
2. Inspect splines of shaft and yoke for nicks, burrs
and excessive wear. Replace if wear is excessive or
splines are nicked. Burrs may be removed with a fine INSTALLATION
file or medium India stone. Numbers in parentheses refer to Fig. 1.

3. Check the surfaces of the components that Note: Tighten all fasteners without special torques
universal joints mate against for parallelism. Refer to specified to standard torques listed in Section
Fig 2. 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Check the condition of mounting capscrews and
replace if required. Note: Extra care should be taken when handling
drivelines since carelessness can result in premature
failure of the components. Chips, dents, burrs, or any

2 SM 1578 12-98
 Driveline - Rear Driveline
Section 130-0020

other deformity of universal joints will prevent MAINTENANCE

accurate mating with the crosses and bearings. This
will cause misalignment, which is accompanied by Lubrication
vibration and excessive wear. Lubricate driveline with either a hand-operated or a
pressure grease gun. Refer to Section 300-0020,
LUBRICATION SYSTEM, for recommended lubricant
WARNINGS and service intervals.
To prevent personnel injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Periodic Inspection
secured and of adequate capacity to do the job Use a small pry bar to check companion flange
safely. yokes for looseness. If loose, drop one end of the
driveline and twist the yoke to check backlash
To prevent serious injury or death, DO between splines and yokes. Replace any yoke that
NOT go under vehicle when the engine is does not fit snugly.
running. Rotating shafts can be dangerous.
You can snag clothes, skin, hair, hands, etc. Using a small pry bar, check the universal joints for
play. If loose, replace the universal joints. Check
1. Using suitable lifting equipment, position driveline splines at slip joint and replace universal joints, if
assembly (1) on the vehicle and align match marks excessively worn.
on universal joints (2) with those on its mating
surfaces. Note: In the event of a failed or worn bearing, a new
universal joint with a new set of bearings must be
2. Apply Loctite 242 to the threads of capscrews (4) installed.
and secure universal joints (2) to their mating
surfaces with capscrews (4). Tighten capscrews (4)
to a torque of 235 Nm (173 lbf ft). SPECIAL TOOLS
There are no special tools required for procedures
3. Ensure the parking brake is applied and start the outlined in this section. Refer to Section 300-0070,
engine. Remove wheel blocks from all road wheels. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.

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 balance.
universal joints and/or run-out 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.

SM 1578 12-98 3
Driveline - Rear Driveline
Section 130-0020

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 3 Capscrew 312 - 325 230 - 240
1 4 Capscrew 235 173

* * * *

4 SM 1578 12-98
 FRONT AXLE - Wheel, Rim and Tyre
Section 140-0040

SM - 228

1 - Clamp 4 - Rim 7 - 'O' Ring

2 - Wheel Nut 5 - Lock Ring 8 - Bead Seat Band
3 - Wheel Stud 6 - Flange 9 - Wheel

Fig. 1 - Sectional View of Typical Wheel Rim Assembly

DESCRIPTION
The wheel is mounted on the axle spindle with two WARNING
tapered roller bearings mounted in the hub. The brake Tyre explosion hazard. Gases that build up
disc is bolted to the wheel. The tyre rim consisting of a inside an air inflated tyre mounted on a rim
base assembly, bead seat band and flanges is during welding and/or heating of rim
mounted on the wheel with clamps and nuts. components can ignite, causing an explosion
of the tyre and rim components. This warning
The wheel itself is a large cylindrical casting with the also applies to Nitrogen gas inflated tyres.
bearing bores and other finished surfaces machined Ignition will not occur in a Nitrogen gas
after the wheel is cast. atmosphere; but the pressure build up from
the applied heat may be sufficient to cause a
The rim assembly consists of a rim base, inner and blowout severe enough to injure or kill. Never
outer flanges, bead seat band, 'O' ring and lock ring. weld or otherwise apply heat on rim
components with the tyre mounted on the rim,
The wheel rim assembly is designed to be replaced whether the tyre is inflated or deflated, to
with a pre-assembled tyre and rim. prevent injury or property damage from the
potential tyre explosion! Also, do not attempt
to repair rims or rim components by welding or
PREPARATION FOR SERVICING heating, even if the tyre is not mounted on the
rim. It is recommended to scrap questionable
rim parts unless specific permission and repair
WARNING procedures are obtained in writing either from
Before loosening rim clamps or performing the company or the rim manufacturer.
any service on the tyre or rim components, to
prevent personal injury and property damage,
completely deflate tyre by removing the valve REMOVING TYRE AND RIM ASSEMBLY
cap and core. Insert a thin wire through the Numbers in parentheses refer to Fig. 1.
valve to be sure the valve is not plugged. Even
a flat tyre, in some cases, will retain sufficient If the tyre and rim assembly is to be replaced with a
air pressure to blow off a rim component with pre-assembled tyre and rim assembly, it is not
enough force to cause injury or death.

SM 2042 Rev1 03-05 1

Front Axle - Wheel, Rim and Tyre
Section 140-0040
necessary to remove the tyre from the rim on the SM - 204
machine. The tyre and rim may be removed from the
machine as an assembly, and transported to a more
desirable location for removing the tyre from the rim.

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

1. Apply parking brake and block the front and rear of

all wheels, except the one to be raised. Use wooden
blocks 100 mm x 100 mm (4 in x 4 in) or larger.

2. For tyre to be removed, set up jack to support

machine weight, but do not raise machine.

3. Completely deflate tyre by removing valve cap and

core. Check valve stem by running a piece of wire
through the stem to make sure it is not plugged. See
warning under 'Preparation For Servicing'. 1 - Outer Flange
2 - Bead Seat Band 4 - Rim
4. Break wheel nuts (2) loose, but do not remove from 3 - Lock Ring 5 - Inner Flange
wheel studs (3). Fig. 2 - Typical Rim Assembly

5. Jack the machine up only as high as necessary to

SM - 205
remove wheel from machine, and place safety blocks
under the frame.

6. Support the tyre with a chain or rope sling of

sufficient strength attached to a suitable lifting device.
Remove wheel nuts (2) and clamps (1) from wheel Fig. 3 - Pry Bar
studs (3). Lift tyre and rim assembly clear.
SM - 206

DISMOUNTING TYRE FROM RIM

Numbers in parentheses refer to Fig. 2, unless
otherwise specified.

Note: The following instructions apply to use of hand

tools. For procedures and tooling required to dismount
the tyre from the rim, using hydraulic tools, contact the
relevant tyre manufacturer.

WARNING
When lifting tyre from rim, be sure the
equipment is of sufficient capacity and
properly secured to do the job safely.

1. Completely deflate tyre if not done previously. See

Fig. 4 - Breaking Typical Tyre Bead Loose
warning under 'Preparation For Servicing'. Tape valve

2 SM 2042 Rev1 03-05

 Front Axle - Wheel, Rim and Tyre
Section 140-0040

threads to protect from damage, leaving valve end INSPECTION

open to avoid any possibility of trapping air inside the
tyre. Tyre
Check interior surface of the tyre to determine its
2. Break outer tyre bead loose by placing the flat condition. Inspect for cuts or fabric breaks that have
hooked end of a pry bar, see Fig. 3, into one of the penetrated the tyre body. The casing should be
breaking slots (C) between the bead seat band (2) and inspected closely for any sharp, pointed objects that
outer flange (1). A length of pipe slipped over straight may have penetrated the tyre body but is invisible from
end of bar will increase leverage. Twist straight end of the outside. All dust, dirt, water or other foreign matter
bar around toward tyre to break this portion of bead. A should be cleaned from the inside of the tyre.
second person may now insert another pry bar of the
same type into the space between the bead seat band Replace valve core assembly if condition is
and flange, and with the same twisting action, hold the questionable.
space gained with the first pry bar. Move first pry bar
all the way around the wheel, twisting and following up
with second pry bar, until inner tyre bead is loose. Rim Assembly
Overloading, improper tyre inflation, rough terrain, high
3. Start bead seat band (2) in away from lock ring (3) speed, accidents, dirt accumulation and corrosion all
by placing hooked end of pry bar in groove of rim (4), tend to reduce service life of rims and rim
between ends of lock ring, and prying up with bar. components. It is recommended that rims be
Using two tools, as in Step 2, work completely around inspected, as below, not less than at every tyre
wheel. change and, as the warranty limit approaches,
consideration be given to rim replacement.
4. Pry lock ring (3) out in same manner by starting at
prying notch (B) in wheel, and work all the way around
wheel with the two pry bars. WARNING
Never mix components of one manufacturer's
5. Remove and discard 'O' ring (7, Fig. 1). rims with those of another. Using the rim base
of one manufacturer with the lock ring of
6. After removing lock ring (3), pry out and remove another or vice versa is dangerous. The lock
bead seat band (2). Outer flange (1) may now be ring of one may not fully engage with the lock
removed. ring groove of the other. Always consult the
rim manufacturer for proper matching and
7. Similar breaking slots are provided on the inside of assembly instructions. Also, use and servicing
rims. The inner bead on the back side of the tyre may of damaged, worn out, or improperly
be broken by using the same method as in Step 2, for assembled rim assemblies is a very dangerous
the outer bead. If the wheel assembly is still on the practice. Failure to comply with the above
machine, another method which can be used is to warnings could result in explosions from tyre
place a small jack between the inner flange and some pressure causing serious personal injury and
solid part of the machine frame. By extending the jack, property damage.
pressure is exerted, which forces the tyre bead off the
rim seat. Work around the wheel until the bead is 1. Clean all rust and dirt from rim parts and wheel.
broken at all points.
2. Coat parts with primer paint. Allow thorough drying
8. Using suitable lifting equipment, remove tyre from before assembling.
rim. This completes the removal of the tyre.
3. Inspect rim assemblies (Fig. 2) for bent, cracked,
Note: If tyre and rim is on machine, and no tyre lifting distorted, battered, and rusted parts which may have
equipment is available, 'walk' tyre off rim as follows: resulted from abusive practices outlined above.
force bottom of tyre outward as far as possible; lower Replace any damaged parts with new parts.
jack enough to allow weight of tyre to rest on ground;
force top of tyre out as far as possible; raise jack to 4. Discard 'O' ring and replace with new one.
original height and repeat the above until tyre is off
rim. Note: Handle 'O' rings carefully, as damage will
prevent an airtight seal for tyre inflation.

SM 2042 Rev1 03-05 3

Front Axle - Wheel, Rim and Tyre
Section 140-0040

MOUNTING TYRE ON RIM SM - 207

Numbers in parentheses refer to Fig. 2, unless

otherwise specified.

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

1. If tubeless tyre valve assembly was removed from

rim, install this assembly in the rim valve hole and
tighten securely.

2. Tyre installations are performed in basically the

same manner whether the rim (4) is on or off the
Fig. 5 - Installing Typical Lock Ring
machine. For off-machine installations, lay the rim on
blocks or a mounting stand with 'O' ring groove up.
The rim should be just off the floor enough so the tyre will automatically spring out, making this step
rests on the rim and does not touch the floor. The unnecessary.
blocks should not extend more than 13 mm (0.5 in)
beyond the rim base, so they won’t interfere with inner
flange (5).
MOUNTING TYRE AND RIM ASSEMBLY
ON WHEEL
3. Install inner flange (5) over rim (4). Numbers in parentheses refer to Fig. 1.

4. Before assembly of tyre to rim, lubricate both tyre

beads and new rubber 'O' ring (7, Fig. 1) with a thin WARNING
solution of vegetable base soap and water. Make Be sure lifting equipment is of sufficient
certain tyre valve assembly is securely in place. Lower capacity and properly secured to do the job
the tyre onto the rim, seating tyre firmly against inner safely.
flange (5).
1. Support tyre and rim assembly with a chain or rope
5. Install outer flange (1) on rim (4). sling attached to an overhead lifting device and slide
onto wheel (9) of the machine. Side with lock ring (5)
6. Install bead seat band (2) on rim (4). and bead seat band (8) should be facing outward.

7. Install lock ring (3) in groove of rim (4). Use pry bar 2. Install clamps (1) and start wheel nuts (2) on wheel
for this operation, as illustrated in Fig. 5. studs (3). Gradually tighten wheel nuts opposite each
other, until all nuts are snug, torque tighten wheel nuts
8. Force bead seat band (2) past 'O' ring groove in rim (2) to 690 Nm (510 lbf ft).
(4) by prying, or with lift truck forks. Use blocking Re-tighten nuts after a few hours operation.
between the forks and tyre to prevent tyre damage.
Lubricate area of rim adjacent to 'O' ring groove with a Note: Wheel rim fastener torque should be checked
thin solution of soap and water or another approved regularly, particularly on new machines or newly-
lubricant which is not harmful to rubber. Avoid using an installed wheels, to maintain the required wheel rim-
excessive amount of lubricant. Insert a new 'O' ring (7, clamp load. A newly installed wheel or a new machine
Fig. 1) in the groove of the rim behind the lock ring. should be checked at 30 day intervals until rim
fasteners show no significant torque loss from the
9. Lift tyre upwards to effect a seal between bead seat previous check. After that, a 90 day torque check
band (2) and 'O' ring (7, Fig. 1). In some cases the tyre interval should be adequate.

4 SM 2042 Rev1 03-05

 Front Axle - Wheel, Rim and Tyre
Section 140-0040

SM - 2559

1 - Lockwire
2 - Bolt
3 - Plate
4 - Shim Pack
5 - Outer Bearing Cone
6 - Outer Bearing Cup
7 - Wheel
8 - Spindle
9 - Inner Bearing Cone
10 - Inner Bearing Cup
11 - Washer
12 - Snap Ring
13 - Seal
14 - Bushing
15 - Bolt
16 - Lockwasher
17 - Brake Disc
18 - Bolt
19 - Lockwasher
20 - Cover
21 - Gasket

Fig. 6 - Sectional View of Front Wheel Assembly.

WHEEL 1. Block the front and rear of all wheels, except the
one to be raised. Jack up or lift machine so its weight
Removal and Disassembly is no longer on that wheel.
Numbers in parentheses refer to Fig. 6.
2. Deflate tyre completely, and remove the tyre and
rim assembly from the wheel. Follow instructions
WARNINGS under 'Removing Tyre and Rim Assembly'.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly WARNING
secured and of sufficient capacity to do the job To prevent possible personal injury, relieve the
safely. pressure in the braking system. The exact
procedure must be followed as described in
To prevent personal injury and property Section 250-0000, BRAKING SYSTEM
damage, completely deflate tyre by removing SCHEMATIC.
the valve cap and core. Insert a thin wire
through valve to be sure valve is not plugged. 3. Relieve the pressure in the braking system. Refer to
Even a flat tyre, in some cases, will retain Section 250-0000, BRAKING SYSTEM SCHEMATIC.
sufficient air pressure to blow off a rim Disconnect brake hydraulic line at brake calliper.
component with enough force to cause injury
or death.

SM 2042 Rev1 03-05 5

Front Axle - Wheel, Rim and Tyre
Section 140-0040

4. Remove brake calliper. Refer to Section 165-0020, Inspection

BRAKE PARTS. 1. Thoroughly clean all metal components, except
bearing cones, in a suitable solvent. Dry with
5. Remove bolts (18) and lockwashers (19) which compressed air and coat all threaded components with
secure cover (20) to wheel (7). Remove cover (20) light oil to facilitate assembly.
and gasket (21).
2. Using a suitable solvent, clean bearings and wipe
6. Remove lockwire (1), bolts (2), plate (3) and shim dry with a lint free cloth. Lubricate lightly with light oil
pack (4) from spindle (8). Retain shim pack (4). and spin by hand, to check for wear and roughness.
Replace with new bearings if excessively worn, or if
7. With suitable lifting equipment, pull wheel (7) off of operation is rough or noisy.
spindle (8), being careful that outer bearing cone (5)
does not fall. 3. Inspect all machined surfaces of all parts for
scoring, pitting, corrosion and burring. Resurface or
8. If required, remove bolts (15) and lockwashers (16) replace with new parts as necessary.
securing brake disc (17) to wheel (7), and remove
brake disc. 4. Inspect all threaded components, and repair or
replace as necessary.
9. Remove seal (13), using hammer and soft drift.

10. Remove snap ring (12). Assembly and Installation

Numbers in parentheses refer to Fig. 6.
11. Tap out washer (11) and remove inner bearing
cone (9) from spindle (8).
WARNINGS
Note: Bearing cups and cones must always be To prevent personal injury and property
replaced as a matched set, never separately. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of sufficient capacity to do the job
WARNING safely.
Be sure to use a soft drift and take care when
driving out bearing cups with a drift, to avoid Be sure to use a soft drift and take care
personal injury from chips or fragments. when driving in bearing cups with a drift, to
avoid personal injury from chips or fragments.
12. If required, remove bearing cups (6 & 10) from
wheel (7), by driving out with a soft drift. 1. If removed, heat bushing (14) to 177 - 205° C
(350 - 400o F) in oil to expand it for installation. If oil
13. During operation, seal (13) rides on bushing (14) heating equipment is not available, heat the bushing
which is shrunk on spindle (8) to provide a smooth evenly to 205° C (400° F). This takes about 1 minute,
contact surface for the seal. If the bushing is found to using a torch with a heating tip. Use a Tempilstik or
be rough or worn, remove bushing (14). other temperature gauge to make sure the bushing is

BEARING ADJUSTMENT
INITIAL SEATING GAUGING BOLT SHIM PACK FINAL BOLT
BOLT TORQUE TORQUE THICKNESS TORQUE
No. of Nm lbf ft No. of Nm lbf ft mm in All Nm lbf ft
Bolts Bolts Bolts
6 54 40 2 54 40 Ave. Gap Ave. Gap 6 224 165
+ 0.025 + 0.001

6 SM 2042 Rev1 03-05

 Front Axle - Wheel, Rim and Tyre
Section 140-0040
hot enough. Slide heated bushing (14) on spindle (8) only two bolts (2) located 180o apart, adjacent to the
and tap lightly with a hammer to seat it. gauging holes in plate (3). Tighten bolts (2) evenly in
equal increments to 'Gauging Bolt Torque', as
Note: Do not apply flame directly to bushing. Place specified in 'Bearing Adjustment Table', while rotating
bushing on steel plate and apply flame to centre of and bumping wheel (7) assembly.
plate, to evenly distribute heat.
11. Determine gap between plate (3) and end of
2. If removed, install bearing cups (6 & 10) in their spindle (8) at both gauging holes. To determine gap,
respective wheel (7) bearing bores with care to avoid use a depth micrometer in both gauging holes to
damaging their raceways. Installation by press fit at measure distance from outer face of plate (3) to end of
ambient temperature is best. Note that the cups must spindle (8). Using a micrometer, measure thickness of
seat fully against the shoulders of the cup bores in the plate (3). Subtract plate thickness reading from depth
wheel hub to assure retention of bearing adjustment. If gauge readings.
carbon dioxide, or dry ice, freezing of the cup is used,
remember to permit the cup and hub to warm to 12. Average the two readings, obtained at Step 11, in
ambient temperature after insertion and then to tap increments of 0.025 mm (0.001 in) and round off to the
them with a soft steel drift and hammer to seat. next higher 0.025 mm (0.001 in). This is the average
gap. The required shim pack (4) thickness is equal to
3. Lubricate the bearings with lubricant specified in the average gap plus the tabulated constant as shown
Section 300-0020, LUBRICATION SYSTEM. Do not in the 'Bearing Adjustment Table'.
pack bearings solidly with lubricant, as too much is
harmful. Fill wheel cavity not less than one-third to not 13. Install the required shim pack (4), plate (3) and
more than one-half full with lubricant. bolts (2) on the end of spindle (8). Tighten bolts (2)
evenly in equal increments to 'Final Bolt Torque', as
4. If removed, install brake disc (17) on wheel (7) and specified in 'Bearing Adjustment Table', while rotating
secure with bolts (15) and lockwashers (16). Tighten and bumping the wheel (7) assembly. Secure bolts (2)
bolts (15) to a torque of 420 Nm (310 lbf ft). with lockwire (1).

5. Install inner cone (9), washer (11), snap ring (12) 14. Install gasket (21) and cover (20) and secure to
and seal (13) in wheel end facing spindle. Seal lip wheel (7) with bolts (18) and lockwashers (19).
must be facing out.
15. Install brake calliper, connect brake hydraulic line
6. With suitable lifting equipment slide wheel (7) and bleed braking system. Refer to Section
assembly onto spindle (8). 165-0020, BRAKE PARTS.

7. Install outer bearing cone (5) on spindle (8) and seat 16. Install tyre and rim assembly as described under
in outer bearing cup (6). 'Mounting Tyre and Rim Assembly on Machine'.

Note: Ensure all dirt, grease, and oil is completely

removed from plate (3), shims (4) and end of spindle TYRE INFLATION
(8) to allow accurate setting of the bearing pre-load.

8. Install plate (3), without shims (4) on end of spindle WARNINGS

(8), and secure with six bolts (2). Tighten bolts (2) To prevent personal injury and property
evenly in equal increments to 'initial seating bolt damage, the tyre and rim assembly should be
torque' as specified in 'Bearing Adjustment Table', placed in a safety cage before inflating. If no
while rotating and bumping the wheel (7) assembly. safety cage is available or tyre is on the
machine, the tyre and rim assembly should be
9. Remove bolts (2) and tap wheel (7) assembly to wrapped with safety chains or with lash cables
free bearings. before inflating.

10. Reassemble plate (3) without shims (4) and using Even with these precautions remember
that air-blast is a potential hazard. Tyre
inflation should be carried out away from busy
working areas.

SM 2042 Rev1 03-05 7

Front Axle - Wheel, Rim and Tyre
Section 140-0040

SM - 208

WARNING
To avoid personal injury and property damage,
never stand or sit in front of a mounted tyre
during tyre inflation. Use a clip-on air chuck
with a long hose and stand to one side while
the tyre is being inflated.

WARNING
To prevent personal injury and property
damage, always prevent flammable vapours
that could produce tyre explosions, from being
pumped into tyres during inflation, by
observing the following precautions:
A.
Use an air compressor and reservoir located
inside a heated building, when available, so
that alcohol, methanol, or other flammable
antifreeze liquids are not needed in the air
tanks to prevent moisture freezing in the tank
and lines in subfreezing temperatures.
B. Fig. 7 - Typical Safety Cage
Make sure that paints, lacquers, paint thinners,
or similar materials that produce volatile,
flammable vapours are not used or stored near
the air intake of the compressor that supplies WARNING - Continued
the air for inflating tyres. The compressor recommended concentration to prevent
should be isolated from all such sources of condensate freezing are below hazardous
flammable vapours. levels for tyre inflation.
C. F.
Be sure to thoroughly flush and blow off all Another source of hazardous flammable
flammable solvents used for cleaning the air vapours in tyres is the tyre bead lubricant.
compressor inlet screen before using the Always use bead lubricants that do not
compressor for tyre inflation, or any other introduce flammable vapours into the tyre.
purpose.
D.
Do not charge batteries, either in or out of a Inflation
machine, near the air inlet of a compressor Note: Always use tyre inflation equipment with an air
used for inflating tyres. Charging batteries filter that removes moisture from the air supply, when
produces highly explosive hydrogen gas which available, to prevent moisture corrosion of internal rim
can be readily drawn into a nearby compressor parts.
inlet and pumped into the tyre.
E. 1. If the tyre is off the machine, it should be placed in a
Never exceed the specified concentration of safety cage before inflating. See Fig. 7.
alcohol when adjusting the alcohol vaporiser,
or adding alcohol to the auxiliary air tank, used 2. Inflate all tyres with ratings of 16-ply and above to
on machine air systems to prevent freezing or 5.2 bar (75 lbf/in²) to seat beads and seal 'O' ring, then
moisture condensate in below-freezing adjust to the recommended pressure.
temperatures. Excessive alcohol, added to the
machines air tanks in this manner can produce 3. For recommended operating air pressure, refer to
flammable vapours that will be pumped into a the chart under the heading, 'Tyre Inflation Pressures'.
tyre when this air supply is used for tyre
inflation if the tyre inflation kit is not equipped
with a moisture filter. Alcohol added to
machine air systems in

8 SM 2042 Rev1 03-05

 Front Axle - Wheel, Rim and Tyre
Section 140-0040

NITROGEN TYRE INFLATION SM - 1040

Note: All Warnings and procedures under 'Tyre

Inflation' will apply, except for differences covered by
this passage.

In certain environments it is recommended that tyres

be inflated with dry nitrogen gas, and that the resulting
oxygen content of the inflation does not exceed 5%. 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

Fig. 8 - Nitrogen Tyre Inflation Kit

WARNINGS assure an upper limit to the pressure available for tyre

DO NOT USE charging assembly, Part No. inflation.
9359489, for tyre inflation because this
assembly does not include a pressure c. A 15.2 m (50 ft) length of flexible hose with
regulator, safety relief valve, and adequate interconnecting fittings. On the tyre end of the hose is
pressure gauging which is mandatory for tyre a large bore quick connect/disconnect clip-on chuck.
inflation purposes. Tyre volume is as much as
90 times greater than the average accumulator 2. The pressure regulator is connected to a nitrogen
volume and hence it takes very much longer to compressed gas cylinder available from local suppliers.
inflate a tyre - up to 40 minutes or more for
very large tyres. 3. The usual procedure for using this type of
equipment is as follows:
Nitrogen gas cylinders used to inflate
tyres are generally charged to approximately a. Connect nitrogen tyre inflation kit to nitrogen
152 bar (2 200 lbf/in2). A tyre blowout and/or compressed gas supply. DO NOT connect clip-on
rim failure could occur if inflation equipment is chuck to the tyre valve at this time.
not properly used. Proper nitrogen charging
equipment and personnel training for its use is b. Open valve on nitrogen supply.
a must to avoid over inflation.
c. With flexible hose and clip-on chuck connected to
1. A nitrogen tyre inflation kit is available from your nitrogen tyre inflation kit assembly but not connected
dealer and consists of the following. Refer to Fig. 8. to the tyre, adjust pressure regulator so that its output
pressure is not more than 1.4 bar (20 lbf/in²) higher
a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with than the desired tyre inflation pressure.
two dual pressure gauges.
d. Connect clip-on chuck to the tyre valve. The tyre will
b. Safety relief valve, 8.6 bar (125 lbf/in²), that will now inflate. Tyre pressure can be monitored by

SM 2042 Rev1 03-05 9

Front Axle - Wheel, Rim and Tyre
Section 140-0040

observing the gauge at the pressure regulator. STAY TYRE EXPLOSION HAZARD
AWAY FROM THE TYRE.

e. When desired inflation pressure has been achieved, WARNINGS

back off the regulator or close the valve on the Whenever a machines tyre(s) is (are) exposed
compressed gas cylinder. to excessive heat such as a machine fire or
extremely hot brakes the hazard of a
f. Remove the clip-on chuck and adjust the tyre subsequent violent tyre explosion must be
pressure with the tyre gauge in the usual manner. recognized. All persons must avoid
approaching the machine so as not to be
physically endangered in the event of an
Re-inflation of a Mounted Tyre explosion of the tyre and rim parts. The
To re-inflate a tyre with dry nitrogen gas which is now machine should be moved to a remote area,
inflated with air, proceed as follows: but only when this can be done with complete
safety to the operator operating or towing the
1. Exhaust the tyre until only air at atmospheric machine. All other persons should stay clear of
pressure remains in the tyre. the machine. The fire or overheated brakes,
wheel, etc. should be extinguished or cooled
2. Re-inflate the tyre using only dry nitrogen gas to from a safe distance. Do not attempt to
4.15 bar (60 lbf/in²) gauge as a minimum, or to bead- extinguish the fire or cool the machine by use
seating pressure as a maximum. of hand-held fire extinguishers.

3. Adjust to the service inflation pressure required: If it is absolutely necessary to approach a

machine with a suspect tyre, approach only
a. If the required service inflation pressure is LESS from the front or the back. Stay at least 15 m
than 4.1 bar (60 lbf/in²), remove the clip-on chuck and (50 ft) from the tread area. Keep observers out
adjust the pressure with the tyre gauge in the usual of the area and at least 460 m (1 500 ft) from
manner. the tyre sidewall. Refer to Fig. 9. The tyre(s)
should be allowed at least eight (8) hours
b. If the required service inflation pressure is greater cooling time after the machine is shut down or
than 4.1 bar (60 lbf/in²), further inflate, with dry the fire extinguished before approaching
nitrogen gas only, to the pressure level required. Then closer.
remove the clip-on chuck and adjust the pressure with
the tyre gauge in the usual manner. DO NOT WELD ON OR HEAT RIM
COMPONENTS. For several years the company
and tyre and rim manufacturers have warned
New Tyre Mounts and Remounts users never to weld rim components with the
To newly mount or remount a tyre to its rim, use only tyre mounted on the rim. The gases that build
dry nitrogen gas; this includes the pressure required to up inside the tyre during arc welding or
seat the beads. After seating the tyre beads, remove heating on rim components can ignite,
the clip-on chuck and adjust the pressure with the tyre resulting in one of these explosive-like failures
gauge in the usual manner. of the tyre and rim. This warning also applies
to nitrogen inflated tyres. Ignition will not
Note: Although a little more nitrogen gas is used to occur in the nitrogen atmosphere, but the
seat beads than that used for re-inflation of a mounted pressure buildup from the heat of welding may
tyre, refer to 'Re-inflation of a Mounted Tyre', its cost is be sufficient to cause a blowout severe enough
generally negligible in comparison to the time and to injure or kill. It is recommended to scrap the
labour saving and, longer tyre life achievable with the part if heat is necessary to repair any rim
reduced oxygen content which results. component.

10 SM 2042 Rev1 03-05

 Front Axle - Wheel, Rim and Tyre
Section 140-0040

SM - 218
AT LEAST 15 m (50 ft) AT LEAST 460 m
(1 500 ft)

Fig. 9 - APPROACH AREA. Do Not Approach Tyre in Shaded Area

without removing the tyre from the rim. Use tyre repair
WARNING plugs and follow the directions given by the
There is always a possibility of a tyre manufacturer.
explosion whenever the smell of burning
rubber or excessively hot brakes is detected. The tyre must be removed from the rim to repair larger
The danger is also present when a fire on the punctures or cuts. Irregular shaped punctures or cuts
machine reaches the tyre and wheel area. less than 13 mm (0.5 in) in size can be repaired with a
Under such conditions, all personnel must plug and hot patch. Insert a repair plug into the hole to
avoid approaching the machine in a manner keep out moisture and to back up the hot patch. Trim
that could result in injury should an explosion the plug off flush with the inside of the casing, buff,
actually occur. Move the machine to a remote and apply the hot patch according to the instructions
area only if it can be done without endangering supplied with the hot-patch equipment.
the operator or other personnel in the area.
Punctures 13 mm (0.5 in) or larger, large cuts, or
bruise breaks require sectional or reinforced
TYRE MAINTENANCE vulcanized repair. Cover the repair patch with a layer
of cushion gum after application to the tubeless tyre to
Tyre Repairs ensure an airtight repair. Any cords of the inside ply
Prompt repair of tyre injuries will prevent small injuries that are exposed in bugging and are not covered with
from enlarging and causing tyre failure. Use the best repair patch must be coated with cushion gum to
tyre facilities available. If good repair facilities are not prevent air leakage into the carcass plies on tubeless
available, have the nearest dealer make the necessary tyres.
repairs.

Minor cuts, snags, or punctures should be repaired Recapping and Retreading

upon discovery. Skive with a sharp pointed knife There are two general methods employed in restoring
around any cut in the tyre tread area that is of the tread surface of off-the-highway tyres: recapping,
sufficient depth or shape to hold pebbles or dirt. The and retreading.
angle of the skive should be no more than sufficient to
expel all foreign material and should extend no deeper A recapped tyre has a new tread cured right over the
than the breaker. The skive should go to the bottom of old tread surface.
the hole. Tyres with shallow cuts, if treated promptly,
may be allowed to continue in service. If the cut A retreaded tyre has the old tread removed entirely
extends deeper into the tyre carcass, the tyre should and a new tread cured directly onto the body of the
be removed for repair. tyre. A tyre can be recapped or retreaded if the cord
body is free of cuts, bruises and separation, and is
Ordinary tubeless tyre punctures can be repaired thoroughly sound, including previous repairs.

SM 2042 Rev1 03-05 11

Front Axle - Wheel, Rim and Tyre
Section 140-0040

TYRE CARE Prevent Tyre Contact With Oil

To obtain maximum service from off-the-highway PREVENT TYRE CONTACT WITH PETROLEUM
tyres, a few common-sense precautions should be PRODUCTS. Rubber that is exposed to oil, petrol, or
followed. grease becomes soft and spongy and deteriorates
rapidly. Always avoid driving machine equipped with
rubber tyres through a puddle of petrol, fuel oil,
Maintain Correct Inflation lubricating oil, or grease. Never let a tyre stand in an
The most common cause of tyre damage is improper oil or grease spot overnight.
inflation. Both over-inflation and under-inflation are
detrimental to tyre life. Tyre pressure should be
checked daily, preferably before the machine is placed Store Tyres Properly
in operation. Refer to 'Tyre Inflation Pressures' for tyre The best of care given to tyres in service by operators
pressure. and maintenance personnel can be completely
nullified by careless storage. Time is not the only
The valve cores should be checked for leaks. Keep in contributing factor to the deterioration of rubber
mind that valve cores are delicate mechanisms that products. Therefore, tyres that are to be stored must
wear out in service; therefore, they should be replaced be protected from light, heat, oils, dirt, moisture and
when they become worn. Each tyre should be ozone. Stored tyres should be carefully covered with a
equipped with a valve cap to prevent dirt from tarpaulin or some other suitable material, such as
damaging the valve core and causing air leakage. opaque plastic sheets, to prevent contact with the
contaminants listed.

Maintain Good Haul Roads Proper Handling of Tubeless Tyres and Rims
Because haul roads are considered temporary roads, Tubeless tyres should be stored vertically. Horizontal
they are frequently neglected. The better the haul stacking may compress the tyre walls making inflation
road, the longer the tyre and machine life of off-the- difficult. If tyres are stored in racks, the lower
highway equipment. supporting members should provide as broad a
surface as possible to the tyre tread to avoid a
Although it takes time and effort to maintain good haul concentration of load.
roads, delay and cost of tyre and machine breakdowns
caused by poor haul roads is many times greater. The beads of tubeless tyres must be protected from
damage or a faulty air seal will result. Do not use
hooks, cables, or chains in contact with the tyre beads
Inspect Tyres Regularly when lifting these tyres. If forklift trucks are used for
A systematic plan for tyre inspection will more than handling they should be equipped with broad, well
pay for itself in lowered tyre costs per hour of rounded arms to distribute the load and prevent
operation. All tyres should be checked regularly for damage to the tyre bead. When handling tyres with the
cuts, bruises, fabric breaks, excessive or uneven fork truck do not scrape the fork across the bead.
wear, embedded foreign matter, and any other
damage which can be repaired. A considerable Tubeless tyre rims perform an important function as
increase in tyre service can be realized if tyre injuries part of the assembly air seal. Proper care therefore
are repaired before they have progressed to the must be taken not to distort or mutilate the rim parts
irreparable stage. The rim mounting nuts should be because they must mate properly to form part of the
checked periodically and tightened to the basic air chamber. Since the rim base, bead seat
recommended torque. bands, and flanges are endless, distortion may
prevent easy assembly as well as possibly resulting in
no seal.
Prevent Overloading
Off-the-highway machines are designed to carry a Never drop, tumble, or roll rim parts.
maximum allowable payload. Excessive loading will
overstress both the machine and tyres and shorten the If rim parts are stored outdoors they should be given a
life of both. protective coat of a good commercial primer.

Similar parts should be stacked neatly to prevent

distortion.

12 SM 2042 Rev1 03-05

 Front Axle - Wheel, Rim and Tyre
Section 140-0040

Babbit or lead hammers, not sledge hammers, should SPECIAL TOOLS

be used in assembling rims. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of special tools outlined in this section and
'O' rings are seals and should be carefully stored in a general service tools required. These tools are
cool, dry place where they will not be injured or damaged. available from your dealer.

Valve cores also should be stored in a cool, dry and

clean place.

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.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 2 Wheel Nut 690 510
6 2 Bolt Refer to 'Bearing Adjustment Table'
6 15 Bolt 420 310

SM 2042 Rev1 03-05 13

Front Axle - Wheel, Rim and Tyre
Section 140-0040

TYRE INFLATION PRESSURES maintenance and length, maximum and workday

E3 tyres may be so roaded up to 48 km/h (30 mile/h), average speed, job t-km/h (ton-mile/h) required and
maximum, with a 30 minute cooling stop after each tyre t-km/h (ton-mile/h) capacity, etc., may require an
80 km (50 miles) or 2 hours sustained operation - increase in inflation pressure. It is recommended that
whichever occurs first - and a 60 minute cooling stop for tyres both listed and unlisted the user consult the
after each aggregate of 4 hours of operation. tyre manufacturer and evaluate all job conditions in
order to make the proper selection.
E4 tyres may be so roaded up to 32 km/h (20 mile/h),
maximum, with a 30 minute cooling stop after each
32 km (20 miles) or 1 hour of sustained operation -
TYRE INFLATION PRESSURES
whichever occurs first - and a 60 minute cooling stop PRESSURE
after each aggregate of 4 hours of operation.
TYRE MAKE/SIZE bar lbf/in²
The inflation pressures listed should be regarded as Bridgestone 24.00 R 35** Radial 7.5 109
nominal only. Specific job conditions, terrain, haul road
Michelin 24.00 R35**Radial 7.35 107

* * * *

14 SM 2042 Rev1 03-05

 REAR AXLE - Differential
Section 160-0020

SM - 2561

1 - Lockwire 12 - Oil Seal 23 - Bolt 34 - Side Gear

2 - Bolt 13 - Cup 24 - Lock 35 - Spider
3 - Plate 14 - Cone 25 - Bearing Adjuster 36 - Spider Pinion Gear
4 - Plug 15 - Pinion Gear 26 - Cup 37 - Bearing
5 - Yoke 16 - Cone 27 - Cone 38 - Plain Case
6 - Sleeve 17 - Cup 28 - Flanged Case Assembly 39 - Bolt
7 - 'O' Ring 18 - Shim* 29 - Ring Gear 40 - Bolt
8 - Set Screw 19 - Carrier Housing 30 - Side Gear 41 - Spring
9 - Retainer 20 - Bushing 31 - Bolt 42 - Reaction Plate
10 - Bolt 21 - Bolt 32 - Thrust Washer 43 - Friction Plate
11 - Shim* 22 - Bearing Cap 33 - Dowel Pin 44 - Clutch Plate

* - Shim Thickness - 0.08, 0.25, 0.76 mm

(0.003, 0.010, 0.030 in)
Fig. 1 - Exploded View of Typical Differential

DESCRIPTION AND OPERATION The differential eliminates wheel skip by allowing

Numbers in parentheses refer to Fig. 1. separate axle shafts inserted into side gears (30 & 34)
to rotate at different speeds as the drive wheels rotate.
The differential performs three functions; it multiplies The spider (35) and spider pinion gears (36) are
torque delivered by the driveline; it transmits this meshed with side gears (30 & 34). This assembly is
torque to the axle shafts; and it allows the drive wheels enclosed in plain case (38) and flanged case assembly
to rotate at different speeds. (28) which are bolted to ring gear (29). Thus, ring gear
(29), plain case (38) and flanged case assembly (28)
When the truck is making a turn, one drive wheel must rotate as an assembly when driven by input pinion gear
travel a greater distance than the other. If the wheels (15). However, side gears (30 & 34), into which each
were connected by a single axle shaft, the wheel axle shaft is inserted, are free to rotate independently
turning the larger radius of the turn circle would have about spider pinion gears (36) with which they are
to override the wheel making the shorter turn. Thus, meshed. Therefore, as each drive wheel travels
one wheel would have to skip or hop causing tyre through a different arc as the truck makes a turn, side
scuffing and strain on the power train. gears (30 & 34) rotate about spider pinion gears (36) to
provide the required differential action.

SM 2045 7-00 1
Rear Axle - Differential
Section 160-0020

REMOVAL 10. Remove the self locking nuts which secure the
Numbers in parentheses refer to Fig. 1. differential housing to the axle banjo housing. Each
time a nut is removed, deeply scribe one of the flats on
the nut. The nuts should not be reused more than five
WARNINGS times.
To prevent personal injury and property
damage, be sure wheel chocks, blocking 11. Turn the four thread protectors in to break the seal
materials and lifting equipment are properly between the differential assembly and banjo housing.
secured and of adequate capacity to do the job If this does not move the differential assembly out
safely. enough, either remove the thread protectors and insert
longer bolts in the four holes, or use a suitable bar to
A come-a-long or chain fall with a pry the differential assembly away from the banjo
minimum capacity of one ton is required for housing and studs. If a bar is used, caution should be
removal and installation of a differential exercised to prevent damaging the mounting surfaces.
assembly.
12. Pull the differential assembly away from the banjo
1. Position the vehicle in a level work area, raise the until it clears the studs of the axle banjo housing, then
body and install the body prop pins. Refer to Section carefully lower the differential assembly.
270-0010, BODY AND MOUNTING.
13. Move differential assembly to a clean work area for
2. Apply the parking brake and switch off the engine. disassembly.

3. Turn the steering wheel in both directions several

times to relieve pressure in the steering system. Block DISASSEMBLY
all road wheels. Numbers in parentheses refer to Fig. 1.

4. With suitable containers in position, drain the

lubricant from the differential banjo housing and wheel WARNING
planetary assemblies. To prevent personal injury and property
damage, be sure lifting equipment is properly
5. Remove the driving flange cover from each wheel secured and of adequate capacity to do the job
and pull the axle shaft and sun pinion gear assembly safely.
of each driving wheel at least 150 mm (6 in) out of the
wheel housing to disengage the inner axle shaft
splines from the splines of side gears (30 & 34). Refer Ring Gear Group
to Section 160-0030, AXLE GROUP. 1. Secure a ‘C' clamp over ring gear (29) to prevent it
from turning. Loosen, do not remove, bolts (2).
6. Identify the relationship of pinion yoke (5) flange
with that of the driveline companion flange using 2. Cut and remove lockwire (1), then loosen, but do
punch marks. Remove rear driveline connecting not remove bolts (21) securing bearing caps (22) to
differential and transmission. Refer to Section carrier housing (19).
130-0020, REAR DRIVELINE.
Note: Make identifying punch marks on both the
7. Remove set screw from differential housing and bearing caps (22) and carrier housing (19), so that the
replace it with a lifting eye. bearing caps can be returned to their original position
in assembly.
8. Install chain fall or come-a-long to the loop placed
on the body just behind the hoist brackets. Attach the 3. Scribe an identifying line on bearing adjusters (25)
other end of the lifting device to eye previously and carrier housing (19) bores which these adjusters
installed in the differential assembly. screw into. If the differential assembly is disassembled
for inspection purposes only, this line will be of
9. Support the weight of the differential assembly with assistance when readjusting the preload on the side
the lifting device. bearing cups (26) and cones (27). If the differential is

2 SM 2045 7-00
 Rear Axle - Differential
Section 160-0020

SM - 094 flanged case assembly (28) together.

11. Loosen bolts (31) which hold ring gear (29) to

flanged case assembly (28). Remove all but two
opposite bolts (31).

12. Remove six of the bolts (39) which hold plain case
(38) and flanged case assembly (28) together.

Note: Before separating the cases, make identifying

punch marks on plain case (38) and flanged case
assembly (28) to show their relationship for assembly
purposes.

13. Place the assembly on a bench so that plain case

(38) is facing upwards.

14. Remove remaining bolts (39), then lift plain case

(38) off flanged case assembly (28).
Fig. 2 - Removing Differential Assembly from Housing
15. Remove one thrust washer (32) and side gear
disassembled and parts replaced, do not rely on this (34), then lift spider (35) and spider pinion gears (36)
line for determining the preload on the side bearings. out of flanged case assembly (28).

4. Cut and remove lockwires (1), then remove bolts 16. Separate the four spider pinion gears (36) from
(23) and locks (24). spider (35) and bearings (37). Do not remove spider
pinion gears (36) or bearings (37) unless worn or
5. Unscrew and remove bearing adjusters (25). damaged.

6. Remove bearing cap bolts (21), then remove 17. Remove remaining side gear (30) and thrust
bearing caps (22) from carrier housing (19). Salvage washer (32) from flanged case assembly (28).
dowel bushings (20) that are seated in the bolt holes
between the bearing caps and the differential housing. 18. Make sure that identifying marks are stamped on
the side of ring gear (29) and flanged case assembly
7. With 'C' clamp still secured to ring gear (29), lift the (28) for assembly purposes.
differential assembly from carrier housing (19). See
Fig. 2. 19. Remove remaining bolts (31), then separate
flanged case assembly (28) from ring gear (29) by
8. Remove side bearing cups (26) and cones (27), tapping the edge of the ring gear with a soft-faced
using a bearing puller. Wire the bearing races together hammer .
for mating in assembly, and tag them for mating to
plain case (38) and flanged case assembly (28), from 20. Remove dowel pins (33) from plain case (38) and
which they were removed. flanged case assembly (28) only if they are damaged
and have to be replaced.
Note: In conjunction with the bearing puller, use a
round steel disc, approximately 95 mm (3.75 in) 21. Place flanged case assembly (28) on a bench so
diameter and 10 mm (0.38 in) thick. This will serve as that bolts (40) are facing upwards.
a centre for the puller screw to push against. Puller
arms must not exert a force on the bearing roller 22. Remove bolts (39) which hold flanged case
separator cage. assembly (28) together. Carefully separate flanged
case assembly (28), taking care not to loose springs
9. Position the differential assembly vertically on a (41).
bench so that a portion of ring gear (29) can be
clamped securely in a soft-jawed vice. 23. Remove reaction plate (42), clutch plates (44) and
friction plates (43) from flanged case assembly (28)
10. Loosen bolts (39) holding plain case (38) and only if they are damaged and have to be replaced.

SM 2045 7-00 3
Rear Axle - Differential
Section 160-0020

Pinion Cage Group SM - 096

Note: Before disassembling, punch identifying marks

on retainer (9) and carrier housing (19) for assembly
purposes.

1. Remove bolts (2) and plate (3). Pull yoke (5)

assembly from pinion gear (15) shaft with care so as
not to damage or distort the yoke flange.

2. Unscrew bolts (10) attaching retainer (9) and shims

(11) to carrier housing (19).

3. Remove and discard 'O' ring (7) from groove in

yoke (5).

4. Remove set screws (8) and screw in two 1/2"-13

UNC bolts in the tapped holes of retainer (9) flange, Fig. 3 - Driving Out Retainer Assembly
using these bolts as pullers to remove retainer (9)
assembly.
SM - 097

Note: If the above retainer assembly removal

procedure is not feasible, the following method may be
used: Invert carrier housing (19), as shown in Fig. 3,
then drive retainer (9) out of the housing. During this
operation, be careful not to obliterate the etched
dimension on the bottom of pinion gear (15) shaft.

5. Separate retainer (9), cup (13) and oil seal (12) from
carrier housing (19), then remove shims (11). Wire
shims (11) together to aid in assembly.

6. Using a soft-jawed vice with the jaws opened

slightly wider than retainer (9) bore, place retainer (9)
on top of the bars, with the flange facing downward.
Tap out cup (13) and oil seal (12) with a soft-faced
hammer. Be careful not to damage the inside machined
surface of retainer (9) when removing cup (13).
Fig. 4 - Removing End Bearing
Note: If the bearing races are still serviceable, wire the
cups and corresponding cones together for mating in
assembly. Bearing assembly (13 & 14) is replaceable INSPECTION
as an assembly only. If any component is defective, Numbers in parentheses refer to Fig. 1.
the complete assembly must be replaced.
The importance of careful and thorough inspection
7. Remove pinion assembly (14, 15 & 16) from carrier cannot be over stressed. Thorough inspection and
housing (19). necessary replacement of parts now, may eliminate
costly and avoidable trouble later.
8. Using a bearing puller similar to that shown in
Fig. 4, remove cone (16) from pinion gear (15) shaft. 1. Clean all parts in a suitable solvent.

9. Remove cones (14) from pinion gear (15) shaft 2. Immediately after cleaning, dry all parts, except
using a suitable bearing puller. bearings, with compressed air, or lint-free cloth.
Bearings are better left to air dry, then inspected and
10. Tap cup (17) and shims (18) from carrier oiled thoroughly with gear lubricant for protection from
housing (19). corrosion.

4 SM 2045 7-00
 Rear Axle - Differential
Section 160-0020
3. With the parts cleaned, coat parts immediately with surfaces of retainer (9). The outer machined surface
light oil to prevent corrosion. If parts are not to be on the hub of the bearing cage must be concentric with
assembled immediately, treat them with a good rust the bearing cup bore within 0.05 mm (0.002 in) total
preventative and wrap them with treated paper or indicator reading (T.I.R.).
other suitable material designed to prevent corrosion.
12. The outer machined surface (OD) on retainer (9)
4. Replace all gaskets, 'O' rings and seals with new must be concentric within 0.05 mm (0.002 in) T.I.R.
parts. with the surface into which oil seal (12) fits.

5. Before installing the differential assembly to the 13. The threads and bores of bearing caps (22) and
banjo, clean the inside and outside of the banjo carrier housing (19) must be concentric within
housing to remove any foreign material. 0.127 mm (0.005 in) T.I.R. and must be square with
the pinion bore within 0.08 mm (0.003 in) when
6. Oil seal (12) rides on a special sleeve (6), which is on checked at points 254 mm (10 in) from the centre line
yoke (5) to provide a smooth contact surface. If the of the pinion bore.
sleeve is rough or worn, pull it from the yoke and install
a new one. Heat the new sleeve to 177 - 205o C Note: Bearing caps (22) and carrier housing (19) can
(350 - 400° F) in oil to expand it for installation. If oil only be replaced as an assembly.
heating equipment is not available, heat the bushing
evenly to 205o C (400o F). This takes about 1 minute using 14. The machined mating surfaces of plain case (38)
a torch with a heating tip. Use a Tempilstik or other and flanged case assembly (28) must be square with
temperature gauge to make sure sleeve (6) is hot the axis of the cases within 0.08 mm (0.003 in) T.I.R..
enough. Slide heated sleeve on the yoke and tap lightly The mating diameters of the cases must also be
with a hammer to seat it. concentric within 0.08 mm (0.003 in) T.I.R..

7. Examine bearing cap bushings (20) for wear or

damage. Replace as necessary. ASSEMBLY
Numbers in parentheses refer to Fig. 1.
8. Inspect all gears, pinions and splines for cracked or
broken teeth, excessive wear, and pitted or scored
surfaces. Repair or replace as necessary. WARNING
To prevent personal injury and property
Note: If either ring gear (29) or pinion gear (15) is damage, be sure lifting equipment is properly
defective, both gears must be replaced, because they secured and of adequate capacity to do the job
are serviced only as a matched set. This set is safely.
identified by a serial number on the OD of ring gear
(29) and outer face of pinion gear (15). It is also
advisable to replace side gears (30 & 34) or spider Pinion Cage Group
pinion gears (36) in matched sets only, because a Note: During assembly and installation, make sure
newer gear installed to operate in conjunction with an that mated, punch-marked or otherwise identified parts
older, worn gear tends to carry an uneven portion of are returned to their original positions, if still
the load. This creates an excessive amount of stress serviceable.
on the new gear.
1. Determine the required shim pack (18) thickness so
9. Check for pitted, scored or worn thrust surfaces of as to give the proper gauging distance within 0.08 mm
differential case halves, spider trunnions and thrust (0.003 in) etched on pinion gear (15) tail shaft (see
washers. It is also advisable to replace thrust washers Fig. 5) as follows:
in sets, as the use of a combination of old and new
washers may cause premature failure. Note: The OD of a bearing cup (17) can be ground to
162 - 161 mm (6.372 - 6.371 in) to provide a slip fit
10. Inspect carrier housing (19), ring gear (29), plain special tool as an aid in determining the required
case (38) and retainer (9) for bore damage, cracks thickness of shims (18).
and wear. Replace as necessary.
a. Install a shim pack (18) of approximately 1.5 mm
11. Check the amount of run-out on the machined (0.060 in), measure and record the actual thickness

SM 2045 7-00 5
Rear Axle - Differential
Section 160-0020
as Dimension 'X', and the loosely fitting bearing SM - 098
cup (17) (see previous note) in the pinion gear shaft
GAUGING DISTANCE
bore of carrier housing (19).
MEASURE GAUGING DISTANCE
WITH ESTIMATED, OR ORIGINAL
b. Install bearing cone (16) and bearing cone (14) on SHIM PACK INSTALLED.
pinion gear (15). Install cup (13) into retainer (9) until
it bottoms against the retainer shoulder. Install pinion ADJUST SHIM PACK TO GIVE
PROPER GAUGING DISTANCE
gear assembly (14, 15 & 16) and retainer (9) into
WITHIN 0.08 mm (0.003 in) OF
carrier housing (19). Secure retainer (9) with eight ETCHED DIMENSION ON TAIL
bolts (10) equally spaced. BEARING END OF PINION GEAR.
SHIM PACK
c. Rotate pinion gear (15) and tighten bolts (10) until
the pinion gear cannot be rotated by hand to seat the
bearing rollers firmly.
Fig. 5 - Measuring Gauging Distance
d. Place a flat plate approximately 450 mm (18 in) long
across the two bearing cap (22) mounting surfaces in SM - 099
carrier housing (19) as shown in Fig. 6. The plate must
lie perfectly flat between the bearing cap mounting
surfaces and must be clean and free of burrs.

e. Measure the distance from the end of pinion gear

(15) shaft to the plate (axle centre line). See Fig. 6.
Record this distance as Dimension 'A'.

f. Record the dimension etched on the end of pinion

gear (15) as Dimension 'B'.

g. The correct thickness of shims (18) to be used is:

Dimension 'X' + Dimension 'B' - Dimension 'A'.

2. Determine shim pack (11) thickness so as to allow Fig. 6 - Checking Shim Requirements
pinion gear (15) 0.025 - 0.08 mm (0.001 - 0.003 in) Using Inside Micrometer
axial end play as follows:
3. Remove bolts (10) and remove retainer (9) from
a. With pinion gear (15) installed as previously carrier housing (19). Adjust shim pack (18) to the
described in Steps 1a through 1f, rotate pinion gear required thickness as calculated in Step 1g and
(15) and tighten the eight bolts (10) evenly spaced, replace the ground bearing cup (17) with bearing cup
to 110 Nm (80 lbf ft) torque to seat the bearing (17) to be installed permanently.
rollers firmly.
4. Install pinion gear assembly (14, 15 & 16) in carrier
b. Remove bolts (10) and reinstall two of them 180° housing (19) as previously described in Steps 1 and 2.
apart. Tighten the two bolts alternately in 30 Nm
(20 lbf ft) increments to a final torque of 110 Nm 5. Install oil seal (12) into retainer (9) flush with the
(80 lbf ft). retainer surface at the top of the seal bore.

c. Measure the gap between retainer (9) and carrier 6. Install measured shim pack (11) as calculated in
housing (19) adjacent to the two installed bolts and Step 2d on retainer (9) and install the assembly on
record the average measurement as Dimension 'C'. carrier housing (19). Align slot in retainer (9) with the
lubrication holes in shims (11) and carrier housing (19)
d. The correct thickness of shim pack (11) is: and install retainer assembly in carrier housing.
0.48 mm (0.019 in) + Dimension 'C' - Dimension 'B'
(Step 1f) - Dimension 'A' (Step 1e). This shim pack 7. Install bolts (10) connecting retainer (9) to carrier
thickness should provide 0.05 mm (0.002 in) axial housing (19) and tighten to a torque of 156 Nm
end play of pinion gear (15). (115 lbf ft). Install set screws (8) in retainer (9).

6 SM 2045 7-00
 Rear Axle - Differential
Section 160-0020
8. Lubricate the lip of sleeve (6) and spline of pinion SM - 101
gear (15) with multipurpose grease No. 2. Lubricant
and insert 'O' ring (7) into yoke (5).

9. Install yoke (5) assembly to pinion gear (15) spline

until it contacts cone (14). DO NOT POUND ON
YOKE FLANGE.

10. Install plate (3) and secure to pinion gear (15) with
bolts (2). Tighten bolts (2) to a torque of 290 Nm
(213 lbf ft).

Ring Gear Assembly

1. If removed, install friction plates (43), clutch plates
(44) and reaction plate in flanged case assembly (28), Fig. 7 - Turning Bearing Adjuster to Set Backlash
as shown in Fig. 1.

2. Locate springs (41) in flanged case assembly (28) using the bearing spreader tool which can be
and align mating parts of flanged case assembly (28). fabricated as shown in Fig. 17.

3. Secure mating parts of flanged case assembly (28) 7. Install other side gear (34) and thrust washer (32),
with bolts (40). with grooved side of washer mating with machined
surface of side gear, in plain case (38).
4. Align identification marks that were made during
disassembly on ring gear (29) and flanged case 8. Assemble plain case (38) to ring gear (29) and
assembly (28). flanged case assembly (28), making certain that thrust
washers (32) do not slip off dowel pins (33). Turn plain
5. Install bolts (31) and tighten to a torque of 700 Nm case (38) until the mating mark made during
(515 lbf ft). disassembly lines up with the mark made on flanged
case assembly (28).
Spider and Component Parts Assembly 9. Apply retaining compound to bolts (39) and install
1. Press thrust washer dowel pins (33) into holes in four bolts (39) equally spaced. Tighten bolts (39) to a
plain case (38) and flanged case assembly (28), if torque of 271 Nm (200 lbf ft).
removed.
10. Check assembly for free gear rotation and correct
2. Lubricate inner walls of flanged case assembly (28) if necessary. Install remaining bolts (39) and tighten to
and plain case (38) and all component parts with gear a torque of 271 Nm (200 lbf ft).
lubricant. Refer to Section 300-0020, LUBRICATION
SYSTEM, for proper lubricant. 11. Press side bearing cones (16) squarely and firmly
over machined cylinders of plain case (38) and flanged
3. Position one thrust washer (32), grooved side facing case assembly (28).
towards side gear in bore of flanged case assembly (28).

4. Install first side gear (30) machined surface against Ring Gear Assembly to Carrier Housing
thrust washer (32) in flanged case assembly (28). Bearing adjusters (25) have two basic functions:
pre-loading cups (26) and cones (27); and positioning
5. Install bearings (37) in spider pinion gears (36) and ring gear (29) to obtain the correct backlash between
install bearings and spider pinion gears on spider (35), the ring gear and pinion gear (15). See Fig. 7. The
if removed. bearing adjuster (25) located on the same side of
pinion gear (15) as ring gear (29), pushes the ring gear
6. Lay complete spider assembly in pinion grooves in toward the pinion gear. Bearing adjuster (25), located
face of flanged case assembly (28). Spread bearings on the opposite side of pinion gear (15) than the ring
(37) against shoulders of flanged case assembly (28), gear, pushes the ring gear away from the pinion gear.

SM 2045 7-00 7
Rear Axle - Differential
Section 160-0020
The ring gear assembly must be installed onto carrier SM - 102
housing (19) so that cups (26) and cones (27) are
properly pre-loaded; correct backlash exists between
ring gear (29) and pinion gear (15), and satisfactory
tooth pattern is established between ring gear and RING GEAR RUNOUT
pinion gear. READING TAKEN AS
SHOWN, AND MUST
NOT EXCEED ± 0.08 mm
These conditions can be obtained by using the (0.003 in).
following procedures:

1. Mount ring gear (29) and differential assembly on

carrier housing (19). Make sure that side bearing cups
(26) are properly positioned on side bearing cones Fig. 8 - Checking Ring Gear Runout
(27). Install bearing caps (22) over cups (26) and
cones (27), then secure bearing caps to the carrier
SM - 104
housing with four dowel bushings (20) and bolts (21).
Secure bolts snugly, but do not tighten them to torque
specifications at this time.

Note: Each bearing cap (22) is mated to carrier

housing (19), therefore, they must be returned to their
original positions by aligning the identification marks
READ RING GEAR BACKLASH.
made during disassembly.
POSITION DIAL INDICATOR AS
2. Install a dial indicator to check the back side of ring SHOWN AND AT RIGHT ANGLES
TO TOOTH SURFACE.
gear (29) for true running. Rotate the assembly with an
easy motion and note the back face runout. The
runout is not to exceed 0.08 mm (0.003 in) with the Fig. 9 - Checking Ring Gear Backlash
dial indicator position as shown in Fig. 8.

3. Using a micrometer, take a measurement diagonally of notches and tightening up the opposite adjuster an
across bearing cap (22) lock pads and record it for equal number of notches.
reference later.
8. When a satisfactory backlash tolerance has been
4. Install bearing adjusters (25) in their respective established, check the gear tooth pattern as described
bearing caps (22). under the heading 'Adjustments'.

5. Place a dial indicator in the position shown in 9. If gear tooth pattern is not correct, some correction
Fig. 9, to check ring gear backlash. Tighten bearing can be made by systematically loosening and
adjuster (25) on the ring gear side until the backlash tightening the bearing adjusters (25), as previously
between ring gear (29) and pinion gear (15) reads described, but in every instance re-check the backlash
0.000 on the dial indicator. tolerance. If a favourable gear tooth pattern cannot be
established within the backlash tolerance, it will be
6. Tighten the opposite bearing adjuster (25) until necessary to alter, add or remove, shims (18) between
another measurement across bearing cap (22) lock bearing cup (17) and carrier housing (19) and alter
pads indicates a 0.05 - 0.13 mm (0.002 - 0.005 in) shims (11) by the same amount.
expansion when compared to the measurement
recorded in Step 3. 10. When altering these shims as described in 'Pinion
Cage Group', disregard all procedures given for
7. At this point the backlash tolerance between ring comparing the micrometer (measured) dimension and
gear (29) and pinion gear (15) should be 0.30 - 0.46 mm etched dimension on pinion gear (15) tail shaft end.
(0.012 - 0.018 in) on gear sets with a 3.73:1 gear ratio.
If this tolerance has not been obtained at this point, it 11. The procedures for keeping differential side
can be accomplished without changing the bearing bearing preload, backlash and favourable gear tooth
preload by backing off one adjuster a certain number pattern within specifications is strictly a 'try, check, and
try again' method.

8 SM 2045 7-00
 Rear Axle - Differential
Section 160-0020
12. After a satisfactory preload, backlash and gear 3. Gear tooth patterns can be interpreted by referring
tooth pattern is obtained, make certain that the retainer to Figs. 10 through 15.
bolts (10) are tightened to a torque of 156 Nm
(115 lbf ft). Again check backlash tolerance and gear a. If a contact pattern similar to that shown in
tooth pattern. Fig. 10 is obtained, the adjustment is correct.

13. Tighten bearing cap bolts (21) to a torque of b. If the contact area is on the inner side of the ring
644 Nm (475 lbf ft) and tie with lockwire (1). The gear teeth, see Fig. 11, move ring gear away from
lockwire passes over the top of bearing cap (22) and pinion by turning bearing adjusters equal amounts
through the heads of the respective bolts. The same until the proper bearing pattern is obtained.
procedure is to be followed for both bearing caps.
c. If the contact area is on the outer part of the ring
14. A final measurement across bearing cap (22) pilot gear teeth, see Fig. 12, move ring gear toward pinion
pads must indicate a 0.05 mm (0.002 in) to 0.13 mm by turning bearing adjuster.
(0.005 in) expansion, after ten ring gear revolutions
under a light load, when compared to the original d. If the contact area is along the root of the ring
measurement recorded in Step 3. This ensures that gear teeth, see Fig. 13, move the pinion out by
the side bearings have the proper preload. adding shims.

15. Install adjuster locks (24) and secure with bolts (23). e. If the contact area is along the top edge of the ring
Tighten bolts (23) to a torque of 33 Nm (24 lbf ft) and gear teeth, see Fig. 14, move the pinion in by
tie with lockwire (1). removing shims.

SM - 105
ADJUSTMENTS
When adjusting a noisy differential that has been in
service for some time, more harm than good can
result. Changes in adjustment will frequently
concentrate the bearing area on a small portion of the
teeth which often results in failure. Therefore, it is
advisable to know exactly what the end result will be
before adjustments are made in an old differential.

Note: A rebuilt differential or one that has not worn

excessively may be adjusted as previously described.

The following suggestions are offered to make gear

tooth pattern analysis and identification easier.
Fig. 10 - Proper Tooth Contact
1. Paint twelve ring gear teeth with Prussian Blue,
oiled red lead, or some other easily removed paint or SM - 106
dye. When the pinion is rotated, the paint is squeezed
away by the contact of the teeth, leaving bare areas
the exact size, shape and location of the contacts.

2. Make this check by rotating the ring gear at least

ten revolutions under light drive load. Another method
for checking contact pattern is to turn the ring gear
clockwise and anticlockwise several times. For
sharper impressions apply a drag on the ring gear by
forcing a wooden block against the edge of the ring
gear while it is being turned.

Fig. 11 - Insufficient Backlash

SM 2045 7-00 9
Rear Axle - Differential
Section 160-0020

SM - 107 SM - 109

Fig. 12 - Excessive Backlash Fig. 14 - Pinion Out Too Far - Remove Shims

SM - 108 SM - 110
MOVE GEAR IN THIS DIRECTION
FOR CORRECTION IN FIG. 13

MOVE PINION IN THIS DIRECTION

MOVE PINION IN THIS DIRECTION

FOR CORRECTION IN FIG. 15

FOR CORRECTION IN FIG. 16

MOVE GEAR IN THIS DIRECTION

FOR CORRECTION IN FIG. 14

Fig. 13 - Pinion In Too Far - Add Shims Fig. 15 - Correct Movement for Adjustment

INSTALLATION 3. Clean mating surfaces of the banjo and differential

Numbers in parentheses refer to Fig. 1. assembly with a Loctite 7063 cleaning agent to
remove dirt, oil, grease, or other foreign matter. Leave
cleaned surfaces to dry. Apply Loctite 5205 sealant to
WARNINGS the banjo mounting face in a 3 to 5 mm
To prevent personal injury and property (0.12 to 0.19 in) diameter bead, ensuring that all stud
damage, be sure wheel chocks, blocking holes are encircled and each circle is connected to the
materials and lifting equipment are properly one on either side (the loop between the studs will be
secured and of adequate capacity to do the job on the inside of any extraction holes). Refer to Fig. 16.
safely.
Note: Install differential within 10 minutes before
A come-a-long or chain fall with a Loctite 5205 sealant cures.
minimum capacity of one ton is required for
removal and installation of a differential 4. Set screw (4) should already have been removed
assembly. from the top of the differential housing and replaced
with a lifting eye during removal. If not, remove set
1. Be sure truck wheels are chocked securely. screw (4) from differential housing and replace it with a
lifting eye.
2. If the body is not already raised, raise body and
install body prop pins. Refer to Section 270-0010, 5. Position the differential assembly under the truck in
BODY AND MOUNTING. front of the banjo housing.

10 SM 2045 7-00
 Rear Axle - Differential
Section 160-0020

SM - 2420 Replace any mounting studs which have become

EXTRACTION HOLE stripped or broken.
LOCTITE
BANJO SEALANT
REF Jack up the drive axle to 'test run' the differential and
listen for noises which may indicate the need for
adjustment or replacement of worn parts. When doing
this, lift BOTH wheels off the ground. Both wheel
brakes should be free to allow both wheels to rotate at
approximately the same speed.

Note: Do not operate with only one wheel jacked up.

Excessive operation in this manner will overheat the
differential spider and cause galling or shearing of the
spider trunnions and bearings.

If the differential is excessively noisy, it should be

Fig. 16 - Applying Loctite 5205 Sealant
removed from the banjo and disassembled for
inspection.
6. Install chain fall or come-a-long to the loop on the
body just behind the hoist brackets. Attach the other
end of the lifting device to the eye previously installed Lubrication
in the differential assembly. The differential is splash lubricated with an extreme
pressure lubricant. The fill level plug is located in the
7. Lift the differential assembly and carefully position it centre rear of the banjo housing.
on the studs of the banjo housing.
The differential should be checked and periodically
8. Secure the differential assembly to the banjo with drained and filled to the bottom of the fill-level hole, or
the self locking nuts removed at removal. Tighten the to no more than 13 mm (0.5 in) below the fill level, with
nuts evenly to a torque of 380 Nm (280 lbf ft). new lubricant as recommended. Refer to Section
300-0020, LUBRICATION SYSTEM. When the
9. Replace the rear driveline, aligning marks made lubricant is drained, remove any chips of steel
during disassembly. Refer to Section 130-0020, REAR particles that may be attached to the magnetic drain
DRIVELINE. plug located in the bottom of the banjo housing.

10. Install the axle shafts, then replace and secure the After draining and refilling an axle, the planetary
driving flange cover to the wheels. Refer to Section gearing should be checked after 10 hours of operation.
160-0030, AXLE GROUP.
1. Check the level in planetaries at oil level plug. If the
11. Fill the drive axle, planetary reservoirs and oil level is low, add oil. This check point is a minimum
differential with the proper grade and quantity of check point only. If the oil level is above the check
lubricant specified in Section 300-0020,LUBRICATION point, do not drain off oil.
SYSTEM.
2. Add oil if needed. The oil level is correct when oil
MAINTENANCE flows from the lube level check plug in the banjo.
These checks should be made every 10 hours until oil
Periodic Inspection level in the differential is maintained.

Inspect regularly the flange yoke mounting bolts,

pinion shaft nut, pinion cage and seal retainer bolts, SPECIAL TOOLS
and differential stud nuts for tightness. Tighten the The spider bearing spreader tool can be fabricated as
stud nuts and flange bolts weekly until they 'set' or shown in Fig. 17. Refer to Section 300-0070,
show that they no longer need tightening. Keep the SERVICE TOOLS for part numbers of measuring tools
nuts tight to reduce the possibility of differential or referenced in this section and general service tools
driveline failure due to excessive vibration or wear. and adhesives required. These tools and adhesives
are available from your dealer.

SM 2045 7-00 11
Rear Axle - Differential
Section 160-0020

SM - 112

in mm
1/8 3.2
ONE-4340 STL. OR EQUIV.-HDN.-GRIND
1/4 6.4
3/8 9.5
7/16 11.1
1/2 12.7
5/8 15.9
3/4 19.1
29/32 23.0
1 25.4
1 1/8 28.6
ACME THD.

1 1/4 31.8
1 3/8 34.9
1 1/2 38.1
APPROX ONE-4340
STL.-HDN.-GRIND 1 7/8 47.6
2 50.8
2 1/32 51.6
2 1/8 54.0
2 15/32 62.7
2 3/4 69.9
4 3/4 120.7
4 7/8 123.8
5 1/2 139.7
5 3/4 146.0
5 31/32 151.6
6 7/8 174.6
7 1/2 190.5
9 1/2 241.3

Fig. 17 - Spider Bearing Spreader Tool Dimensions

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 2 Bolt 290 213
1 10 Bolt 156 115
1 23 Bolt 33 24
1 21 Bolt 644 475
1 31 Bolt 700 515
1 39 Bolt 271 200
- - Self Locking Nut 380 280

12 SM 2045 7-00
 Rear Axle - Differential
Section 160-0020

DIAGNOSIS CHART
CONDITION REASON REMEDY
Vibration. Broken gear teeth. Replace damaged gear.
Excessive runout of pinion or flanged case. Disassemble, correct or replace faulty part.
Continual noise. Bearing worn. Replace worn parts.
Gears damaged or worn. Replace gears.
Noise on drive. Ring and pinion gear adjustment tight. Adjust.
Noise on coast. Bearing damaged. Replace bearings.
Loose ring and pinion gear adjustment. Adjust gears.
Excessive pinion gear end play. Adjust.
Noise on turns. Worn spider gears or side gears. Replace gears.
Worn or damaged spider bushings. Replace bushings.
Loss of lubricant. Oil seals worn. Replace seal.
Loose nuts. Tighten nuts to correct torque.
Cracked housing. Repair or replace housing.

* * * *

SM 2045 7-00 13
 REAR AXLE - Axle Group
Section 160-0030

SM - 235

1 - Ring Gear Carrier

2 - Ring
3 - Retainer Plate
4 - Bolt
5 - 'O' Ring
6 - Washer
7 - Spacer
8 - Planet Pinion
9 - Sun Gear
10 - Pinion Bearing
11 - Snap Ring
12 - Planet Pin
13 - 'O' Ring
14 - Planetary Carrier
15 - Gasket
16 - Cover
17 - Bolt
*18 - Magnetic Plug
*19 - Screw
20 - Nut
21 - Stud
22 - Ring Gear
23 - Bolt
24 - Nut
25 - Lockwire
26 - Axle Shaft
27 - Snap Ring

* Shown in Fig. 2.

Fig. 1 - Sectional View of Planetary Assembly

PLANETARY
Description and Operation Axle shaft (26) is driven by the differential and turns
Numbers in parentheses refer to Fig. 1. sun gear (9) to which it is splined. Sun gear (9)
meshes with and rotates planetary pinions (8). Since
The planetary gearing is a single stage planetary gear ring gear (22) is splined to the wheel spindle it cannot
assembly. This assembly contains sun gear (9), turn and forces the planetary carrier (14) to rotate.
planetary carrier (14) with planet pinions (8) and ring This results in planetary carrier (14) being the output to
gear (22), to provide gear ratio to the drive wheels. the drive wheels.

SM 1184 2-98 1
Rear Axle - Axle Group
Section 160-0030

SM - 236

1 - Ring Gear Carrier 8 - Planet Pinion 15 - Gasket

2 - Ring 9 - Sun Gear 16 - Cover 22 - Ring Gear
3 - Retainer Plate 10 - Pinion Bearing 17 - Bolt 23 - Bolt
4 - Bolt 11 - Snap Ring 18 - Magnetic Plug 24 - Nut
5 - 'O' Ring 12 - Planet Pin 19 - Screw 25 - Lockwire
6 - Washer 13 - 'O' Ring 20 - Nut 26 - Axle Shaft
7 - Spacer 14 - Planetary Carrier 21 - Stud 27 - Snap Ring

Fig. 2 - Exploded View of Typical Planetary

Planetary Gearing - Towing 1. Position the vehicle in a level work area with
Numbers in parentheses refer to Fig. 1. magnetic plug (18) at its lowest point. Apply the
parking brake and switch off the engine.

WARNING 2. Turn the steering wheel in both directions several

Be sure adequate steering and braking times to relieve pressure in the steering system. Block
pressure are available before towing to prevent all road wheels.
injury or damage enroute.
3. With a suitable container in position, remove
If the truck is to be towed, as in the case of a magnetic plug (18) and drain all lubricant from the
breakdown, the axle shaft (26) and sun gear (9) planetary assembly.
should be removed from the planetary assemblies.
4. Remove bolts (17), cover (16) and gasket (15) from
The removal will prevent possible damage to the planetary assembly.
power train components during towing.
5. Pull out sun gear (9), snap ring (27) and axle shaft
The axle shafts and sun gears can be removed easily (26) assembly from planetary housing. Remove snap
by taking off driving flange cover (16) and simply ring (27) from axle shaft (26) and remove sun gear (9)
sliding the axle shaft, together with the sun gear, out of from axle shaft (26).
each planetary assembly by hand. Be certain the
driving flange covers are installed to protect the
planetary assemblies from road dust and dirt while WARNING
towing is in progress. To prevent personal injury and property
damage, be sure lifting equipment is of
adequate capacity and properly secured to do
Removal and Disassembly the job safely.
Numbers in parentheses refer to Fig. 2.
6. The driving flange and planetary gear assembly can
Note: The planetary assembly can be removed from now be pulled from the wheel by removing the thread
the wheel without removing the tyre and rim assembly. protectors and threading screws (19) into the exposed

2 SM 1184 2-98
 Rear Axle - Axle Group
Section 160-0030

SM - 237 4. Inspect bearings for damage or excessive wear. In

addition, check for free fit in planet pinions and on the
planet pins. Replace any parts which are in
questionable condition.

5. Inspect for pitted, scored or worn thrust surfaces

and burrs on planetary carrier (14).

6. Inspect ring gear (22) and planetary carrier (14) for

cracks and wear.

Assembly and Installation

Numbers in parentheses refer to Fig. 2.

Note: Tighten all fasteners to standard torques listed

Fig. 3 - Removing Planetary Assembly in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.

holes. A hoist should be used, as shown in Fig. 3, to Note: If ring gear carrier (1) is replaced, the wheel
support the assembly during removal. Remove studs bearing adjustment must be checked and corrected
(21) if damaged. as required, as described in Section 160-0050,
WHEEL, RIM AND TYRE.
7. Remove and discard 'O' ring (13) and place
planetary assembly on a clean work surface with gear 1. Insert snap rings (11) in planet pinion (8) grooves.
side up. Oil bearing sets (10) and insert spacers (7) and
bearings (10) in planet pinions (8).
8. Remove nuts (24), bolts (4) and washers (6) from
planet pinion (8) assemblies. Slide planet pinion (8) 2. Install new 'O' rings (5) in planetary carrier (14).
assemblies from planetary carrier (14). Slide assembled planet pinions into their respective
positions in planetary carrier (14).
9. Separate pinion bearing (10) sets and spacers (7)
from planet pinions (8) and remove snap rings (11) 3. Insert planet pins (12) through planet pinion (8)
from internal grooves of planet pinion (8). assemblies into planetary carrier (14) bores. Install
washers (6) on bolts (4) and insert bolts (4) through
10. Remove and discard 'O' rings (5) from planetary planetary carrier (14) and planet pinions (8). Install
carrier (14). nuts (24) on bolts (4) and tighten securely. Check
planet pinions (8) for free rotation.

INSPECTION
Numbers in parentheses refer to Fig. 2. WARNING
To prevent personal injury and property
1. Clean all parts thoroughly in suitable solvent and dry damage, be sure lifting equipment is of
with moisture-free compressed air or a clean, lint-free adequate capacity and properly secured to do
cloth. Allow bearings to air dry and dip in clean the job safely.
planetary lubricant.
4. Install new 'O' ring (13) in its groove in planetary
2. Inspect all parts for damage. Repair or replace as carrier (14). Place the planetary assembly in position
necessary. on the wheel. Mesh planet pinions (8) with ring gear
(22) and push the planetary assembly into place.
3. Inspect all pinions, gears and splines for excessive Install studs (21), if removed, and install nuts (20).
wear, cracked or broken teeth and pitted or scored
surfaces. If replacing planet pinions or sun gear, be 5. If sun gear (9) was removed during 'Disassembly',
sure the new pinions or gear have the same number of slide sun gear (9) over splines of axle shaft (26) and
teeth as the old ones so torque multiplication will install snap ring (27). Install ring (2) on axle shaft (26)
remain the same. and insert axle shaft assembly into the spindle and

SM 1184 2-98 3
Rear Axle - Axle Group
Section 160-0030
banjo housing, pushing the axle shaft part way into the SM - 238
differential side gear. Mesh sun gear (9) with planet
pinions (8).

6. Push axle shaft (26) and sun gear (9) inward as far
as they will go. With a steel rule and straight edge,
measure from cover mounting surface on planetary
carrier (14) to the end of axle shaft (26). Note as
dimension 'A'. See Fig. 4.

7. Next, lay cover (16) on flat surface and again use a

straight edge and steel rule to measure the height of
the inside raised surface of cover (16). Note as
dimension 'B'. See Fig. 5. Subtract dimension 'B' from Fig. 4 - Measuring Dimension 'A'
dimension 'A' and the clearance should be within
2.7 - 11.9 mm (0.106 - 0.469 in).
SM - 239

Note: If the end play is too small, the axle shaft is not
pushed completely into the differential side gear. If the
end play is greater than the allowable maximum, either
the axle shaft end or the driving flange thrust cover, or
both are excessively worn. To correct this, replace
cover (16) first. If the end play is still too great, a new
axle shaft must be installed.

8. Replace magnetic plug (18) and fill the planetary

reservoir with lubricant specified in Section 300-0020,
LUBRICATION SYSTEM, through the driving flange Fig. 5 - Measuring Dimension 'B'
opening or fill plug until the correct level is reached.

9. Spread sealing compound on the surface of Removal

cover (16) which contacts the driving flange. Position Numbers in parentheses refer to Fig. 6.
gasket (15) and install cover (16) on driving flange
using bolts (17). Be sure to replace any thread Note: If differential only is to be removed, it can be
protectors which have been removed. done while axle is attached to the truck, as outlined in
Section 160-0020, DIFFERENTIAL.

REAR AXLE
WARNINGS
Description and Operation Heavy machine. Make sure lifting device or
Numbers in parentheses refer to Fig. 6. jack has proper lifting capacity and is
adequately secured to do the job safely.
The rear axle assembly consists of banjo (1) assembly Personal injury and damage may result if
and A-frame (39). The banjo provides the housing for machine falls or jack or lifting device
the differential and axle shafts which drive the wheels, collapses.
and spindles (2) to which the wheels are mounted. The
banjo also connects the rear wheels to the chassis To prevent possible personal injury,
through A-frame (39), link (16), and the rear ride relieve the pressure in the braking system. The
cylinders. exact procedure must be followed as
described in Section 250-0000, BRAKING
The rear axle is centrally mounted on the rear frame SYSTEM SCHEMATIC.
crossmember with a tapered pin (12) and component
parts, which allows the axle to oscillate as the truck 1. Position the vehicle in a level work area, apply the
moves over uneven terrain. parking brake and switch off the engine.

4 SM 1184 2-98
 Rear Axle - Axle Group
Section 160-0030

SM - 1380

30 - Hardened Washer
31 - Bolt
32 - Pin
17 - Spacer 33 - Bolt
18 - Snap Ring 34 - Hardened Washer
19 - Bearing 35 - Hardened Washer
20 - Lube Fitting 36 - Locknut
8 - Retainer 21 - Lube Fitting 37 - Axle Shaft
9 - Washer 22 - Coupling 38 - Snap Ring
1 - Banjo 10 - Split Cup 23 - Elbow 39 - A-Frame
2 - Spindle 11 - Spacer 24 - Nut 40 - Nipple
3 - Stud 12 - Tapered Pin 25 - Bolt 41 - Bushing
4 - Bearing Ring 13 - Bearing 26 - Bolt 42 - Connector
5 - Hardened Spacer 14 - Lube Line 27 - Magnetic Plug 43 - Breather Line
6 - Oscillation Stop 15 - Breather 28 - Plug 44 - Elbow
7 - Tapped Retainer 16 - Link 29 - Bolt 45 - Spacer

Fig. 6 - Exploded View of Axle Assembly and Mounting

2. Turn the steering wheel in both directions several deteriorate the rubber.
times to relieve pressure in the steering system. Operate
the treadle valve continuously to relieve pressure in the 4. Jack up or lift the vehicle so its weight is no longer
braking system. Block all road wheels. resting on the tyres of the axle assembly. Securely
block the vehicle in this position.
3. Disconnect brake, cooling, breather and lubrication
lines. Drain all the lubricant from the axle, brake assemblies 5. Remove four bolts from the driveline flange and
and planetary assemblies into suitable containers. Refer swing-driveline away from the differential. Punch mark
to Section 160-0020, DIFFERENTIAL, and, Section both flanges to facilitate installation. Refer to
165-0030, BRAKE PARTS. Cap all open lines and fittings Section 130-0020, REAR DRIVELINE.
to prevent entry of dirt.
6. If necessary remove the tyre and rim assemblies as
Note: Avoid spilling lubricant on tyres, as it will described in Section 160-0050, WHEEL, RIM AND TYRE.

SM 1184 2-98 5
Rear Axle - Axle Group
Section 160-0030
7. Position a hydraulic jack under the axle at the 6. Remove lube line (14), elbow (23) and lube fitting
differential housing, being sure jack is of suitable (21) from link (16).
capacity and proportions to lift and balance the axle
assembly. Place wheeled dollies at both ends of the 7. Remove breather line (43) and elbow (44) from
axle for wheels to rest on when the axle is lowered. banjo (1).
Raise axle just enough to take weight off centre
tapered pin (12). 8. If differential is to be removed, remove nuts (36),
hardened spacers (5) and hardened washers (35).
8. Remove lower ends of rear ride cylinders. Refer to Using suitable lifting equipment, remove differential
Section 180-0050, RIDE CYLINDER. assembly from banjo (1). Refer to Section 160-0020,
DIFFERENTIAL.
9. Remove bolt (33), hardened washer (34) and pin
(32) which mount link (16) to the chassis. Remove 9. If required, remove magnetic plug (27) and plug (28)
spacers (17). from banjo (1).

10. Remove nut (24), washers (9) and bolt (25) 10. If required, remove snap rings (38) and axle shafts
attaching A-frame (39) to the chassis. Remove split (37) from spindles (2).
cups (10) from tapered pin (12).

11. Drive tapered pin (12) out of the chassis using a Inspection
soft drift. As tapered pin (12) moves out, remove 1. Clean all metal parts in a suitable solvent, using a
spacers (11). Lower the axle assembly onto the brush to clean bearings. Dry all parts on a clean
wheeled dollies and roll out from beneath the vehicle. surface and allow bearings to dry naturally. Make sure
parts are free from dirt.

Disassembly 2. Check all inner and outer grooves for cleanliness.

Numbers in parentheses refer to Fig. 6. Check components for cracks, scores, blemishes or
burrs. Use a fine stone to smooth out defective areas.
Replace any parts that show excessive wear.
WARNING
To prevent personal injury and property 3. Inspect fittings, plugs, studs and their seating
damage, be sure lifting equipment is of positions for thread wear. If threads in any of these
adequate capacity and properly secured to do parts are damaged, replace parts.
the job safely.
4. Check bushings, bearings and snap rings for wear
1. Remove bolts (26) from A-frame (39) and remove or warped condition. Replace defective parts.
retainer (8) and tapped retainer (7). Drive bearing (13)
from A-frame (39). If required, remove lube fitting (20) 5. Replace old washers with new ones.
from A-frame (39).

2. Remove A-frame (39) from banjo (1) by removing Assembly

bolts (31). Numbers in parentheses refer to Fig. 6.

3. Remove bolts (29) and hardened washers (30) Note: Tighten all fasteners without special torques
securing oscillation stop (6) to banjo (1). Remove specified to standard torques listed in Section
oscillation stop (6) and spacer (45). 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
4. Remove bolt (33), hardened washer (34) and pin
(32) which mount link (16) to banjo (1). Remove Note: If heating of banjo (1) is required to assemble
spacers (17). spindles (2) and banjo (1), banjo interference areas
must cool to 66° C (150° F) maximum before welding.
5. Remove link (16) from banjo (1) brackets. Remove For welding spindles (2) to banjo (1) preheat spindles
snap rings (18) and bearings (19) from link (16). and banjo to 150° C (300° F) minimum in weld area
and maintain during welding.

6 SM 1184 2-98
 Rear Axle - Axle Group
Section 160-0030

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

1. If axle shafts (37) have been removed from spindles 1. After banjo (1) and its components are
(2) install axle shafts in the spindles and secure with reassembled, roll the assembly under the vehicle and
snap rings (38). align under the chassis.

2. If removed, install magnetic plug (27) and plug (28) 2. Using a hydraulic jack of suitable capacity and
in banjo (1). proportions to lift and balance the axle assembly, raise
the axle assembly into position in the chassis. Insert
3. If differential was removed, position differential in spacers (11) and, using a soft drift, drive in tapered pin
banjo (1) and secure with nuts (36), hardened (12).
spacers (5) and hardened washers (35). Refer to
Section 160-0020, DIFFERENTIAL. 3. Install split cups (10) and washers (9) on tapered
pin (12) and secure with bolt (25) and nut (24).
4. Install elbow (44) in banjo (1) and connect breather
line (43) to elbow (44). Note: Since tapered pin (12) relies on bolt (25)
clamping to spread out and seat split cups (10) against
5. Install lube fitting (21) and elbow (23) in link (16) the pin for retention at initial assembly, the pin tends to
and connect lube line (14) to elbow (23). loosen up after the vehicle is in operation. Positive
seating is required and accomplished by re-tightening
6. Install bearings (19) in link (16) and secure with bolts (25) after the first few hours of operation, and
snap rings (18). Position link (16) assembly in banjo thereafter, until bolts (25) retain their torque.
(1) brackets and install spacers (17). Secure link (16)
to banjo (1) with pin (32), hardened washer (34) and 4. Align link (16) assembly and spacers (17) with the
bolt (33). chassis and install pin (32). Secure pin (32) to the
chassis with hardened washer (34) and bolt (33).
7. Position spacer (45) and oscillation stop (6) on
banjo (1) and secure with bolts (29) and hardened 5. Install rear ride cylinders to the chassis and axle
washers (30). assembly as outlined in Section 180-0050, RIDE
CYLINDER.
8. Install bearing (13) in A-frame (39). Fit retainer (8)
and tapped retainer (7) to A-frame (39) and secure 6. With the axle group securely fastened to the rear
with bolts (26). If removed, install lube fitting (20) in ride cylinders and the two sections of the chassis at
A-frame (39). link (16) and A-frame (39), release and remove the
hydraulic jack.
9. Position A-frame (39) assembly to banjo (1) and
secure with bolts (31). Tighten bolts (31) to a torque of 7. Align the punch marks, as marked during removal,
2 034 Nm (1 500 lbf ft). on the driveline and differential flanges, and secure
with four bolts. Refer to Section 130-0020, REAR
DRIVELINE.
Installation
Numbers in parentheses refer to Fig. 6. 8. If removed, replace tyre and rim assemblies as
outlined in Section 160-0050, WHEEL, RIM AND
Note: Tighten all fasteners to standard torques listed TYRE.
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. 9. Remove blanking caps and reconnect all brake,
cooling, breather and lubrication lines. Refer to Section
Note: Tighten all hydraulic lines fitted with ORFS 160-0020, DIFFERENTIAL, and, Section
connections, as described in Section 230-0000, BODY 165-0030, BRAKE PARTS.
SYSTEM SCHEMATIC. Renew all 'O' rings where
used.

SM 1184 2-98 7
Rear Axle - Axle Group
Section 160-0030

10. Fill banjo, planetaries and disc brake assemblies AXLE DIAGNOSIS
with lubricant specified in Section 300-0020, Noises originating in the tyres, transmission or
LUBRICATION SYSTEM. driveline might be attributed by mistake to the axle.
Therefore, all possible sources of noise should be
11. Lubricate the rear axle assembly through lube investigated before deciding the axle is at fault.
fittings (20 & 21) with lubricant specified in
Section 300-0020, LUBRICATION SYSTEM. True axle noises may be located by lifting or jacking
the truck until all driving wheels are clear of the floor or
12. Bleed the braking system as described in ground. Securely block the truck in this position. Run
Section 165-0030, BRAKE PARTS. power train at moderate speed. Be certain all tyres are
off the ground and, to prevent damage to the
differential, see that neither rear brake drags.
MAINTENANCE
Proper lubrication of the axle group is essential if axles
are to deliver the service intended. Refer to Section SPECIAL TOOLS
300-0020, LUBRICATION SYSTEM for lubrication There are no special tools required for procedures
intervals and lubricant specifications. outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general service
tools and sealants required. These tools and sealants
are available from your dealer.

AXLE DIAGNOSIS
CONDITION REASON REMEDY
Noise Insufficient or incorrect lubricant Check level; fill with proper type and
grade lubricant
Wheel bearings scored or rough Replace bearings
Gear teeth in planetary chipped Replace gear
Loss of lubricant Lubricant level too high Drain and fill to proper level
Lubricant foams excessively Drain and fill with correct type and
grade lubricant
Worn or broken oil seal Replace oil seal
Restricted breather vent Clean vents
Loose nuts or bolts Tighten nuts or bolts
Gain of lubricant Restricted differential housing vent Clean vent
Planetaries running hot Insufficient or incorrect lubricant Check level; fill with proper type and
grade of lubricant
Pinion bearings seized Replace bearings

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
6 31 Bolt 2 034 1 500

* * * *

8 SM 1184 2-98
 REAR AXLE - Wheel, Rim and Tyre
Section 160-0050

SM - 203

1 - Flange 4 - Clamp 7 - Bead Seat Band 10 - Spacer Band

2 - Wheel Stud 5 - Wedge Band 8 - Lock Ring 11 - Wheel
3 - Nut 6 - 'O' Ring 9 - Rim

Fig. 1 - Sectional View of Typical Dual Wheel Rim Assembly

DESCRIPTION
Each drive wheel is mounted on its spindle with two WARNING
tapered roller bearings. All the weight of the truck Tyre explosion hazard. Gases that build up
resting on the drive axle is supported by the wheels inside an air inflated tyre mounted on a rim
and bearings; none of the weight is supported by, or during welding and/or heating of rim
transmitted through, the axle shafts. This type of components can ignite, causing an explosion
construction is known as 'Full Floating'. of the tyre and rim components. This warning
also applies to Nitrogen gas inflated tyres.
The wheel itself is a large cylindrical casting with the Ignition will not occur in a Nitrogen gas
bearing bores and other finished surfaces machined atmosphere; but the pressure build up from the
after the wheel is cast. applied heat may be sufficient to cause a
blowout severe enough to injure or kill. Never
The dual rim assembly consists of two rim bases, inner weld or otherwise apply heat on rim
and outer flanges, bead seat bands, 'O' rings and lock components with the tyre mounted on the rim,
rings. whether the tyre is inflated or deflated, to
prevent injury or property damage from the
The tyre and rim assembly is designed to be replaced potential tyre explosion! Also, do not attempt to
with a pre-assembled tyre and rim. repair rims or rim components by welding or
heating, even if the tyre is not mounted on
the rim. It is recommended to scrap questionable
PREPARATION FOR SERVICING rim parts unless specific permission and repair
procedures are obtained in writing
either from the company or the rim manufacturer.
WARNING
Before loosening rim clamps or performing any
service on the tyres or rim components, to REMOVING TYRE AND RIM ASSEMBLY
prevent personal injury and property damage, Numbers in parentheses refer to Fig. 1.
completely deflate BOTH TYRES of dual
assembly by removing the valve caps and If the tyre and rim assembly is to be replaced with a
cores. Insert a thin wire through valves to be pre-assembled tyre and rim assembly, it is not
sure valves are not plugged. Even a flat tyre, in necessary to remove the tyre from the rim on the truck.
some cases, will retain sufficient air pressure to The tyre and rim may be removed from the truck as an
blow off a rim component with enough force to assembly, and transported to a more desirable location
cause bodily injury or death. for removing the tyre from the rim.

SM 2044 Rev1 03-05 1

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

SM - 204

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

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

parking brake and switch off the engine.

2. Turn the steering wheel in both directions several

times to relieve any pressure in the steering system.
Block all road wheels, except the ones to be raised.
Use wooden blocks 100 x 100 mm (4 x 4 in) or larger.

3. For the tyre to be removed, set up jack to support

truck weight, but do not raise truck.

4. Completely deflate both tyres by removing valve

caps and cores. Check valve stems by running a piece
of wire through the stems to make sure they are not
plugged. See warning under 'Preparation For Servicing'. 1 - Outer Flange
2 - Bead Seat Band 4 - Rim
5. Break wheel nuts (3) loose, but do not remove from 3 - Lock Ring 5 - Inner Flange
wheel studs (2).
Fig. 2 - Typical Rim Assembly
6. Jack the machine up only as high as necessary to
remove the wheel from the truck, and place safety SM - 205
blocks under the axle.

7. Support the outer tyre with a chain or rope sling of

sufficient strength attached to a suitable lifting device.
Remove nuts (3) and clamps (4) from wheel studs (2).
Remove wedge band (5) and lift tyre and rim assembly Fig. 3 - Pry Bar
clear.

8. If inner rim assembly is being removed, remove SM - 206

spacer band (10), attach a lifting device to tyre and rim

assembly, and remove from truck.

DISMOUNTING TYRE FROM RIM

Numbers in parentheses refer to Fig. 2, unless
otherwise specified.

Note: The following instructions apply to use of hand

tools. The procedure and tooling required to dismount
the tyre from the rim using hydraulic tools is outlined
under the heading 'Hydraulic Bead Breaking Tool'.

Fig. 4 - Breaking Typical Tyre Bead Loose

2 SM 2044 Rev1 03-05

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

Note: If tyre and rim is on the truck, and no tyre lifting

WARNING equipment is available, 'walk' tyre off rim as follows: force
When lifting tyre from rim, be sure the bottom of tyre outward as far as possible; lower jack
equipment is of sufficient capacity and properly enough to allow weight of tyre to rest on ground; force top
secured to do the job safely. of tyre out as far as possible; raise jack to original height
and repeat above until tyre is off rim.
1. Completely deflate tyre if not done previously. See
warning under 'Preparation For Servicing'. Tape valve
threads to protect from damage, leaving valve end INSPECTION
open to avoid any possibility of trapping air inside the
tyre. Tyre
Check the interior surface of the tyre to determine its
2. Break outer tyre bead loose by placing the flat condition. Inspect for cuts or fabric breaks that have
hooked end of a pry bar, see Fig. 3, into one of the penetrated the tyre body. The casing should be
breaking slots 'C' between bead seat band (2) and inspected closely for any sharp, pointed objects that
flange (1). A length of pipe slipped over straight end of may have penetrated the tyre body but is invisible from
pry bar will increase leverage. Twist straight end of pry the outside. All dust, dirt, water or other foreign matter
bar around toward tyre to break this portion of bead. A should be cleaned from the inside of the tyre.
second person may now insert another bar of the same
type into the space between the bead seat band and Replace valve core assembly if condition is
flange, and with the same twisting action, hold the questionable.
space gained with first pry bar. Move first pry bar all
the way around the wheel, twisting and following up
with second pry bar, until inner tyre bead is loose. Rim Assembly
Overloading, improper tyre inflation, rough terrain, high
3. Start bead seat band (2) in away from lock ring (3) speed, accidents, dirt accumulation and corrosion all
by placing hooked end of pry bar in groove of rim (4), tend to reduce the service life of rims and rim
between ends of lock ring, and prying up with pry bar. components. It is recommended that the rims be
Using two pry bars, as in Step 2, work completely inspected, as below, not less than at every tyre change
around wheel. and as the warranty limit approaches, consideration be
given to rim replacement.
4. Pry lock ring (3) out in same manner by starting at
prying notch 'B' in wheel, and work all the way around
wheel with the two pry bars. WARNING
Never mix components of one manufacturer's
5. Remove and discard 'O' ring (6, Fig. 1). rims with those of another. Using the rim base
of one manufacturer with the lock ring of
6. After removing lock ring (3), pry out and remove another or vice versa is dangerous. The lock
bead seat band (2). Outer flange (1) may now be ring of one may not fully engage with the lock
removed. ring groove of the other. Always consult the rim
manufacturer for proper matching and
7. Similar breaking slots are provided on the inside of assembly instructions. Also, use and servicing
rims. The inner bead on the back side of the tyre may of damaged, worn out, or improperly
be broken by using the same method as in Step 2, for assembled rim assemblies is a very dangerous
the outer bead. If the wheel assembly is still on the practice. Failure to comply with the above
truck, inner wheel only, another method which can be warnings could result in explosions from tyre
used is to place a small jack between the inner flange pressure causing serious personal injury and
and some solid part of the truck frame. By extending property damage.
the jack, pressure is exerted, which forces the tyre
bead off the rim seat. Work around the wheel until the 1. Clean all rust and dirt from rim parts and wheel.
bead is broken at all points.
2. Coat parts with primer paint. Allow thorough drying
8. Using suitable lifting equipment, remove tyre from before assembling.
rim. This completes the removal of the tyre.
3. Inspect rim assemblies (Fig. 2) for bent, cracked,

SM 2044 Rev1 03-05 3

Rear Axle - Wheel, Rim and Tyre
Section 160-0050
distorted, battered, and rusted parts which may have SM - 207
resulted from abusive practices outlined above. Replace
any damaged parts with new parts.

4. Discard 'O' rings and replace with new ones.

Note: Handle 'O' rings carefully, as damage will prevent

an airtight seal for tyre inflation.

MOUNTING TYRE ON RIM

Numbers in parentheses refer to Fig. 2, unless
otherwise specified.

WARNING
Fig. 5 - Installing Typical Lock Ring
When lifting tyre onto rim, be sure the
equipment is of sufficient capacity and properly
secured to do the job safely. thin solution of soap and water or another approved
lubricant which is not harmful to rubber. Avoid using an
1. If tubeless tyre valve assembly was removed from excessive amount of lubricant. Insert new 'O' ring (6,
rim, install this assembly in the rim valve hole and Fig. 1) in groove of the rim behind lock ring.
tighten securely.
9. Lift the tyre upwards to effect a seal between bead
2. Tyre installations are performed in basically the same seat band (2) and 'O' ring (6, Fig. 1). In some cases the
manner whether the rim (4) is on or off the truck. For tyre will automatically spring out, making this step
off-truck installations, lay the rim on blocks or a unnecessary.
mounting stand with 'O' ring groove up. The rim should
be just off the floor enough so the tyre rests on the rim
and does not touch the floor. Blocks should not extend
MOUNTING TYRE AND RIM ASSEMBLY
more than 13 mm (0.5 in) beyond the rim base, so they ON WHEEL
won’t interfere with inner flange (5). Numbers in parentheses refer to Fig. 1.

3. Install inner flange (5) over rim (4).

WARNING
4. Before assembly of the tyre to the rim, lubricate both Be sure lifting equipment is of sufficient
tyre beads and new rubber 'O' rings (6, Fig. 1) with a capacity and properly secured to do the job
thin solution of vegetable base soap and water. Make safely.
certain the tyre valve assembly is securely in place.
Lower the tyre onto the rim, seating the tyre firmly 1. Support inner tyre and rim assembly, if removed,
against inner flange (5). with a chain or rope sling attached to an overhead
lifting device and slide onto wheel (11) of the truck.
5. Install outer flange (1) on rim (4). Side with lock ring (8) and bead seat band (7) should
be facing outward. Install spacer band (10).
6. Install bead seat band (2) on rim (4).
2. Install outer tyre and rim assembly in the same
7. Install lock ring (3) in groove of rim (4). Use pry bar manner, except with bead seat band (7) and lock ring
for this operation, as illustrated in Fig. 5. (8) facing inward, toward spacer band (10). Install
wedge band (5).
8. Force bead seat band (2) past 'O' ring groove in rim
(4) by prying, or with lift truck forks. Use blocking 3. Install clamps (4) and start nuts (3) on wheel
between the forks and tyre to prevent tyre damage. studs (2). Gradually tighten nuts opposite each other,
Lubricate area of rim adjacent to 'O' ring groove with a until all nuts are snug, and torque nuts (3) to 690 Nm

4 SM 2044 Rev1 03-05

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

SM - 202

1 - Lockwire 5 - Ring Gear

2 - Bolt 6 - Wheel 9 - Inner Bearing Cup 12 - Spacer
3 - Plate 7 - Outer Bearing Cone 10 - Inner Bearing Cone 13 - Wheel Driver
4 - Shim Pack 8 - Outer Bearing Cup 11 - Spindle 14 - 'O' Ring

Fig. 6 - Sectional View of Drive Wheel Assembly

(510 lbf ft). Re-tighten nuts after a few hours operation. WHEEL

Note: Wheel rim fastener torque should be checked Removal and Disassembly
regularly, particularly on new trucks or newly-installed Numbers in parentheses refer to Fig. 6.
wheels, to maintain the required wheel rim-clamp load.
A newly installed wheel or a new truck should be
checked at 30 day intervals until the rim fasteners WARNING
show no significant torque loss from the previous To prevent personal injury and property
check. After that, a 90 day torque check interval damage, be sure wheel blocks, blocking
should be adequate. materials and lifting equipment are properly
secured and of sufficient capacity to do the job
safely.

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

parking brake and switch off the engine.

SM 2044 Rev1 03-05 5

Rear Axle - Wheel, Rim and Tyre
Section 160-0050
2. Turn the steering wheel in both directions several light oil to facilitate assembly.
times to relieve pressure in the steering system. Block
all road wheels, except the ones to be raised. 2. Using a suitable solvent, clean bearings and wipe
dry with a lint free cloth. Lubricate lightly with light oil
3. Release parking brake. and spin by hand, to check for wear and roughness.
Replace with new bearings if excessively worn, or if
operation is rough or noisy.
WARNING
To prevent personal injury and property 3. Inspect all machined surfaces of all parts for
damage, completely deflate BOTH TYRES of scoring, pitting, corrosion and burring. Resurface or
dual assembly by removing the valve caps and replace with new parts as necessary.
cores. Insert a thin wire through valves to be
sure valves are not plugged. Even a flat tyre, in 4. Inspect all threaded components, and repair or
some cases, will retain sufficient air pressure to replace as necessary.
blow off a rim component with enough force to
cause bodily injury or death.
Assembly and Installation
4. Deflate both tyres completely, and remove the tyre Numbers in parentheses refer to Fig. 6.
and rim assembly from the wheel. Follow instructions
under 'Removing Tyre and Rim Assembly'.
WARNING
5. Drain differential and planetary gear lubricant and To prevent personal injury and property
remove planetary gear assembly from the wheel. Refer damage, be sure wheel blocks, blocking
to Section 160-0030, AXLE GROUP. materials and lifting equipment are properly
secured and of sufficient capacity to do the job
6. Remove lockwire (1), bolts (2), plate (3) and shim safely.
pack (4) from spindle (11). Retain shim pack (4).
1. Install bearing cups (8 & 9) in their respective wheel
7. Pull ring gear (5) from end of spindle (11). (6) bearing bores with care to avoid damaging their
raceways. Installation by press fit at ambient
8. With suitable lifting equipment, pull wheel (6) off of temperature is best. Note that cups must seat fully
spindle (11), being careful that outer bearing cone (7) against shoulders of cup bores in the wheel hub to
does not fall. assure retention of bearing adjustment. If carbon
dioxide, or dry ice, freezing of the cup is used,
9. Remove and discard 'O' ring (14) from wheel remember to permit the cup and hub to warm to
driver (13). ambient temperature after insertion and then to tap
them with a soft steel drift and hammer to seat.
Note: The wheel driver (13) portion of the disc brake
assembly is bolted to inner face of wheel (6), when the 2. If removed, install spacer (12), onto spindle (11).
wheel is removed, the attached disc brake wheel driver
(13) will also be removed. Refer to Section 165-0030, 3. Lubricate inner bearing cone (10) with lubricant
BRAKE PARTS, if necessary to remove wheel driver. specified in Section 300-0020, LUBRICATION
SYSTEM. Install inner bearing cone (10) onto spindle
Note: Bearing cups and cones must always be (11), hard against spacer (12).
replaced as a matched set, never separately.
4. If removed, install wheel driver (13) on wheel (6).
10. Remove inner bearing cone (10) from spindle (11). Refer to Section 165-0030 BRAKE PARTS.

11. If required, remove bearing cups (8 & 9) from wheel. 5. Install new 'O' ring (14) on wheel driver (13). Refer to
Section 165-0030, BRAKE PARTS.

Inspection 6. With suitable lifting equipment slide wheel (6)

1. Thoroughly clean all metal components, except assembly onto spindle (11), carefully mating splines of
bearing cones, in a suitable solvent. Dry with disc brake wheel driver (13) with splines of disc brake
compressed air and coat all threaded components with disc driver. Refer to Section 165-0030, BRAKE
PARTS.

6 SM 2044 Rev1 03-05

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

BEARING ADJUSTMENT TABLE

GAUGING BOLT TORQUE FINAL BOLT TORQUE
No. of Bolts Nm lbf ft No. of Bolts Nm lbf ft
2 203 150 8 380 280

7. Lubricate outer bearing cone (7) with lubricant 15. Install planetary gear assembly and fill planetary
specified in Section 300-0020, LUBRICATION and differential assemblies with lubricant specified in
SYSTEM. Install outer bearing cone (7) on spindle (11) Section 300-0020, LUBRICATION SYSTEM. Install
and seat in outer bearing cup (8). tyre and rim assembly as described under 'Mounting
Tyre and Rim Assembly on Machine'.
8. Install ring gear (5) on end of spindle (11).

Note: Ensure all dirt, grease and oil is completely TYRE INFLATION
removed from plate (3), shim pack (4) and end of
spindle (11) to allow accurate setting of the bearing pre-
load. WARNING
To prevent personal injury and property
9. Install plate (3), without shim pack (4) on end of damage, the tyre and rim assembly should be
spindle (11), and secure with eight bolts (2). Tighten placed in a safety cage before inflating. If no
bolts (2) evenly in equal increments to 'Gauging Bolt safety cage is available or tyre is on the
Torque', as specified in 'Bearing Adjustment Table', machine, the tyre and rim assembly should be
while rotating and bumping wheel (6) assembly. wrapped with safety chains or with lash cables
before inflating.
10. Remove bolts (2) and tap the wheel (6) assembly to
free bearings. Even with these precautions remember that air-
blast is a potential hazard. Tyre inflation should
11. Reassemble plate (3) without shim pack (4) and be carried out away from busy working areas.
using only two bolts (2) located 180° apart, adjacent to
gauging holes in plate (3). Tighten bolts (2) evenly in
equal increments to 'Gauging Bolt Torque' (ref. 'Bearing WARNING
Adjustment Table'), while rotating and bumping wheel To avoid personal injury and property damage,
(6) assembly. never stand or sit in front of a mounted tyre
during tyre inflation. Use a clip-on air chuck
12. Determine gap between plate (3) and end of spindle with a long hose and stand to one side while
(11) at both gauging holes. To determine gap, use a the tyre is being inflated.
depth micrometer in both gauging holes to measure
distance from outer face of plate (3) to end of spindle
(11). Using a micrometer, measure thickness of plate WARNING
(3). Subtract plate thickness reading from depth gauge To prevent personal injury and property
readings. damage, always prevent flammable vapours
that could produce tyre explosions, from being
13. Average the two readings, obtained at Step 12, in pumped into tyres during inflation, by
increments of 0.03 mm (0.001 in) and round off to the observing the following precautions:
next higher 0.03 mm (0.001 in). This is the average
gap. The required shim pack (4) thickness is equal to A.
the average gap plus 0.18 mm (0.007 in). Use an air compressor and reservoir located
inside a heated building, when available, so
14. Install required shim pack (4), plate (3) and bolts (2) that alcohol, methanol, or other flammable
on end of spindle (11). Tighten bolts (2) evenly in equal antifreeze liquids are not needed in the air
increments to 'Final Bolt Torque' (ref. 'Bearing tanks to prevent moisture freezing in the tank
Adjustment Table'), while rotating and bumping wheel and lines in subfreezing temperatures.
(6) assembly. Secure bolts (2) with lockwire (1).

SM 2044 Rev1 03-05 7

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

SM - 208
B.
Make sure that paints, lacquers, paint thinners,
or similar materials that produce volatile,
flammable vapours are not used or stored near
the air intake of the compressor that supplies
the air for inflating tyres. The compressor
should be isolated from all such sources of
flammable vapours.

C.
Be sure to thoroughly flush and blow off all
flammable solvents used for cleaning the air
compressor inlet screen before using the
compressor for tyre inflation, or any other
purpose.

D.
Do not charge batteries, either in or out of a
machine, near the air inlet of a compressor
used for inflating tyres. Charging batteries Fig. 7 - Typical Safety Cage
produces highly explosive hydrogen gas which
can be readily drawn into a nearby compressor
SM - 1040
inlet and pumped into the tyre.

E.
Never exceed the specified concentration of
alcohol when adjusting the alcohol vaporiser,
or adding alcohol to the auxiliary air tank, used
on machine air systems to prevent freezing or
moisture condensate in below-freezing
temperatures. Excessive alcohol, added to the
machines air tanks in this manner can produce
flammable vapours that will be pumped into a
tyre when this air supply is used for tyre
inflation if the tyre inflation kit is not equipped
with a moisture filter. Alcohol added to
machine air systems in recommended
concentration to prevent condensate freezing
are below hazardous levels for tyre inflation.

F.
Another source of hazardous flammable
vapours in tyres is the tyre bead lubricant.
Always use bead lubricants that do not
introduce flammable vapours into the tyre.

Inflation
Fig. 8 - Nitrogen Tyre Inflation Kit
Note: Always use tyre inflation equipment with an air
filter that removes moisture from the air supply, when
available, to prevent moisture corrosion of internal rim 2. Inflate all tyres with ratings of 16-ply and above to
parts. 5.2 bar (75 lbf/in²) to seat beads and seal 'O' ring, then
adjust to the recommended pressure.
1. If the tyre is off the truck, it should be placed in a
safety cage before inflating. See Fig. 7. 3. For recommended operating air pressure, refer to the
chart under the heading, 'Tyre Inflation Pressures'.

8 SM 2044 Rev1 03-05

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

NITROGEN TYRE INFLATION b. Safety relief valve, 8.6 bar (125 lbf/in²), that will
Note: All Warnings and procedures under 'Tyre assure an upper limit to the pressure available for tyre
Inflation' will apply, except for differences covered by inflation.
this passage.
c. A 15.2 m (50 ft) length of flexible hose with
In certain environments it is recommended that tyres interconnecting fittings. On the tyre end of the hose is
be inflated with dry nitrogen gas, and that the resulting a large bore quick connect/disconnect clip-on chuck.
oxygen content of the inflation does not exceed 5%. All
machines whose tyres are factory inflated with dry 2. The pressure regulator is connected to a nitrogen
nitrogen gas will be identified by a decal on the body or compressed gas cylinder available from local suppliers.
frame.
3. The usual procedure for using this type of equipment
Nitrogen gas improves tyre pressure retention, is as follows:
increases tyre life by reducing carcass oxidation from
within, minimizes rim rust and has no detrimental a. Connect nitrogen tyre inflation kit to nitrogen
effects on the tyre. It also reduces the potential of a compressed gas supply. DO NOT connect clip-on
tyre explosion because it is an inert gas and will not chuck to the tyre valve at this time.
support combustion inside the tyre.
b. Open valve on nitrogen supply.
The same tyre inflation pressure used for air inflation
should be used for nitrogen inflation. Tyre valves c. With flexible hose and clip-on chuck connected to
formerly used with air inflation are entirely satisfactory nitrogen tyre inflation kit assembly but not connected
for use with nitrogen gas. to the tyre, adjust pressure regulator so that its output
pressure is not more than 1.4 bar (20 lbf/in²) higher
than the desired tyre inflation pressure.
Nitrogen Tyre Inflation Kit
d. Connect clip-on chuck to the tyre valve. The tyre will
now inflate. Tyre pressure can be monitored by
WARNINGS observing the gauge at the pressure regulator. STAY
DO NOT USE charging assembly, Part No. AWAY FROM THE TYRE.
9359489, for tyre inflation because this
assembly does not include a pressure e. When desired inflation pressure has been achieved,
regulator, safety relief valve, and adequate back off the regulator or close the valve on the
pressure gauging which is mandatory for tyre compressed gas cylinder.
inflation purposes. Tyre volume is as much as
90 times greater than the average accumulator f. Remove the clip-on chuck and adjust the tyre
volume and hence it takes very much longer to pressure with the tyre gauge in the usual manner.
inflate a tyre - up to 40 minutes or more for very
large tyres.
Re-inflation of a Mounted Tyre
Nitrogen gas cylinders used to inflate To re-inflate a tyre with dry nitrogen gas which is now
tyres are generally charged to approximately inflated with air, proceed as follows:
152 bar (2 200 lbf/in2). A tyre blowout and/or rim
failure could occur if inflation equipment is not 1. Exhaust the tyre until only air at atmospheric
properly used. Proper nitrogen charging pressure remains in the tyre.
equipment and personnel training for its use is
a must to avoid over inflation. 2. Re-inflate the tyre using only dry nitrogen gas to
4.15 bar (60 lbf/in²) gauge as a minimum, or to bead-
1. A nitrogen tyre inflation kit is available from your seating pressure as a maximum.
dealer and consists of the following. Refer to Fig. 8.
3. Adjust to the service inflation pressure required:
a. Pressure regulator, 0 - 13 bar (0 - 200 lbf/in2), with
two dual pressure gauges. a. If the required service inflation pressure is LESS
than 4.1 bar (60 lbf/in²), remove the clip-on chuck and

SM 2044 Rev1 03-05 9

Rear Axle - Wheel, Rim and Tyre
Section 160-0050
adjust the pressure with the tyre gauge in the usual SM - 214
manner.

b. If the required service inflation pressure is greater

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

New Tyre Mounts and Remounts

To newly mount or remount a tyre to its rim, use only
dry nitrogen gas; this includes the pressure required to
seat the beads. After seating the tyre beads, remove
the clip-on chuck and adjust the pressure with the tyre
gauge in the usual manner.

Note: Although a little more nitrogen gas is used to

Fig. 9 - Typical Hydraulic Bead Breaking Tool
seat beads than that used for re-inflation of a mounted
tyre, refer to 'Re-inflation of a Mounted Tyre', its cost is
generally negligible in comparison to the time and 4. Adjust the locking screw to a position which will hold
labour saving and, longer tyre life achievable with the the tool in a line perpendicular to the face of the rim.
reduced oxygen content which results.
5. Close valve on the hydraulic pump and apply
pressure to take up the slack in the tool and rim parts.
HYDRAULIC BEAD BREAKING TOOL This will cause the tool to tilt slightly downward.
The hydraulic bead breaking tool illustrated in Fig. 9 is Release pressure and adjust the screw again so that
specifically designed to break tyre beads on rusted the tool will be perpendicular to the rim when under
rims, and is available from your dealer. Refer to pressure.
Special Tools. It can be used on rims having pry bar
slots. The recommended procedure for using this tool 6. Apply enough pressure to move the flange back
is described below. approximately 13 mm (0.5 in) and hold this distance by
dropping a nut, or similar object, in the space between
1. Prepare the vehicle for dismounting the tyre by the flange and bead seat band.
following the necessary steps outlined under the
headings 'Preparation for Servicing' and 'Dismounting 7. Release pressure and move the tool about 300 mm
Tyre from Rim'. (12 in) around the rim in either direction. Insert lip of
tool between bead seat band and flange. Repeat cycle
2. Before using the tool, make sure the tyre has been until 3/4 of the rim circumference has been covered.
completely deflated by removing the valve core. Refer Apply pressure at this point until bead breaks loose.
to the Warning under 'Preparation for Servicing'. Tape
valve threads to protect from damage, leaving valve 8. Remove lock ring, bead seat band and rim flange as
end open to avoid the possibility of trapping air inside described previously in this section under 'Dismounting
the tyre. Tyre from Rim'.

3. Place the lip of the hydraulic tool in one of four 9. After lock ring, bead seat band and rim flange have
breaking slots between the bead seat band and the rim been removed, inner bead must be broken loose by
flange. following the procedure outlined for the outer bead,
(steps 3 through 7).

10 SM 2044 Rev1 03-05

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

SM - 218

AT LEAST 15 m (50 ft) AT LEAST 460 m

(1 500 ft)

Fig. 10 - APPROACH AREA. Do Not Approach Tyre in Shaded Area

TYRE EXPLOSION HAZARD

WARNINGS There is always a possibility of a tyre

Whenever a machines tyre(s) is (are) exposed to explosion whenever the smell of burning
excessive heat such as a machine fire or rubber or excessively hot brakes is detected.
extremely hot brakes the hazard of a The danger is also present when a fire on the
subsequent violent tyre explosion must be machine reaches the tyre and wheel area. Under
recognized. All persons must avoid such conditions, all personnel must avoid
approaching the machine so as not to be approaching the machine in a manner that
physically endangered in the event of an could result in injury should an explosion
explosion of the tyre and rim parts. The actually occur. Move the machine to a remote
machine should be moved to a remote area, but area only if it can be done without endangering
only when this can be done with complete the operator or other personnel in the area.
safety to the operator operating or towing the
machine. All other persons should stay clear of DO NOT WELD ON OR HEAT RIM
the machine. The fire or overheated brakes, COMPONENTS. For several years the company
wheel, etc. should be extinguished or cooled and tyre and rim manufacturers have warned
from a safe distance. Do not attempt to users never to weld rim components with the
extinguish the fire or cool the machine by use tyre mounted on the rim. The gases that build
of hand-held fire extinguishers. up inside the tyre during arc welding or heating
on rim components can ignite, resulting in one
If it is absolutely necessary to approach a of these explosive-like failures of the tyre and
machine with a suspect tyre, approach only rim. This warning also applies to nitrogen
from the front or the back. Stay at least 15 m (50 inflated tyres. Ignition will not occur in the
ft) from the tread area. Keep observers out of nitrogen atmosphere, but the pressure buildup
the area and at least 460 m (1 500 ft) from the from the heat of welding may be sufficient to
tyre sidewall. Refer to Fig. 10. The tyre(s) cause a blowout severe enough to injure or kill.
should be allowed at least eight (8) hours It is recommended to scrap the part if heat is
cooling time after the machine is shut down or necessary to repair any rim component.
the fire extinguished before approaching closer.

SM 2044 Rev1 03-05 11

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

TYRE MAINTENANCE A retreaded tyre has the old tread removed entirely and
a new tread cured directly onto the body of the tyre. A
Tyre Repairs tyre can be recapped or retreaded if the cord body is
Prompt repair of tyre injuries will prevent small injuries free of cuts, bruises and separation, and is thoroughly
from enlarging and causing tyre failure. Use the best sound, including previous repairs.
tyre facilities available. If good repair facilities are not
available, have the nearest dealer make the necessary
repairs. TYRE CARE
To obtain maximum service from off-the-highway tyres,
Minor cuts, snags, or punctures should be repaired a few common-sense precautions should be followed.
upon discovery. Skive with a sharp pointed knife
around any cut in the tyre tread area that is of
sufficient depth or shape to hold pebbles or dirt. The Maintain Correct Inflation
angle of the skive should be no more than sufficient to The most common cause of tyre damage is improper
expel all foreign material and should extend no deeper inflation. Both over-inflation and under-inflation are
than the breaker. The skive should go to the bottom of detrimental to tyre life. Tyre pressure should be
the hole. Tyres with shallow cuts, if treated promptly, checked daily, preferably before the machine is placed
may be allowed to continue in service. If the cut in operation. Refer to 'Tyre Inflation Pressures' for tyre
extends deeper into the tyre carcass, the tyre should pressure.
be removed for repair.
The valve cores should be checked for leaks. Keep in
Ordinary tubeless tyre punctures can be repaired mind that valve cores are delicate mechanisms that
without removing the tyre from the rim. Use tyre repair wear out in service; therefore, they should be replaced
plugs and follow the directions given by the when they become worn. Each tyre should be equipped
manufacturer. with a valve cap to prevent dirt from damaging the
valve core and causing air leakage.
The tyre must be removed from the rim to repair larger
punctures or cuts. Irregular shaped punctures or cuts
less than 13 mm (0.5 in) in size can be repaired with a Maintain Good Haul Roads
plug and hot patch. Insert a repair plug into the hole to Because haul roads are considered temporary roads,
keep out moisture and to back up the hot patch. Trim they are frequently neglected. The better the haul road,
the plug off flush with the inside of the casing, buff, the longer the tyre and truck life of off-the-highway
and apply the hot patch according to the instructions equipment.
supplied with the hot-patch equipment.
Although it takes time and effort to maintain good haul
Punctures 13 mm (0.5 in) or larger, large cuts, or bruise roads, the delay and cost of tyre and truck breakdowns
breaks require sectional or reinforced vulcanized repair. caused by poor haul roads is many times greater.
Cover the repair patch with a layer of cushion gum after
application to the tubeless tyre to ensure an airtight
repair. Any cords of the inside ply that are exposed in
Inspect Tyres Regularly
bugging and are not covered with repair patch must be A systematic plan for tyre inspection will more than
coated with cushion gum to prevent air leakage into the pay for itself in lowered tyre costs per hour of
carcass plies on tubeless tyres. operation. All tyres should be checked regularly for
cuts, bruises, fabric breaks, excessive or uneven wear,
embedded foreign matter, and any other damage which
Recapping and Retreading can be repaired. A considerable increase in tyre
There are two general methods employed in restoring service can be realized if tyre injuries are repaired
the tread surface of off-the-highway tyres: recapping, before they have progressed to the irreparable stage.
and retreading. The rim mounting nuts should be checked periodically
and tightened to the recommended torque.
A recapped tyre has a new tread cured right over the
old tread surface.

12 SM 2044 Rev1 03-05

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

Prevent Overloading hooks, cables, or chains in contact with the tyre beads
Off-the-highway trucks are designed to carry a when lifting these tyres. If forklift trucks are used for
maximum allowable payload. Excessive loading will handling they should be equipped with broad, well
overstress both the truck and tyres and shorten the life rounded arms to distribute the load and prevent
of both. damage to the tyre bead. When handling tyres with the
fork truck do not scrape the fork across the bead.
Prevent Tyre Contact With Oil Tubeless tyre rims perform an important function as
PREVENT TYRE CONTACT WITH PETROLEUM part of the assembly air seal. Proper care therefore
PRODUCTS. Rubber that is exposed to oil, petrol, or must be taken not to distort or mutilate the rim parts
grease becomes soft and spongy and deteriorates because they must mate properly to form part of the
rapidly. Always avoid driving trucks equipped with basic air chamber. Since the rim base, bead seat
rubber tyres through a puddle of petrol, fuel oil, bands, and flanges are endless, distortion may prevent
lubricating oil, or grease. Never let a tyre stand in an oil easy assembly as well as possibly resulting in no seal.
or grease spot overnight.
Never drop, tumble, or roll rim parts.
Store Tyres Properly If rim parts are stored outdoors they should be given a
The best of care given to tyres in service by operators protective coat of a good commercial primer.
and maintenance personnel can be completely nullified
by careless storage. Time is not the only contributing Similar parts should be stacked neatly to prevent
factor to the deterioration of rubber products. Therefore, distortion.
tyres that are to be stored must be protected from light,
heat, oils, dirt, moisture, and ozone. Stored tyres Babbit or lead hammers, not sledge hammers, should
should be carefully covered with a tarpaulin or some be used in assembling rims.
other suitable material, such as opaque plastic sheets,
to prevent contact with the contaminants listed. 'O' rings are seals and should be carefully stored in a
cool, dry place where they will not be injured or
damaged.
Proper Handling of Tubeless Tyres and
Rims Valve cores also should be stored in a cool, dry and
Tubeless tyres should be stored vertically. Horizontal clean place.
stacking may compress the tyre walls making inflation
difficult. If tyres are stored in racks, the lower
supporting members should provide as broad a surface SPECIAL TOOLS
as possible to the tyre tread to avoid a concentration of Refer to Section 300-0070, SERVICE TOOLS, for part
load. numbers of special tools outlined in this section and
general service tools required. These tools are
The beads of tubeless tyres must be protected from available from your dealer.
damage or a faulty air seal will result. Do not use

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 3 Nut 690 510
6 2 Bolt Refer to 'Bearing Adjustment Table'

SM 2044 Rev1 03-05 13

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

TUBELESS TYRE LEAK DIAGNOSIS

Occasionally a tubeless off highway tyre/rim assembly may leak in field service. To determine cause of
leakage, the entire assembly including valve hardware, multi-piece rim assembly, 'O' ring and tyre should be
checked using a soap solution.
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.

TYRE INFLATION PRESSURES maintenance and length, maximum and workday

E3 tyres may be so roaded up to 48 km/h (30 mile/h), average speed, job t-km/h (ton-mile/h) required and tyre
maximum, with a 30 minute cooling stop after each t-km/h (ton-mile/h) capacity, etc., may require an
80 km (50 miles) or 2 hours sustained operation - increase in inflation pressure. It is recommended that
whichever occurs first - and a 60 minute cooling stop for tyres both listed and unlisted the user consult the
after each aggregate of 4 hours of operation. tyre manufacturer and evaluate all job conditions in
order to make the proper selection.
E4 tyres may be so roaded up to 32 km/h (20 mile/h),
maximum, with a 30 minute cooling stop after each
32 km (20 miles) or 1 hour of sustained operation - TYRE INFLATION PRESSURES
whichever occurs first - and a 60 minute cooling stop PRESSURE
after each aggregate of 4 hours of operation.
TYRE MAKE/SIZE bar lbf/in²
The inflation pressures listed should be regarded as Bridgestone 24.00 R 35** Radial 7 102
nominal only. Specific job conditions, terrain, haul road
Michelin 24.00 R35**Radial 6.5 94

* * * *

14 SM 2044 Rev1 03-05

 BRAKE PARTS - Front Axle
Section 165-0020

DESCRIPTION AND OPERATION SM - 244

WARNINGS
Use only hydraulic oils meeting specifications
outlined in Section 300-0020, LUBRICATION
SYSTEM. DO NOT use BRAKE FLUID (J1703).
Use of improper fluids is destructive to rubber
components of brakes resulting in loss of
braking and possible catastrophic failure.

Exercise extreme caution while working

on the braking system. The braking system
operates at high pressure.

When servicing wheel brake parts, do not

create dust by grinding or sanding brake pads
or wheel brake parts with a dry brush or
compressed air. A water dampened cloth
should be used for cleaning wheel brake parts.

The service brakes are of the calliper disc-type. The

calliper brake head is designed for use with hydraulic
oils meeting the specifications outlined in Section
300-0020, LUBRICATION SYSTEM. DO NOT use
BRAKE FLUID (J1703). 1 - Brake Disc 4 - Bolt
2 - Bolt 5 - Washer
The head is bolted to a mounting plate on the spindle. 3 - Washer 6 - Brake Head
The disc is bolted to the wheel. There are two brake Fig. 1 - Brake Head and Disc Mounting
heads and a brake disc for each wheel.

Each calliper brake head assembly consists of a

torque plate, two brake pads; one on each side of the WARNING
disc and six brake pistons; three on each side of the Failure to replace pads when worn to limits will
disc. result in loss of braking and possible
catastrophic failure.
The brake is actuated by hydraulic oil entering the
brake head through one of the bleeder ports. The 2. Inspect brake disc for wear. Measure thickness of
piston bores on each side of the torque plate are brake disc at three points on the brake pad friction
interconnected by internal passages. material contact circumference and determine the
average disc thickness.
When the brake is actuated, the hydraulic pressure
forces the pistons against the brake pads which are, in If the average disc thickness is 16 mm (0.63 in) or
turn, forced against each side of the brake disc, less, the disc must be replaced. Refer to Section
slowing or stopping the disc and wheel rotation. 140-0040, WHEEL, RIM AND TYRE, for disc
replacement instructions.
GENERAL INSPECTION
1. Inspect brake pads for wear. If the brake pad friction Disc Run Out
material is worn down to 3 mm (0.120 in) thickness, Maximum acceptable disc run out for disc speeds
the pads must be replaced. lower than 100 rev/min is 0.762 mm (0.030 in) total
indicated reading (T.I.R.). Replace disc or repair hub If
necessary to correct this condition. Refer to
Section 140-0040, WHEEL, RIM AND TYRE.

SM 1916 7-00 1
Brake Parts - Front Axle
Section 165-0020

SM - 043

1- Bleeder 5- Brake Pad 9- Plug 13 - Packing

2- Bolt 6- Torque Pin 10 - Seal 14 - Backup Ring
3- Torque Pin 7- Bolt 11 - Piston 15 - Torque Plate
4- Brake Pad 8- Cover Plate 12 - Boot 16 - Washer

Fig. 2 - Exploded View of Typical Brake Head

BRAKE PAD REMOVAL AND 2. Turn the steering wheel in both directions several
INSTALLATION times to relieve pressure in the steering system. Block
Numbers in parentheses refer to Fig. 2. all road wheels. Remove tyre and rim, as described in
Section 140-0040, WHEEL, RIM AND TYRE.
Note: Tighten all fasteners without special torques
specified, to torques listed in Section 300-0080, 3. Loosen two bolts (2) securing large torque pins (3)
STANDARD BOLT AND NUT TORQUE at the end of the brake head. It is not necessary to
SPECIFICATION. loosen or remove the two smaller torque pins (6) at
opposite end.

WARNINGS 4. Move the two unlocked torque pins (3) away from
To prevent personal injury and property the brake disc.
damage, be sure blocking or lifting equipment
is of sufficient capacity and properly secured 5. Attach a bleeder line and open bleeder valve (1).
to do the job safely. Use a screwdriver or pry bar inserted between the
brake disc and brake pads to press pistons (11) back
Use extreme caution to prevent personal into torque plate (15) piston bores, as far as possible.
injury when removing wheel. The exact Close bleeder valve.
procedure must be adhered to as described in
Section 140-0040, WHEEL, RIM AND TYRE. 6. Rotate brake pads (4 & 5) out of the opened end of
the brake.
To prevent personal injury, keep hands
and fingers etc. clear of the area between the 7. Install new brake pads (4 & 5) by placing friction
brake disc and the brake head pistons. material next to the brake disc and rotating into
position in the brake head.
1. Position the vehicle in a level work area, apply the
parking brake and shutdown the engine. 8. Push the two unlocked pins (3) toward the brake disc.

2 SM 1916 7-00
 Brake Parts - Front Axle
Section 165-0020

9. Thread the two loosened bolts (2) in until bolts seat BRAKE REMOVAL AND DISASSEMBLY
in grooves of pins (3). This can be checked by limited Numbers in parentheses refer to Fig. 2, unless
axial movement of pins as the bolts are being seated. otherwise specified.
Tighten bolts (2) to a torque of 30 - 38 Nm (22 - 28 lbf ft).

Note: Make sure torque pins (3 & 6) do not touch the WARNINGS
brake disc. If they do, loosen bolts (2) and adjust pins To prevent personal injury and property
to clear disc by 1.5 to 3.0 mm (0.060 to 0.120 in). damage, be sure blocking or lifting equipment
Check to make sure that bolts (2) fully engage in pins is of sufficient capacity and properly secured
and retighten bolts. to do the job safely.

10. Depress the brake pedal until brake pads (4 & 5) Use extreme caution to prevent personal
contact the brake disc. injury when removing wheel. The exact
procedure must be adhered to as described in
Section 140-0040, WHEEL, RIM AND TYRE.
WARNING
Ensure the steering and brake control tank is To prevent personal injury, follow the
maintained at the proper level at all times. procedure given for relieving the pressure in
Refer to Section 220-0040, STEERING AND the braking system and exercise extreme
BRAKE CONTROL TANK. caution when loosening brake pipes or lines.

11. When new brake pads are installed on a truck, the 1. Position the vehicle in a level work area, apply the
brake pad friction material should be burnished in parking brake and switch off the engine.
accordance with the following procedure to achieve
maximum braking performance: 2. Turn the steering wheel in both directions several
times to relieve pressure in the steering system.
a. Drive truck at 8 - 15 km/h (5 - 10 mile/h) with brakes Operate the treadle valve continuously to relieve
applied at just enough pressure to produce a pressure in the brake accumulators. Block all road
noticeable drag. Heavy smoke and foul odour from the wheels. Remove tyre and rim, as described in Section
brake pad friction material is normal during this 140-0040, WHEEL, RIM AND TYRE.
procedure.
3. Carefully loosen brake pipes at base of both
Note: An infrared thermometer pointed at the disc accumulators to check that pressure has released.
after stopping, can safely and easily determine the Re-tighten brake pipes.
brake disc temperature. Refer to 'Special Tools'.
4. Remove hydraulic oil inlet line at brake head
b. Continue cycle until the brake disc achieves a assembly. Plug the line and brake head to prevent
temperature of 315 - 370o C (600 - 700o F). entry of dirt.

c. Permit the brake disc to cool to a temperature of 5. Remove bolts (4, Fig. 1) and washers (5, Fig. 1)
less than 95o C (200o F). from mounting at spindle and remove brake head
assembly to working area.
d. Repeat Steps a and b.
6. Disassemble brake head assembly in sequence of
e. Allow brake disc to cool to within 10o C (50o F) of index numbers. Items (1, 2 & 3) may be left in torque
ambient temperature. plate (15) when servicing packings (13), seals (10),
backup rings (14) and boots (12), if desired.
f. Repeat Steps a and b until full braking performance
(per applicable government regulations) is achieved. 7. Repair kits are available which include new boots
(12), backup rings (14), packings (13) and seals (10)
in quantities sufficient to rebuild a calliper brake head.
All parts included in a repair kit should be replaced
each time a brake head is rebuilt.

SM 1916 7-00 3
Brake Parts - Front Axle
Section 165-0020
8. Inspect brake pads (4 & 5) per Step 1 in the to press pistons the remainder of the way into piston
'General Inspection Procedure'. bores. Snap open end of boot (12) into groove of
piston.
9. Clean torque plate (15) making sure no solvent
remains in the oil passages or grooves. Inspect dust 6. Install seals (10) and piston plugs (9) into open end
boot and seal grooves, and, land areas between of piston bores of torque plate (15).
grooves for damage or cracks. Minor nicks and
scratches may be blended with crocus cloth. Replace 7. Attach cover plate (8) to torque plate with bolts (7)
torque plate (15) if corrosion is excessive or dust boot and washers (16). Tighten bolts (7) to a torque of
and seal grooves are damaged, prohibiting proper 380 Nm (280 lbf ft).
rebuild of brake head.
8. When installing torque pins (3 & 6) and bolts (2)
10. Inspect pistons (11) for minor scratches and nicks make sure the groove in the pin is directly under the
and blend with crocus cloth. If piston is badly nicked or bolt so that bolt (2) can perform its locking and
scratched or if the chrome plate is worn off, replace retaining function.
piston.
Note: Lubricate torque pins (3 & 6) with a corrosion
11. Torque pins (3 & 6) which are deeply grooved resistant lubricant prior to installation, to facilitate next
should be replaced. pin removal.

9. Replace brake disc (1, Fig. 1) if worn per

ASSEMBLY instructions under 'General Inspection' in this section.
Numbers in parentheses refer to Fig. 2 unless Refer to Section 140-0040, WHEEL, RIM AND TYRE,
specified otherwise. for replacement instructions.

Note: Tighten all fasteners without special torques

specified, to torques listed in Section 300-0080, INSTALLATION
STANDARD BOLT AND NUT TORQUE Numbers in parentheses refer to Fig. 1, unless
SPECIFICATION. otherwise specified.

1. Lubricate packings (13), seals (10) and pistons (11) Note: Tighten all fasteners without special torques
with petroleum base lubricating oil or vaseline. specified to torques listed in Section 300-0080,
STANDARD BOLT AND NUT TORQUE
SPECIFICATION.
WARNING
Do not use brake fluid (SAE J1703).
WARNINGS
2. Install backup rings (14), packings (13) and boots To prevent personal injury and property
(12) into torque plate (15) piston bores. Lubricate per damage, be sure blocking or lifting equipment
Step 1. is of sufficient capacity and properly secured
to do the job safely.
3. Install pistons (11) in torque plate (15) as follows:
Position lubricated piston (11) into dust boot (12) and Use extreme caution to prevent personal
piston bore, holding piston at a slight angle. Insert injury when installing wheel. The exact
forefinger between piston and dust boot and rotate procedure must be adhered to as described in
forefinger around piston OD, lifting dust boot ID over Section 140-0040, WHEEL, RIM AND TYRE.
OD of piston. Make sure OD lip of dust boot remains in
the groove in the piston bore. 1. Install washers (5) on bolts (4).

4. After piston (11) is through dust boot (12), centre 2. Position brake head over brake disc on brake
piston by feel over packing (13). Apply, by hand, a mounting plate, aligning holes. Install assembled bolts
turning thrusting pressure, working piston into and (4) and washers (5) through mounting plate and into
through packing. torque plate. Tighten bolts (4) to a torque of 610 Nm
(450 lbf ft).
5. When assured pistons (11) are through packings
(13), pressure other than hand pressure may be used Note: Ensure torque pins (3 & 6, Fig. 2) do not touch

4 SM 1916 7-00
 Brake Parts - Front Axle
Section 165-0020
the brake disc. If they do, loosen bolts (2) and adjust air bubbles. Close bleeder valve and release the brake
pins to clear disc by 1.5 - 3.0 mm (0.060 - 0.120 in). treadle. Remove bleeder line.
Check to make sure that bolts (2, Fig. 2) fully engage
in pins and tighten bolts to a torque of 30 - 38 Nm Note: This system is equipped with accumulators
(22 - 28 lbf ft). which maintain pressure in the system even after
engine shutdown. However, If the system pressure is
3. Remove plugs from brake head and hydraulic inlet zero, it will be necessary to start the engine to charge
line and attach hydraulic inlet line at brake head. the system prior to bleeding. Always shutdown the
engine before starting bleeding procedure.
4. Bleed the braking system as described under the
heading 'Bleeding' in this section. 4. Repeat Steps 1 through 3 at each brake head
assembly.
5. Install tyre and rim. Refer to Section 140-0040,
WHEEL, RIM AND TYRE.
MAINTENANCE
Every 10 Hours of Operation (Daily)
BLEEDING Inspect brake assembly to ensure that all bolts are
Numbers in parentheses refer to Fig. 2. tight and there are no leaks. Inspect for boot
deterioration.
In order to obtain satisfactory braking, the system
should be bled as follows to eliminate any air in the Check oil level in the steering and brake control tank
hydraulic brake lines: and add oil if low. Refer to Section 220-0040,
STEERING AND BRAKE CONTROL TANK, for
1. Check oil level in the steering and brake control correct fill level and Section 300-0020, LUBRICATION
tank and add oil if low. Refer to Section 220-0040, SYSTEM, for oil specification.
STEERING AND BRAKE CONTROL TANK, for
correct fill level and Section 300-0020, LUBRICATION Every 250 Hours of Operation
SYSTEM, for oil specification. Check the brake pads and discs for wear and adjust or
replace where necessary. Test for proper function.
2. Securely connect a bleeder line to bleeder valve (1),
and place loose end of line in clean container. Note: This service interval applies to normal driving.
Check the pads more frequently under more severe
conditions. Thickness of pad friction material should
WARNING never be allowed to wear below 3 mm (0.12 in).
Loosen bleed nipples carefully. The braking
system operates at high pressure.
SPECIAL TOOLS
3. Depress brake treadle valve and gradually open Refer to Section 300-0070, SERVICE TOOLS, for part
bleeder valve (1). Bleeder valve should remain open numbers of the non-contact infrared thermometer and
until oil exhausting from the bleeder valve is free from general service tools required. These tools are
available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 4 Bolt 610 450
2 2 Bolt 30 - 38 22 - 28
2 7 Bolt 380 280

* * * *
SM 1916 7-00 5
 BRAKE PARTS - Rear Axle
Section 165-0030

DESCRIPTION AND OPERATION plates (30). The rotating discs are compressed
Numbers in parentheses refer to Figs. 1 and 2. between the splined plates and are held stationary,
thus keeping the wheels from rotating. As long as
Service Brakes there is no hydraulic pressure at port 'F', Fig. 2,
Note: The service brakes are of 'Upright Design', i.e. parking brake will be applied. When hydraulic oil
requiring pressure to hold the brakes on. pressure is applied at port 'F', Fig. 2, parking brake
will be released.
The rear service brakes are hydraulically actuated to
slow or stop drive wheel rotation. When the service
brake treadle in the operators' compartment is REMOVAL
depressed, or when the retarder control lever on the Numbers in parentheses refer to Figs. 1 and 2.
centre console is actuated, with the retarder selection
switch at the disc brake position, hydraulic pressure
is transmitted to port 'D', Fig. 2, on the disc brake WARNINGS
assembly. Hydraulic pressure entering port 'D', Fig. To prevent personal injury and property
2, forces service piston (31) against the brake disc damage, be sure wheel blocks, blocking
pack consisting of damper assemblies (28), rotating materials and lifting equipment are properly
friction discs (29) and splined plates (30). secured and of sufficient capacity to do the
job safely.
The rotating friction discs, which are driven by the
wheel, through wheel drivers (5) and disc drivers Hydraulic fluid will remain within the
(27), are compressed between splined plates (30). braking system after engine shutdown.
This slows down and stops rotation of the driving Operate the treadle valve continuously until
wheels. The force applied against the disc pack is the pressure has dissipated before carrying
directly proportional to the degree of which the out any work on the braking system or serious
service brake treadle is depressed. injury could result.

When the service brake treadle or retarder control Use extreme caution to prevent personal
lever is released, hydraulic pressure against service injury when removing wheels. The exact
piston (31) is relieved, brake return springs (36) procedure must be followed as described in
tension against heads of retaining pins (35) forces Section 160-0050, WHEEL, RIM AND TYRE.
the pins to return service piston (31) to its original
position, thus, relieving the pressure against the Note: Before removing and disassembling disc brake
brake disc pack. assemblies, measure and record the amount of wear
of the brake disc and damper plates. Refer to 'Disc
Assembly Wear Measurement Procedure', under
Parking Brakes 'Inspection' in this section, for the measurement
Note: The parking brake is of 'Inverted Design', i.e. procedure and the maximum allowable wear limits.
requiring pressure to hold the brakes off.
1. Position the vehicle in a level work area, apply the
The parking brakes are controlled by the park/ parking brake and switch off the engine.
emergency brake control mounted on the instrument
panel. The parking brakes are applied by spring 2. Turn the steering wheel in both directions several
tension and released by hydraulic pressure. With the times to relieve any pressure in the steering circuit.
control pulled 'OUT', hydraulic oil enters port 'F', Fig. Operate the treadle valve continuously to relieve any
2, flows through a channel in disc housing (25) into a pressure in the braking system. Block all road
passage behind parking piston (23). Hydraulic oil wheels.
pressure forces parking piston (23) against the
tension of springs (20 & 21), keeping pressure off of 3. Remove plug (47) and drain cooling oil from disc
the damper assemblies (28), thereby keeping brake assembly into a clean container. Reinstall plug.
pressure off the disc pack. With the control pushed
'IN', hydraulic pressure at port 'F', Fig. 2, is released, 4. Open bottom bleeder valve (52) and drain brake
pressure against parking piston (23) is released. hydraulic oil into a clean container. Close bleeder
Spring (20 & 21) tension forces the parking piston valve.
against damper assembly (28) and disc pack
consisting of rotating friction discs (29) and splined

SM 2038 7-00 1
Brake Parts - Rear Axle
Section 165-0030

SM - 2550

SPINDLE

BEARING

SECTION E-E

1 - Inner Seal Housing 16 - Hardened Washer 30 - Splined Plate 44 - Stud

2 - 'O' Ring 17 - 'O' Ring 31 - Service Piston 45 - Pipe Plug
3 - Face Seal *18 - Dowel 32 - Pin 46 - 'O' Ring
4 - 'O' Ring 19 - Dowel 33 - Bolt 47 - Plug
5 - Wheel Driver 20 - Spring 34 - Retainer Plate 48 - Bleeder Valve
6 - Hardened Washer 21 - Spring 35 - Retaining Pin 49 - Hardened Washer
7 - Bolt 22 - Seal 36 - Return Spring 50 - Nut
8 - 'O' Ring 23 - Parking Piston 37 - 'O' Ring 51 - 'O' Ring
9 - Bolt 24 - Seal 38 - 'D' Section Seal 52 - Bleeder Valve
10 - Seal Housing 25 - Disc Housing 39 - 'D' Section Seal 53 - Hardened Washer
11 - Face Seal * 26 - Dowel 40 - 'O' Ring 54 - Bolt
12 - Bolt 27 - Disc Driver 41 - Piston Housing Assembly 55 - Spacer Ring
13 - Hardened Washer 28 - Damper Assembly 42 - Hardened Washer 56 - Spacer Ring
14 - Spring Housing 29 - Friction Disc 43 - Socket Head Screw 57 - Cap
15 - Socket Head Screw
* Shown on Fig. 2.
Fig. 1 - Cutaway View of Typical Disc Brake Assembly (SECTION A-A - Fig. 2)

2 SM 2038 7-00
 Brake Parts - Rear Axle
Section 165-0030

SM - 2551

NOTE: SECTION A-A Shown on Fig. 1.

14 - Spring Housing 28 - Damper Assemblies 37 - 'O' Ring 42 - Hardened Washer

17 - 'O' Ring 29 - Friction Disc 38 - 'D' Section Seal 43 - Socket Head Screw
18 - Dowel 30 - Splined Plates 39 - 'D' Section Seal 45 - Pipe Plug
22 - Seal 31 - Service Piston 40 - 'O' Ring 48 - Bleeder Valve
25 - Disc Housing 33 - Bolt 41 - Piston Housing Assembly 52 - Bleeder Valve
26 - Dowel

Fig. 2 - Typical Disc Brake Assembly

Note: To minimize loss of brake hydraulic oil when 5. Tag and disconnect brake cooling lines from ports
the brake tubes are removed from the brake 'B' and 'C' on piston housing assembly (41). See
assemblies, remove the air breather from the steering Fig. 2. Plug lines and ports to prevent ingress of dirt
and brake control tank and connect a vacuum pump and hold oil in lines and tank.
to the breather port. Evacuate the air in the tank to a
vacuum of 0.5 - 0.7 bar (15 - 20 inches of mercury). 6. Tag and disconnect service brake tube from port 'D'

SM 2038 7-00 3
Brake Parts - Rear Axle
Section 165-0030

SM - 2552

42 43
28 31 33 34 36 32 35 37 38 39 41

50
45
44 49

51

48 52
46 47

24 56 25 4 27 28 29 30 29

40
18 26

12 13 14 20 21 23
17
3 10 11

9 53
15 16
19 55 22
4 5 8 1 2

6 7 54

Fig. 3 - Exploded View of Typical Disc Brake Assembly

4 SM 2038 7-00
 Brake Parts - Rear Axle
Section 165-0030

1 - Inner Seal Housing 16 - Hardened Washer 30 - Splined Plate 44 - Stud

2 - 'O' Ring 17 - 'O' Ring 31 - Service Piston 45 - Pipe Plug
3 - Face Seal 18 - Dowel 32 - Pin 46 - 'O' Ring
4 - 'O' Ring 19 - Dowel 33 - Bolt 47 - Plug
5 - Wheel Driver 20 - Spring 34 - Retainer Plate 48 - Bleeder Valve
6 - Hardened Washer 21 - Spring 35 - Retaining Pin 49 - Hardened Washer
7 - Bolt 22 - Seal 36 - Return Spring 50 - Nut
8 - 'O' Ring 23 - Parking Piston 37 - 'O' Ring 51 - 'O' Ring
9 - Bolt 24 - Seal 38 - 'D' Section Seal 52 - Bleeder Valve
10 - Seal Housing 25 - Disc Housing 39 - 'D' Section Seal 53 - Hardened Washer
11 - Face Seal 26 - Dowel 40 - 'O' Ring 54 - Bolt
12 - Bolt 27 - Disc Driver 41 - Piston Housing Assembly 55 - Spacer Ring
13 - Hardened Washer 28 - Damper Assembly 42 - Hardened Washer 56 - Spacer Ring
14 - Spring Housing 29 - Friction Disc 43 - Socket Head Screw 57 - Lockwire
15 - Socket Head Screw
Legend for Fig. 3

on piston housing assembly (41). See Fig. 2. Plug a clean flat surface with spring housing (14) side up.
tube and port to keep out dirt and hold oil in tube.
17. Repeat Steps 3 through 16 to remove the opposite
7. Tag and disconnect parking brake tube from port 'F' disc brake assembly.
on piston housing assembly (41). See Fig. 2. Plug
tube and port to keep out dirt and hold oil in tube.
DISASSEMBLY
8. Remove wheel assembly from the truck as Numbers in parentheses refer to Fig. 3.
described in Section 160-0050, WHEEL, RIM AND
TYRE.
WARNING
9. Lay wheel down with wheel driver (5) up. To prevent personal injury and property
damage, ensure lifting equipment is of
10. Remove and discard 'O' ring (8) from outer sufficient capacity and properly secured to do
diameter of wheel driver (5). the job safely.

11. Remove bolts (7) and hardened washers (6) 1. Remove bolts (9) and hardened washers (53)
securing wheel driver (5) to wheel. Using a suitable securing seal housing (10) to disc driver (27) and
lifting device, lift wheel driver from wheel. remove seal housing.

12. Remove and discard 'O' ring (4) from spindle. 2. Remove and discard 'O' ring (4) from outer
diameter of disc driver (27).
13. Remove and discard bolts (54) securing inner seal
housing (1). Remove seal housing from spindle. 3. Remove face seal (11) from disc driver (27) and
Remove and discard 'O' ring (2) from seal housing. discard toric rings of face seal. Retain metallic
elements unless scratched or damaged.
14. Remove face seal (3) from spindle and discard
toric rings of face seal. Retain metallic seal elements 4. Using a suitable lifting device attached to disc driver
and set aside for 'Inspection'. (27), carefully lift disc driver from disc brake assembly.

15. Remove one bolt (12) and hardened washer (13) from 5. Using a suitable lifting device, turn disc brake
spring housing (14) and one socket head screw (43) and assembly over, with piston housing assembly (41) up.
hardened washer (42) from piston housing assembly
(41), remove both bolts from as close to 12:00 o’clock 6. Remove and discard 'O' ring (51) from piston
position as possible. Install a lifting eye in each bolt hole. housing assembly (41).

16. Attach a suitable lifting device to disc brake 7. If necessary, remove caps (57) and bleeder valves
assembly (at lifting eyes installed in Step 15) and take (48 & 52) from piston housing assembly (41).
up slack. Remove nut (50) and hardened washer (49).
Using lifting device, carefully remove disc brake 8. If necessary, remove plug (47) and 'O' ring (46)
assembly from spindle. Place disc brake assembly on

SM 2038 7-00 5
Brake Parts - Rear Axle
Section 165-0030
from piston housing assembly (41). Discard 'O' ring. SM - 116

9. If necessary, remove studs (44) and pipe plug (45)

from piston housing assembly (41).

10. Remove socket head screw (43) and hardened

washers (42) from piston housing assembly (41).

Fig. 4 - Spring Compression Tool

WARNING
Piston housing assembly (41) is under
SM - 117
pressure from spring (20 & 21) compression.
To prevent personal injury and property
damage, use care when removing socket head
screws (43) and hardened washers (42).

11. Very carefully, remove socket head screws (43)

and hardened washers (42), by turning screws out
alternately, one turn at a time on each screw. Piston
housing assembly (41) is under spring (20 & 21)
compression. Using a suitable lifting device, lift piston
housing assembly (41) from disc housing (25) and
place on a flat surface, service piston (31) side up. Fig. 5 - Using Spring Compression Tool on
Typical Service Piston Assembly
12. Remove and discard 'O' ring (37) from piston
housing assembly (41). SM - 118

13. Remove and discard 'O' rings (40) from piston

housing assembly (41).

14. Using spring compression tool (shown in Fig. 4),

screw the 'T' handle of the tool into the threaded hole
in the end of one retaining pin (35), see Fig. 5.

Note: Spring compression tool may be fabricated as

shown in Fig. 37.

15. With the base of the tool resting on the flat

surface of service piston (31), press down on the tool
handle to raise retaining pin (35) against the tension Fig. 6 - Removing Typical Pin
of spring (36). Raise retaining pin (35) enough to allow
pin (32) to be removed from retaining pin. See Fig. 6.
SM - 119
Remove spring compression tool from retaining pin
(35).

16. Repeat Steps 14 and 15 to remove pin (32) from

each retaining pin (35).

17. Install three 0.5 - 13 UNC bolts in three threaded

holes in service piston (31). Alternately turn puller
bolts in, gradually pulling service piston (31) from
piston housing assembly (41). Remove the three
puller bolts and remove service piston.

18. Remove and discard 'D' section seals (38 & 39)
Fig. 7 - Removing/Installing 'D' Section Seal
from piston housing assembly (41). See Fig. 7.

6 SM 2038 7-00
 Brake Parts - Rear Axle
Section 165-0030

SM - 120

WARNING
Return springs (36) are under compression.
To prevent personal injury and property
damage, use care when removing bolts (33)
and retaining plates (34).

19. Very carefully, remove bolts (33) and retainer

plates (34) securing return springs (36) in piston
housing assembly (41). See Fig. 8.

Fig. 8 - Removing/Installing Retainer Plate

SM - 121 20. Remove retaining pins (35) and return springs

(36) from piston housing assembly (41). See Fig. 9.

Fig. 9 - Removing/Installing Retaining Pin and Spring

SM - 122 21. Remove damper assembly (28). Remove friction

discs (29) and splined plates (30) alternately and final
damper assembly (28) from disc housing (25). See
Fig. 10.

22. If required, remove dowels (26) from disc

housing (25).

23. With a suitable lifting device, lift disc housing (25)

and turn over, with spring housing (14) side up.

Fig. 10 - Removing/Installing Typical Damper Assembly

SM - 123 24. Remove bolts (12) and hardened washers (13)

from spring housing (14). See Fig. 11.

WARNING
Spring housing (14) is under pressure from
spring (20 & 21) compression. To prevent
personal injury and property damage, use care
when removing socket head screws (15) and
hardened washers (16).

25. Remove socket head screws (15) and hardened

Fig. 11 - Removing/Installing Typical Spring Housing washers (16), by turning screws out alternately, one turn

SM 2038 7-00 7
Brake Parts - Rear Axle
Section 165-0030
at a time. Using a suitable lifting device, lift spring SM - 125
housing (14) from disc housing (25). Refer to Fig. 12.

26. Remove and discard 'O' ring (17) from spring

housing (14).

27. Remove springs (20 & 21) from parking piston (23).
See Fig. 12.

28. Place lifting tool (shown in Fig. 13) over parking

piston (23) with the legs resting on the edge of disc
housing (25). Make sure the three holes of the tool
are aligned with the three 0.5 - 13 UNC threaded Fig. 13 - Lifting Tool
holes in parking piston (23). Insert three 0.5 - 13
UNC lifting eyes into the three holes and thread into SM - 127
the three threaded holes in parking piston (23). The
lifting eyes should be full threaded, with a 0.5 - 13
UNC nut on each lifting eye. Tighten the nuts down
onto parking piston (23) until the parking piston is
free of disc housing (25). Using a suitable lifting
device attached to the lifting eyes of the lifting tool,
raise and remove parking piston (23). See Fig. 14.

Note: The lifting tool shown in Fig. 13 may be

fabricated as shown in Fig. 38.

29. Remove and discard seal (22) from parking Fig. 14 - Removing/Installing Parking Piston
piston (23). See Fig. 15. Remove spacer ring (58)
from parking piston (23).
SM - 128

30. If required, remove dowels (19) from parking

piston (23).

31. Remove and discard seal (24) from disc housing

(25). See Fig. 16. Remove spacer ring (56) from disc
housing (25).

32. If required, remove dowels (18) from disc

housing (25).

SM - 124
Fig. 15 - Removing/Installing Parking Piston Seal

SM - 129

Fig. 12 - Removing/Installing Spring Housing Fig. 16 - Removing/Installing Typical Disc Housing Seal

8 SM 2038 7-00
 Brake Parts - Rear Axle
Section 165-0030

SM - 2553

1 - Pipe Plug 4 - Friction Disc 22 - Seal 25 - Disc Housing

2 - Retainer Pin 5 - Splined Plate 23 - Parking Piston 55 - Spacer Ring
3 - Damper Assembly 6 - Piston Housing 24 - Seal 56 - Spacer Ring

Fig. 17 - Typical Disc Assembly Wear Measurement

INSPECTION machined surface on piston housing (6). This is

dimension 'A'. Record this dimension.
Disc Assembly Wear Measurement
Procedure 5. Record the dimension that is stamped on piston
Note: This measurement should be made prior to housing (6). Subtract the stamped dimension from
removal and disassembly of the disc brake dimension 'A' (Ref. Step 4). The difference is the
assemblies to determine the amount of wear on the amount of brake wear. Refer to 'Disc Brake Wear
brake discs. Limits' table for permissible wear limits.

Numbers in parentheses refer to Fig. 17, unless

otherwise specified. New and Worn Disc Brake Wear Limits
Friction Disc Thickness
1. Pull out the parking - emergency brake control. New Disc .......... 5.08 ± 0.13 mm (0.200 ± 0.005 in)
This will pressurize parking brake cavity and Worn Disc - Minimum
compress parking brake springs (20 & 21, Fig. 1). Permissible Size ...................... 4.57 mm (0.180 in)

2. Depress service brake treadle or, with retarder Splined Plate Thickness
selection mode switch in the disc brake position, New Plate ... 2.413 ± 0.064 mm (0.095 ± 0.0025 in)
place retarder control lever in the applied position. Worn Plate - Minimum
This will pressurize the service brake piston cavity. Permissible Size ...................... 2.29 mm (0.090 in)

3. Carefully remove pipe plug (1) from piston housing (6). Damper Plate Thickness
New Damper
4. Insert a depth micrometer into the pipe plug hole Plate ................. 6.9 ± 0.051 mm (0.270 ± 0.020 in)
and measure distance from end of retainer pin (2) to Compression 'Set' after use ..... 5.84 mm (0.230 in)

SM 2038 7-00 9
Brake Parts - Rear Axle
Section 165-0030

DISC BRAKE WEAR LIMITS

THICKNESS
NUMBER OFF New Worn
Friction Discs 10 50.80 mm (2.00 in) 45.70 mm (1.79 in)
Splined Plates 9 21.72 mm (0.86 in) 20.61 mm (0.81 in)
Damper Plates 2 13.72 mm (0.54 in) 11.68 mm (0.46 in)
Stack Thickness 86.24 mm (3.40 in) 77.99 mm (3.06 in)
Maximum Allowable Wear 8.22 mm (0.32 in)

Disassembled Parts SM - 1014

Numbers in parentheses refer to Fig. 3. OUTER HALF

OF SEALING FACE
1. Clean all parts in a suitable solvent.

2. Immediately after cleaning, dry all parts with

compressed air.

3. After cleaning and drying, coat all parts with light oil
to prevent corrosion.

4. The sealing face of face seals (3 & 11) metallic

rings must be carefully inspected to determine if Wear concentric and on Wear on inner half of
reuse is possible. The 'sealing band', which is a highly outer half of sealing face. sealing face.
polished surface on the sealing face of each metallic Seal ring acceptable for Seal not acceptable for
rebuilding. rebuilding.
ring, must be within the outer half of the total seal
area, be concentric with the seal face diameters, of
uniform width and free from wear marking. Refer to Fig. 18 - Metallic Ring Inspection
Fig. 18.
9. Check seal surfaces of service piston (31) for
Note: Do not interchange metallic seal elements pitting, scoring or wear. Repair or replace as necessary.
between assemblies. This can cause improper fit into
seal housing (10) and prevent the correct metal to 10. Check springs (20, 21 & 36) for cracks or other
metal sealing contact. damage and for spring tension.

Note: When using metallic rings which have satisfied 11. Check all disc (29) and plate (30) contact
inspection requirements, a slight 'overlap' condition, surfaces for nicks, pits or corrosion. Check teeth of
related to the original orientation of the seal faces, discs and plates for wear and damage.
could occur and cause initial light leakage which will
stop when the assembly has been 'run in'. 12. Check finished surfaces of all other parts for
scored or worn surfaces. Repair or replace as necessary.
5. Before installing the disc brake assembly, clean all
exterior surfaces to remove any foreign material.
ASSEMBLY
6. Inspect all splines for cracked or broken teeth, Numbers in parentheses refer to Fig. 3.
excessive wear and pitted or scored surfaces. Repair
or replace as necessary. Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
7. Check for pitted, scored or worn mating surfaces of 300-0080, STANDARD BOLT AND NUT TORQUE
housings. SPECIFICATIONS.

8. Check all threaded holes and threaded parts for dirt Note: All 'O' rings, seals and all contacting surfaces
or damaged threads. Repair or replace as necessary. must be clean and lubricated at assembly.

10 SM 2038 7-00
 Brake Parts - Rear Axle
Section 165-0030

SM - 131 install in parking piston (23) as shown in Fig. 17.

8. Lubricate disc housing seal (24) and area around

the seal generously with 'Wynns S.T.P.'. Install
parking piston (23) into disc housing (25).

9. Place spring housing (14) on parking piston (23) to

align with dowel (19). Rotate spring housing (14) so
that dowel (18) in disc housing (25) aligns with the
hole in the spring housing. Seat parking piston (23) in
disc housing with six bolts (12). Use care to prevent
damage to seals (22 & 24). Remove bolts (12) and
Fig. 19 - Typical Disc Housing spring housing (14).

SM - 132
10. Install springs (20 & 21) in bores in parking piston
(23). See Fig. 12.

11. Instal new 'O' ring (17) in groove in face of spring

housing (14).

12. With a suitable lifting device, carefully install

spring housing (14) over springs (20 & 21) on disc
housing (25). Make sure springs are aligned with
spring bores in spring housing and that dowels (19)
are aligned with dowel holes in spring housing.

Fig. 20 - Disc Driver Installed in Typical Disc Housing 13. Install five socket head screws (15) and hardened
washers (16) in holes under protruding ears on spring
housing (14). Tighten socket head screws (15)
alternately, one turn at a time, to draw spring housing
WARNING (14), against the tension of springs (20 & 21), down
To prevent personal injury and property to disc housing (25). Tighten socket head screws
damage, make sure lifting equipment is of (15) to a torque of 260 - 280 Nm (190 - 210 lbf ft).
adequate capacity and properly secured to do
the job safely. 14. Install bolts (12) and hardened washers (13) in
remaining holes in spring housing (14) and disc
1. With a suitable lifting device, place disc housing housing (25). Tighten bolts (12) to a torque of
(25) on a clean level surface, with spring housing (14) 260 - 280 Nm (190 - 210 lbf ft). See Fig. 11.
end up.
15. With a suitable lifting device, turn disc housing
2. If removed, install dowels (18) in disc housing (25). (25) over and place on a clean flat surface, spring
housing (14) side down. See Fig. 19.
3. Stretch new seal (24) slightly. Lubricate seal groove
in disc housing (25) and seal (24) with 'Wynns S.T.P.' 16. If removed, install dowels (26) in disc housing (25).
to aid seal installation. Install seal (24). See Fig. 16.
17. With a suitable lifting device attached to disc
4. Lubricate spacer ring (56) with 'Wynns S.T.P' and driver (27), position disc driver inside disc housing
install in disc housing (25) as shown in Fig. 17. (25), with large splined end up. See Fig. 20. Block up
disc driver with 50 mm x 100 mm (2 in x 4 in) blocks.
5. If removed, install dowels (19) in parking piston (23).
18. Install damper assembly (28) in disc housing
6. Lubricate new seal (22) and groove in outer (25), aligning teeth of damper with splines in disc
diameter of parking piston (23) with 'Wynns S.T.P.'. housing. See Fig. 10. Ensure cork side of damper
Install seal (22). See Fig. 15. faces downward toward parking piston (23).

7. Lubricate spacer ring (55) with 'Wynns S.T.P' and Note: Prior to installing friction discs (29), apply a

SM 2038 7-00 11
Brake Parts - Rear Axle
Section 165-0030
coating of oil, of the type used in the system, to the SM - 133
discs.

19. Install friction disc (29) over disc driver (27),

aligning teeth of friction disc with splines on disc driver.

20. Install splined plate (30) over friction disc (29)

followed by another friction disc and a splined plate
alternately until all are installed.

21. Install another damper assembly (28) over the

last friction disc (29). See Fig. 21. Ensure cork side
of damper assembly faces upward, toward service Fig. 21 - Final Damper Assembly Installed
piston (31).
SM - 136
22. Install three new 'O' rings (40) in counterbore in
three holes in mounting face of disc housing (25).

23. If removed, install studs (44) in piston housing

assembly (41). See Fig. 22.

24. With a suitable lifting device, place piston housing

assembly (41) on a clean flat surface, interior side up.

25. Install retaining pin (35) and return springs (36) in

bores in piston housing assembly (41).
Fig. 22 - Installing Studs in Piston Housing
26. Install retainer plates (34) over retaining pins (35)
and return springs (36) and secure with bolts (33).
SM - 135
See Figs. 8 & 9.

27. Stretch new 'D' section seal (39) slightly. Install

new 'D' section seals (38 & 39) in grooves in sides of
channel in piston housing assembly (41). See Fig. 7.

Note: Install 'D' section seals in piston housing

assembly as shown in the section in Fig. 17.

28. Install service piston (31), with flat surface up,

into piston housing assembly (41). Ensure three 14
mm (0.56 in) drilled holes in service piston are
Fig. 23 - Installing 'O' Ring on Piston Housing
aligned with three 0.5 - 13 UNC threaded holes in the
piston housing. Be careful to prevent damaging the
two 'D' section seals in piston housing assembly. pull retaining pin (35) up far enough to insert pin (32)
Install three 0.5 - 13 UNC bolts, with flat washers into hole in end of retaining pin. See Fig. 6. Release
through service piston to piston housing and draw pressure on tool handle, making sure pin (32) is
service piston down gradually by turning bolts inserted far enough into retaining pin (35) to clear
alternately, one turn at a time. both sides of retaining pin hole in service piston (31).
Remove spring compression tool.
29. Using fabricated spring compression tool (shown
in Fig. 4), screw the threaded end of the 'T' handle 31. Repeat Step 28 to install pin (32) in each retaining
into the threaded hole of a retaining pin (35), as pin (35).
shown in Fig. 5.
32. Remove the three 0.5 - 13 UNC bolts and flat
30. With base of the tool resting on the flat surface of washers.
service piston (31), depress the handle of the tool to

12 SM 2038 7-00
 Brake Parts - Rear Axle
Section 165-0030

SM - 137 SM - 138

Fig. 24 - Installing Piston Housing on Disc Housing Fig. 25 - Tightening Piston Housing to Disc Housing

SM - 140

DISC BRAKE
ASSY PORT F

3/8 NPT
PORTABLE ADAPTOR
HAND POWERED
3/8 NPT
OIL PUMP
CONNECTOR
7.6 litre
(2 US gal)
3/8 NPT 9.5 mm (0.375 in) MEDIUM
CAPACITY
CONNECTORS PRESSURE HOSES
1 830 mm (6.0 ft) LONG

3/8 NPT 3/8 NPT

CROSS CONNECTOR
3/8 NPT-HEX 3/8 NPT
STEEL NIPPLE ADAPTOR
137.9 bar (2 000 lbf/in²)
PRESSURE GAUGE DISC BRAKE
ASSY PORT F

Fig. 26 - Typical Pressure Test Setup for Service and Parking Brakes

33. Install new 'O' ring (37) on piston housing hardened washers (42), in holes under protruding
assembly (41) as shown in Fig. 23. ears on piston housing assembly (41). Tighten socket
head screws (43) alternately, one turn at a time, to
34. With a suitable lifting device, turn piston housing draw piston housing assembly down snug on disc
assembly (41) over, with service piston (31) down. housing (25). Tighten socket head screws (43) to a
torque of 260 - 280 Nm (190 - 210 lbf ft).
35. If removed, install bleeder valves (48 & 52) and
caps (57) in piston housing assembly (41). 39. Install socket head screws (43) and hardened
washers (42) in piston housing assembly (41).
36. If plug (47) was removed, install new 'O' ring (46) Tighten socket head screws (43) to a torque of
on plug and install plug in piston housing assembly (41). 260 - 280 Nm (190 - 210 lbf ft). See Fig. 25.

37. Using a suitable lifting device attached to piston Note: Be careful that disc driver (27) does not slide
housing assembly (41), position piston housing out of disc housing (25) when turning disc brake
assembly (41) on disc housing (25), making sure assembly over.
dowel pin holes in housing are aligned with dowels
(26) on disc housing. Gradually lower piston housing 40. Refer to Fig. 26 for typical pressure test setup.
onto disc housing. See Fig. 24. Position brake assembly vertically with bleeder
valves (48 & 52, Fig. 2) at the 12:00 o’clock position.
38. Install five socket head screws (43), with Connect a portable hand pump filled with clean brake

SM 2038 7-00 13
Brake Parts - Rear Axle
Section 165-0030
hydraulic oil to Port 'D', Fig. 2, and pressurize service SM - 139
brake piston cavity to 52 bar (750 lbf/in2). See Fig. 27.

Open bleeder valve (52, Fig. 2) slightly while pressurizing

Port 'D' to release any trapped air. When hydraulic oil
only, flows from bleeder valve (52), close the valve
and pressurize piston cavity to 52 bar (750 lbf/in2).
Apply and release the pressure ten times to seat the
piston seals. After seating the piston seals, apply
52 bar (750 lbf/in2) pressure and close hand pump
valve to hold the pressure. If service brake piston
cavity does not lose more than 3.5 bar (50 lbf/in2)
pressure in 15 minutes, service brake piston
assembly is satisfactory.

Disconnect the pump hose from Port 'D', Fig. 2 and

connect it to port 'F', Fig. 2 to seat and pressure test
Fig. 27 - Charging Brake Pack With Oil
parking brake piston seals. Refer to Fig. 28.
Pressurize parking brake piston cavity to 83 bar
(1 200 lbf/in2) and open bleeder valve (48, Fig. 2) until SM - 142
all trapped air is released. When hydraulic oil only,
flows, close the bleeder valve and pressurize parking
brake cavity to 83 bar (1 200 lbf/in2). Apply and
release the pressure ten times to seat parking piston
seals. After seating seals, apply 83 bar (1 200 lbf/in2)
pressure and close hand pump valve to hold the
pressure. If parking brake cavity does not lose more
than 7.0 bar (100 lbf/in2) pressure in 15 minutes,
parking brake piston assembly is satisfactory.

INSTALLATION
Numbers in parentheses refer to Figs. 1 and 2.

WARNING
Fig. 28 - Pressurizing Parking Brake Assembly
To prevent personal injury and property damage,
ensure lifting equipment is of adequate capacity
and properly secured to do the job safely. studs (44) of disc brake assembly through holes in
spindle flange, making sure 'O' ring (51) remains in
1. Install new 'O' ring (51) in counterbore on mounting counterbore on piston housing assembly.
face of piston housing assembly (41).
4. Install nuts (50) and hardened washers (49) on
2. Remove one bolt (12) and hardened washer (13) studs (44). Tighten nuts (50) to a torque of
from spring housing (14) and one socket head screw 1 166 - 1 193 Nm (860 - 880 lbf ft). Remove lifting
(43) and hardened washer (42) from piston housing device and lifting eyes and reinstall bolts (12) and
assembly (41), both bolts from as close to 12:00 socket head screws (43) and hardened washers (13 &
o’clock position as possible. Install a lifting eye in 42) and tighten bolts and socket head screws to
each bolt hole. specified torque.

3. With a suitable lifting device attached to the disc Note: Prior to installing face seal (11), clean face seal
brake assembly, at the lifting eyes installed in Step 2, (11) and toric rings in '1.1.1. Trichlorethane' liquid.
position disc brake assembly on spindle. When
installing right-hand brake assembly, 'INLET' port Note: Seal installation kit (ref. Special Tools)
should be at the top. When installing left-hand brake comprises of seal sleeve, seal driver and a spring.
assembly, 'INLET' port should be at the bottom. Insert

14 SM 2038 7-00
 Brake Parts - Rear Axle
Section 165-0030

SM - 450 SM - 451

Fig. 29 - Seal Sleeve Fig. 30 - Seal Driver

SM - 452

DISC
DRIVER

SEAL METALLIC
ELEMENT

TORIC
RING

SEAL
SPRING
DRIVER

SEAL PARKING
SLEEVE PISTON

SPRING
HOUSING

Fig. 31 - Using Seal Installation Tool

5. Insert seal sleeve tool (Fig. 29) in spring housing (14) 7. Install one half of face seal (11) with 'O' ring and
until it is in as far as it can go. toric ring fitted, toric ring end first, inside seal sleeve
and into spring housing (14).
6. Insert seal installation kit spring on one half of face
seal (11) and install toric ring on face seal. The 8. Press home face seal (11) with seal driver (Fig. 30)
spring prevents the toric ring from riding up the ramp until inside face of seal driver is flush with outside face
on face seal (11) hence leading to easier installation. of seal sleeve. See Fig. 31.

SM 2038 7-00 15
Brake Parts - Rear Axle
Section 165-0030
9. Remove seal driver from spring housing (14) and SM - 148
slowly remove seal sleeve. When seal driver and seal
sleeve are removed, withdraw the spring from face
seal (11). Apply a thin film of oil to metal contacting
surface of face seal (11).

10. Install toric ring in other half of face seal and install
in seal housing (10), toric ring side down. Refer to Figs.
32 & 33. Install seal installation tool (Fig. 34 'B') over face
seal and press face seal into housing. See Fig. 35.
Remove seal installation tool.

11. Coat 'O' ring (4) with grease and install in groove Fig. 32 - Seal Housing (10)
of disc driver (27). Apply a thin film of oil to metal
contacting surface of face seal (11). Install seal
SM - 149
housing (10), with half seal installed, over disc driver
(27). Secure seal housing to disc driver with bolts (9)
and hardened washers (53).

Note: Prior to installing face seal (3), clean face seal

(3) and toric rings in '1.1.1. Trichlorethane' liquid.
Apply a thin film of oil to the metal contacting
surfaces of the seal.

12. Install one half of new face seal (3), toric ring side
inward, over spindle. Using seal installation tool (Fig.
34 'A'), press seal into disc driver (27) by tapping tool Fig. 33 - Half of Seal (11) Installed in Seal Housing
with a soft hammer. Remove seal installation tool.

SM - 150
13. Install other half of new face seal (3), toric ring
side inward, into inner seal housing (1). Using seal
installation tool (Fig. 34 'A'), press seal into seal
housing. Remove seal installation tool.

14. Coat 'O' ring (2) with grease and install in groove
on seal housing (1). Install seal housing (1), with face
seal (3) installed, and secure with new bolts (57).

15. Install new 'O' ring (4) in groove on wheel.

16. Install wheel driver (5) on wheel and secure with

Fig. 34 - Seal Installation Tools
bolts (7) and hardened washers (6). Make sure
'O' ring stays in groove on wheel. Tighten bolts (7) to
a torque of 1 166 - 1 193 Nm (860 - 880 lbf ft). SM - 151

17. Install new 'O' ring (8) on wheel driver (5).

WARNING
Use extreme caution to prevent personal injury
when installing wheels. The exact procedure
must be followed, as described in Section
160-0050, WHEEL, RIM AND TYRE.

18. Install wheel on spindle as described in Section

160-0050, WHEEL, RIM AND TYRE. Be careful, when Fig. 35 - Installing Seal (11) in Seal Housing (10)

16 SM 2038 7-00
 Brake Parts - Rear Axle
Section 165-0030

SM - 1486

2 1

4,5

6,7 11 12

1 2

13
8,9,10 TO MAIN AIRLINE
14,15
18,19
16,17

1 - Blanking Plate (Port 'B') 6 - Hose Assembly 11 - Pressure Gauge

2 - Blanking Plate (Port 'C') 7 - Female Swivel Connector 12 - Shutoff Valve 16 - Hose Assembly
3 - 'O' Ring 8 - Pipe Coupling 13 - Pressure Regulator 17 - Female Swivel Connector
4 - Reducer Bush 9 - Nipple 14 - Reducer Bush 18 - Clip
5 - Connector 10 - Tee Piece 15 - Connector 19 - Adaptor

Fig. 36 - Typical Brake Pressure Test Setup

inserting wheel driver (5) on disc driver (27), not to seals are properly seated, to prevent oil leaks.
damage 'O' ring (8) and to align wheel driver splines
with splines on disc driver. Note: Be sure to uncap and install only one hydraulic
line at a time to prevent loss of oil from brake
19. Fill service brake pack with 11 litres (3 US gal) of hydraulic oil tank. The vacuum pump, installed during
clean hydraulic oil, of the same type used in the brake removal, cannot retain oil in tank if more than one line
cooling circuit. Pressurize the brake assembly with 2 bar is uncapped at a time.
(30 lbf/in2) air pressure through Port 'B' (Inlet), Fig. 2, with
the opposite Port 'C' (Outlet), Fig. 2, plugged. 20. Remove plugs and install service brake hydraulic
tube in port 'D', Fig. 2, as tagged at removal.
Note: Refer to Fig. 36 for typical brake pressure test
setup. Blanking plates for ports 'B' and 'C' may be 21. Remove plugs, and install parking brake hydraulic
fabricated as shown in Figs. 39 and 40. tube in port 'F', Fig. 2, as tagged at removal.

While rotating the wheel, observe for air pressure loss 22. Remove plugs and install cooling lines in ports 'B'
on the air supply hose gauge. Less than 0.14 bar and 'C', Fig. 2, as tagged at removal.
(2 lbf/in2) air pressure loss in 15 minutes is
satisfactory. If the air pressure loss is greater than 23. Remove vacuum pump from brake hydraulic oil
0.14 bar (2 lbf/in2) in 15 minutes, rotate the wheel tank, installed during removal and reinstall air
additionally to reseat all seals and pressurise the breather, in tank.
brake assembly to 2 bar (30 lbf/in2). If the brake
assembly again leaks more than 0.14 bar (2 lbf/in2) air 24. Fill steering and brake control tank with hydraulic
pressure in 15 minutes, loosen the wheel retainer oil specified in Section 300-0020, LUBRICATION
bolts, rotate the wheel to reseat the seals, and tighten SYSTEM. Refer to SECTION 220-0040, STEERING
the bolts. Repeat the air pressure test to be sure the AND BRAKE CONTROL TANK, for correct fill level.

SM 2038 7-00 17
Brake Parts - Rear Axle
Section 165-0030
Note: If brake discs, service and/or parking pistons,
piston housing, or the complete brake assembly have WARNING
been replaced, a new brake-disc-stack-height Loosen bleeder valves carefully. The braking
measurement should be taken as described under system operates at high pressure.
'Disc Assembly Wear Measurement Procedure',
under 'Inspection' in this section. This dimension 5. Depress service brake pedal and gradually open
should then be stamped on the machined surface of bleeder valve (52). Bleeder valve should remain open
pipe plug (45, Fig. 1) hole location for future until oil coming from bleeder valve is free of air
reference. bubbles. Close bleeder valve and release brake
pedal.
BLEEDING
Note: Recharge the system when necessary by
Numbers in parentheses refer to Fig. 1. repeating Step 2.

6. Securely connect bleeder hose to upper bleeder

WARNING valve (48) and place loose end of hose in a clean
To prevent personal injury and property container. Gradually open bleeder valve (48). Bleeder
damage, be sure wheel blocks are properly valve should remain open until oil coming from
secured and of sufficient capacity to do the bleeder valve is free of air bubbles. Close bleeder
job safely. valve.
In order to obtain satisfactory braking, the service 7. Repeat entire process for opposite brake
brake and parking brake hydraulic systems must be assembly.
bled to eliminate any air in the hydraulic lines, tubes
and systems. Note: Steering and brake control tank must be kept
at correct level at all times with hydraulic oil specified
1. Make sure the steering and brake control tank is in Section 300-0020, LUBRICATION SYSTEM. Refer
filled with oil specified in Section 300-0020, to Section 220-0040, STEERING AND BRAKE
LUBRICATION SYSTEM. CONTROL TANK, for correct fill level.
2. Start engine, build up oil pressure in accumulators Note: If brake assembly has been serviced, repeat
until accumulator pressure warning lights are entire bleeding process to ensure all air is evacuated
extinguished, then shut down engine. from the brake assemblies.
3. Block all road wheels. Pull out park/emergency
brake control to release the brakes. SPECIAL TOOLS
Refer to Figs. 37 through 40 for fabrication details of
4. Securely connect a clean bleeder hose to upper special tools and blanking plates referenced in this
bleeder valve (52) and place loose end of hose in a section. Refer to Section 300-0070, SERVICE
clean container. TOOLS, for part numbers of the seal installation tools
outlined in this section and general service tools
required. These tools are available from your dealer.

18 SM 2038 7-00
 IN

0.62
0.50
0.47
0.38
0.26
0.25
0.22
0.19
0.18
0.12
0.06
0.03

0.177
0.139
0.130

SM 2038 7-00
9.6
6.6
6.3
5.6
4.8
4.6
3.0

4.5
3.5
3.3
MM

15.7
12.7
11.9
1.52
0.76
IN

5.50
4.00
3.00
2.56
2.50
2.00
0.81

1.68
1.12
1.00

6.00
0.75
0.72

20.00
SPRING COMPRESSOR TOOL
MM

140
101

152
508
76.2
65.0
63.5
50.8
20.5

42.7
28.4
25.4
19.0
18.2

MATERIAL: PLAIN CARBON STEEL

ITEM #2 - BASE
(WELDMENT)

100 SQ.
STOCK
ITEM #1 - HANDLE

.250 DIA.
HOLE THRU.

KNURL

DIA. HOLE
ITEM #5 - 'T' HANDLE
(WELDMENT)

Fig. 37 - Fabrication of Spring Compressor Tool

.19 SQ.
8-32 UNC 2B X .38 MIN. FULL STOCK
THD. MINOR DIA. .130/.139 X .72 ITEM #3 - PIVOT BLOCK
DEEP

1 - Handles ITEM #4 - RETAINER .22 DIA. HOLE

2 - Base
3 - Pivot Block
4 - Retainer (2 Req’d)
5 - ”T” Handle
6 - Capscrew # 8-32 x .38 in long (4 Req’d.)
7 - Plain Washer # 10 (2 Req’d.) ROUND HD.
8 - Nut # 10-24 (4 Req’d.) MACHINE SC.
9 - Roll Pin .25 in Dia x 1.12 in long #16 DRILL (.1770) 10-24 X 3.00 LG.
2-HOLES FULL THD.
SM - 134
Brake Parts - Rear Axle
Section 165-0030

19
Brake Parts - Rear Axle
Section 165-0030

SM - 126

0.56 - 3 HOLES
in mm
EQUALLY SPACED
0.12 3.0
0.50 12.7
0.56 14.22
0.62 15.7
1.00 25.4
1.62 41.1
2.00 50.8
2.50 63.5
MATERIAL: 3.25 82.5
PLAIN CARBON STEEL 3.31 84.0
9.38 238
15.88 403
26.25 668

Fig. 38 - Fabrication of Lifting Tool

SM - 1487 SM - 1488
117 16 108 16
77.8 4.45 77.8 4.45
+- 0.13 +- 0.13
14 R51.6 R51.6
7.1 14 7.1
+- 0.13 +- 0.13
66.7 +- 0.25

66.7 +- 0.25
28.4
42.9
57

42.9
42.9

R0.50
/0.76 R0.50
½in NPT R15 /0.76
R0.13/0.25 R15 R0.13/0.25
Fig. 39 - Fabrication of Blanking Plate for Port 'B' Fig. 40 - Fabrication of Blanking Plate for Port 'C'

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
3 7 Bolt 1 166 - 1 193 860 - 880
3 12 Bolt 260 - 280 190 - 210
3 15 Screw 260 - 280 190 - 210
3 43 Screw 260 - 280 190 - 210
3 50 Nut 1 166 - 1 193 860 - 880

* * * *
20 SM 2038 7-00
 SUSPENSION SYSTEM - Ride Cylinder
Section 180-0030

SM - 1544

*1 - Pipe Plug
2 - Relief Valve
3 - Ball Bearing
4 - Bolt
5 - Locknut
*6 - Valve Assembly
*7 - Check Valve
8 - Hardened Washer
9 - Wiper
10 - Seal
11 - Wear Ring
12 - Backup Ring
13 - Piston
14 - Inner Tube
15 - 'O' Ring
*16 - Shear Key
17 - Bolt
18 - Tube
19 - Seal Retainer
20 - End Cap
21 - Lube Fitting
22 - 'O' Ring
23 - Seal
24 - Piston Rod
25 - Wear Ring

* - Shown on Fig. 3

Fig. 1 - Cutaway View of Typical Ride Cylinder

DESCRIPTION AND OPERATION Oil and compressed nitrogen fill the inside of tube (18).
Numbers in parentheses refer to Fig. 1. When the wheel hits a bump, piston rod (24) is forced
into tube (18). Inward movement of piston rod (24)
The front ride cylinder suspends the front wheel and compresses the nitrogen within tube (18) thereby
spindle from the chassis and absorbs road shock as slowing the piston rod travel speed. As piston rod (24)
the wheel travels over rough and uneven surfaces. moves inward in tube (18), oil pressure unseats ball

SM 1921 Rev 1 08-03 1

Suspension System - Ride Cylinder
Section 180-0030
bearing (3), allowing oil to fill the cavity between piston SM - 1545
rod (24) and tube (18).

When the force of piston rod (24) is expended, the

compressed nitrogen pushes the piston rod outward to
its original position. The oil in the cavity between piston
rod (24) and tube (18) slows and smooths the return
travel of the piston rod.

REMOVAL
Numbers in parentheses refer to Fig. 2.

WARNINGS
Pressurized cylinders. Release pressure as
described under 'Relieving Cylinder Pressure'
before removing valves or fittings. Accidental
release of pressure will result in personal injury
and property damage.

To prevent personal injury and property 1 - Bolt 5 - Hardened Washer

2 - Shear Key 6 - Bolt
damage, be sure blocking materials and lifting
3 - Cover Plate 7 - Ride Cylinder Assembly
equipment are properly secured and of 4 - Hardened Washer 8 - Bolt
adequate capacity to do the job safely.
Fig. 2 - Exploded View of Typical Ride Cylinder Mounting
Hydraulic oil pressure will remain in the
braking system after engine shut down. Operate Refer to Section 220-0120, STEERING CYLINDER
the treadle pedal continuously until the AND LINKAGE.
pressure has dissipated before carrying out any
work on the braking system or serious injury 8. Using suitable lifting equipment, support ride
could result. cylinder, spindle and wheel assembly. Remove bolts
(6 & 8) and hardened washers (5) securing ride cylinder
1. Position the vehicle in a level work area, apply the assembly (7) to the chassis.
parking brake and switch off the engine. Turn the
steering wheel in both directions several times to 9. Carefully remove ride cylinder assembly (7), spindle
relieve pressure in the steering system. and wheel assembly to a suitable work area for
disassembly.
2. Operate the treadle valve continuously to discharge the
braking accumulators. Block all road wheels. 10. Follow procedures in Steps 4 through 9 if the other
ride cylinder assembly (7) is to be removed.
3. Relieve nitrogen pressure from BOTH front ride
cylinders. Refer to 'Relieving Cylinder Pressure'.
DISASSEMBLY
4. Jack frame up at 'horse collar' until front ride cylinder Numbers in parentheses refer to Fig. 3.
is fully extended.

5. Jack up ride cylinder until tyre is off the ground and WARNING
block steering arm in position. To prevent personal injury and property
damage, be sure blocking materials and lifting
6. Remove front tyre and rim. Refer to Section equipment are properly secured and of
140-0040, WHEEL, RIM, AND TYRE. adequate capacity to do the job safely.

7. Remove cotter pins and castle nuts attaching tie rod 1. Remove locknuts (5) and bolts (4) securing end
and steering cylinder to steering arm. Secure both tie cap (20) to tube (18). Remove end cap (20).
rod and steering cylinder away from the work area.

2 SM 1912 Rev 1 08-03

 Suspension System - Ride Cylinder
Section 180-0030

SM - 1546

6 4
1-7 17
12 11

8
20
25

10
13
5 15
9 22

16
3 2

24 30
29 14

21 22
18
12
30
31

19

28
23
27
26

1 - Pipe Plug 9 - Wiper 17 - Bolt

2 - Relief Valve 10 - Seal 18 - Tube 25 - Wear Ring
3 - Ball Bearing 11 - Wear Ring 19 - Seal Retainer 26 - Bolt
4 - Bolt 12 - Backup Ring 20 - End Cap 27 - Hardened Washer
5 - Locknut 13 - Piston 21 - Lube Fitting 28 - Cover
6 - Valve Assembly 14 - Inner Tube 22 - 'O' Ring 29 - Bolt
7 - Check Valve 15 - 'O' Ring 23 - Seal 30 - Hardened Washer
8 - Hardened Washer 16 - Shear Key 24 - Piston Rod 31 - Bolt

Fig. 3 - Exploded View of Typical Front Ride Cylinder

2. Remove and discard 'O' ring (22) and backup ring 5. The spindle can be removed from piston rod (24) by
(12) from end cap (20). applying hydraulic pressure through the annular groove
machined on the spindle taper. This can be done by
3. Drain oil from ride cylinder assembly into a suitable removing the small plug from the spindle, and
container. connecting a hand pump or high pressure grease gun.
Refer to Fig. 4.
4. Remove bolts (26) and hardened washers (27) securing
cover (28) to piston rod (24). Remove cover. 6. Remove bolts (17) and hardened washers (8)
securing piston (13) to the top of piston rod (24).
Note: Piston rod (24) must be separated from spindle
for proper disassembly and assembly. It is best to 7. Install a lifting eye in the top of piston rod (24) and
disassemble and assemble the piston rod from the top attach to an adequate lifting device. Slide piston rod
of the cylinder so that holes in the piston rod do not (24) and piston (13) out from the top of tube (18) as
have to pass over seals. an assembly.

SM 1921 Rev 1 08-03 3

Suspension System - Ride Cylinder
Section 180-0030
SM - 193
4. Inspect pipe plug (1), check valve (7), valve
assembly (6), relief valve (2) and lube fitting (21).
Check their seating positions in end cap (20) and tube
(18). If threads in any of these parts are damaged,
restore the threads. Replace defective parts
if necessary.

5. Inspect wear rings (11 & 25) for excessive wear or

damage. Replace if damaged.

PLUG ASSEMBLY
Numbers in parentheses refer to Fig. 3.
Fig. 4 - Spindle Annular Groove For Separating Tapers
WARNING
Note: When removing piston rod (24), seal retainer (19) To prevent personal injury and property
and inner tube (14) should come out as an assembly. If damage, be sure blocking materials and lifting
they do not come out intact after removing piston rod equipment are properly secured and of
(24), remove inner tube (14) and seal retainer (19) adequate capacity to do the job safely.
individually from tube (18).
Note: Apply a light coating of clean hydraulic oil to all
8. Slide piston (13) up piston rod (24) and remove ball components as they are assembled. This facilitates
bearing (3). the assembly procedure. Make sure that all work is
done in a clean area so that no contaminants can get
Note: Do not misplace ball bearing (3). into the oil.

9. Remove piston (13) and remove wear ring (11) from Note: For proper assembly procedure, seal (10) and
the piston. wiper (9) should not pass over holes in piston rod (24).

10. Remove and discard 'O' ring (15) from inner 1. Install new seal (23), backup ring (12) and 'O' ring
tube (14). (22) to seal retainer (19). Press seal retainer (19)
assembly down into tube (18) until the retainer bottoms
11. Remove and discard 'O' ring (22), backup ring (12) at the lower end of the tube. Refer to Fig. 5.
and seal (23) from seal retainer (19).
2. Install new 'O' ring (15) on inner tube (14). Insert
12. Remove and discard seal (10) and wiper (9) from inner tube (14) into tube (18). Refer to Fig. 5.
tube (18). Remove wear ring (25).
3. Install wear ring (11) to piston (13) and install
piston assembly to piston rod (24). Slide piston (13) up
INSPECTION piston rod (24) enough to install ball bearing (3) in the
Numbers in parentheses refer to Fig. 3. piston rod.

1. Wash all parts thoroughly in a suitable solvent. Dry 4. Secure piston (13) assembly to piston rod (24) with
all parts with compressed air. Check all inner and outer bolts (17) and hardened washers (8). Do not tighten
grooves in seal retainer (19) for cleanliness. bolts (17) at this time.

2. Inspect tube (18), piston rod (24) and piston (13) for 5. Install wear ring (25) in tube (18) with wear ring joint
scores, scuffing or small ridges in the walls. Use a fine in line with lube fitting (21).
stone to smooth out any defective areas. If damage is
too extensive, replace the defective component. 6. Install seal (10) and wiper (9) in tube (18).

3. Inspect all cylinder assembly components for signs 7. Insert piston rod (24), piston (13) and wear ring (11)
of unusual distortion or excessive wear. Replace through the top of tube (18) as an assembly. Make sure
defective components. ball bearing (3) is correctly positioned in piston rod (24).

4 SM 1912 Rev 1 08-03

 Suspension System - Ride Cylinder
Section 180-0030

SM - 194

TUBE BACKUP 'O' RING

RING

WIPER SEAL WEAR INNER

SEAL
RING SEAL TUBE
RETAINER

Fig. 5 - Cutaway View of Front Ride Cylinder Tube Assembly

SM - 195 the full extended position and tighten bolts (17) to a

torque of 95 - 122 Nm (70 - 90 lbf ft). This will help to
centre parts and eliminate binding.

8. Install new 'O' ring (22) and backup ring (12) to end
cap (20). Secure end cap (20) to the top of tube (18)
with bolts (4) and locknuts (5). Tighten locknuts (5)
evenly to a torque of 260 - 285 Nm (190 - 210 lbf ft).

9. Insert tapered end of piston rod (24) into the spindle

and secure cover (28) to the bottom of piston rod (24)
with bolts (26) and hardened washers (27). Tighten
bolts (26) to a torque of 271 Nm (200 lbf ft).

Fig. 6 - Installing Piston Rod in Outer Tube. Note: A periodic inspection should be made to ensure
proper torque is maintained on bolts (26).

Note: A convenient method for pressing piston rod (24) 10. Manually grease the ride cylinders through lube
into tube (18) is as follows. Refer to Fig. 6. fitting (21) until excess grease can be seen at relief
valve (2). Refer to Section 300-0020, LUBRICATION
a) Using two 915 mm (36 in) long pieces of 12 mm SYSTEM, for specification of grease required.
(0.5 in) threaded rod stock, four washers and nuts,
connect end cap (20) (outboard side facing inward) to
the outer tube. INSTALLATION
Numbers in parentheses refer to Fig. 2.
b) Support one end of a hydraulic jack against end
cap (20) and the other end against a block of wood
long enough to extend beyond the circumference of WARNING
piston rod (24). This will prevent a metal-to-metal To prevent personal injury and property
contact between the jack and piston rod; avoiding damage, be sure blocking materials and lifting
possible piston rod/piston damage. equipment are properly secured and of
adequate capacity to do the job safely.
c) Extend the jack until piston rod (24) is flush with
tube (18). 1. Using suitable lifting equipment, position front ride
cylinder assembly to chassis mounting surface.
d) Remove the jack, threaded rod stock, nuts and
washers. Remove any wood debris left from the Note: It may be helpful to use two guide studs
wood block. approximately 25 mm (1 in) in diameter and 200 mm (8
in) long to guide the front ride cylinder into position on
e) Move piston rod (24) and piston (13) assembly to the frame’s horse collar.

SM 1921 Rev 1 08-03 5

Suspension System - Ride Cylinder
Section 180-0030
2. Secure ride cylinder assembly (7) to the chassis SM - 196
with hardened washers (5) and bolts (6 & 8).
Alternately tighten bolts (6 & 8) to a torque of 1 830 Nm
(1 350 lbf ft).

3. Remove equipment used to position front ride

cylinder to the chassis mounting surface.

4. Attach steering cylinder and tie rod to steering arm

with castle nuts and cotter pins. Tighten tie rod nut to a
torque of 2 035 - 2 300 Nm (1 500 - 1 700 lbf ft) and
steering cylinder nut to a torque of 4 000 - 4 500 Nm
(3 000 - 3 300 lbf ft).

Note: If necessary, refer to Section 220-0120,

STEERING CYLINDER AND LINKAGE, for procedure
in Step 4 above.

5. Connect brake hydraulic line to brake calliper and

bleed the braking system. Refer to Section 165-0020,
BRAKE PARTS.

6. Install front tyre and rim assembly as described in

Section 140-0040, WHEEL, RIM AND TYRE.
1 - Relief Valve
7. If the opposite ride cylinder was removed, follow steps 2 - Pipe Plug 4 - Charging Valve Assembly
3 - Check Valve (Oil Fill Port) 5 - Lube Fitting
1 through 6 to install the ride cylinder.
Dimension 'A' is 155.4 - 162 mm (6.12 - 6.38 in)
8. Charge ride cylinders as described in 'Charging with the Truck Empty
Instructions'.
Fig. 7 - Typical Ride Cylinder Installation

CHARGING THE RIDE CYLINDER 1. Support the chassis near the ride cylinder with
Numbers in parentheses refer to Fig. 7, unless blocking and/or a hydraulic jack with adequate
otherwise specified. capacity.

2. Remove the cap from charging valve (4) at the top of

WARNING the cylinder. Turn the hex nut on the valve 1/4 to
To prevent personal injury and property 1/2 turn counter-clockwise and depress the valve core.
damage, be sure blocking materials and lifting If no gas escapes, continue to turn the hex nut in 1/4
equipment are properly secured and of turn increments until the nitrogen releases as the valve
adequate capacity to do the job safely. core is depressed.

3. Remove blocking or release pressure on the

Relieving Cylinder Pressure hydraulic jack and allow the trucks weight to fully
retract the ride cylinder rod.

WARNING
Pressurized cylinders. Release pressure as WARNING
described below before removing valves or Pressurised cylinders. Keep valve core
fittings. Accidental release of pressure will depressed until all gas is bled from cylinder.
result in personal injury and property damage. Failure to release all pressure may result in
personal injury or property damage.
Note: The truck must be empty and on a level surface
prior to relieving ride cylinder pressure. 4. Depress charging valve (4) core again to be sure all
pressure has been relieved.

6 SM 1912 Rev 1 08-03

 Suspension System - Ride Cylinder
Section 180-0030
Note: Nitrogen leaving the cylinder will often carry oil a) Modify a spare check valve assembly by
with it. This results from foaming of the oil in the removing the internal valve and spring or
cylinder. The foaming takes place as nitrogen which
was dissolved in the oil at high pressure expands at b) Make a fill-fitting by drilling through a 5/8 - 18 x 1.5
atmospheric pressure. The oil lost in this operation in bolt and tapping the head end 1/4 NPT.
must be replaced in the charging operation. The longer
the oil is allowed to stand at atmospheric pressure after Use either of these methods for filling the ride
discharging cylinder, the easier it will be to purge cylinder and reinstall the standard fitting for truck
cylinder of bubbles in the oil when recharging. operation.

2. With cylinder rod in its retracted position, fill the cylinder

Charging Instructions until oil flows free of air bubbles from charging valve (4)
Note: To ensure that both ride cylinders will be equally port. It may be necessary to wait 30 or more minutes after
charged to the correct pressure, both cylinders should nitrogen pressure has been released to clear the foam
be charged simultaneously. A tee may be installed in which has formed inside the cylinder.
the line from the pressure regulator for this purpose.
3. Remove oil fill equipment, reinstall plug (2) in check
Also, when front ride cylinders are being charged, both valve (3) or reinstall check valve (3) if it was removed
rear ride cylinders should be extended equally. This at Step 1. Reinstall nitrogen charging valve (4) in
can be accomplished by placing equal thickness its port.
blocks between axle and frame at the bump stops. It
may be necessary to raise the frame slightly to install
spacers. Be sure to remove spacers when charging WARNING
is complete. Use dry nitrogen to charge the cylinder.
Do not use a gas such as oxygen which, if used
Note: The pressure of a confined gas varies directly by mistake for pressurizing, will explode
with its temperature. Hence, extreme changes in ride violently when coming into contact with oil or
cylinder ambient temperature will change its nitrogen grease, possibly causing personal injury and
charge volume and, consequently, its operating height. property damage.
It might be necessary, therefore, to add or remove
nitrogen to maintain proper cylinder height as ambient To charge the cylinder, a charging assembly tool
temperature changes. can be used. See Fig. 8. If both cylinders are to
be charged, install a tee and charge both at the
same time.
WARNINGS
Pressurized cylinders. Release pressure as 4. Use suitable lifting equipment to fully extend
described under 'Relieving Cylinder Pressure', ride struts.
before removing valves or fittings. Accidental
release of pressure will result in personal injury 5. Attach the gauging head to the nitrogen bottle by
and property damage. turning down on gland nut (8, Fig. 8).

A high pressure nitrogen pressure 6. Install valve chuck (2, Fig. 8) to cylinder charging
regulator must be used with the charging valve (4) as follows: Rotate 'T' handle of valve chuck
assembly. Failure to use a pressure regulator (2, Fig. 8) counter-clockwise until it stops. Screw the
could cause property damage, personal injury, swivel nut down on valve until it seats. Turn the small
or death. hex on the charging valve two to three turns counter-
clockwise to unseat the valve internally. Rotate 'T'
1. Remove pipe plug (2) from check valve (3). Attach hose handle clockwise until it seats, opening check valve
from a pressure pump filled with hydraulic oil specified in (valve core) in charging valve (4).
Section 300-0020, LUBRICATION SYSTEM, to check
valve (3). Remove charging valve (4). 7. To check the amount of pressure in the nitrogen
bottle, close cylinder valve (4, Fig. 8) and open tank
Note: Approximately 14 bar (200 lbf/in²) pressure is valve (6, Fig. 8). Open valve on the nitrogen bottle
required to open the check valve allowing oil to flow slowly and note the reading on pressure gauge
through the fitting into the cylinder. If a pump is not available (5, Fig. 8). The available pressure in the nitrogen bottle
to overcome this check valve cracking pressure: must be over 31 bar (450 lbf/in²).

SM 1921 Rev 1 08-03 7

Suspension System - Ride Cylinder
Section 180-0030
8. Close tank valve (6, Fig. 8) and open cylinder valve (4, SM - 1273
Fig. 8). Charge both cylinders to 17.2 bar (250 lbf/in²) by
opening tank valve (6, Fig. 8) slowly, closing it occasionally.
To check the pressures in the cylinders, close tank valve
(6, Fig. 8) and note the reading on the pressure gauge. If
both cylinders do not extend evenly, check rear ride
cylinders. Right and left rear ride cylinders should be
extended equally (both can be fully collapsed). Also
check that the truck is on a flat, level surface and the body
is empty.

Note: The cylinders should be set according to

pressure, rather than height 'A' shown in Fig. 7. The
height shown is for reference only.

Note: It is advised to charge the ride struts by an

additional 1.4 bar (20 lbf/in²) to allow for pressure lost
while carrying out pressure checks.

9. When required pressure has been attained, close valve

on the nitrogen bottle and tank valve (6, Fig. 8) securely.
1 - Line 6 - Tank Valve
Turn small hex on charging valves (4) clockwise to close 2 - Valve Chuck 7 - Gland Fitting
valve internally. Rotate the 'T' handle of valve chuck 3 - Valve Extension 8 - Gland Nut
counter-clockwise until it stops. 4 - Cylinder Valve 9 - Cylinder Adaptor
5 - Pressure Gauge 10 - Bleeder Valve

10. With cylinder valve (4, Fig. 8) open and tank valve Fig. 8 - Charging Assembly
(6, Fig. 8) closed, bleed pressure gauge (5, Fig. 8) and
hoses through bleeder valve (10, Fig. 8). Loosen the Refer to Section 300-0070, SERVICE TOOLS, for part
swivel nut and remove valve chuck (2, Fig. 8) from numbers of the charging assembly shown in
charging valve (4). Fig. 8, additional parts required for simultaneous
charging of both ride cylinders, general service tools
Note: On new or rebuilt cylinders, the seals and wipers and adhesives required. These parts, tools and
may grip the piston rods tighter and make it difficult to adhesives are available from your dealer.
obtain the height shown in Fig. 7. If this happens, the
cylinders should be charged as accurately as possible, To simultaneously charge the ride cylinders, the
the machine operated for several days, and then the charging assembly can be modified as follows:
cylinder re-checked.
a. Disconnect hose (1) assembly from cylinder
11. Check cylinder charging valve (4) for leakage with valve (4) and install a tee piece in cylinder valve (4).
soapy water. If core is leaking, depress it quickly once
or twice to reseat the core. If leakage persists, replace b. Connect hose (1) assembly to one branch of the
core. Tighten charging valve lock nut and replace valve tee piece and secure.
cap. Tighten valve cap so that it cannot be removed
by hand. c. To make the second hose assembly, connect both
additional hoses together with a coupling. Install a
12. After charging the cylinders, the machine should be valve extension in a chuck valve and install the
operated to allow seals to settle and oil to mix with chuck valve assembly on the hose assembly.
nitrogen. If the cylinders bottom out or do not meet the
reference height when charged to the correct pressure, d. Connect the second hose assembly to the
and the truck is not being overloaded, the oil level may remaining branch of the tee piece and secure.
be incorrect. The ride cylinders should be discharged,
refilled with oil, and recharged as described above.
MAINTENANCE
SPECIAL TOOLS Visually check ride cylinder heights daily. Lubricate the
ride cylinders at service intervals and with lubricant
Numbers in parentheses refer to Fig. 8. specified in Section 300-0020, LUBRICATION SYSTEM.

8 SM 1912 Rev 1 08-03

 Suspension System - Ride Cylinder
Section 180-0030

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
2 6&8 Bolt 1 830 1 350
4 5 Locknut 260 - 285 190 - 210
4 17 Bolt 95 - 122 70 - 90
4 26 Bolt 271 200
- - Tie Rod Nut 2 030 - 2 300 1 500 - 1 700
- - Steering Cylinder Nut 4 000 - 4 500 3 000 - 3 300

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 1921 Rev 1 08-03 9

 SUSPENSION SYSTEM - Ride Cylinder - Rear
Section 180-0050

SM - 1369

PASSAGE 'A'

1 - Piston Rod 7 - Plug

2 - Spherical Bushing 8 - Ball 13 - Bolt 18 - Bolt
3 - Snap Ring 9 - Wiper 14 - Backup Ring 19 - Tube
4 - Lube Fitting 10 - Lube Fitting 15 - 'O' Ring 20 - Spherical Bearing
5 - Washer 11 - Seal 16 - Wear Ring 21 - Snap Ring
6 - Check Valve 12 - Seal Retainer 17 - Piston 22 - Charging Valve Assembly

Fig. 1 - Cutaway View of Typical Rear Ride Cylinder

DESCRIPTION AND OPERATION REMOVAL

Numbers and letters in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 2.

The rear ride cylinders are used to absorb road shocks.

The cylinder contains piston rod (1), tube (19) and WARNINGS
piston (17). Oil and compressed nitrogen fill the inside Pressurized cylinders. Release pressure as
of the cylinder. described under 'Relieving Cylinder Pressure'
before removing valves or fittings. Accidental
When the wheel hits a bump on the ground, piston rod (1) release of pressure will result in personal injury
is forced inward in the cylinder. The pressurized nitrogen and property damage.
compresses against the oil inside the cylinder. As the
nitrogen pressure builds up in the cylinder, piston rod (1) To prevent personal injury and property
slows down until it stops. Nitrogen pressure causes piston damage, be sure blocking or lifting equipment
rod (1) to extend back to its original position. As piston rod is of sufficient capacity and properly secured to
(1) is compressing, ball (8) is forced off its seat, allowing do the job safely.
the increased pressure to fill the cavity between tube (19)
and piston rod (1) faster. As piston rod (1) returns to the 1. Position the vehicle in a level work area, apply the
normal ride position, the pressure in the cavity forces ball parking brake and switch off the engine.
(8) against its seat. Pressure in the cavity is forced to
return through passage 'A' thereby slowing the return of 2. Turn the steering wheel in both directions several
piston rod (1) to the normal ride position. times to relieve pressure in the steering system. Block
all road wheels.

SM 2033 Rev 1 08-03 1

Suspension System - Ride Cylinder - Rear
Section 180-0050

SM - 1543

1 - Ride Cylinder
2 - Spacer 5 - Bolt 8 - Anti-seize Lubricant 11 - Locknut
3 - Pin 6 - Bolt 9 - Bolt 12 - Pin Assembly
4 - Bolt Assembly 7 - Lube Fitting 10 - Washer 13 - Hardened Washer

Fig. 2 - Typical Rear Ride Cylinder Mounting

3. Place a 35 mm (1.38 in) spacer between the frame cylinder (1) and rear axle housing brackets. Remove
and oscillation stop on both sides. spacers (2).

4. Relieve nitrogen pressure from BOTH rear ride 7. Remove bolt (6) and hardened washer (13) securing
cylinders. Refer to 'Relieving Cylinder Pressure', in pin assembly (12) through upper end of ride cylinder (1)
this section. and frame mounting. Drive pin assembly (12) out of
frame and upper ride cylinder (1) eyes and remove
5. Attach a suitable lifting device or 'come-along' to ride spacers (2).
cylinder (1). If a 'come-along' is used, place a bar or
heavy pipe through both body prop pin holes in the 8. Lower ride cylinder (1) assembly and move to a
frame. Attach the 'come-along' to the bar or pipe. Place clean work area for disassembly.
a suitable strap or chain around ride cylinder (1) and
take up the slack. 9. If required, repeat Steps 5 through 8 to remove
second ride cylinder (1).
Note: Lower end of ride cylinder (1) must be
disconnected before upper end.
DISASSEMBLY
6. Remove locknut (11), washers (10) and bolt (9) Numbers in parentheses refer to Fig. 3.
securing pin (3) through lower end of ride cylinder (1)
and rear axle housing brackets. Drive pin (3) out of ride 1. Remove clamp (30), bolts (27) and plate (29)

2 SM 2033 Rev 1 08-03

 Suspension System - Ride Cylinder - Rear
Section 180-0050

SM - 1378

1 - Piston Rod 9 - Wiper

2 - Spherical Bushing 10 - Lube Fitting 17 - Piston 24 - Small Ring
3 - Snap Ring 11 - Seal 18 - Bolt 25 - Valve Core
4 - Lube Fitting 12 - Seal Retainer 19 - Tube 26 - Cap
5 - Washer 13 - Bolt 20 - Spherical Bearing 27 - Bolt
6 - Check Valve 14 - Backup Ring 21 - Snap Ring 28 - Boot
7 - Plug 15 - 'O' Ring 22 - Charging Valve Assembly 29 - Plate
8 - Ball 16 - Wear Ring 23 - Large Ring 30 - Clamp

Fig. 3 - Exploded View of Typical Ride Cylinder

securing boot (28) to piston rod (1) and seal retainer

(12). Remove boot (28). WARNING
Flying metal chips. Use a soft drift and drive
2. Remove check valve (6) and plug (7) assembly from to remove piston (17). Flying chips from a hard
tube (19) and loosen bolts (13). Drain oil from ride metal drift can cause serious personal injury.
cylinder assembly into a suitable container.
6. Use a soft drift to tap piston (17) assembly off end
3. Place ride cylinder assembly into a suitable position of piston rod (1) assembly. This action frees ball (8) for
for disassembly and remove bolts (13) securing seal removal from its seat in piston rod (1). Remove wear
retainer (12) to tube (19). ring (16) from piston (17).

4. Carefully remove tube (19) from piston rod (1) 7. Place piston rod (1) assembly securely into position
assembly. in a press bed with piston rod eye down. Press piston
rod (1) out of seal retainer (12).
5. Remove bolts (18) and washers (5) from piston (17)
end of piston rod (1) assembly. 8. Remove and discard 'O' ring (15) and backup ring
(14) from seal retainer (12) outer groove.

SM 2033 Rev 1 08-03 3

Suspension System - Ride Cylinder - Rear
Section 180-0050
9. Remove and discard seal (11) and wiper (9) from ASSEMBLY
seal retainer (12) inner grooves.
Numbers in parentheses refer to Fig. 3.
10. Remove check valve (6) and plug (7) assembly
Note: Apply a light coating of clean hydraulic oil to all
from piston rod (1). If required, remove plug (7) from
components to facilitate assembly procedure. Make
check valve (6).
certain that all work is carried out in a clean area so no
dirt or other contaminants can get into the oil.
11. Remove charging valve assembly (22) from piston
rod (1). Do not disassemble charging valve assembly
1. If removed, install snap ring (21) into tube (19) eye.
(22) unless required.
Use a hand press to position spherical bushing (20)
against snap ring (21) in eye of tube (19). Retain
12. Remove lube fitting (10) from piston rod (1) and
spherical bushing with remaining snap ring (21). Use
lube fitting (4) from tube (19).
similar procedure to install spherical bushing (2) and
snap rings (3) in piston rod (1) eye end.
13. Spherical bushings (2 & 20) can be removed by
removing retainer snap rings (3 & 21) and pressing
2. Install new seal (11) and wiper (9) into inner groove
spherical bushings out of piston rod (1) and
of seal retainer (12). See Fig. 4.
tube (19) eyes.
3. Install new backup ring (14) and 'O' ring (15) into
INSPECTION outer groove of seal retainer (12). See Fig. 4.
Numbers in parentheses refer to Fig. 3.
4. Install seal retainer (12) on piston rod (1). Be careful
not to damage wiper (9).
1. Wash all parts thoroughly in a suitable solvent. Dry
all parts with compressed air. Check all inner and outer
5. Place ball (8) into its seat in piston rod (1). Install
grooves in seal retainer (12) for cleanliness.
wear ring (16) on piston (17) and press piston assembly
into position on end of piston rod (1). Secure piston
2. Inspect tube (19), piston rod (1) and piston (17) for
(17) assembly to piston rod (1) with bolts (18) and
scores, scuffing or small ridges in the walls. Use a fine
washers (5). Tighten bolts (18) evenly to a torque of 95
stone to smooth out any defective areas. If damage is
- 117 Nm (70 - 86 lbf ft).
too extensive, replace with a new part.
SM - 1373
3. Check all cylinder assembly components for signs
of unusual distortion or excessive wear. Replace
defective components.

4. Inspect all plugs (7), check valves (6), charging

valve assembly (22) and lube fittings (4 & 10). Check
their seating positions in piston rod (1) and tube (19). If
threads in any of these parts are damaged, restore the
threads. If threads are not repairable, the defective part
must be replaced.

5. Inspect both cylinder eye surfaces for scratches or

signs of excessive wear. Check spherical bushings
(2 & 20) and snap rings (3 & 21) for wear or warped
condition. Replace defective parts.

6. Inspect wear ring (16) for excessive wear or

damage. Replace if damaged.

1 - Piston Rod 12 - Seal Retainer

9 - Wiper 14 - Backup Ring
11 - Seal 15 - 'O' Ring
Fig. 4 - Cutaway View of Seal Retainer Assembly

4 SM 2033 Rev 1 08-03

 Suspension System - Ride Cylinder - Rear
Section 180-0050
Note: Because of close tolerances, care will have to be 5. Remove lifting device or 'come-along' from ride
taken when assembling piston rod (1) and piston (17) cylinder (1).
assembly into tube (19).
6. If the opposite ride cylinder (1) was removed, follow
6. Install tube (19) over piston rod (1) assembly, Steps 1 through 5 to install the cylinder.
pushing tube (19) in until piston (17) bottoms inside
the tube. 7. Charge ride cylinders as described in 'Charging
Instructions', in this section.
7. Install bolts (13) in seal retainer (12) and tube (19).
Tighten bolts (13) evenly to a torque of 1 120 - 1 220 Nm
(820 - 900 lbf ft). CHARGING RIDE CYLINDER

8. Install lube fittings (4 & 10), check valves (6),

plugs (7) and charging valve assembly (22) in ride WARNING
cylinder assembly as shown in Fig. 3. Lifting heavy parts or machines. To prevent
personal injury and property damage, be sure
9. Install boot (28) over piston rod (1) and secure to blocking or lifting equipment is of sufficient
piston rod (1) and seal retainer (12) with clamp (30), capacity and properly secured to do the
plate (29) and bolts (27). job safely.

INSTALLATION Relieving Cylinder Pressure

Numbers in parentheses refer to Fig. 2.

Note: Tighten all fasteners without special torques WARNING

specified to standard torques listed in Section Pressurized cylinders. Release pressure as
300-0080, STANDARD BOLT AND NUT TORQUE described below before removing valves or
SPECIFICATIONS. fittings. Accidental release of pressure will
result in personal injury and property damage.

WARNING Note: Vehicle must be empty and on a flat level

To prevent personal injury and property surface prior to relieving ride cylinder pressure.
damage, be sure blocking or lifting equipment
is of sufficient capacity and properly secured to 1. Support the frame near the ride cylinders with
do the job safely. blocking and/or a hydraulic jack with adequate
capacity.
1. Attach a suitable lifting device or a 'come-along' to
ride cylinder (1). If a 'come-along' is used, follow 2. Place a 35 mm (1.38 in) spacer on each oscillation
instructions in Step 5 under 'Removal' in this section. stop to facilitate charging procedure, as shown in Fig. 5.

Note: Lower end of ride cylinder (1) must be 3. Remove cap from nitrogen charging valve (2) at top
attached first. of ride cylinder. Turn hex nut on charging valve
1/4 to 1/2 turn anticlockwise and depress the valve
2. Apply an anti-seize lubricant (8) to pin (3). core. If no gas escapes, continue to turn hex nut in 1/4
turn increments until nitrogen releases as the charging
3. Install spacers (2) in place as pin (3) is driven valve core is depressed.
through banjo housing bracket and lower ride cylinder
(1) mounting eyes. Install washer (10) on bolt (9) and 4. Repeat step 3 for second ride cylinder.
install bolt (9) through pin (3) and mounting brackets.
Secure bolt (9) with washer (10) and locknut (11). 5. Remove blocking or release pressure on the
hydraulic jack and allow the vehicles weight to retract
4. Install upper end of ride cylinder (1) to frame by ride cylinder rods.
installing spacers (2) in place as pin assembly (12) is
being driven through frame and upper ride cylinder (1) Note: Ride cylinders will not be fully retracted due to the
eyes. Secure pin assembly (12) to frame with hardened spacers between the oscillation stops and frame rail.
washer (13) and bolt (6).

SM 2033 Rev 1 08-03 5

Suspension System - Ride Cylinder - Rear
Section 180-0050

SM - 160

FRAME
1 - Lube Fitting
2 - Nitrogen Charging Valve
3 - Plug SPACER
4 - Check Valve 35 mm (1.38 in)
5 - Check Valve TOP OF SEAL
RETAINER

DIMENSION 'A'
RIDE POSITION
TRUCK EMPTY
mm in
374 - 381 14.75 - 15.00

BANJO
ASSY

Fig. 5 - Typical Ride Cylinder Installation

WARNING WARNINGS
Pressurized cylinders. Keep valve core Pressurized cylinders. Release pressure as
depressed until all gas is bled from cylinder. described under 'Relieving Cylinder Pressure',
Failure to release all pressure may result in before removing valves or fittings. Accidental
personal injury or property damage. release of pressure will result in personal injury
and property damage.
6. Depress nitrogen charging valve (2) core again to
ensure all pressure has been relieved. A high pressure nitrogen pressure
regulator must be used with the charging
assembly. Failure to use a pressure regulator
Charging Instructions could cause property damage, personal injury,
Numbers in parentheses refer to Fig. 6, unless or death.
otherwise specified.
1. Remove pipe plug (3) from check valve (5). Loosen
Note: To ensure that both ride cylinders will be equally check valve (4) slowly until groove in check valve
charged to the correct pressure, both cylinders should thread is exposed. This opens a bleed path from the
be charged simultaneously as shown in Fig. 6. inside of the cylinder to the atmosphere. Attach hose
from a pressure pump filled with hydraulic oil specified
Note: The pressure of a confined gas varies directly in Section 300-0020, LUBRICATION SYSTEM, to
with its temperature. Hence, extreme changes in ride check valve (5).
cylinder ambient temperature will change its nitrogen
charge volume and, consequently, its operating height. Note: Approximately 14 bar (200 lbf/in2) pressure is
It might be necessary, therefore, to add or remove required to open the check valve allowing oil to flow
nitrogen to maintain proper cylinder height as ambient through the fitting into the cylinder.
temperature changes.
Note: To readjust oil level, the truck must remain
stationary for at least 10 hours to avoid, and release,

6 SM 2033 Rev 1 08-03

 Suspension System - Ride Cylinder - Rear
Section 180-0050

SM - 1372

1 - Lube Fitting
2 - Nitrogen Charging Valve
3 - Pipe Plug
4 - Check Valve (upper)
5 - Check Valve (lower)
6 - Ride Cylinder
7 - Hose
8 - Tee Piece
9 - Pressure Gauge
10 - Charging Assembly
11 - Nitrogen Bottle
12 - Valve Chuck
13 - Pressure Regulator
Fig. 6 - Charging Two Ride Cylinders Simultaneously

foaming of the oil. If the truck cannot be left idle for

10 hours, oil should be completely drained by removing
top pin assembly (12, Fig. 2) and, using suitable lifting WARNING
equipment, lower the cylinder until oil can be drained out Use dry nitrogen to charge cylinder. Do not use
of check valve (4 & 5) ports and nitrogen charging valve a gas such as oxygen which, if used by mistake
(2) port. Reinstall ride cylinder and secure with top pin for pressurizing, will explode violently when
assembly (12, Fig. 2). coming into contact with oil or grease, possibly
causing personal injury and property damage.
2. With cylinder rod in its retracted position (except for the
spacers on oscillation stops as shown in Fig. 5), fill the To charge both cylinders simultaneously with nitrogen, a
cylinder until oil flows free of air bubbles from check valve tee piece (8), hose (1, Fig. 7), valve chuck (2, Fig. 7) and
(4) port. It may be necessary to wait 30 or more minutes valve extension (3, Fig. 7) can be added to the charging
after nitrogen pressure has been released to clear the assembly (See Fig. 7). Assembly of this kit is described
foam which has formed inside the cylinder. Screw in under 'Special Tools'.
check valve (4) and close bleed valve with pipe plug (3).
Remove nitrogen charging valve (2) from cylinder rod. 4. Use suitable lifting equipment, lift frame to fully
Continue filling the cylinder with oil through check valve extend ride struts.
(5) port until it flows free of air bubbles, from nitrogen
charging valve (2) port. 5. Attach the charging assembly kit to nitrogen bottle
(11) by turning down on gland nut (8, Fig. 7).
3. Remove oil fill equipment, reinstall plug (3) in check
valve (5) and reinstall nitrogen charging valve (2) in 6. Install valve chucks (12) to nitrogen charging
its port.

SM 2033 Rev 1 08-03 7

Suspension System - Ride Cylinder - Rear
Section 180-0050
valves (2) as follows: SM - 1273

a. Rotate 'T' handle of valve chucks (12) anticlockwise

until they stop.

b. Screw the swivel nuts down on nitrogen charging

valves (2) until they seat.

c. Turn small hex on nitrogen charging valves (2)

two to three turns anticlockwise to unseat the
valves internally.

d. Rotate 'T' handles clockwise until they seat, opening

check valves (valve cores) in nitrogen charging valves
(2).

7. To check the amount of pressure in nitrogen bottle

(11), close cylinder valve (4, Fig. 7) and open tank
valve (6, Fig. 7). Open the valve on the nitrogen bottle
slowly and note the reading on pressure gauge (9). The
1 - Line 6 - Tank Valve
available pressure in nitrogen bottle (11) must be over 2 - Valve Chuck 7 - Gland Fitting
14 bar (200 lbf/in2). 3 - Valve Extension 8 - Gland Nut
4 - Cylinder Valve 9 - Cylinder Adaptor
8. Close tank valve (6, Fig. 7) and open cylinder valve 5 - Pressure Gauge 10 - Bleeder Valve
(4, Fig. 7). Charge both cylinders to 8.3 bar (120 lbf/in²)
by opening tank valve (6, Fig. 7) slowly and closing it Fig. 7 - Charging Assembly
occasionally. To check pressures in the cylinders,
close tank valve (6, Fig. 7) and note the reading on handles of valve chucks (12) anticlockwise until
pressure gauge (9). they stop.

Note: If both cylinders do not extend evenly, check 10. With cylinder valve (4, Fig. 7) open and tank valve
front ride struts. Both front struts should be extended (6, Fig. 7) closed, bleed pressure gauge (9) and
equally (both can be fully collapsed). Also check hoses (7) through bleeder valve (10, Fig. 7). Loosen the
that machine is on a flat, level surface and the body swivel nuts and remove valve chucks (12) and hoses
is empty. (7) from nitrogen charging valves (2).

Note: Cylinder height 'A' shown in Fig. 5 is intended to Note: On new or rebuilt cylinders, the seals and wipers
be for REFERENCE only. Cylinders should be charged may grip the piston rods tighter and make it difficult to
according to the pressure chart below and NOT solely obtain the correct height shown in Fig. 5. If this
on the basis of monitoring cylinder height. happens, the cylinders should be charged as
accurately as possible, the vehicle operated for several
Note: It is advised to charge the ride struts by an days, and then the cylinder re-checked.
additional 1.4 bar (20 lbf/in²) to allow for pressure lost
while carrying out pressure checks. 11. Check nitrogen charging valves (2) for leakage with
soapy water. If either core is leaking, depress it quickly
9. When required pressure has been attained, close the once or twice to reseat the core. If leakage persists,
valve on nitrogen bottle (11) and tank valve (6, Fig. 7) replace core. Tighten charging valve lock nut and
securely. Turn small hex on nitrogen charging valves replace valve cap. Tighten valve cap so that it cannot
(2) clockwise to close valves internally. Rotate 'T' be removed by hand.

CYLINDER CHARGING PRESSURE 12. Remove spacers from oscillation stops.

bar lbf/in² 13. After charging the cylinders, the machine should be
Standard Body 8.3 120 operated to allow seals to settle and oil to mix with
nitrogen. The vehicle, with rated load, should have a 35
Rock Body 9.0 130 mm (1.38 in) gap or more, between the oscillation

8 SM 2033 Rev 1 08-03

 Suspension System - Ride Cylinder - Rear
Section 180-0050
stops with the truck on a level surface. If there is less additional parts required for simultaneous charging of both
than 30 mm (1.25 in) between stops, check for ride cylinders and general service tools required. These
machine overload. If the machine is not being parts and tools are available from your dealer.
overloaded, the oil level may be incorrect. Ride
cylinders should be discharged, filled with oil, and To simultaneously charge the ride cylinders, the
recharged with nitrogen as described above. charging assembly can be modified as follows:

a. Disconnect hose (1) assembly from cylinder valve

MAINTENANCE (4) and install a tee piece in cylinder valve (4).
Visually check ride cylinder heights daily. Lubricate the
ride cylinders at service intervals and with lubricant b. Connect hose (1) assembly to one branch of the tee
specified in Section 300-0020, LUBRICATION SYSTEM. piece and secure.

c. To make the second hose assembly, install a valve

SPECIAL TOOLS extension in a chuck valve and install the chuck valve
Numbers in parentheses refer to Fig. 7. assembly on the hose assembly.

Refer to Section 300-0070, SERVICE TOOLS, for part d. Connect the second hose assembly to the remaining
numbers of the charging assembly shown in Fig. 7, branch of the tee piece and secure.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
3 13 Bolt 1 120 - 1 220 820 - 900
3 18 Bolt 95 - 117 70 - 86

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 2033 Rev 1 08-03 9

 ELECTRICAL SYSTEM - Circuit Diagrams
Section 190-0000

COMPONENT DESIGNATIONS

A4 - Radio/Cassette Player K2 - Battery Disconnect Relay S5 - Engine Oil Pressure Switch

A5 - Speaker K4 - Dir Inds Flasher Unit S6 - Trans Oil Pressure Switch
K5 - Air Cond Comp Clutch S7 - Park/Emergency Brake Switch*
B2 - Coolant Temp Sender K15 - Headlamp Relay S8 - Blower Switch
B8 - Fuel Level Sender K17 - Reverse Relay S9 - Washer Switch
B19 - Electronic Throttle K23 - Engine Run Relay S10 - Wiper Switch
B21 - Trans Oil Temp Sender K32 - Retarder Select Solenoid S13 - Horn Button
B22 - Engine Oil Press Sender K38 - Main Beam Relay S14 - Hazard Lights Switch
B23 - Trans Oil Press Sender K41 - Brake Valve Timer (TR100) S16 - Brake Pressure Switch
K42 - Pre-lube Timer (TR100) S18 - Lights Switch
E3 - Interior Light S19 - Dipswitch
E5 - Reverse Light L3 - Reverse Alarm S22 - Body-up W/L Switch*
E7 - Instrument Panel Lights L4 - Buzzer S31 - Park Brake W/L Switch
E11 - Side Marker Light, L L5 - Forward Horn S34 - Trans Oil Temp Switch
E12 - Tail Light, L S36 - Trans Oil Filter Press Sw
E13 - Side Marker Light, R M1 - Starter Motor S38 - Steering Filter Press Sw
E14 - Tail Light, R M3 - Heater Blower Motor S46 - Coolant Temp Switch
E26 - High Beam Headlamp, L M4 - Washer Motor S47 - Coolant Level Switch
E27 - High Beam Headlamp, R M5 - Wiper Motor S48 - Accumulator Press Sw, F
E28 - Dipped Beam Headlamp, L M13 - Air Seat Compressor S49 - Accumulator Press Sw, R
E29 - Dipped Beam Headlamp, R M14 - Electric Window Motor S50 - Brake Oil Temp Switch
S51 - Reverse Hoist Press Switch
F - Fuse (with number) N2 - Voltage Regulator S52 - Manual Mode Keyswitch
N3 - Voltage Converter 12V S53 - Power/Economy Keyswitch
G1 - Generator S54 - Steering Tank Oil Level Sw
G2 - Battery P1 - Speedometer S56 - Air Cleaner Ret'n Switch
P2 - Tachometer S57 - Low Steering Press Sw
H6 - Direction Indicator F,L P3 - Coolant Temp Gauge S59 - Retarder Select Switch
H7 - Direction Indicator B,L P4 - Fuel Level Gauge S62 - Retarder On Switch
H8 - Direction Indicator F,R P5 - Engine Oil Press Gauge S68 - Diagnostic Request Switch
H9 - Direction Indicator B,R P8 - Trans Oil Temp Gauge S88 - Park Brake Switch (TR100)
H10 - Brake Light, L P14 - Trans Oil Press Gauge
H11 - Brake Light, R X1 - Handlamp Socket
H13 - Retarder Light R7 - Cigar Lighter
H27 - Check Trans W/L Y1 - Fuel Solenoid
S2 - Starter Keyswitch Y4 - Park/Auxilliary Solenoid
K1 - Starter Relay S4 - Test Switch Y16 - CEC Lockup Drop-out Valve
Y21 - 50% Front Brake Valve
Y22 - Park Brake Valve (TR100)
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 Y25 - Quick-dump Brake Valve (TR100)

* NOTE: S22 SHOWN IN BODY-UP POSITION

S7 SHOWN IN PARK BRAKE APPLIED POSITION Wire Colours:
B - Black O - Orange
N - Brown Y - Yellow
L - LEFT R - RIGHT F - FRONT B - BACK U - Blue P - Purple
R - Red W - White
G - Green S - Slate
DIODE FUSE L - Lt Green K - Pink

INDICATOR LIGHT RESISTOR

SM 1924 7-00 1
Electrical System - Circuit Diagrams
Section 190-0000

Fuses, Relays and Warning Lights CEC Fuses and Relays - Located in Interface Box
Fuses, relays and warning lights which were not Fuses - Current Ratings Relay Functions
described under 'Component Designations' on the
previous page, are identified in the following tables. 1 - 8A 1 - ECU Initial Start
2 - 5A 2 - ECU Supply
3 - 8A 3 - Retarder (Not Used)
FUSES - Located in Fuse Box 4 - 5A 4 - Transmission Check
Current 5 - 5A 5 - Reverse Warning
Column Fuse No. Circuit Rating 6 - 8A 6 - Neutral Start
7 - 5A
1 Spare -
2 Spare -
3 Engine ECM 5A WARNING LIGHTS - Located in Dash Panel
4 Spare -
5 Fuel Solenoid 5A A Front Brake Accumulator Pressure
A 6 Spare - B Rear Brake Accumulator Pressure
7 CEC 10A C Low Steering Accumulator Pressure
8 Park Brake/Brake Lights 5A D Low Steering and Brake Tank Oil Level
9 Spare - E Parking Brake
10 Warning Lights 5A F Main Beam
11 Instruments 5A G Direction Indicators
12 Body-up Circuit 5A H Body-up
13 Wiper/Washer/Horn 10A J Alternator Charging
14 Wiper Self Park 10A K Engine Oil Pressure
15 Horn 10A L Engine Coolant Temperature
16 Spare - M Engine Diagnostic Light (Stop)
17 Heater & Air Cond. 25A N Engine Coolant Level
18 Spare - P Engine Diagnostic Light (Warning)
B 19 Lights & Dipped Beam 10A Q Air Cleaner Restriction
20 Main Beam 10A R Engine Diagnostic Light (Fluid)
21 Direction Indicators 5A S Transmission Oil Temperature
22 Hazards 5A T Check Transmission
23 Spare - U Disc Brake Hydraulic Oil Temperature
24 Headlamp Flash 10A V Steering Filter Restriction
25 Spare - W Retarder On
26 Front Brakes Press Red'n 5A X Transmission Oil Filter Restriction
27 Lockup Drop-out Solenoid 5A Y Converter Drive
28 Retarder Controls 5A Z Manual Mode
29 Reverse Alarm 5A
C 30 Spare -
31 Electric Window 10A
32 Worklamp/Cab Light/Radio 5A
33 Cigarette Lighter 10A
34 Spare -
35 Air Suspension Seat 15A
36 Spare -

Relays - Located in Fuse Box

Engine
Reverse Flasher
Run

Body Trans
X
up Filter

Horn X X

Dipped Main
Beam X
Beam

2 SM 1924 7-00
 Electrical System - Circuit Diagrams
Section 190-0000
SM - 2433A

15307288 Rev A
SM 1924 7-00 3
Electrical System - Circuit Diagrams
Section 190-0000
SM - 12433B

15307288 Rev A
4 SM 1924 7-00
 Electrical System - Circuit Diagrams
Section 190-0000
SM - 2433C

15307288 Rev A
SM 1924 7-00 5
Electrical System - Circuit Diagrams
Section 190-0000
SM - 2433D

15307288 Rev A
6 SM 1924 7-00
 Electrical System - Circuit Diagrams
Section 190-0000
SM - 2433E

CEC D75
15307288 Rev A
SM 1924 7-00 7
Electrical System - Circuit Diagrams
Section 190-0000
SM - 2433F

CEC 211
CEC 222 CEC 309
15307288 Rev A
8 SM 1924 7-00
 Electrical System - Circuit Diagrams
Section 190-0000
SM - 2433G

15307288 Rev A
SM 1924 7-00 9
10

Section 190-0000
Electrical System - Circuit Diagrams
SM - 2433H

SM 1924 7-00

15307288 Rev A CEC TRANSMISSION E.C.U. INTERFACE TO VEHICLE

SM 1924 7-00
SM - 2433I
CEC TRANSMISSION E.C.U. INTERFACE TO VEHICLE

Electrical System - Circuit Diagrams

Section 190-0000
15307288 Rev A
11
12

Section 190-0000
Electrical System - Circuit Diagrams
SM - 2433J

SM 1924 7-00

15307288 Rev A QUANTUM ENGINE E.C.M. INTERFACE TO VEHICLE

SM 1924 7-00
SM - 2433K

Electrical System - Circuit Diagrams

Section 190-0000
DETROIT DIESEL DDEC IV ENGINE E.C.M. POWER SUPPLY
15307288 Rev A
13
14

Section 190-0000
Electrical System - Circuit Diagrams
SM - 2433L

SM 1924 7-00

15307288 Rev A DETROIT DIESEL DDEC IV ENGINE E.C.M. INTERFACE TO VEHICLE

 Electrical System - Circuit Diagrams
Section 190-0000
SM - 2433M

CEC 45 CIRCUITS SPECIFIC TO TR100 ONLY

CEC 309
CEC 222

15307288 Rev A
SM 1924 7-00 15
Electrical System - Circuit Diagrams
Section 190-0000
SM - 2433N

OPTIONAL EQUIPMENT
15307288 Rev A
* * * *
16 SM 1924 7-00
 ELECTRICAL SYSTEM - Circuit Diagrams
Section 190-0000

C.E.C. - 2 Transmission Controls, D.D.E.C. IV and Cummins Quantum Select

COMPONENT DESIGNATIONS

A4 - Radio/Cassette Player K4 - Dir Inds Flasher Unit S13 - Horn Button

A5 - Speaker K5 - Air Cond Comp Clutch S14 - Hazard Lights Switch
K15 - Headlamp Relay S16 - Brake Pressure Switch
B2 - Coolant Level Sender K17 - Reverse Relay S18 - Lights Switch
B8 - Fuel Level Sender K23 - Engine Run Relay S19 - Dipswitch
B19 - Electronic Throttle K32 - Retarder Select Solenoid S22 - Body-up W/L Switch*
B21 - Trans Oil Temp Sender S31 - Park Brake W/L Switch
B22 - Engine Oil Press Sender L3 - Reverse Alarm S34 - Trans Oil Temp Switch
B23 - Trans Oil Press Sender L4 - Buzzer S36 - Trans Oil Filter Press Sw
L5 - Forward Horn S38 - Steering Filter Press Sw
E3 - Interior Light S46 - Coolant Temp Switch
E5 - Reverse Light M1 - Starter Motor S47 - Coolant Level Switch
E7 - Instrument Panel Lights M3 - Heater Blower Motor S48 - Accumulator Press Sw, F
E11 - Side Marker Light, L M4 - Washer Motor S49 - Accumulator Press Sw, R
E12 - Tail Light, L M5 - Wiper Motor S50 - Brake Oil Temp Switch
E13 - Side Marker Light, R M13 - Air Seat Compressor S51 - Reverse Hoist Press Switch
E14 - Tail Light, R M14 - Electric Window Motor S52 - Manual Mode Keyswitch
E26 - High Beam Haedlamp, L S53 - Power/Economy Keyswitch
E27 - High Beam Headlamp, R N2 - Voltage Regulator S54 - Steering Tank Oil Level Sw
E28 - Dipped Beam Headlamp, L N3 - Voltage Converter 12V S56 - Air Cleaner Ret'n Switch
E29 - Dipped Beam Headlamp, R S57 - Low Steering Press Sw
P1 - Speedometer S59 - Retarder Select Switch
F - Fuse (with number) P2 - Tachometer S62 - Retarder On Switch
P3 - Coolant Temp Gauge S68 - Diagnostic Request Switch
G1 - Generator P4 - Fuel Level Gauge
G2 - Battery P5 - Engine Oil Press Gauge X1 - Handlamp Socket
P8 - Trans Oil Temp Gauge
H6 - Direction Indicator F,L P14 - Trans Oil Press Gauge Y1 - Fuel Solenoid
H7 - Direction Indicator B,L Y4 - Brake Oil Diverter Valve
H8 - Direction Indicator F,R R7 - Cigar Lighter Y16 - Lockup Drop-out Valve
H9 - Direction Indicator B,R Y21 - 50% Front Brake Valve
H10 - Brake Light, L S2 - Starter Keyswitch
H11 - Brake Light, R S4 - Test Switch
H13 - Retarder Light S5 - Engine Oil Pressure Switch
S7 - Emergency Brake Switch*
K1 - Starter Relay S8 - Blower Switch
K2 - Battery Disconnect Relay S10 - Wiper Switch

Wire Colours:
TERMINAL DESIGNATIONS IN ACCORDANCE WITH DIN 72 552 B - Black O - Orange
N - Brown Y - Yellow
* NOTE: S22 SHOWN IN BODY-UP POSITION U - Blue P - Purple
S7 SHOWN IN PARK BRAKE APPLIED POSITION R - Red W - White
G - Green S - Slate
L - Lt Green K - Pink
L - LEFT R - RIGHT F - FRONT B - BACK

DIODE FUSE

INDICATOR LIGHT RESISTOR

SM 2245 07-03 1
Electrical System - Circuit Diagrams
Section 190-0000
SM2921

2 SM 2245 07-03
 Electrical System - Circuit Diagrams
Section 190-0000
SM2941A
SM 2245 07-03 3
Electrical System - Circuit Diagrams
Section 190-0000
SM2941B

4 SM 2245 07-03
 Electrical System - Circuit Diagrams
Section 190-0000
SM2941C
SM 2245 07-03 5
Electrical System - Circuit Diagrams
Section 190-0000
SM2941D

6 SM 2245 07-03
 Electrical System - Circuit Diagrams
Section 190-0000
SM2941E

CEC 309
SM 2245 07-03 7
Electrical System - Circuit Diagrams
Section 190-0000
SM2923

Refer to Power Module Detail, Ref. Fig. 15

8 SM 2245 07-03
 Electrical System - Circuit Diagrams
Section 190-0000
SM2922
Refer to Power Module Detail, Ref. Fig. 15
SM 2245 07-03 9
Electrical System - Circuit Diagrams
Section 190-0000
SM2921I

10 SM 2245 07-03
 Electrical System - Circuit Diagrams
Section 190-0000
SM2921J
SM 2245 07-03 11
Electrical System - Circuit Diagrams
Section 190-0000
SM2930

Refer to Interface Box Detail, Ref. Fig. 17

12 SM 2245 07-03
 Electrical System - Circuit Diagrams
Section 190-0000
SM2929

Refer to Interface Box Detail, Ref. Fig. 17

SM 2245 07-03 13
Electrical System - Circuit Diagrams
Section 190-0000
SM2941F

14 SM 2245 07-03
 Electrical System - Circuit Diagrams
Section 190-0000
SM2941G
SM 2245 07-03 15
Electrical System - Circuit Diagrams
Section 190-0000

Fuses, Relays and Warning Lights WARNING LIGHTS - Located in Dash Panel
Fuses, relays and warning lights which were not
A Front Brake Accumulator Pressure
described under 'Component Designations' on the
B Rear Brake Accumulator Pressure
previous page, are identified in the following tables. C Low Steering Accumulator Pressure
D Low Steering and Brake Tank Oil Level
FUSES - Located in Fuse Box E Parking Brake
F Main Beam
Current
G Direction Indicators
Column Fuse No. Circuit Rating
H Body-up
1 Spare - J Alternator Charging
2 Spare - K Engine Oil Pressure
3 Engine ECM 5A L Engine Coolant Temperature
4 Spare - M Engine Diagnostic Light (Stop)
5 Fuel Solenoid 5A N Engine Coolant Level
A 6 Spare - P Engine Diagnostic Light (Warning)
7 CEC 2 - Trans. ECU 10A Q Air Cleaner Restriction
8 Park Brake/Brake Lights 5A R Engine Diagnostic Light (Fluid)
9 Spare -
10 Warning Lights 5A S Transmission Oil Temperature
11 Instruments 5A T Check Transmission
12 Body-up W/L 5A U Disc Brake Hydraulic Oil Temperature
V Steering Filter Restriction
13 Wiper/Washer/Horn 10A W Retarder On
14 Wiper Self Park 10A X Transmission Oil Filter Restriction
15 Horn 10A Y Converter Drive
16 Spare - Z Engine Overspeed
17 Heater & Air Cond. 25A
18 Spare -
B 19 Lights & Dipped Beam 10A
20 Main Beam 10A
21 Direction Indicators 5A
22 Hazard Warning Lamps 5A
23 Spare -
24 Headlamp Flash 10A
25 Spare -
26 Front Brakes Press Red'n 5A
27 Lockup Drop-out Solenoid 5A
28 Retarder Controls 5A
29 Reverse Alarm 5A
C 30 Spare -
31 Electric Window 10A
32 Worklamp/Cab Light/Radio 5A
33 Cigarette Lighter 10A
34 Heated Mirrors 15A
35 Air Suspension Seat 15A
36 Spare -

Relays - Located in Fuse Box

Engine
Reverse Flasher
Run

Body Trans
X
up Filter

Horn X X

Dipped Main
Beam X
Beam

16 SM 2245 07-03
 Electrical System - Circuit Diagrams
Section 190-0000
SM2680 SM2940
1 2 3 4 5 6 7 1 2 3 8 9

10 7

A B C D A C B

1. Control Fuse 6. Transmission ECU Fuse 1. Check Trans. Relay 7. Converter Drive Relay
2. Engine Master ECM Fuse 7. Transmission ECU Fuse 2. Neutral Start Relay 8. On Board Weighing Relay
3. Engine Receiver ECM Fuse A. Ignition Sense Relay 3. Reverse Relay 9. Rear View Camera Relay
4. Engine Master ECM Fuse B. Engine ECM Power Relay 1 4. Body Up Relay 10. Ignition Signal Fuse
5. Engine Receiver ECM Fuse C. Engine ECM Power Relay 2 5. Delta P Relay A. Manual/Automatic Key
D. Trans. ECU Power Relay 6. Lock Up Off Relay B. Power/Economy Key
C. Manual Mode Light
Fig. 15 - Power Module Fig. 17- Interface Box
SM2679

L. E. D.

Release delay
On-off pulse
On-pulse
Off-pulse SET DIAL TO 'Release delay'

0.6 - 6 sec
6 - 60 sec
0.6 - 6 min
6 - 60 min SET DIAL TO '6 - 60 sec'
4
5
3
6
SET DIAL TO '3'
LOCK IN POSITION 2
USING ARALDITE OR
1
SIMILAR

Fig. 16 - Timer Relay Setting

* * * *

SM 2245 07-03 17
Electrical System - Circuit Diagrams
Section 190-0000

18 SM 2245 07-03
 ELECTRICAL SYSTEM - Switches and Sensors
Section 190-0270

SM - 2541

21 RETARDER
VALVE

17 12
19 18 BODY

HEADER
11
TANK BRAKE MANIFOLD VALVE

20 TREADLE FUEL TANK HYD. CONTROL VALVE

VALVE

14 6
1
16 15 3

2
4 7
13
5 10
ENGINE

TRANSMISSION 8 HYDRAULIC
TANKS
22 9

15 - Rear Brake Accumulator Press Sw.

1 - Engine Water Temperature Sender/Sw. 8 - Steering Oil Temperature Switch 16 - Front Brake Accumulator Press Sw.
2 - Engine Oil Pressure Sender/Switch 9 - Steering Filter Restriction Pressure Sw. 17 - Retarder Pressure Switch
3 - Transmission Oil Pressure Sender/Sw. 10 - Disc Brake Hydraulic Temp Switch 18 - Stop Light Pressure Switch
4 - Converter Drive Pressure Switch 11 - Fuel Level Sender 19 - Lockup Drop Out Pressure Switch
5 - Transmission Oil Temp. Sender/Sw. 12 - Body Up Proximity Switch 20 - Engine Water Level Probe
6 - Hoist Interlock Pressure Switch 13 - Steering Pressure Switch 21 - Engine Water Level Probe
7 - Hydraulic Oil Level Probe 14 - Parking Brake Pressure Switch 22 - Transmission Oil Temp. Sw.
Fig. 1 - Layout View of Switches and Sensors

DESCRIPTION Engine
Numbers in parentheses refer to Fig. 1, unless The DDEC IV engine management system monitors
otherwise specified. the engine at all times and sends a signal to the
engine stop light (6, Fig. 3) and engine warning light
This section describes the location and function of the (7, Fig. 3) on the dash panel to alert the operator of a
various switches and sensors fitted to the vehicle to fault in the engine circuit. Refer to Section 110-0030,
monitor all major components and systems. Gauges ENGINE AND MOUNTING.
and indicator/warning lights mounted on the dash
panel relay this information to the operator. Engine Oil Pressure Sender/Switch (2) - Combined
sender and switch unit, located in an elbow at the front
Note: Always make sure all gauges, indicator/warning of the engine.
lights and controls are working properly before
operating the vehicle. The pressure switch sends a signal to illuminate
engine oil pressure warning light (5, Fig. 3) to indicate
when the engine oil pressure drops below the safe
operating pressure.

SM 2032 Rev 2 10-04 1

Electrical System - Switches and Sensors
Section 190-0270

SM - 3307

1 2

15 P
20 30
10 RPM x100 20 20
20 MPH 20
10 40
5 25
2 6 km/h 20

0 30 0 50

STOP

ENG TRANS
OIL PRESS OIL PRESS

1 4 7
120
140

ENG TRANS
WATER TEMP 3 5 50
OIL TEMP
150

1 - Tachometer/Hourmeter Gauge
2 - Engine Oil Pressure Gauge 4 - Fuel Gauge 6 - Transmission Oil Pressure Gauge
3 - Engine Water Temperature Gauge 5 - Transmission Oil Temperature Gauge 7 - Speedometer/Odometer Gauge

Fig. 2 - Layout View of Gauges

The pressure sender sends a signal to the Engine Oil Tachometer/Hourmeter (1, Fig. 2) - Driven from the
Pressure Gauge (4, Fig.2). The gauge should read in engine ECM, the tachometer indicates the engine speed
the lower end of the green zone at normal operating in revolutions per minute (rev/min). Never accelerate the
speeds and may fall to the lower end of the yellow engine to speeds indicated by the red zone on the dial
zone at engine idle. Stop the engine if the gauge does face. A digital hourmeter is incorporated in the tachometer
not rise above the red zone until the fault is corrected. to record total hours of engine operation.

Engine Water Temperature Sender/Switch (1) - Tachometer Calibration Table -

Combined sender and switch unit, located at the front
All units with standard tyres
of the engine in the thermostat housing.
Unit Engine Pulses/revolution
The temperature switch sends a signal to illuminate TR35 Cummins M11 16.56
engine water temperature warning light (2, Fig. 3) TR40 Cummins N14 16.80
when engine water temperature rises above the safe TR45 Cummins QSK 12.00
operating temperature. TR60 Cummins QSK 12.00
TR70 DD Series 2000 12.00
The temperature sender sends a signal to the Engine TR100 Cummins KTA 15.72
Water Temperature Gauge (3, Fig. 2). The gauge TR100 DD Series 2000 12.00
should read in the green zone after the engine has
warmed. If the gauge reads in the red zone, stop the Tachometer Calibration
engine until the fault is corrected. 1. Determine the impulse setting required. Reference
tachometer calibration table.
Engine Water Level Probe (21) - Located in the
bottom of the coolant system header tank. Sends a 2. Using a suitable screwdriver, depress and hold
signal to illuminate engine water level warning light calibration button at the rear of the tachometer and
(3, Fig. 3) when engine water level falls below the safe turn the ignition keyswitch to position '1'. Release
operating level. button when PULSE is displayed.

2 SM 2032 Rev 2 10-04

 Electrical System - Switches and Sensors
Section 190-0270

SM - 3306
9 10 11 12

1 2

1 21
13 14 15 16
5 17
2 22

STOP
6 18
3 23

7 19
4 24

8 20

1 - Alternator Charging 9 - Front Brake Accumulator Pressure 17 - Transmission Oil Temperature

2 - Engine Water Temperature 10 - Rear Brake accumulator Pressure 18 - Disc Brake Hydraulic Temperature
3 - Engine Water Level 11 - Low Steering Pressure 19 - Retarder Indicator
4 - Air Cleaner Restriction 12 - Steering & Braking Tank Low Oil Level 20 - In-converter Indicator
5 - Engine Oil Pressure 13 - Parking Brake 21 - Transmission Check
6 - Engine Stop 14 - Headlight Main Beam 22 - Steering & Brake Filter Restriction
7 - Engine Warning 15 - Direction Indicator 23 - Transmission Oil Filter Restriction
8 - Not Used 16 - Body-up 24 - Transmission Overspeed
Fig. 3 - Layout View of Warning/Indicator Lights

3. After a few seconds, the digits will flash in in-converter indicator light (20, Fig. 3) to indicate
sequence. Depress the button until the desired when the transmission is in torque converter drive.
number is displayed the release the button for a few The light goes out when transmission lockup is
seconds until the next digit flashes. engaged.

4. Repeat step 3 to obtain the desired impulses/ Transmission Oil Filter Pressure Switch - Located
revolution. The tachometer is now calibrated. in the transmission oil filter head. Sends a signal to
transmission oil filter restriction indicator light (23, Fig.
3) to indicate that the filter is restricted and that the
Transmission element requires to be changed. Refer to Section
Transmission Oil Pressure Sender (3) - Located at 120-0100, TRANSMISSION OIL FILTER.
the top of the converter housing, the pressure sender
sends a signal to the Transmission Oil Pressure Transmission Oil Temperature Sender/Switch (5) -
Gauge (6, Fig.2) to indicate clutch application Combined sender and switch unit, located at the outlet
pressure. The reading will vary during shifts and with port for the transmission oil cooler.
varying speeds and loads. The needle should remain
in the green zone during normal operation but might The temperature switch sends a signal to illuminate
rise into the upper red zone for short periods under transmission oil temperature warning light (17, Fig. 3)
heavy loading. When the load decreases, the needle when the transmission oil temperature rises above the
should return to the green zone and may fall safe operating temperature.
momentarily into the lower red zone. If the needle
remains in either of the extreme zones for extended The temperature sender sends a signal to the
periods, stop the vehicle until the fault is corrected. Transmission Oil Temperature Gauge (5, Fig. 2) to
indicate converter-out oil temperature. The gauge
Converter Drive Pressure Switch (4) - Located on should read in the green zone during normal
the right hand side of the transmission at the lockup operation.
valve body. Sends a signal to illuminate transmission

SM 2032 Rev 2 10-04 3

Electrical System - Switches and Sensors
Section 190-0270
Watch for wide deviations from normal readings on field at the end of the sensor. The passing of each
the gauge during vehicle operation. If the gauge, on gear tooth generates an electrical pulse which is
vehicles which do not have a transmission retarder directed to the ECU. The ECU recognises this signal
fitted, shows oil temperature consistently rising as output speed. Refer to Section 120-0070, CEC
above the green zone (43 - 135° C; 100 - 275° F) SHIFT SYSTEM.
under normal operating conditions; check for external
causes. If none are evident shift to Neutral 'N' and CEC Lockup Drop Out Pressure Switch (19) - The
operate the engine at 1 200 - 1 500 rev/min. If the normally open (NO) pressure switch is located in the
transmission oil temperature does not decrease into front plate of the treadle valve in the 'B2' circuit. As
the green zone within 2 or 3 minutes, the cause of brake pressure increases to 20.5 bar (301 lbf/in²) and
overheating should be corrected before the vehicle is above, the circuit should close and send a signal to
operated further. the lockup drop out solenoid, which in turn drops the
transmission out of lockup. As pressure drops below
Watch the gauge when operating on upgrades. If the 20.5 bar (301 lbf/in²) the circuit should open and
oil temperature goes into the red zone (135 - 176° C; lockup can be engaged. This will prevent the drive
275 - 350° F), select the range which will limit upshifts between the engine and transmission from locking up
to the highest range in which the transmission will and subsequently stalling the engine.
operate within the normal temperature range. If
upshifting must be consistently limited to ranges lower
than normal for the loads and the grades encountered Braking and Retardation
to prevent overheating the transmission oil, the causes Front Brake Accumulator Pressure Switch (16) -
should be determined and corrected. The normally closed (NC) pressure switch, located in
port 'PS1' of the brake manifold valve, senses the
During transmission retarder operation oil temperature pressure in the front brake accumulator. The pressure
can enter the yellow 'Retarder On' zone but should not switch sends a signal to illuminate front brake
enter the red zone. Do not allow the temperature to accumulator pressure warning light (9, Fig. 3) when
stay at or near the top of the yellow zone for more than pressure drops below 90 bar (1 323 lbf/in²). An audible
three minutes. Reduce downgrade travel speed to alarm also sounds.
avoid the oil overheating and possible damage to the
transmission. Rear Brake Accumulator Pressure Switch (15) -
The normally closed (NC) pressure switch, located in
Speedometer/Odometer (7, Fig. 2) - Driven by a port 'PS2' of the brake manifold valve, senses the
signal from the CEC, the speedometer indicates pressure in the rear brake accumulator. The pressure
vehicle travel speed in kilometres per hour (km/h) and switch sends a signal to illuminate rear brake
miles per hour (mph). A digital odometer is accumulator pressure warning light (10, Fig. 3) when
incorporated in the speedometer to record the pressure drops below 83 bar (1 200 lbf/in²). An audible
distance travelled by the vehicle at any given time. For alarm also sounds.
speedometer calibration details, refer to Section
120-0070, CEC SHIFT SYSTEM. Parking Brake Pressure Switch (14) - The normally
closed (NC) pressure switch, located in port 'PS3' of
Transmission Oil Temperature Switch (22) - The the brake manifold valve, senses pressure in the
temperature switch is mounted at the front right hand parking brake line. The pressure switch sends a signal
side of the transmission. The transmission oil to illuminate parking brake indicator light (13, Fig. 3)
temperature is continuously monitored by the ECU. when pressure drops below 65 bar (940 lbf/in²).
The ECU will only permit operation in a range best
suited for the temperature condition and the 'Check Stop Light Pressure Switch (18) - The normally open
Transmission' light will illuminate. Refer to Section (NO) pressure switch is located in the front plate of the
120-0070, CEC SHIFT SYSTEM. treadle valve in the 'B1' circuit. As brake pressure
increases to 2.7 bar (39 lbf/in²) and above, the circuit
Output Speed Sensor - The output speed sensor should close and send a signal to illuminate the brake
(magnetic pick-up) is installed in the rear cover of the lights. As pressure drops below 2.7 bar (39 lbf/in²) the
transmission. The magnetic end of the sensor is circuit should open and brake lights go out.
positioned adjacent to the gear located on the
transmission output shaft. Rotation of the output shaft Retarder Pressure Switch (17) - The normally open
causes the gear teeth to pass through the magnetic (NO) pressure switch is located in the retarder control

4 SM 2032 Rev 2 10-04

 Electrical System - Switches and Sensors
Section 190-0270
valve body. As retarder pressure increases to 2.7 bar brake hydraulic temperature warning light (16, Fig. 3)
(39 lbf/in²) and above, the circuit should close and when a temperature of 121° C (250° F) is reached. If
send a signal to illuminate retarder indicator light the light illuminates, reduce speed and shift
(19, Fig. 3), and the retarder light at the rear of the transmission to the range that will maintain an engine
vehicle. As pressure drops below 2.7 bar (39 lbf/in²) speed as high as possible, without exceeding the
the circuit should open and the retarder lights should maximum recommendation, to increase oil circulation
go out. and cooling. If trouble persists, stop the vehicle and
have the fault corrected.

Steering Body Up Proximity Switch (12) - Mounted off a

Steering Pressure Switch (13) - The normally bracket on the platform to the rear right hand side of
closed (NC) pressure switch is located in a tee at the cab. When the body is raised off the chassis, the
accumulator valve mounted off the left hand side of proximity switch opens and completes the electrical
the transmission. Sends a signal to illuminate low circuit to the ECU. The ECU then prevents the
steering pressure warning light (11, Fig. 3) when transmission from shifting above 1st gear until the
steering pressure drops to 83 bar (1 200 lbf/in²) or body is fully lowered and the switch closes. Body-up
lower. An audible alarm also sounds. warning light (16, Fig. 3) illuminates to indicate when
the body is not resting on the chassis. Refer to Section
Steering Filter Restriction Pressure Switch (9) - 120-0070, CEC SHIFT SYSTEM.
The normally open (NO) oil pressure switch is located
beside steering oil temperature switch (8) in the Note: Never move the vehicle until body-up warning
manifold block at the return port of the steering and light (16, Fig. 3) goes out.
brake control tank. The oil pressure switch will close
and illuminate steering filter restriction indicator light Hoist Interlock Pressure Switch (6) - Located in a
(22, Fig. 3) when the restriction pressure exceeds tee installed in body hoist control valve. The hoist
2.7 bar (39 lbf/in2), indicating a filter change is interlock is a safety feature to prevent the vehicle from
required. backing up while the body is being raised. If the
pressure switch is opened by the body control joystick
Steering Oil Temperature Switch (8) - The normally being moved to the raise position, current is
open (NO) oil temperature switch closes when a interrupted and the ECU will shift the transmission to
temperature of 50° C (122° F) is reached. The oil neutral. To obtain reverse gear whilst the body is held
temperature switch is connected in series with steering in the raise position, move the transmission shift lever
pressure switch (9), therefore, steering filter restriction to neutral, then re-select reverse gear. This interlock
indicator light (22, Fig. 3) will not illuminate until the oil will not prohibit shifts to a forward range while the body
reaches normal operating temperature. is being raised. Refer to Section 120-0070, CEC
SHIFT SYSTEM.
Low Oil Level Switch (7) - Located in the steering
and brake control tank, with electrical connection at
the rear of the tank. Sends a signal to illuminate Fuel Tank
steering and braking tank low oil level warning light Fuel Level Sender (11) - Located in the rear of the
(12, Fig. 3) when the oil level in the tank falls below the fuel tank, the fuel level sender sends a signal to the
safe operating level. An audible alarm also sounds. fuel level gauge to indicate the amount of fuel left in
Refer to Section 220-0040 STEERING AND BRAKE the fuel tank.
CONTROL TANK.

Air Cleaner
Body and Disc Brake Cooling Air Cleaner Restriction Gauges - Located in the air
Disc Brake Hydraulic Temperature Switch (10) - cleaner outlet pipes, the gauges send a signal to
Located in the disc brake oil return tube to indicate if illuminate air cleaner restriction indicator light
the disc brake cooling oil is overheating. The oil (4, Fig. 3) to indicate that the air cleaner(s) is restricted
temperature switch sends a signal to illuminate disc and that the element requires to be cleaned/changed.

* * * *

SM 2032 Rev 2 10-04 5

 FUEL SYSTEM - Fuel Tank, Lines and Mounting
Section 200-0010

SM - 2437

20 34 25
33
21 24
32
1 19
24
23

18 15 26
16
5 28
17 6 7 8

21 27
31
22

29
20

30 21

4 18
14
13
17

21
3
22
12
11
10
9 2

1 - Fuel Tank 26 - Bolt

2 - Drain Plug 10 - Gasket 18 - Mounting Bracket 27 - Isolation Mount
3 - Cover 11 - Dial 19 - Plate 28 - Snubbing Washer
4 - Gasket 12 - Screw 20 - Bolt 29 - Strainer
5 - Filler Cap 13 - Bolt 21 - Hardened Washer 30 - Padlock
6 - Gasket 14 - Lockwasher 22 - Locknut 31 - Key
7 - Gasket 15 - Plug 23 - Bolt 32 - Fuel Level Sender
8 - Latch 16 - Mounting Bracket 24 - Washer 33 - Screw
9 - Gauge Fuel Level 17 - Clamp 25 - Locknut 34 - Cover

Fig. 1 - Exploded View of Fuel Tank and Mounting

DESCRIPTION level gauge in the dash panel to indicate the amount of

Numbers in parentheses refer to Fig. 1. fuel left in the fuel tank.

Note: Refer to Section 300-0020, LUBRICATION

SYSTEM, for fuel tank capacity and fuel specifications. REMOVAL
Numbers in parentheses refer to Fig. 1.
Fuel tank (1) is mounted off the right hand frame rail
and hoist bracket at three points.
WARNING
Integral with fuel tank (1) are fuel strainer (29) and fuel To prevent personal injury and property
level sender (32). Fuel strainer (29) helps prevent damage, be sure wheel chocks and lifting
foreign particles from entering fuel tank (1) when fuel equipment are properly secured and of
tank (1) is being filled. Fuel level sender (32), located adequate capacity to do the job safely.
in the rear of fuel tank (1), sends a signal to the fuel

SM 1927 7-00 1
Fuel System - Fuel Tank, Lines and Mounting
Section 200-0010

SM - 2539
33 12 18 13
36 35

12
34 13
AT REAR
ENGINE MOUNT R.H.S.

5
1 20 21 24 15
PORT 22
6 TOP OF
ENGINE

4 16
SECONDARY
FILTERS 16
23 25
3 25 24
32 30
31
19 22
17 21 26
FROM FUEL 14
PUMP
23 27

5 7
7
10 8 1
2
5 11
29 4
9 28
PRIMARY FILTERS

1 - Fuel Line 10 - Shut Off Valve 19 - Bracket 28 - Bolt

2 - Fuel Line 11 - Clamp 20 - Plate 29 - Washer
3 - Fuel Line 12 - Clamp 21 - P-Clip 30 - Bolt
4 - Fuel Line 13 - Clamp 22 - Locknut 31 - Locknut
5 - Connector 14 - Fuel Cooler 23 - Bolt 32 - Washer
6 - Connector 15 - Mounting Bracket 24 - Bolt 33 - P-Clip
7 - Connector 16 - Bracket 25 - Washer 34 - P-Clip
8 - Adaptor 17 - Mounting Bracket 26 - Washer 35 - Locknut
9 - Elbow - 90° 18 - Plate Assembly 27 - Bolt 36 - Bolt

Fig. 2 - Fuel Lines

1. Position the vehicle in a level work area, raise the 8. Identify and tag fuel lines (3 & 4, Fig. 2) connected
body and install the body safety pins. Refer to to fuel tank (1) and, with a suitable container available
Section 270-0010, BODY AND MOUNTING. to catch leakage, disconnect fuel lines (3 & 4, Fig. 2)
from fuel tank (1). Cap open line ends to prevent entry
2. Apply the parking brake and switch off the engine. of dirt.

3. Turn the steering wheel in both directions several 9. Using a suitable lifting device, support fuel tank (1)
times to relieve any pressure in the steering system. and take up any slack. Remove bolts (23), hardened
Block all road wheels. washers (24), nuts (25) and shims (19) (if fitted)
securing lower mounting bracket (16) to hoist bracket.
4. Close fuel shut off valve (10, Fig. 2) at the fuel filters
to prevent loss of fuel prime at the engine. 10. Remove bolts (20), hardened washers (21) and
locknuts (22) securing securing clamps (17) and upper
5. Remove filler cap (5) from fuel tank (1). Discard mounting brackets (18) to fuel tank (1). Remove fuel
gaskets (6 & 7) from filler cap (5) if damaged. tank (1) from vehicle.

6. Remove cover (34) from fuel level sender (32) and

disconnect electrical connections at fuel level DISASSEMBLY
sender (32). Numbers in parentheses refer to Fig. 1.

7. With a suitable container in position, remove drain 1. Remove fuel strainer (29) from fuel tank (1).
plug (2) and drain fuel from fuel tank (1). Reinstall
drain plug (2) when fuel tank (1) is completely drained. 2. Remove screws (33) securing fuel level sender (32)

2 SM 1927 7-00
 Fuel System - Fuel Tank, Lines and Mounting
Section 200-0010
to fuel tank (1) and remove fuel level sender (32). 6. If removed, install rubber isolation mount (27) into
Check condition of rubber sealing ring on fuel level mounting bracket (16). Secure mounting bracket (16)
sender (32) and replace if required. to fuel tank (1) using bolt (26) and snubbing washer
(28). Do not fully tighten bolt (26) at this stage.
3. Remove screws (12) securing level gauge (9 &11)
to fuel tank (1) and remove level gauge (9 & 11).
Check condition of gasket (10) on level gauge (9 & 11) INSTALLATION
and replace if required. Numbers in parentheses refer to Fig. 1.

4. Remove bolts (13), lockwashers (14), cover plate (3) Note: Tighten all fasteners to standard torques listed
and 'O' ring (4) from fuel tank (1). Discard in Section 300-0080, STANDARD BOLT AND NUT
'O' ring (4). TORQUE SPECIFICATIONS.

5. Remove bolt (26) and snubbing washer (28)

securing mounting bracket (16) to fuel tank (1). WARNING
Remove mounting bracket (16) from fuel tank (1). If To prevent personal injury and property
required, remove isolation mount (27) from lower damage, be sure lifting equipment is properly
mounting bracket (16). secured and of adequate capacity to do the job
safely.

CLEANING 1. Using suitable lifting equipment, position fuel tank

Numbers in parentheses refer to Fig. 1. (1) assembly to right hand frame rail. Locate top
mounts and secure in position using clamps (17) and
1. Remove all dirt particles from fuel strainer (29) and upper mounting brackets (18), bolts (20), hardened
clean fuel strainer (29) with clean diesel fuel. washers (21) and locknuts (22).

2. Cover plate (3) port in fuel tank (1) can be used as 2. Remove blanking caps from fuel lines (3 & 4, Fig. 2)
an opening to remove dirt and sludge from the bottom and connect fuel lines to fuel tank (1) as identified at
of fuel tank (1) with a clean dry cloth. Remove drain removal. Tighten fuel lines securely.
plug (2) and flush fuel tank (1) with clean diesel fuel to
remove any remaining dirt particles. Reinstall drain 3. Connect electrical connections to fuel level sender
plug (2) and tighten securely. (32) and install cover (34) over fuel level sender (32).

4. Remove filler cap (5) assembly from filler neck on

ASSEMBLY fuel tank (1) and fill fuel tank (1) with fuel specified in
Numbers in parentheses refer to Fig. 1. Section 300-0020, LUBRICATION SYSTEM. Ensure
vent hole in filler cap (5) is clear and install filler cap
1. Install new 'O' ring (4) in groove of fuel tank (1) boss (5) assembly on filler neck. Tighten filler cap (5)
and secure cover plate (3) to fuel tank (1) boss with securely.
lockwashers (14) and bolts (13).
5. Secure filler cap (5) on the filler neck with latch (8)
2. Ensure rubber sealing ring is located on fuel level and padlock (30).
sender (32) and position fuel level sender (32) in fuel
tank (1). Secure fuel level sender (32) to fuel tank (1) 6. Open fuel shut off valve (10, Fig. 2) at the fuel
with screws (33). filters.

3. Ensure gasket (10) is located on level gauge (9 & 11) 7. Start the engine and run for a few minutes to ensure
and position level gauge (9 & 11) in fuel tank (1). Secure fuel is being supplied to the engine. Check for leaks at
level gauge (9 & 11) to fuel tank (1) with screws (12). fuel lines and tighten if required.

4. Install fuel strainer (29) in fuel tank (1). If removed 8. Remove body safety pins and lower the body.
install new gaskets (6 & 7) in filler cap (5) and install Remove wheel chocks from all road wheels.
filler cap assembly loosely to prevent entry of dirt.

5. Ensure that plug (15) and drain plug (2) are securely
tightened in fuel tank (1).

SM 1927 7-00 3
Fuel System - Fuel Tank, Lines and Mounting
Section 200-0010
SM - 2441 Operation
Numbers in parentheses refer to Fig. 3.
2
Attach the fast fuel nozzle to receiver (1) and turn the
handle to the 'On' position. As fuel enters the tank, it
forces the air inside the tank through the hollow stem
in fuelling vent (2). When the fuel level in the tank
nears the top, two hollow floating balls force the third
ground ball against an 'O' ring seal and stops the flow
of air from the tank. Fuel continues to flow into the tank
and pressure begins to build. At approximately 0.4 bar
(5.5 lbf/in2), a diaphragm operated piston inside the
nozzle starts to shut off the flow of fuel and system line
pressure picks up and brings the nozzle to the 'Off'
position. The nozzle is then disconnected from
receiver (1).

1
MAINTENANCE
Numbers in parentheses refer to Fig. 1.
1 - Receiver 2 - Fuelling Vent
3 - Plug Prior to starting the vehicle check the fuel level. Fuel
Fig. 3 - Fast Fuelling Option tank (1) should be filled at the end of each shift to
prevent condensation from gathering in the tank.
FAST FUELLING - Optional Ensure vent hole in filler cap (5) is clear to prevent a
vacuum from building up in fuel tank (1). Check
Numbers in parentheses refer to Fig. 3, unless
condition of all fuel lines.
otherwise specified.
When filling fuel tank (1) check that there is no buildup
A fast fuel system can be installed in the fuel tank as an
of dirt and sludge at fuel strainer (29). Remove and
option. It involves replacing cover plate (3, Fig. 1)
clean fuel strainer (29) and filler cap (5) as required.
with a flange and nipple receiver (1) and plug (15, Fig. 1)
From time to time make a visual check on the
with diesel fuelling vent (2). Receiver (1) is located
electrical connections at fuel level sender (32).
near the bottom of the tank for bottom filling which
helps eliminate foaming that occurs during the
The condition of fuel tank (1) mounting should be
traditional 'splash fill' method at the top of the tank.
checked carefully. Check isolation mounts (27),
clamps (17) and mounting brackets (16 & 18) for any
The advantages of fast fuelling are:
sign of wear or damage and repair or replace as
a. Reduces the fill time by around two thirds.
required. Check that nuts (22 & 25) and bolts (20, 23 &
b. Reduces foaming which results in a full tank and
26) are securely tightened and that no wear on
more running time between fill-ups.
mounting holes is evident. Tighten nuts (22 & 25) and
c. Reduces spillage because the nozzle automatically
bolts (20, 23 & 26) as required.
shuts off when the tank is full.
d. Reduces accidents because refuelling is done from
ground level.

* * * *

4 SM 1927 7-00
 FUEL SYSTEM - Electronic Foot Pedal
Section 200-0051

SM - 2540

1
28

27
25 26

24
23 3 4

16
22 17
21 20 18
19
15 5 17,18
6
7
26,27

11 10
14 13 12
9 10 29,30 ENGINE

REF. 8,9
31
8 FLOORPLATE

1 - Pedal Assembly 9 - Lockwasher 17 - Bolt

2 - Screw 10 - Plate Assembly 18 - Lockwasher 25 - Thrust Washer
3 - Bushing 11 - Plate 19 - Bushing 26 - Cover
4 - Pin 12 - Pin 20 - Shaft 27 - Potentiometer
5 - Snap Ring 13 - Snap Ring 21 - Thrust Washer 28 - Screw
6 - Bushing 14 - Roller 22 - Spring 29 - Screw
7 - Spring 15 - Lever 23 - Bearing 30 - Clamp
8 - Bolt 16 - Bushing 24 - Pin 31 - Harness

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 secured and of adequate capacity to do the job
preset and therefore no adjustment is necessary. safely.

Note: The engine MUST be started with foot 'OFF' 1. Position the vehicle in a level work area, ensure
pedal assembly (1). the body is fully lowered, apply the parking brake and
switch off the engine.

SM 2031 7-00 1
Fuel System - Electronic Foot Pedal
Section 200-0051
2. Turn steering wheel in both directions several 1. Position pedal assembly (1) on plate assembly
times to relieve any pressure in the steering circuit. (10) and secure with bolts (17) and lockwashers (18).
Block all road wheels.
2. Secure plate assembly (10) and pedal assembly
3. Disconnect electrical harness (31) from the mating (1) to the cab floor plate with mounting bolts (8) and
engine harness. lockwashers (9) removed during removal.

4. Move cab floor mat back and clear from pedal 3. Connect electrical harness (31) to the mating
assembly (1) and mounting plates. engine harness.

5. Remove mounting bolts (8) and lockwashers (9) 4. Position floor mat on cab floor and ensure that
securing plate assembly (10) and pedal assembly (1) pedal assembly (1) is free to operate.
to cab floor plate. Remove plate assembly (10) and
pedal assembly (1). 5. Remove wheel blocks and start the engine. Ensure
that pedal assembly (1) operates correctly.
6. Remove bolts (17) and lockwashers (18) securing
pedal assembly (1) to plate assembly (10). Remove Note: The engine MUST be started with the foot
pedal assembly (1) from plate assembly (10). 'OFF' pedal assembly (1).

INSTALLATION MAINTENANCE
Numbers in parentheses refer to Fig. 1. Limited repair of the electronic foot pedal assembly is
by replacement of parts only. Refer to vehicle Parts
Note: Tighten all fasteners to standard torques listed Book for part numbers of overhaul kits.
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.

* * * *

2 SM 2031 7-00
 COOLING SYSTEM - Cooling System
Section 210-0000

SM - 3147

1
13

13

12

12

16
10
12 THERMOSTATS
12

ENGINE
WATER 2
PUMP
TO ENGINE 4
(AIR COOLER
PIPE AT TURBO)

5 15
14
11

TO ENGINE
OIL COOLER
3
1 - Radiator
2 - Engine Water Pump 7 - Coolant Pipe 12 - Deaeration Lines
3 - Engine Oil Cooler 8 - Coolant Pipe 13 - Coolant Lines
4 - Disc Brake Oil Cooler 9 - Make-up Line 14 - Coolant Pipe
5 - Coolant Pipe 10 - Thermostat Housings 15 - Coolant Pipe
6 - Transmission Oil Cooler 11 - Coolant Pipe 16 - Header Tank

Fig. 1 - Cooling System

DESCRIPTION The main components of the cooling system are;

Numbers in parentheses refer to Fig. 1. header tank (16), radiator (1), engine water pump (2),
disc brake oil cooler (4), transmission oil cooler (6),
A radiator and fan cooling system is used on the engine oil cooler (3) and thermostat housings (10).
engines installed in these machines. This system has
a centrifugal type engine water pump (2) to circulate
coolant throughout the system. Three full blocking
thermostats located in each of the two thermostat
housings (10) control the flow of coolant throughout
the system.

SM 2278 04-04 1
Cooling System - Cooling System
Section 210-0000

OPERATION
Numbers in parentheses refer to Fig. 1.
WARNING
Do not remove the pressure control cap from
The engine water pump (2) draws coolant from the
the header tank or attempt to drain the coolant
radiator bottom tank, through coolant pipes (14 & 15)
until the engine has cooled. Once the engine
and into engine water pump (2). Engine water pump (2)
has cooled, use extreme caution when
pumps coolant through disc brake oil cooler (4) and into
removing the cap. Always release pressure
transmission oil cooler (6). Coolant flows through
from the system by depressing the pressure
transmission oil cooler (6), through coolant pipe (7)
relief button on the cap. Remove cap slowly as
and into engine oil cooler (3) and water jackets.
the sudden release of pressure from a heated
cooling system can result in a loss of coolant
When thermostats are closed, coolant flows through
and possible personal injury (scalding) from
engine coolant pipe and back into engine water
the hot liquid.
pump (2).

Note: Engine coolant thermostats start to open at As Required:

74° C (165° F) and are fully open at 87° C (189° F).
Tighten water manifold, water pump (2), oil coolers and
radiator mounting bolts. Clean radiator (1) core fins.
Deaerated coolant from header tank (16) through make-
up line (9) enters engine water pump (2) through
Note: Under extreme conditions it may be necessary
coolant pipe (14).
to clean radiator core fins several times per shift.
Aerated coolant is drawn off to header tank (16) from
thermostat housings (10), Disc brake oil cooler (4) and Every 10 hours/Daily:
radiator (1) top tank through deaeration lines (12).
Check the coolant level. Fill header tank (16) with
Excess coolant at header tank (16) is discharged
coolant until coolant reaches the bottom of the filler
through overflow line from the filler neck. The upper
neck and holds at that level.
portion of the radiator top tank is a deaeration chamber
blocked off from the lower portion by a solid baffle, and
Note: Any time a significant amount of coolant is
its only connection to the radiator core is through stand
added, the coolant inhibitor MUST be checked. If the
pipeswhich deaerate the radiator core.
concentration is low, engine damage will result.
Conversely, over-inhibiting antifreeze solutions can
When the coolant is below operating temperature, the
result in silicate dropout. Refer to 'Test Kit Procedures'.
engine thermostats remain closed and coolant flowing
into thermostat housings (10) returns through engine
Note: Never pour cold coolant into a hot engine.
coolant pipe and back into engine water pump (2). When
the coolant reaches operating temperature, the
Note: If untreated water is used to top up the
thermostats open, allowing coolant to flow into the
coolant system in an emergency, the coolant
lower portion of the radiator top tank through coolant
concentration must be checked and rectified at the
lines (13). Coolant then travels through the radiator
earliest opportunity.
core, where heat is drawn off by air circulating through
the core, and into the radiator bottom tank. Coolant is
Note: Removal of the filler cap when the system
then recirculated back through coolant pipes (14 & 15),
is hot vents the pressure in the system. If the filler
into engine water pump (2) and back through the coolers.
cap is reinstalled while the system is hot, normal
system build up to the rated pressure will not take
The use of antifreeze is mandatory with the cooling
place. This may result in a serious temporary reduction
system. The lack of coolant flow through the radiator (1) with
of coolant flow due to cavitation at the water pump
the thermostats closed allows the coolant in radiator (1) to
inlet, particularly if the truck is being operated at
freeze under low ambient temperature conditions.
high altitude.

PREVENTIVE MAINTENANCE Check cooling fan for cracks, loose rivets and bent
or loose blades. Check fan mounting and tighten if
Numbers in parentheses refer to Fig. 1.
required. Replace the cooling fan if required.
To ensure the continued efficient functioning of the
cooling system, certain checks and operations should
Check all cooling lines, pipes and components for leaks.
be performed at regular intervals.

2 SM 2278 04-04
 Cooling System - Cooling System
Section 210-0000

After first 200 hours: 2. Allow engine to cool and open pressure control cap
Check coolant level. Check and replenish inhibitor on header tank.
concentration.
3. Drain the coolant from the engine and radiator into a
Note: Failure to use and maintain coolant and coolant suitable container. Drain engine coolant at blanking
inhibitor mixture at sufficient concentration levels can plugs on engine banks at flywheel housing.
result in damage to the cooling system and its related
components. Conversely, over-concentration of coolant 4. Refill cooling system with clean soft water and a
and/or inhibitor can result in poor heat transfer, leading good radiator cleaning compound.
to engine dropout, or both. Always maintain
concentrations at recommended levels. 5. Start the engine and operate the truck for fifteen (15)
minutes to circulate the solution thoroughly.

Every 500 hours: 6. Drain the cooling system completely.

Check coolant level. Check and replenish inhibitor
concentration. 7. Refill cooling system with clean, soft water and
operate the truck for fifteen (15) minutes. Drain the
Check radiator (1) for leaks, clean radiator core fins. cooling system completely to remove all cleaner
residue from the system.
Inspect the engine water pump (2) weep hole for
coolant or oil leakage. Clean the weep hole if dirty. 8. Refill cooling system with proper mix of antifreeze
and water.
Note: A minor chemical buildup or streaking at the water
pump weep hole is normal. Do not repair or replace the Note: If engine overheats and fan belt tension and
water pump unless an actual leak is confirmed. water level are satisfactory, the entire cooling system
may require cleaning with a descaling solvent and
back flushing.
Every 4 000 hours/24 months:
Replace engine thermostats and seals. In general, any flushing compound put out by a
reputable manufacturer will do an acceptable job.
Oxalic acid and sodium bisulphate type cleaners are
Every 6 000 hours: the most generally used. Be certain to use the
Replace coolant level sensor. neutralizer compound after flushing radiator with an
acid cleaner. The neutralizer is usually supplied with
the acid cleaner.
DRAINING AND FLUSHING
The draining and flushing of the cooling system should Back Flushing Engine Jacket
be performed as follows:
Whenever the engine water jacket is rust clogged,
pressure back flushing should be used after the
WARNING draining of the cleaning compound. Be certain to
Do not remove the pressure control cap from the remove thermostats from thermostat housings before
header tank or attempt to drain the coolant until beginning back flushing operation.
the engine has cooled. Once the engine has
cooled, use extreme caution when removing the 1. Remove thermostats from each thermostat housing,
cap. Always release pressure from the system by reinstall thermostat housings, and clamp flushing gun
depressing the pressure relief button on the cap. to the front neck of the water manifold.
Remove cap slowly as the sudden release of
pressure from a heated cooling system can result 2. Temporarily block the engine water pump inlet
in a loss of coolant and possible personal injury opening and fill engine jacket with clean, soft water.
(scalding) from the hot liquid.
3. Unblock the engine water pump inlet opening and
1. Position the vehicle in a level work area, apply the blow water from the engine jacket with air from the
parking brake and shutdown the engine. Turn the flushing gun clamped to the neck of water manifold.
steering wheel in both directions several times to Use full air pressure.
relieve pressure in the steering system.

SM 2278 04-04 3
Cooling System - Cooling System
Section 210-0000
4. Repeat the operation by alternately filling the engine formulation) and if these compounds are combined a
with clean, soft water and blowing out with air until green sludge will be produced. This sludge will deposit
flushing water runs out clean. on cooling system passages and reduce heat transfer
from the engine to coolant.
5. Remove the flushing gun from the water manifold
and reinstall thermostats in the thermostat housings. Methyl alcohol-based antifreeze is not recommended
for use because of its effect on the nonmetallic
components of the cooling system and its low boiling
Back Flushing Radiator point. Methoxy propanol-based antifreeze is also not
1. Disconnect coolant lines at the thermostat housings. recommended for use because it is not compatible
with fluoroelastomer seals found in the cooling system.
2. Disconnect coolant pipe from the water pump inlet
and block off the make-up line connection at coolant Soluble oil additives are not approved for use in the
pipe. Clamp the flushing gun to the coolant pipe end cooling system. A small amount of oil adversely
and fill the radiator with clean, soft water from the affects heat transfer; 1.25% concentration increases
flushing gun. the fire deck temperature 6% and 2.5% concentration
increases fire deck temperature 15%.
3. Apply air pressure gradually increasing to a
pressure of 0.7 bar (10 lbf/in²). DO NOT EXCEED
THIS PRESSURE. Supplemental Coolant Additives (SCA)
SCA's provide protection for the cooling system
4. Alternatively fill the radiator with clean, soft water components. The coolant must have the proper
and flush with air until water runs out clear. concentration of SCA's. Detroit Diesel Maintenance products
are recommended for use in all Detroit Diesel Engines.

COOLANT RECOMMENDATIONS The proper application of SCA will provide:

Antifreeze a - pH control to prevent corrosion.
Use genuine Detroit Diesel Power Cool or an equivalent b - Water-softening to deter formation of mineral
ethylene glycol base coolant (low silicate formulation) deposits.
that meets or exceeds the standard of either the GM c - Cavitation protection to reduce the effects of
6038-M formulation (GM 1899-M performance) or cavitation.
ASTM D 4985 requirements.
Note: Pre-diluted coolant conforming to ASTM D5345 POWER Cool 3000 is the SCA added to the Series
can also be used. 2000 engines. Initial fill is 3% of the coolant volume.
The concentration of SCA will gradually deplete during
A 50% antifreeze/water solution is normally used as a normal engine operation and should be checked after
factory fill. Concentrations over 70% are not every 200 hours using coolant test strips. Additional
recommended because of poor heat transfer capability, SCA must be added to the coolant when it becomes
adverse freeze protection and possible silicate dropout. depleted according to the additive indicator supplied
Concentrations below 30% offer little freeze, boil over with test strips. Refer to 'Test Kit Procedures'.
or corrosion protection.
Maintenance dosage of SCA must only be added if nitrite
Antifreeze solution should be used year-round to concentration is less than 800 parts per million (PPM). If
provide freeze and boil over protection as well as a nitrite concentration is greater than 800 PPM, do not add
stable environment for seals and hoses. In extremely additional SCA. Refer to 'Test Kit Procedures'.
hot environments, clean, soft, properly inhibited water
may be used if Detroit Diesel Maintenance Product
supplemental corrosion inhibitors are also added in the Test Kit Procedures
right concentration. If water is used, supplemental Coolant Test Strips should be used to measure nitrite,
coolant additive levels should be increased from 3% to glycol and additive concentrations (See Special Tools).
6% by volume. Cavitation/corrosion protection is indicated on the strip
by the level of nitrite concentration. Freeze/boil over
Only non-chromate inhibitors should be used with protection is determined by glycol concentration. SCA
coolant solutions. Chromate coolant inhibitors are not concentration is indicated by the additive indicator. Use
compatible with ethylene glycol antifreeze (low silicate the test strips as follows:

4 SM 2278 04-04
 Cooling System - Cooling System
Section 210-0000
a. Dip the strip into coolant for one second. Remove Note: Failure to properly maintain coolant with SCA
and shake briskly to eliminate excess fluid. can result in damage to the cooling system and its
related components. Conversely, over-concentration of
b. At 15 seconds after dipping strip, compare % glycol SCA inhibitor can result in poor heat transfer, leading to
(end pad) to colour chart. engine damage. Always maintain concentrations at
recommended levels.
c. At 45 seconds compare additive indicator (middle
pad) to colour chart.
SPECIAL TOOLS
d. At 60 seconds compare nitrite pad to colour chart. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of the coolant test strips and general service
For best results make the tests while the coolant is tools required. These strips and tools are available
between 10° - 55° C (50° - 130° F). Wait at least 60, but from your dealer.
not longer than, 75 seconds before reading the nitrite
level. Promptly replace and tighten container cap after
each use. Discard unused strips if they have turned
light pink or tan.

COOLING SYSTEM DIAGNOSIS CHART

CONDITION REASON REMEDY
Engine coolant temperature Low coolant level Fill cooling system to correct fill level
too high
Check for leaks and repair
Faulty header tank 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 slipping Check fan belt tension. Replace fan belt
if broken.
Thermostats not opening Replace thermostats
Restricted cooling system passages Flush cooling system
Faulty engine water pump Repair or replace water pump
Engine coolant temperature Thermostats remain open or open Replace thermostats
too low at too low a temperature
Leakage around thermostat seals Replace thermostat seals
Extremely cold weather Cover radiator or install radiator shutters
Sudden rise in engine coolant Lack of coolant Check for coolant leaks
temperature
Fill cooling system to correct fill level

* * * *

SM 2278 04-04 5
 COOLING SYSTEM - Radiator, Header Tank and Mounting
Section 210-0040

SM - 2544
4 35
5 30
4 30
25
28

4
5 34 33
3
6 32
7 31
6
5 27
4 29

14 30

16 2
15 27

12 13

23
20

8
19
19
9 1 26
17 21
18 24 22
10 11

9 - Bolt 18 - Washer 27 - Lower Baffle Plate

1 - Shroud 10 - Washer 19 - Screen 28 - Upper Baffle Plate - LH
2 - Ring 11 - Locknut 20 - Bolt 29 - Upper Baffle Plate - RH
3 - Support Rod 12 - Bolt 21 - Washer 30 - Rubber Seal
4 - Nut 13 - Washer 22 - Nut 31 - Beading
5 - Lockwasher 14 - Bolt 23 - Bolt 32 - Bolt
6 - Washer 15 - Washer 24 - Nut 33 - Lockwasher
7 - Flexible Mounting 16 - Locknut 25 - Plug 34 - Washer
8 - Flexible Mounting 17 - Bolt 26 - Plug 35 - Radiator Assembly
Fig. 1 - Exploded View of Radiator Mounting

DESCRIPTION REMOVAL
Numbers in parentheses refer to Fig. 1, unless Numbers in parentheses refer to Fig. 1, unless
otherwise specified. otherwise specified.

Radiator assembly (35) is mounted at the front of the

chassis in front of the engine cooling fan. It is fed from WARNING
radiator header tank (1, Fig. 2) mounted on the Do not remove the pressure control cap from
platform to the right of the cab and air cleaners. the radiator header tank or attempt to drain the
coolant until the engine has cooled. Once the
A fan shroud assembly comprising of shroud (1) and engine has cooled, use extreme caution when
ring (2) improves the engine cooling fan efficiency, removing the cap. Always release pressure
provides a more uniform distribution of air over the from the system by depressing the pressure
radiator core and helps restrict recirculation of air relief button on the cap. Remove cap slowly as
within the engine compartment. the sudden release of pressure from a heated
cooling system can result in a loss of coolant
Recirculation baffle plates (27, 28 & 29) and rubber and possible personal injury (scalding) from
seals (30) around radiator assembly (35) prevent hot the hot liquid.
air from the engine cooling fan from being reintroduced
into the cooling air circuit.

SM 2034 7-00 1
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040

SM - 2545
29
5 26 TO ENGINE
(AIR COOLER PIPE
6 27 AT TURBO)
28 30 24
19 21 25
17
40
4
TO BRAKE
COOLER L.H.S.
1 47
43
44 41 46
31
17 23
TO RADIATOR
45 42 TOP TANK
9 R.H.S.
8
20
22
38 16 32
15 36
19 35
37 TO
10 21 ENGINE
11 14 39 (THERMOSTAT
7 HOUSING)
38
2 34 40
3 37
39
13 12
RADIATOR
PIPE
48 17 (BOTTOM)
33 18
16 13
52
51
50
49
39 - Nut
13 - Band Clamp 26 - Filler Cap 40 - Clamp
1 - Header Tank 14 - Deaeration Line 27 - Filler Neck 41 - Bracket
2 - Bolt 15 - Elbow 28 - Gasket 42 - Bolt
3 - Washer 16 - Deaeration Line 29 - Bolt 43 - P-Clip
4 - Heat Shield 17 - Reducer 30 - Overflow Tubing 44 - Bolt
5 - Bolt 18 - Adaptor 31 - Window Nut 45 - Nut
6 - Hardened Washer 19 - Deaeration Line 32 - Adaptor 46 - P-Clip
7 - Bracket 20 - Elbow 33 - Plug 47 - Bolt
8 - Bolt 21 - Deaeration Line 34 - Bracket 48 - Float Level Switch
9 - Washer 22 - Elbow 35 - Bracket 49 - Gasket
10 - Bolt 23 - Adaptor 36 - Bolt 50 - Adaptor Plate
11 - Washer 24 - Adaptor 37 - P-Clip 51 - Bolt
12 - Hose 25 - Adaptor 38 - Bolt 52 - Level Sensor
Fig. 2 - Radiator Header Tank Mounting and Lines

assembly to the vehicle and, using suitable lifting

WARNING equipment, remove the hood assembly. Refer to
To prevent personal injury and property Section 100-0010, CHASSIS, HOOD AND FENDERS.
damage, be sure wheel chocks and lifting
equipment are properly secured and of 4. Disconnect electrical connections to lights on the
adequate capacity to do the job safely. radiator guard and remove mounting hardware
securing radiator guard to the vehicle. Using suitable
1. Position the vehicle in a level work area, apply the lifting equipment, remove radiator guard assembly.
parking brake and switch off the engine. Refer to Section 100-0010, CHASSIS, HOOD AND
FENDERS.
2. Turn the steering wheel in both directions several
times to relieve pressure in the steering system. Block 5. Depress pressure relief button on filler cap (26, Fig. 2)
all road wheels. and remove filler cap from filler neck (27, Fig. 2).

3. Remove mounting hardware securing the hood 6. With a suitable container in position, remove drain

2 SM 2034 7-00
 Cooling System - Radiator, Header Tank and Mounting
Section 210-0040

SM - 2546

8
7
2

2 2
3

TO HEADER TANK

1 6
2
5
6
2 4
1

6
TO ENGINE
5
2
6

1 - Silicone Hose 4 - Coolant Tube 7 - Washer

2 - Band Clamp 5 - Silicone Hose 8 - Lockwasher
3 - Bracket 6 - Band Clamp 9 - Nut

Fig. 3 - Radiator Piping

plug (26) at the bottom of radiator assembly (35) and 12. Remove nuts (4) and lockwashers (5) securing
drain the cooling system. Install drain plug (26) support rods (3) to radiator side columns.
securely when coolant is completely drained.
13. If necessary, remove nuts (4), lockwashers (5),
7. Remove locknuts (16), washers (15) and bolts (14) washers (6) and flexible mountings (7) from bottom
securing screens (19) to ring (2). Remove screens end of each support rod (3). Loosen inside nuts (4),
(19) from the vehicle. lockwashers (5) and washers (6) securing support
rods (3) to chassis brackets. Remove both support
8. Slacken band clamps (2, Fig. 3) and pull silicone rods (3) from radiator side columns and chassis
hoses (1, Fig. 3) away from radiator top tank brackets.
connections.
14. Attach suitable lifting equipment to radiator
9. Slacken band clamps (6, Fig. 3) and slide hose assembly (35) and remove nuts (22), washers (21)
(5, Fig. 3) back over coolant tube (4, Fig. 3) and away and bolts (20) securing radiator assembly (35) on
from radiator bottom tank connection. flexible mounting (8). Remove radiator assembly (35).

10. Identify and disconnect deaeration line (14, Fig. 2) 15. If necessary, remove nuts (24) and bolts (23)
from adaptor (23, Fig. 2) in radiator top tank. securing flexible mountings (8) to chassis mounting
brackets.
11. Ensure all coolant pipes and lines have been
disconnected from radiator assembly (35).

SM 2034 7-00 3
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040

SM - 2547

1,2
1

12,13,14

6
11

9
3 10
3 4

7
8

5 9

6
12,13,14

15,16,17 2
18,19

1 - Top Tank 6 - Stiffener 11 - Rubber Ferrule

2 - Bottom Tank 7 - Crossbrace Clamps 12 - Nut 16 - Washer
3 - Side Column - LH 8 - Tube Stay Strip 13 - Locknut 17 - Screw
4 - Side Column - RH 9 - Spacer 14 - Washer 18 - Setscrew
5 - Crossbrace Rod 10 - Joule Tube 15 - Lockwasher 19 - Nut

Fig. 4 - Radiator Assembly

Header Tank 6. Remove header tank (1) assembly from the

Numbers in parentheses refer to Fig. 2. platform.

1. Slacken band clamps (13) and slide hose (12) off of

header tank (1) connection. DISASSEMBLY/ASSEMBLY
Numbers in parentheses refer to Fig. 4, unless
2. Disconnect deaeration lines (14, 19 & 21) from otherwise specified.
elbows (15, 20 & 22) in header tank (1). Disconnect
deaeration line (16) from adaptor (18) in header tank 1. Remove bolts (12, Fig. 1) and washers (13, Fig. 1)
(1). securing shroud (1, Fig. 1) and ring (2, Fig. 1)
assembly to radiator assembly (35, Fig. 1).
3. Disconnect overflow tubing (30) from filler neck (27).
2. If required, remove bolts (32, Fig. 1), washers (34,
4. Disconnect electrical connection from float level Fig. 1) and lockwashers (33, Fig. 1) securing baffle
switch (48) and level sensor (52). plates (27, 28 & 29, Fig. 1) to radiator assembly (35,
Fig. 1). Remove baffle plates (27, 28 & 29, Fig. 1) and
5. Attach suitable lifting equipment to header tank (1) rubber seals (30, Fig. 1) from the radiator assembly
and remove bolts (2) and hardened washers (3) (35, Fig. 1).
securing header tank (1) to the platform.

4 SM 2034 7-00
 Cooling System - Radiator, Header Tank and Mounting
Section 210-0040
Note: Joule tube (10) type radiators are designed in 5. If removed, install rubber seals (30, Fig. 1) and
such a way that individual tubes can be replaced baffle plates (27, 28 & 29, Fig. 1) to front of the
without the need to replace the entire radiator core. radiator assembly (35, Fig. 1). Secure baffle plates
(27, 28 & 29, Fig. 1) to radiator assembly (35, Fig. 1)
Note: It may be necessary to remove several with bolts (32, Fig. 1), lockwashers (33, Fig. 1) and
undamaged joule tubes (10) in order to gain access to washers (34, Fig. 1).
the damaged tube.
6. Secure shroud (1, Fig. 1) and ring (2, Fig. 1)
Note: The top and bottom ends of joule tube (10) are assembly to radiator assembly (35, Fig. 1) with
distinguished by the top end of the tube having a long washers (13, Fig. 1) and bolts (12, Fig. 1).
length of tube bare of grilling and the bottom end being
fitted with a locating washer.
Header Tank
3. Removal of joule tube (10) and rubber ferrules (11) Numbers in parentheses refer to Fig. 2.
is as follows:
1. Remove bolts (29) securing filler neck (27)
a. Insert a lever under the locating washer of joule assembly to header tank (1). Remove filler neck (27)
tube (10) and exert pressure to push the tube into assembly and discard gasket (28).
top tank (1).
2. Remove bolts (51) securing adaptor plate (50) and
b. Carefully pull joule tube (10) clear of bottom tank float level switch (48) assembly to header tank (1).
(2) and pull out from top tank (1). Remove adaptor plate (50), gasket (49) and float level
switch (48) from header tank (1). Discard gasket (49).
c. Remove and discard rubber ferrules (11) from top
tank (1) and bottom tank (2). 3. If required, remove lock nut from float level
switch (48) and remove float level switch from adaptor
4. Replacement of joule tube (10) and rubber ferrules plate (50).
(11) is as follows:
4. Remove level sensor (52) from header tank (1).
a. Lightly coat outside diameter of new rubber
ferrules (11) and tube holes in top tank (1) and 5. Remove window nut (31) from header tank (1).
bottom tank (2) with petroleum jelly.
6. Assembly of header tank (1) is the reverse of
b. Press rubber ferrules (11) by hand into the tube disassembly. Be sure to use new gaskets (28 & 49)
holes in the top and bottom tanks (1 & 2), taking when assembling filler neck (27) assembly and
care that the flange of each rubber ferrule (11) fits adaptor plate (50) assembly to header tank (1).
flush on the respective tank plate face. It may be
necessary to lightly tap the top of rubber ferrule (11)
flange with a hammer to ensure a flush fit. INSTALLATION
Numbers in parentheses refer to Fig. 1, unless
c. Lightly coat the bore of rubber ferrules (11) and otherwise specified.
each end of joule tube (10) with petroleum jelly.
Note: Tighten all fasteners to standard torques listed
d. Enter the top (longer) end of joule tube (10) into in Section 300-0080, STANDARD BOLT AND NUT
rubber ferrule (11) in top tank (1) and press upward TORQUE SPECIFICATIONS.
until the short end of the tube is clear of rubber
ferrule (11) flange in bottom tank (2). 1. If removed, position flexible mountings (8) on
chassis mounting brackets and secure with bolts (23)
e. Carefully enter the bottom of joule tube (10) into and nuts (24).
rubber ferrule (11) in bottom tank (2) taking care that
the tube does not damage rubber ferrule (11) by 2. Using suitable lifting equipment, position radiator
scoring. Press down firmly until the locating washer assembly (35) on flexible mountings (8) and secure
rests on the flange of rubber ferrule (11). with bolts (20), washers (21) and nuts (22).

SM 2034 7-00 5
Cooling System - Radiator, Header Tank and Mounting
Section 210-0040

3. Install nut (4), lockwasher (5), washer (6) and one Header Tank
half of flexible mounting (7) on the bottom end of each Numbers in parentheses refer to Fig. 2, unless
support rod (3). Install support rods (3) in chassis otherwise specified.
support brackets and secure with opposite half of
flexible mountings (7), washers (6), lockwashers (5) 1. Using suitable lifting equipment, position header
and nuts (4). tank (1) on the platform and secure with bolts (2) and
hardened washers (3).
Note: Before securing support rods (3) to mounting
brackets on radiator side columns, align the radiator 2. Slide hose (12) over bottom connection on header
core assembly to be parallel with the leading end of tank (1) and secure to header tank (1) with band
the cooling fan. Adjust fan ring (2) to obtain adequate clamps (13).
fan tip clearance.
3. Connect deaeration lines (14, 19 & 21) to elbows
4. Install nuts (4) and lockwashers (5) on top end of (15, 20 & 22) and tighten lines securely.
support rods (3) and secure support rods (3) to
mounting brackets on radiator side columns with 4. Connect deaeration line (16) to adaptor (18) and
lockwashers (5) and nuts (4). tighten line securely.

5. Connect deaeration line (14, Fig. 2) to adaptor (23, 5. Connect overflow tubing (30) to filler neck (27).
Fig. 2) and tighten securely.
6. Connect electrical connections to float level switch
6. Slide coolant tubes (1, Fig. 3) over radiator top tank (48) and level sensor (52).
connections. Secure coolant tubes (1, Fig. 3) to
radiator top tank connections with band clamps
(2, Fig. 3). Initial Fill and Start-up
Numbers in parentheses refer to Fig. 2, unless
7. Slide hose (5, Fig. 3) over radiator bottom tank otherwise specified.
connection. Secure hose (5, Fig. 3) to coolant tube
(4, Fig. 3) and radiator bottom tank connection with 1. Refer to Section 210-0000, COOLING SYSTEM for
band clamps (6, Fig. 3). correct selection of heavy duty coolant.

8. Install screens (19) on ring (2) and secure with bolts 2. Ensure drain plug (26, Fig. 1) is securely closed
(14), washers (15) and locknuts (16). and fill the cooling system through filler neck (27)
on header tank (1). Fill with coolant until coolant
9. Using suitable lifting equipment, position radiator reaches the bottom of filler neck (27) and holds at that
guard assembly on the front of the chassis and secure level.
with mounting hardware removed during removal.
Refer to Section 100-0010, CHASSIS, HOOD AND 3. Check all line and pipe connections for leaks prior to
FENDERS. starting the vehicle. Tighten as required.

10. Connect all electrical connections to lights in 4. Start the engine and check for leaks. Tighten lines
radiator guard assembly. and fittings and top up coolant level as required.
Window nut (31) should show full at all times. Fit filler
Note: Do not secure hood assembly on the vehicle cap (26).
until vehicle has been started and checked for leaks.
Refer to 'Initial Fill and Start-up'. 5. Using suitable lifting equipment, position hood
assembly on the vehicle and secure with mounting
hardware removed during removal. Refer to
Section 100-0010, CHASSIS, HOOD AND FENDERS.

6. Remove all wheel blocks.

6 SM 2034 7-00
 Cooling System - Radiator, Header Tank and Mounting
Section 210-0040

MAINTENANCE 1. Direct a steam jet at 100 - 300 kN/m², or

Refer to Section 210-0000, COOLING SYSTEM for compressed air at 500 - 700 kN/m² on to the faces of
recommended preventive maintenance procedures, the radiator core assembly.
service intervals and coolant selection procedures.
2. Liberally brush a liquid detergent on to those
surfaces which were not satisfactorily cleaned at
Internal Cleaning - Water Tubes step 1. Leave to soak for at least 1 hour.
If scale deposits are present inside the water tubes of
the radiator, it is necessary to use a suitable scale 3. Apply a high pressure steam jet at 100 - 300 kN/m²,
remover such as 'Powdered Scale Solvent', or or compressed air at 500 - 700 kN/m² on to the treated
equivalent. This material is a free-flowing powder, surfaces, forcing the fouling material out from the
inhibited to prevent attack on the cooling system radiator core assembly.
materials.
4. Leave radiator core assembly to dry before
reinstalling the cooling equipment.
WARNING
Take care to avoid contact of skin or eyes with Note: In the case of grossly fouled surfaces which are
the solvent. If contact is made it should be not cleaned adequately in steps 1 through 4, the
washed off immediately with clean water and following procedure may be used.
medical advice should be taken.
5. Ensure that the radiator core assembly is dry.
For general cleaning use it is recommended to use a
concentration of 50 - 100 kg/m³ of water at a 6. Liberally brush on to both sides of the radiator core
temperature of up to 60° C. Rapid circulation or assembly an emulsifying cleaner such as 'Gunk', or
agitation with compressed air will reduce the time for equivalent, and leave to soak for at least 1 hour.
cleaning.
7. Apply a high pressure steam jet at 100 -300 kN/m²,
Note: If scale deposits within the radiator are or compressed air at 500 - 700 kN/m² on to the treated
exceptionally heavy, concentrations up to 200 kg/m³ surfaces, from several different angles, forcing the
may be used. fouling material out from the radiator core assembly.

The most convenient method of use is to prepare a 8. For surfaces with stubborn deposits, it may be
concentrated solution by mixing the powder in hot necessary to repeat steps 5 through 7, brushing the
water in a tank and then adding the concentrated surfaces between stages using a stiff bristle brush.
solution to water contained in the radiator.
9. Leave radiator core assembly to dry before
Note: The solvent must always be added carefully to reinstalling the cooling equipment.
water, not water to solvent.

SPECIAL TOOLS
External Cleaning There are no special tools required for procedures
Note: If a build up of dirt is apparent during routine outlined in this section. Refer to Section 300-0070,
inspection, the following cleaning procedure should be SERVICE TOOLS, for part numbers of general service
adopted. tools required. These tools are available from your
dealer.

WARNING
To prevent possible injury when using
compressed air or steam jet, wear adequate
eye protection and do not exceed pressure
values stated.

* * * *
SM 2034 7-00 7
 COOLING SYSTEM - Disc Brake Oil Cooler
Section 210-0050

SM - 2548

32 21
TO DISC 21
BRAKE ASSYS
33
33
34 24
15 23
13
10 24
14
22

11 26
12 FROM
DISC BRAKE
OIL FILTERS 25
A

B
18 19 FROM ENGINE
20
3 WATER PUMP
14
2 18 27
14 28 TO TRANSMISSION
16 29 OIL COOLER
4 17 16
9
17
C D
8
7 31
6
30
E 29
1
4
5,6,7
3

1 - Disc Brake Oil Cooler 10 - Mounting Bracket

2 - Heat Exchanger 11 - Split Flange 19 - Oil Inlet Line 27 - Gasket
3 - Cooler Flange 12 - 'O' Ring 20 - Oil Inlet Line 28 - Bolt
4 - Gasket 13 - Bolt 21 - Clamp 29 - Clamp
5 - Bolt 14 - Lockwasher 22 - Coolant Sleeve 30 - Coolant Sleeve
6 - Bolt 15 - Oil Outlet Line 23 - Coolant Inlet Tube 31 - Coolant Outlet Tube
7 - Lockwasher 16 - Split Flange 24 - Clamp 32 - Bolt
8 - Nut 17 - 'O' Ring 25 - Coolant Sleeve 33 - Washer
9 - Mounting Bracket 18 - Bolt 26 - Coolant Elbow 34 - Nut
Fig. 1 - Exploded View of Disc Brake Oil Cooler

DESCRIPTION AND OPERATION Coolant is pumped from the engine water pump to port
Numbers and letters in parentheses refer to Fig. 1. 'A', circulates through cooler tubes in heat exchanger
(2), and exits from port 'E' to the transmission oil
The disc brake oil cooler is connected in the cooling cooler.
system between the engine water pump outlet and
transmission oil cooler. Refer to Section 210-0000, Disc brake cooling oil enters through ports 'C' and 'D'
COOLING SYSTEM. The disc brake oil cooler is from the disc brake oil filters, circulates around cooler
connected in the hydraulic system between disc brake tubes in heat exchanger (2) and exits at port 'B' to the
filters and disc brake assemblies, and is used to cool disc brakes.
disc brake cooling oil.
Note: Oil flow must always flow in the opposite
The disc brake oil cooler consists mainly of heat direction to coolant flow through the disc brake oil
exchanger (2) and two cooler flanges (3), and is cooler.
mounted at the engine front crossmember.

SM 2035 7-00 1
Cooling System - Disc Brake Oil Cooler
Section 210-0050

REMOVAL 11. Loosen clamps (21) and slide coolant tube (22) off
Numbers in parentheses refer to Fig. 1. connection at port 'A'. Drain coolant tube into a
suitable container.

WARNING 12. Loosen clamps (29) and slide coolant tube (30) off
To prevent personal injury and property connection at port 'E'. Drain coolant tube into a
damage, be sure wheel blocks and lifting suitable container.
equipment are properly secured and of
adequate capacity to do the job safely. 13. Support disc brake oil cooler with a suitable lifting
device and remove bolts (32), washers (33) and
1. Position the vehicle in a level work area, apply the locknuts (34) securing disc brake oil cooler mounting
parking brake and switch off the engine. brackets (9 & 10) to mounting bracket on engine front
crossmember. Lower disc brake oil cooler and remove
2. Turn the steering wheel in both directions several to a clean work area for disassembly.
times to relieve pressure in the steering system. Block
all road wheels.
CLEANING AND DISASSEMBLY
3. Remove filler cap from body and disc brake cooling Numbers in parentheses refer to Fig. 1.
tank. With a suitable container in position, remove
drain plug from the bottom of the body and disc brake Note: In the event of a major mechanical failure,
cooling tank and drain the oil. transmission oil cooler assembly should be cleaned
thoroughly or replaced. Do not attempt to clean cooler
4. Using a suitable lifting device, support engine pan cores, after a transmission failure in which metal
guard and remove attaching bolts, nuts, lockwashers particles from worn or broken parts are released into
and washers. Remove engine pan guard from truck. the oil. Replace the cooler cores.

5. Open drain cocks and drain cooling system. Refer In many areas, raw water is extremely corrosive or
to Section 210-0000, COOLING SYSTEM, for scale forming and should be treated to prevent
procedure. damage to the disc brake oil cooler. A properly
maintained cooling system will significantly reduce
6. Slacken bolts (5 & 6) securing cooler flanges (3) to cleaning intervals. Refer to Section 210-0000,
heat exchanger (2) slowly, and drain coolant from disc COOLING SYSTEM.
brake oil cooler into a suitable container.

7. Remove drain plugs on underside of disc brake oil Cleaning Oil Side
cooler and drain oil into a suitable container.

8. Remove bolts (18), lockwashers (14) and split WARNING

flanges (16) securing oil inlet line (19) at port 'C'. Drain Dangerous fumes. To prevent personal injury,
oil inlet line (19) into a suitable container and discard use trichloroethane only in the open or in a
'O' ring (17). Cap oil inlet line (19) end and port 'C' to well ventilated room.
prevent ingress of dirt.
1. Clean disc brake oil cooler before sludge hardens.
9. Remove bolts (18), lockwashers (14) and split After disc brake oil cooler is completely drained,
flanges (16) securing oil inlet line (20) at port 'D'. Drain circulate a solution of trichloroethane through the
oil inlet line (20) into a suitable container and discard passages surrounding the cooler tubes in heat
'O' ring (17). Cap oil inlet line (20) end and port 'D' to exchanger (2) to remove sludge.
prevent ingress of dirt.
2. If cooler tubes are badly clogged, circulate an oakite
10. Remove bolts (13), lockwashers (14) and split or alkaline solution through heat exchanger (2).
flanges (11) securing oil outlet line (15) at port 'B'. Solution should be circulated through heat exchanger
Drain oil outlet line (15) into a suitable container and (2), in the reverse direction to normal flow, for
discard 'O' ring (12). Cap oil outlet line (15) end and approximately 15 minutes, after soaking for 10
port 'B' to prevent ingress of dirt. minutes. The duration of circulation depends on how
badly clogged the cooler tubes are. Flush thoroughly
with clean hot water.

2 SM 2035 7-00
 Cooling System - Disc Brake Oil Cooler
Section 210-0050

Cleaning Water Side

1. Match mark cooler flanges (3) and heat exchanger WARNING
(2) to aid in assembly. To prevent personal injury and property
damage, be sure wheel blocks and lifting
2. Match mark mounting brackets (9 & 10), to aid equipment are properly secured and of
assembly, and remove bolts (5 & 6), washers (7) and adequate capacity to do the job safely.
nuts (8) securing cooler flanges (3) to heat exchanger
(2). Remove cooler flanges (3) and mounting brackets 1. Using suitable lifting equipment, position disc brake
(9 & 10) from heat exchanger (2) and discard gaskets oil cooler to mounting bracket on engine front
(4). crossmember and secure with bolts (32), washers (33)
and locknuts (34).
3. Make up a solution composed of 1/3 muriatic acid
and 2/3 water. To each 9.5 litres (2.5 gal) of solution, 2. Install coolant tube (22) on connection at port 'A'
add 227 g (0.5 lb) of oxalic acid. and secure with clamps (21).

4. Immerse heat exchanger (2) in the cleaning 3. Install coolant tube (30) on connection at port 'E'
solution. Cleaning action is noticeable by bubbling and and secure with clamps (29).
foaming. The process must be carefully observed and
when bubbling stops, usually between 30 - 60 sec, 4. Install new 'O' ring (12) on oil outlet line (15) and
remove heat exchanger (2) from cleaning solution and secure oil oulet line (15) to port 'B' with split flanges
flush thoroughly with clean, hot water. After cleaning, (11), bolts (13) and lockwashers (14).
dip disc brake oil cooler in light oil.
5. Install new 'O' ring (17) on oil inlet line (19) and
Note: Severely fouled cooler tubes can be cleaned by secure oil inlet line (19) to port 'C' with split flanges
use of a rotary brush if normal cleaning is not (16), bolts (18) and lockwashers (14).
sufficient.
6. Install new 'O' ring (17) on oil inlet line (20) and
secure oil inlet line (20) to port 'D' with split flanges
ASSEMBLY (16), bolts (18) and lockwashers (14).
Numbers in parentheses refer to Fig. 1.
7. Fill the body and disc brake cooling tank with
Note: Tighten all fasteners without special torques hydraulic oil specified in Section 300-0020,
specified to standard torques listed in Section LUBRICATION SYSTEM. Refer to Section 230-0040,
300-0080, STANDARD BOLT AND NUT TORQUE BODY AND DISC BRAKE COOLING TANK for correct
SPECIFICATIONS. fill level. Install filler cap.

1. Install new gaskets (4) to cooler flanges (3) and 8. Ensure all drain cocks on the cooling system are
align cooler flanges (3) and mounting brackets (9 & securely locked and fill cooling system with coolant
10) to heat exchanger (2) as match marked at specified in Section 210-0000, COOLING SYSTEM.
disassembly. Secure with bolts (5 & 6), washers (7)
and nuts (8) tightening alternately to give an even seal 9. Using suitable lifting equipment, install engine pan
around cooler flange area. guard on the truck. Secure engine pan guard to the
truck with bolts, lockwashers, washers and nuts.
2. Install drain plugs in underside of heat exchanger (2).
10. Start the engine and check for leaks. Tighten lines
and fittings as required. Remove wheel blocks from all
INSTALLATION road wheels.
Numbers and letters in parentheses refer to Fig. 1.

Note: Tighten all fasteners without special torques SPECIAL TOOLS

specified to standard torques listed in Section There are no special tools required for procedures
300-0080, STANDARD BOLT AND NUT TORQUE outlined in this section. Refer to Section 300-0070,
SPECIFICATIONS. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.
* * * *
SM 2035 7-00 3
 COOLING SYSTEM - Transmission Oil Cooler
Section 210-0060

SM - 2549

17,18,19,20,21 16 FROM CONVERTOR

28,29,30,31 15 OUTLET

TO
CONVERTOR
22 INLET
32 33
36 23
32 TO ENGINE
33 WATER PUMP
32 25 27
24
35
32
3,4 13
14
D C
13
2 26
B
28,29,30,31
32 33 32
32 33 32
34

1 A
33
32
4,5
8
FROM DISC 9
BRAKE 32
OIL COOLER
10

6 7

12 11

1 - Transmission Oil Cooler 10 - Nut 19 - Nut - Stacking 28 - Clamp

2 - Heat Exchanger 11 - Bolt 20 - Bolt 29 - Bushing
3 - Cooler Flange 12 - Nut 21 - Washer 30 - Nut - Stacking
4 - Gasket 13 - Adaptor 22 - 'O' Ring 31 - Bolt
5 - Cooler Flange 14 - Oil Inlet Line 23 - Split Flange 32 - Clamp
6 - Bolt 15 - Oil Line 24 - Bolt 33 - Sleeve
7 - Lockwasher 16 - Bracket 25 - Lockwasher 34 - Coolant Inlet Elbow
8 - Clamp 17 - Clamp 26 - Oil Outlet Line 35 - Coolant Outlet Elbow
9 - Bolt 18 - Bushing 27 - Oil Line 36 - Coolant Outlet Tube

Fig. 1 - Exploded View of Transmission Oil Cooler

DESCRIPTION AND OPERATION convertor outlet port, circulates around cooler tubes in
Numbers and letters in parentheses refer to Fig. 1. heat exchanger (2), and exits at port 'B' to the
transmission convertor inlet port.
The transmission oil cooler is connected between the
radiator and transmission to maintain transmission oil Note: Oil flow must always flow in the opposite
within its required operating temperature range. Refer direction to coolant flow through transmission oil
to Section 210-0000, COOLING SYSTEM. cooler.

Coolant enters port 'A' from the disc brake oil cooler, Transmission oil temperature switch, located on the left
circulates through cooler tubes in heat exchanger (2), hand side of the transmission, sends a signal to illuminate
and exits at port 'D' to the engine water pump. the transmission oil temperature warning light (on the
dash panel) when transmission oil temperature rises
Oil to be cooled enters port 'C' from the transmission above the safe operating temperature.

SM 2036 7-00 1
Cooling System - Transmission Oil Cooler
Section 210-0060

REMOVAL 11. Remove adaptor (13) from port 'B'. Plug port 'B' to
Numbers in parentheses refer to Fig. 1. prevent entry of dirt.

12. Using suitable lifting equipment, support

WARNING transmission oil cooler (1) and remove bolts (9 & 11),
To prevent personal injury and property nuts (10 & 12) and clamp (8) from transmission oil
damage, be sure wheel blocks and lifting cooler (1). Remove bolts (6) and lockwashers (7)
equipment are properly secured and of securing transmission oil cooler (1) to mounting
adequate capacity to do the job safely. bracket. Lower transmission oil cooler (1) and remove
to a clean work area for disassembly.
1. Position the vehicle in a level work area, apply the
parking brake and shutdown the engine.
CLEANING AND DISASSEMBLY
2. Turn the steering wheel in both directions several Numbers in parentheses refer to Fig. 1.
times to relieve pressure in the steering system. Block
all road wheels. Note: In the event of a major mechanical failure,
transmission oil cooler (1) assembly should be
3. Open drain cocks and drain the cooling system. cleaned thoroughly or replaced. Do not attempt to
Refer to Section 210-0000, COOLING SYSTEM, for clean cooler cores, after a transmission failure in
procedure. which metal particles from worn or broken parts are
released into the oil. Replace the cooler cores.
4. Remove drain plug from underside of the
transmission and drain transmission oil into a suitable In many areas, raw water is extremely corrosive or
container. scale forming and should be treated to prevent
damage to transmission oil cooler (1). A properly
5. Loosen clamps (32) and slide sleeve (33) over maintained cooling system will significantly reduce
coolant inlet elbow (34) from connection at port 'A'. cleaning intervals. Refer to Section 210-0000,
Drain coolant from port 'A' and coolant inlet elbow (34) COOLING SYSTEM.
into a suitable container.

6. Loosen clamps (32) and slide sleeve (33) over Cleaning Oil Side
coolant outlet elbow (35) from connection at port 'D'.
Drain coolant from coolant outlet elbow (35) into a
suitable container. WARNING
Dangerous fumes. To prevent personal injury,
7. Remove drain plugs on underside of transmission use trichloroethane only in the open or in a
oil cooler (1) and drain oil into a suitable container. well ventilated room.

8. Remove oil inlet line (14) from adaptor (13). Drain 1. Clean transmission oil cooler (1) before sludge
oil inlet line (14) into a suitable container. Cap oil inlet hardens. After transmission oil cooler (1) is completely
line (14) to prevent entry of dirt. drained, circulate a solution of trichloroethane through
the passages surrounding the cooler tubes in heat
9. Remove adaptor (13) from port 'C'. Plug port 'C' to exchanger (2) to remove sludge.
prevent entry of dirt.
2. If cooler tubes are badly clogged, circulate an oakite
10. Remove oil outlet line (26) from adaptor (13). Drain or alkaline solution through heat exchanger (2).
oil outlet line (26) into a suitable container. Cap oil Solution should be circulated through heat exchanger
outlet line (26) to prevent entry of dirt. (2), in the reverse direction to normal flow, for
approximately 15 minutes, after soaking for 10
minutes. The duration of circulation depends on how
badly clogged the cooler tubes are. Flush thoroughly
with clean hot water.

2 SM 2036 7-00
 Cooling System - Transmission Oil Cooler
Section 210-0060

Cleaning Water Side

1. Match mark cooler flanges (3 & 5) and heat WARNING
exchanger (2) to aid in assembly. To prevent personal injury and property
damage, be sure wheel blocks and lifting
2. Remove mounting hardware securing cooler flanges equipment are properly secured and of
(3 & 5) to heat exchanger (2). Remove cooler flanges adequate capacity to do the job safely.
(3 & 5) from heat exchanger (2) and discard gaskets
(4). 1. Using suitable lifting equipment, position
transmission oil cooler (1) to mounting bracket and
3. Make up a solution composed of 1/3 muriatic acid secure with bolts (6) and lockwashers (7). Install
and 2/3 water. To each 9.5 litres (2.5 gal) of solution, clamp (8) to transmission oil cooler (1) and mounting
add 227 g (0.5 lb) of oxalic acid. bracket and secure with bolts (9 & 11) and nuts (10 &
12).
4. Immerse heat exchanger (2) in the cleaning
solution. Cleaning action is noticeable by bubbling and 2. Install adaptor (13) on port 'B'. Secure oil outlet line
foaming. The process must be carefully observed and (26) to adaptor (13).
when bubbling stops, usually between 30 - 60 sec.,
remove heat exchanger (2) from cleaning solution and 3. Install adaptor (13) on port 'C'. Secure oil inlet line
flush thoroughly with clean, hot water. After cleaning, (14) to adaptor (13).
dip heat exchanger (2) in light oil.
4. Install coolant outlet elbow (35) on connection at
Note: Severely fouled cooler tubes can be cleaned by port 'D' and secure with sleeve (33) and clamps (32).
use of a rotary brush if normal cleaning is not
sufficient. 5. Install coolant inlet elbow (34) on connection at port
'A' and secure with sleeve (33) and clamps (32).
ASSEMBLY 6. Install drain plug in underside of transmission and fill
Numbers in parentheses refer to Fig. 1. transmission with transmission oil specified in Section
300-0020, LUBRICATION SYSTEM.
Note: Tighten all fasteners, without special torques
specified, to standard torques listed in Section 7. Ensure all drain cocks on the cooling system are
300-0080, STANDARD BOLT AND NUT TORQUE securely locked and fill cooling system with coolant,
SPECIFICATIONS. specified in Section 210-0000, COOLING SYSTEM.

1. Install new gaskets (4) to cooler flanges (3 & 5) and 8. Start up engine and check for leaks. Tighten lines
align cooler flanges (3 & 5) to heat exchanger (2), as and fittings as required.
match marked at disassembly. Secure with mounting
hardware tightening alternately to give an even seal 9. Remove wheel blocks from all road wheels.
around cooler flange area.

2. Install drain plug in underside of heat exchanger (2). SPECIAL TOOLS

There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
INSTALLATION SERVICE TOOLS, for part numbers of general service
Numbers and letters in parentheses refer to Fig. 1. tools required. These tools are available from your
dealer.
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.

* * * *

SM 2036 7-00 3
 STEERING SYSTEM - Steering System Schematic
Section 220-0000

DESCRIPTION Mounted off the frame at the rear of the steering and
Numbers in parentheses refer to Figs. 2 through 6. brake control tank, the accumulator assembly consists
of a charging valve, end cap, cylinder and piston.
The steering system is of the accumulator type which
provides uniform steering, regardless of engine speed, The charging valve is equipped with a locking feature
and provides a limited amount of reserve steering which, when opened, will allow the precharge to be
pressure should the engine stall. checked or the accumulator charged. The piston acts
as a separator dividing the cylinder into two sections.
A brief description of the individual components used
in the steering system are listed below. Detailed The section nearest the charging valve contains the
service and operating instructions for the individual nitrogen precharge. The other section receives the
components can be found in their relative component hydraulic oil from the steering pump, via accumulator
sections in this manual. valve (4).

Steering and Brake Control Tank (1) Accumulator Valve (4)

Refer to Section 220-0040, STEERING AND BRAKE Refer to Section 220-0130, ACCUMULATOR VALVE.
CONTROL TANK.
Note: The relief valve cartridge can be replaced only
The steering and brake control tank is the common oil as an assembly.
reservoir for the steering system and the brake control
system. It is mounted off the LH frame rail beside the Incorporated in this assembly are three valves; a
main hydraulic tank. check valve, accumulator two-way valve and a system
pressure protection valve.
An Oil Level Switch (9), mounted at the rear of the
tank, is used to indicate low oil level in the tank. The An accumulator two-way valve is located in the centre
switch terminal is wired to a warning light on the right portion of the assembly. In the operating position,
hand dash panel. engine running and two-way valve energized, this
valve allows the accumulator to retain its pressure. In
its non-operating position, engine shutdown and two-
Steering Pump (2) way valve de-energized, a controlled bleed-down of
Refer to Section 220-0050, STEERING PUMP. the accumulator pressure to the steering and brake
control tank occurs. This bleed-down takes 3 to 5
The steering pump is an axial piston, variable minutes.
displacement (adjustable) pump, capable of high
pressure operation. Mounted off the transmission A relief valve cartridge, at the lower portion of the
power takeoff the steering pump is the common assembly, is preset to 207 bar (3 000 lbf/in2) and
pressure supply to both the steering and brake control seated. This valve acts as a backup in the event of a
systems. Output is controlled to meet system malfunction of the steering pump compensator valve.
requirements at any given time. Should the compensator valve allow steering system
pressure to exceed the preset pressure of the relief
A compensator valve assembly regulates system valve cartridge, valve will open and relieve excess oil
pressure at 159 bar (2 300 lbf/in2). pressure to the steering and brake control tank.

The steering pump is assembled for right hand (clockwise)

rotation, as viewed from the driveshaft end. Steering Valve (5)
Refer to Section 220-0090, STEERING VALVE.
Note: Never drive a pump in the wrong direction of
rotation, as pump seizure may result. The steering valve is mounted to the cab firewall and
is connected to the steering column, and controls
hydraulic flow in the steering system. The steering
Accumulator (3) valve is a closed centre orbitrol type valve. Closed
Refer to Section 220-0080, ACCUMULATOR. centre means that the valve does not have any flow
through it when it is in the neutral or no steering
The accumulator is of the piston type and is position.
precharged with Nitrogen to 55 bar (800 lbf/in2).

SM 1591 12-98 1
Steering System - Steering System Schematic
Section 220-0000

Double Relief Valve (6) Steering Filter (12)

Refer to Section 220-0110, DOUBLE RELIEF VALVE. Refer to Section 220-0150, STEERING FILTER.

The double relief valve is installed in the lines between The steering filter is mounted off the rear left hand side
the steering cylinders and the steering valve. Its transmission mounting bracket. It is connected in the
purpose is to relieve shock loads on the steering steering line between the accumulator valve and the
cylinders by transferring the excessive pressure steering valve.
applied to the oil by the road shock, to the opposite
end of the cylinders. This shock, if left unchecked, There are two external ports ‘A’ and ‘B’ and an internal
might damage steering linkage components. bypass port ‘C’ in the steering filter assembly.

The double relief valve pressure setting is 172 bar

(2 500 lbf/in²) Pressure Test Point
A diagnostic pressure test point at the rear left hand
cab support provides a quick and easy method of
Steering Cylinder (7) checking the steering system pressure. The pressure
Refer to Section 220-0120, STEERING CYLINDER. is taken from a tee at port 'G2' of the accumulator
valve and system pressure is 159 bar (2 300 lbf/in2).
There are two single stage, double acting steering
cylinders installed on the machine. These exert the
necessary hydraulic force on the steering linkage to 'O' RING FACE SEALS (ORFS)
pivot the front wheels. Single stage, double acting Where hydraulic lines are fitted with ORFS
means that the piston rod can have oil applied to either connections, the following procedure should be carried
side, extending or retracting the piston rod. out during 'Installation'. Refer to Fig. 1.

SM - 1335
Pressure Switch (8) FITTING NUT

Refer to Section 220-0130, ACCUMULATOR VALVE. TUBE

The normally closed (NC) oil pressure switch is

located in a tee at port 'G2' of the accumulator valve
and illuminates a dash mounted indicator lamp when
the steering pressure drops to 83 bar (1 200 lbf/in2), or
lower.
SLEEVE
'O' RING 'O' RING
Oil Pressure Switch (10) and Oil Fig. 1 - Assembly of Typical ORFS Connector
Temperature Switch (11)
The normally open (NO) oil pressure switch is located a. Ensure 'O' ring/seal is in place and that joining
beside the oil temperature switch in the manifold block surfaces are clean. If necessary, retain 'O' ring/seal in
at the return port of the steering and brake control place with a light coating of grease or vaseline.
tank. The oil pressure switch will close and illuminate
an indicator lamp on the right hand dash panel when b. Initially, the nuts should be tightened by hand.
the restriction pressure exceeds 2.7 bar (39 lbf/in2),
indicating a filter change is required. c. Where a hose is fitted, ensure that it is not twisted or
kinked when the nuts are tightened so that it is allowed
The normally open (NO) oil temperature switch closes to adopt a natural position.
when a temperature of 50° C (122° F) is reached. The
oil temperature switch is connected in series with the d. Where a tube is fitted, ensure that the connection is
oil pressure switch, therefore, the steering filter aligned correctly.
restriction indicator light will not illuminate until the oil
reaches normal operating temperature. e. Tighten the nut a further 1/4 to 1/2 a turn using the
correct size spanner (wrench).

f. Check that a satisfactory hose or tube routing has

been achieved.

2 SM 1591 12-98
SM 1591 12-98
SM - 1988A

A A

B B

LT 6
RT
7 5 7

Steering System - Steering System Schematic

T P
C B 8
G2
COMPONENTS 3
D
1 - Steering and Brake Control Tank
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
8 - Oil Pressure Switch R A SUPPLY TO
BRAKE CIRCUIT
9 - Oil Level Switch RETURN FROM MONOBLOCK BRAKE VALVE
RETURN FROM DIRECTIONAL CONTROL, RETARDER
10 - Oil Pressure Switch
10 CONTROL, RETARDER SOLENOID VALVES
11 - Oil Temperature Switch 12 RETURN FROM TREADLE &
BRAKE MANIFOLD VALVES
12 - Steering Filter
11 TO TANK BREATHER

PRESSURE TEST POINTS

A - System Pressure 1
COLOUR CODES 9
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 2

Section 220-0000
Orange - Pilot Pressure
Yellow - Static Oil

Fig. 2 - Steering System Schematic - Engine Shutdown

3
4

Section 220-0000
Steering System - Steering System Schematic
SM - 1988B

A A

B B

LT 6
RT
7 5 7

T P
C B 8
G2
COMPONENTS 3
1 - Steering and Brake Control Tank
D
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
8 - Oil Pressure Switch R A SUPPLY TO
BRAKE CIRCUIT
9 - Oil Level Switch RETURN FROM MONOBLOCK BRAKE VALVE
RETURN FROM DIRECTIONAL CONTROL, RETARDER
10 - Oil Pressure Switch CONTROL, RETARDER SOLENOID VALVES
10
11 - Oil Temperature Switch 12 RETURN FROM TREADLE &
BRAKE MANIFOLD VALVES
12 - Steering Filter
11 TO TANK BREATHER

PRESSURE TEST POINTS

A - System Pressure 1
9
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 2
Orange - Pilot Pressure
Yellow - Static Oil
SM 1591 12-98

Fig. 3 - Steering System Schematic - Engine Running, Steering Valve Neutral

SM 1591 12-98
SM - 1988C

A A

B B

LT 6
RT
7 5 7

Steering System - Steering System Schematic

T P
C B 8
G2
COMPONENTS 3
1 - Steering and Brake Control Tank D
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
8 - Oil Pressure Switch R A SUPPLY TO
BRAKE CIRCUIT
9 - Oil Level Switch RETURN FROM MONOBLOCK BRAKE VALVE
RETURN FROM DIRECTIONAL CONTROL, RETARDER
10 - Oil Pressure Switch CONTROL, RETARDER SOLENOID VALVES
11 - Oil Temperature Switch 10 RETURN FROM TREADLE &
12 BRAKE MANIFOLD VALVES
12 - Steering Filter
TO TANK BREATHER
11
PRESSURE TEST POINTS
A - System Pressure 1
9
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 2

Section 220-0000
Orange - Pilot Pressure
Yellow - Static Oil

Fig. 4 - Steering System Schematic - Engine Running, Steering Valve Left Turn
5
6

Section 220-0000
Steering System - Steering System Schematic
SM - 1988D

A A

B B

LT 6
RT
7 5 7

T P
C B 8
G2
COMPONENTS 3
1 - Steering and Brake Control Tank
D
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
8 - Oil Pressure Switch R A SUPPLY TO
BRAKE CIRCUIT
9 - Oil Level Switch RETURN FROM MONOBLOCK BRAKE VALVE
RETURN FROM DIRECTIONAL CONTROL, RETARDER
10 - Oil Pressure Switch CONTROL, RETARDER SOLENOID VALVES
11 - Oil Temperature Switch 10
12 RETURN FROM TREADLE &
BRAKE MANIFOLD VALVES
12 - Steering Filter
11 TO TANK BREATHER

PRESSURE TEST POINTS

A - System Pressure 1
9
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 2
Orange - Pilot Pressure
Yellow - Static Oil
SM 1591 12-98

Fig. 5 - Steering System Schematic - Engine Running, Steering Valve Right Turn
SM 1591 12-98
SM - 1988E

A A

B B

LT 6
RT
7 5 7

Steering System - Steering System Schematic

T P
C B 8
G2
COMPONENTS 3
1 - Steering and Brake Control Tank D
2 - Steering Pump
3 - Accumulator E
4 - Accumulator Valve
5 - Steering Valve
6 - Double Relief Valve G1
7 - Steering Cylinder 4
8 - Oil Pressure Switch R A SUPPLY TO
BRAKE CIRCUIT
9 - Oil Level Switch RETURN FROM MONOBLOCK BRAKE VALVE
RETURN FROM DIRECTIONAL CONTROL, RETARDER
10 - Oil Pressure Switch CONTROL, RETARDER SOLENOID VALVES
11 - Oil Temperature Switch 10
12 RETURN FROM TREADLE &
BRAKE MANIFOLD VALVES
12 - Steering Filter
TO TANK BREATHER
11
PRESSURE TEST POINTS
A - System Pressure 1
9
COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 2

Section 220-0000
Orange - Pilot Pressure
Yellow - Static Oil

Fig. 6 - Steering System Schematic - Engine Running, Steering Cylinder Shock Load
7
Steering System - Steering System Schematic
Section 220-0000

RELIEVING SYSTEM PRESSURE 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.
WARNING
The steering system is equipped with an
accumulator which maintains pressure in the Multi-gauge
system, even after engine shutdown. To
The multi-gauge is basically four pressure gauges in
prevent possible personal injury, follow the
one. Continuous system pressure readings are
procedure for relieving the pressure and
indicated on one of three simultaneously reading
exercise extreme caution when loosening the
gauges through a pressure range of 762 mm (30 in) of
steering lines.
vacuum to 345 bar (5 000 lbf/in2).
1. Apply the parking brake and shut off the engine.
Non-contact Infrared Thermometer
2. Turn steering wheel in both directions until the
The infrared thermometer can be used to spot heat
pressure is relieved in the steering system (pressure
problems early in electrical, mechanical and hydraulic
at the steering system diagnostic test point should be
systems. Hand held and easy to use, you simply aim,
0 bar (0 lbf/in2)).
pull the trigger, and read the temperature. Since there
is no need to touch what you are measuring,
SERVICE TOOLS temperatures of hard-to-reach or moving components
can be taken without getting burned or shocked.
It is recommended that the following tools are used
when carrying out pressure or temperature checks

STEERING SYSTEM DIAGNOSIS

CONDITION REASON REMEDY
Slow response or hard Wear or damage to front axle Make necessary adjustment and/or replace defective
steering. linkage. parts. Refer to Section 220-0120, STEERING
CYLINDER AND LINKAGE.
Low steering oil level. Fill steering and brake control tank to proper level.
Refer to Section 220-0040, STEERING AND BRAKE
CONTROL TANK.
Steering pump not delivering Adjust pressure as described in Section 220-0050,
proper pressure. STEERING PUMP.
Defective steering cylinder. Replace steering cylinder. Refer to Section 220-0120,
STEERING CYLINDER AND LINKAGE.
Defective line(s) in the Repair or replace faulty line(s) or fitting(s).
steering system.
Contaminated filter in steering Replace oil filter. Refer to Section 220-0040,
tank. STEERING AND BRAKE CONTROL TANK.
Malfunctions in steering valve, Check out each of the valves. Refer to the
accumulator valve or double appropriate Section for repair/replacement
relief valve. procedures.
Incorrect tyre inflation. Refer to Section 140-0040, WHEEL, RIM AND TYRE
for inflation procedure and pressures.
Low pressure in front ride Refer to Section 180-0030, RIDE CYLINDER for
cylinders. servicing procedure.
Lack of lubrication. Refer to Section 300-0020, LUBRICATION SYSTEM
for lubrication points, lubricant specifications and
service intervals.

8 SM 1591 12-98
 Steering System - Steering System Schematic
Section 220-0000

STEERING SYSTEM DIAGNOSIS (Continued)

CONDITION REASON REMEDY
No steering response. Completely failed steering Repair or replace steering pump and set at
pump. recommended pressure. Refer to Section 220-0050,
STEERING PUMP.
Burst hydraulic line in steering Isolate defective line and replace with new one.
system. Check steering and brake control tank oil level and
add oil as necessary. Also, check for contamination
in the system.
Failed steering valve. Repair or replace steering valve. Refer to
Section 220-0090, STEERING VALVE.
Completely contaminated Drain and flush entire steering system. Check all
steering system. component valves, cylinders, tank, etc.. Install new
filters and refill system to correct level with fresh
hydraulic fluid. Check new filter frequently.
Opposite steering. Hydraulic lines connected Reconnect lines as necessary. Refer to schematics.
incorrectly.

* * * *

SM 1591 12-98 9
 STEERING SYSTEM - Steering and Brake Control Tank
Section 220-0040

SM - 1989
22

A 21 A
2-3

1
21
20
17
19 18 15
19 10

23-24
6
16 5
13
14
12
B

21
12
22
20
21
B 25
9 6
8 26

7
11 27

1 - Tank 8 - Lockwasher 15 - Gasket 22 - Nut

2 - Filler Cap 9 - Plug 16 - Bracket 23 - Oil Level Switch
3 - Gasket 10 - Filter Assembly 17 - Bolt 24 - Seal
4 - Access Cover 11 - Suction Screen 18 - Nut *25 - Adaptor
5 - Access Cover 12 - Window Nut 19 - Washer *26 - Valve
6 - Gasket 13 - Rod 20 - Bolt *27 - Drain Plug Kit
7 - Bolt 14 - Wing Nut 21 - Hardened Washer
* - Optional
Fig. 1 - Exploded View of Steering and Brake Control Tank

DESCRIPTION OPERATION
Numbers in parentheses refer to Fig. 1. Numbers in parentheses refer to Fig. 1, unless otherwise
specified. Letters in parentheses refer to Fig. 3. Refer to
The Steering and Brake Control Tank can be Fig. 2 for hydraulic schematic of steering and brake
identified as item 1 in Section 220-0000, STEERING control tank.
SYSTEM SCHEMATIC, in this manual.
The steering and brake control oil flow is drawn from
The steering and brake control tank (1) is the port 'A', through suction screen (11), by the steering
common oil reservoir for the steering and brake pump mounted on the transmission power takeoff. Oil
control systems. It is mounted off the left hand frame is then pumped to the accumulator valve in the
rail beside the main hydraulic tank. steering circuit and the brake manifold valve in the
brake control circuit. Internal pump leakage oil is
Integral with tank (1) assembly are filter assembly returned to tank (1) at port 'B' from a line at the case
(10), suction screen (11), window nuts (12) and oil drain port on the steering pump.
level switch (23). Access covers (4 & 5) give easy
access to replace filter assembly (10) and suction Port 'C' is plugged and provides a tank drain point.
screen (11).

SM 1592 12-98 1
Steering System - Steering and Brake Control Tank
Section 220-0040

SM - 1567 SM - 1990

RETURN FROM DIRECTIONAL CONTROL, RETARDER

TO ACCUMULATOR & BRAKE

RETURN FROM MONOBLOCK BRAKE VALVE

FROM ACCUMULATOR VALVE

CONTROL & RETARDER SOLENOID VALVES

RETURN FROM TREADLE & BRAKE
MANIFOLD VALVES

TO TANK BREATHER
MANIFOLD VALVES
10

2 11
A B D K J G H
1
9
F

1 - Tank
2 - Steering Pump 10 - Oil Pressure Switch
9 - Oil Level Switch 11 - Oil Temperature Switch
Fig. 2 - Hydraulic Schematic Fig. 3 - Port Locations

Return oil from the steering circuit enters the tank at brake cooling tank. This allows any air entering tank
port 'D' from the accumulator valve. The oil enters (1) to be released to atmosphere, preventing a
filter assembly (10) chamber and flows through a pressure build up in tank (1) assembly. Refer to
centre tube and filter element to tank (1) body. Section 230-0040, BODY AND DISC BRAKE
COOLING TANK.
Should filter assembly (10) become blocked, oil
restriction pressure will increase and oil pressure Return oil from the directional control valve, retarder
switch (10, Fig. 2) will close sending a signal to the control valve and retarder solenoid valve enters tank
steering filter restriction warning light on the right hand (1) at port 'J'.
dash panel, indicating that a filter change is required.
Return oil from the monoblock brake valve enters
Note: Temperature switch (11, Fig. 2) opens when a tank (1) at port 'K'.
temperature of 50° C (122° F) is reached.
Temperature switch (11, Fig. 2) is connected in series An inter-connecting hose assembly (3, Fig. 4) links
with pressure switch (10, Fig. 2), therefore, steering the steering and brake control tank and the body and
filter restriction warning light will not illuminate until disc brake cooling tank. Refer to Section 230-0040,
the oil reaches normal operating temperature. BODY AND DISC BRAKE COOLING TANK.

Port 'E' is plugged.

MAINTENANCE
A float oil level switch (23) is located in port 'F' and Numbers in parentheses refer to Fig. 1.
sends an electrical signal to a warning light on the
dash panel to indicate when the oil level falls below Note: Tighten all fasteners to torques listed in
the safe operating level. Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
Return oil from the brake treadle valve and brake
manifold valve enters tank (1) at port 'G'.
Checking Oil Level
A breather line at port 'H' is connected to a common Cold check: With the engine off, operate the steering
tank breather mounted on top of the body and disc left and right to discharge the steering accumulator.

2 SM 1592 12-98
 Steering System - Steering and Brake Control Tank
Section 220-0040
Operate treadle valve continuously to discharge SM - 1991
braking accumulators. Oil should be showing in
middle window nut (12).

If oil is required, remove filler cap (2) and fill tank (1)
with hydraulic oil specified in Section 300-0020,
LUBRICATION SYSTEM, until oil shows in bottom
window nut (12). Fit filler cap (2).

Hot check: With the engine running, oil at normal

operating temperature and accumulators charged, oil
must be between top and middle window nuts (12).
Switch off the engine and operate the steering left
and right to discharge the steering accumulator.
Operate treadle valve continuously to discharge
braking accumulators. Oil should show in top window
nut (12). 1 3 2

If oil is required, remove filler cap (2) and fill tank (1)
with hydraulic oil specified in Section 300-0020,
1 - Steering and Brake Control Tank
LUBRICATION SYSTEM, until oil shows in top
2 - Body and Disc Brake Cooling Tank
window nut (12). Fit filler cap (2). 3 - Inter-Connecting Hose Assembly

Replacing Hydraulic Oil Fig. 4 - Layout View of Hydraulic Tanks

Tank (1) assembly should be drained, cleaned and

refilled with clean hydraulic oil at the recommended Operate treadle valve continuously to discharge
service interval specified in Section 300-0020, braking accumulators. Block all road wheels.
LUBRICATION SYSTEM. Use only hydraulic oil as
specified in Section 300-0020, LUBRICATION 3. With suitable containers in position, remove drain
SYSTEM. plugs from tank (1) and body and disc brake cooling
tank (2, Fig. 4) and drain the oil. Refer to Section
Note: When oil in tank (1) is being replaced due to 230-0040, BODY AND DISC BRAKE COOLING
overheated oil, hydraulic component failure, or at TANK. Reinstall drain plugs in tanks and tighten
recommended change interval, filter assembly (10) securely.
should be replaced.
4. Remove bolts (7), lockwashers (8), access cover
(5) and gasket (6) from tank (1). Discard gasket (6).
Changing Filter Assembly
Change filter assembly (10) at interval specified in 5. Remove wing nuts (14) from rods (13). Remove and
Section 300-0020, LUBRICATION SYSTEM. discard filter assembly (10) and gasket (15) from tank
(1).

WARNING 6. Install new gasket (15) and filter assembly (10) in

To prevent personal injury and property tank (1) and secure with wing nuts (14).
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job 7. Install new gasket (6) and access cover (5) on
safely. tank (1) and secure with bolts (7) and lockwashers (8).

1. Position the vehicle in a level work area, be sure 8. Fill tank (1) to correct level with hydraulic oil
the body is fully lowered, apply the parking brake and specified in Section 300-0020, LUBRICATION
switch off the engine. SYSTEM. Install filler cap (2).

2. Turn the steering wheel in both directions several 9. Remove wheel blocks, start the engine and charge
times to relieve any pressure in the steering system. the steering and brake control systems. Check oil
level as described under 'Checking Oil Level'.

SM 1592 12-98 3
Steering System - Steering and Brake Control Tank
Section 220-0040

Removing Suction Screen 9. Fill tank (1) to correct level with hydraulic oil
Remove and clean suction screen (11) at interval specified in Section 300-0020, LUBRICATION
specified in Section 300-0020, LUBRICATION SYSTEM. Install filler cap (2).
SYSTEM.
10. Remove wheel blocks, start the engine and
charge the steering and brake control systems.
WARNING Check oil level as described under 'Checking Oil
To prevent personal injury and property Level'.
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
safely. TANK ASSEMBLY

1. Position the vehicle in a level work area, be sure Removal

the body is fully lowered, apply the parking brake and Numbers in parentheses refer to Fig. 1, unless
switch off the engine. otherwise specified.

2. Turn the steering wheel in both directions several

times to relieve any pressure in the steering system. WARNING
Operate treadle valve continuously to discharge To prevent personal injury and property
braking accumulators. Block all road wheels. damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
3. With suitable containers in position, remove drain secured and of adequate capacity to do the job
plugs from tank (1) and body and disc brake cooling safely.
tank (2, Fig. 4) and drain the oil. Refer to Section
230-0040, BODY AND DISC BRAKE COOLING 1. Position the vehicle in a level work area, be sure
TANK. Reinstall drain plugs in tanks and tighten the body is fully lowered, apply the parking brake and
securely. switch off the engine.

4. If required, remove inter-connecting hose 2. Turn the steering wheel in both directions several
(3, Fig. 4) from access cover (4). Fit blanking caps times to relieve any pressure in the steering system.
and plugs to hydraulic line and tank port. Remove Operate treadle valve continuously to discharge
bolts (7), lockwashers (8), access cover (4) and braking accumulators. Block all road wheels.
gasket (6) from tank (1). Discard gasket (6).
3. With suitable containers in position, remove drain
5. Reach inside tank (1) and unscrew suction screen plugs from tank (1) and body and disc brake cooling
(11) by turning hex head at the neck of suction tank (2, Fig. 4) and drain the oil. Refer to Section
screen (11). 230-0040, BODY AND DISC BRAKE COOLING
TANK. Reinstall drain plugs in tanks and tighten
securely.
WARNING
Splashing liquid. Wear a suitable face shield 4. Ensure all hydraulic lines connected to tank (1)
when using compressed air to dry tank and assembly are identified for ease of installation and,
components. with suitable containers available to catch leakage,
disconnect all hydraulic lines. Fit blanking caps and
6. Clean suction screen (11) and tank (1) with plugs to all hydraulic lines and tank ports.
paraffin and dry with compressed air. Inspect for
damage and renew if necessary. 5. Remove and tag electrical connections from oil
level switch (23), oil temperature switch (12, Fig. 2)
7. Install suction screen (11) in tank (1) and secure and oil pressure switch (11, Fig. 2).
by turning on hex head at the neck of suction screen
(11).
WARNING
8. Install new gasket (6) and access cover (4) on Heavy tank. Ensure lifting device is of
tank (1) and secure with bolts (7) and lockwashers adequate capacity and properly secured to
(8). Remove blanking cap and plug and install inter- avoid personal injury or property damage.
connecting hose (3, Fig. 4).

4 SM 1592 12-98
 Steering System - Steering and Brake Control Tank
Section 220-0040

6. Using suitable lifting equipment, support tank (1) Installation

assembly. Remove bolts (20), hardened washers Numbers in parentheses refer to Fig. 1, unless
(21) and nuts (22) securing tank (1) assembly to otherwise specified.
mounting brackets (16).
Note: Tighten all fasteners to torques listed in
7. Remove tank (1) assembly to a suitable work area Section 300-0080, STANDARD BOLT AND NUT
for disassembly. TORQUE SPECIFICATIONS.

Note: Tighten all hydraulic lines fitted with ORFS

Disassembly connections, as described in Section 220-0000,
Numbers in parentheses refer to Fig. 1. STEERING SYSTEM SCHEMATIC. Renew all 'O'
rings where used.
1. Remove internal components from tank (1)
assembly as described in 'Maintenance'.
WARNING
2. If required, remove rods (13) and window nuts (12) Heavy tank. Ensure lifting device is of
from tank (1) assembly. adequate capacity and properly secured to
avoid personal injury or property damage.
3. If required, remove oil level switch (23) from inside
of tank (1) and discard seal (24). 1. Using suitable lifting equipment, position tank (1)
assembly on mounting brackets (16) and secure with
bolts (20), hardened washers (21) and nuts (22).
Inspection
Numbers in parentheses refer to Fig. 1. 2. Remove blanking caps and plugs and install all
hydraulic lines to tank (1) assembly, as tagged at
'Removal'.
WARNING
Splashing liquid. Wear a suitable face shield 3. Install electrical connections to oil level switch
when using compressed air to dry tank and (23), oil temperature switch (12, Fig. 2) and oil
components. pressure switch (11, Fig. 2).

1. Clean tank (1) and components with paraffin and 4. Fill tank (1) with hydraulic oil specified in
dry with compressed air. Section 300-0020, LUBRICATION SYSTEM. Install
filler cap (2).
2. Inspect tank (1) for weld cracks and security of
internal pipes and weld fitments. 5. Remove wheel blocks, start the engine and charge
the steering and brake control systems. Check oil
3. Check suction screen (11) for damage and renew level as described under 'Checking Oil Level'.
if necessary.
5. Check all hydraulic line connections for leaks and
tighten as required.
Assembly
Numbers in parentheses refer to Fig. 1.
SPECIAL TOOLS
1. If removed, install window nuts (12) and rods (13) There are no special tools required for procedures
in tank (1). outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general
2. If removed, install new seal (24) on oil level switch service tools required. These tools are available from
(23) and install level switch assembly in tank (1). your dealer.

3. Install all internal components as previously

described in 'Maintenance'. Renew filter assembly
(10) and gaskets (6 & 15).

* * * *
SM 1592 12-98 5
 STEERING SYSTEM - Steering Pump
Section 220-0050

SM - 3342

6 12

36 8
11
18
17

3 25

23
2

1 29

24

32
20

13 14 15 21 26

1 - Retaining Ring 12 - Plug Assembly 20 - Drive Shaft 26 - Pin

2 - Shaft Seal 13 - Crush Ring 21 - Rotating Group 29 - End Cover
3 - Pump Housing 15 - Swash Plate 23 - Valve Plate 32 - Screw
6 - Pump Compensator 17 - Spring 24 - Bearing 33 - Retaining Ring
8 - Cap 18 - Bearing Swash Plate 25 - 'O'-Ring 34 - Spring
11 - Piston Control 35 - Spring Guide
36 - Piston
Fig. 1 - Cutaway View Of Steering Pump

DESCRIPTION Note: Never drive a pump in the wrong direction of

Numbers in parentheses refer to Figs. 1 & 6. rotation as pump seizure may result.

The steering pump is mounted on the transmission The major pump components include driveshaft (20),
PTO and can be identified as item 2 in Section pump housing (3), swash plate (15), rotating group (21),
220-0000, STEERING SYSTEM SCHEMATIC. control piston (11), bias spring (17), end cover (29) and
pump compensator (6).
The steering pump is an axial piston, variable
displacement (adjustable) pump, capable of high The variable displacement unit incorporates a
pressure operation. It is the common pressure supply mechanism that governs the angle of bearing swash
to both the steering and brake control systems. Output plate (18) which, in turn controls the stroke length of
is controlled to meet system requirements at any given each piston (36) as rotating group (21) assembly and
time. Pump compensator (6) regulates system driveshaft (20) rotate. End cover (29) includes the inlet
pressure at 159 bar (2 300 lbf/in²). and outlet ports. Tapered bearing (14) in pump housing
(3) and tapered bearing (24) in end cover (29) support
The steering pump is assembled for right hand driveshaft (20).
(clockwise) rotation, as viewed from driveshaft (20) end.

SM 2356 01-05 1
Steering System - Steering Pump
Section 220-0050

SM - 395

PISTON SUB ASSEMBLY

OUTLET VALVE
PLATE SLOT
SWASH PLATE

OUTLET
PORT

INLET
PORT DRIVESHAFT

SHOE PLATE
INTAKE VALVE
PLATE SLOT
CYLINDER BLOCK BORE

Fig. 2 - Pump Rotation and Oil Flow

OPERATION SM - 553

Refer to Fig. 3 for hydraulic schematic of steering

TO
pump operation. ACCUMULATOR
VALVE
TO BRAKE
Rotation of pump driveshaft causes rotating group
MANIFOLD
cylinder block, shoe plate and pistons to rotate. See VALVE
Fig. 2. The piston shoes are held against the yoke face
by the shoe plate. The angle of the yoke face imparts a
reciprocating motion to each piston within the cylinder
block. Inlet and outlet ports connect to a kidney slotted
valve plate. As the pistons move out of the cylinder
block, a vacuum is created and fluid is forced into the
void by atmospheric pressure. The fluid moves with the
cylinder block, past the intake kidney slot, to the outlet
SUPPLY CASE DRAIN
(pressure) kidney slot. The motion of the piston FROM TO TANK
reverses and fluid is pushed out of the cylinder block TANK
into the outlet port.
Fig. 3 - Hydraulic Schematic of Steering Pump Operation
Oil flows from the outlet (pressure) port to the
accumulator valve which supplies steering circuit as shown by views ‘A’, ‘B’ and ‘C’ in Fig. 4.
pressure. Pressure is tapped off from a tee in the
accumulator valve to the brake manifold valve to During pump operation, load or system pressure is
supply brake circuit pressure. continually fed to the bias piston and the compensator
spool chamber.
Internal pump leakage oil is returned to tank through a
line at the case drain port on the steering pump. The operation of the compensator is such that when
the system pressure (pump outlet) reaches the
compensator spring setting, the valve spool moves to
Variable Displacement meter fluid to the pump control piston. As the force
Variable displacement is effected by altering the produced by the control piston overcomes the force of
angularity between the shoe plate and driveshaft axes, the bias piston, the shoe plate angle moves toward the

2 SM 2356 01-05
 Steering System - Steering Pump
Section 220-0050

SM - 377

MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUM DISPLACEMENT)
VIEW A VIEW B VIEW C

Fig. 4 - Variable Displacement Action

minimum displacement position. (View ‘C’ Fig. 4). SM - 3340

The amount of angular movement of the shoe plate

(i.e. displacement change) is determined by system
flow demand and the resulting system pressure. 8,9

Equilibrium is achieved when the new displacement 4,5

matches the system requirement. 1

REMOVAL
Numbers in parentheses refer to Fig. 5.

WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly 2,3 3,6 7

secured and of adequate capacity to do the job

safely.
1 - Steering Pump 6 - Hardened Washer
1. Position the vehicle in a level work area, raise the 2 - Bolt 7 - Bolt
body and secure in place with the body safety pins. 3 - Lockwasher 8 - Coupling
4 - Pump Adaptor 9 - 'O' Ring
Apply the parking brake and switch off the engine. 5 - Gasket 10 - Snap Ring

2. Turn steering wheel in both directions several times Fig. 5 - Plan View of Steering Pump Installation
to relieve pressure in accumulator and steering
system. Block all road wheels.
and, with suitable containers available to
3. With a suitable container in position, remove drain catch leakage, disconnect hydraulic lines. Fit blanking
plug from bottom of steering and brake control tank and caps and plugs to all hydraulic lines and tank ports.
drain the oil. Reinstall the drain plug and tighten
securely. 6. Support steering pump (1) with a suitable lifting
device and remove two mounting bolts (2) and
4. With a suitable container in position, remove drain lockwashers (3). Pull steering pump (1) rearward to
plug from underside of steering pump (1) housing and disengage pump driveshaft from drive coupling (8).
drain the oil.
7. Pull steering pump (1) and gasket (5) straight out
5. Ensure hydraulic lines connected to steering from the mounting flange of pump adaptor (4). Discard
pump (1) assembly are identified for ease of installation gasket (5). Do not remove pump adaptor (4) from its
mounting unless it is to be replaced.

SM 2356 01-05 3
Steering System - Steering Pump
Section 220-0050

17 SM - 3341
16
7 12
8

11
16
10

9 15 31
5
14 29 32
4

13*
3 30

9
28

27
26 25
24

2
1 22
23

21

20

18

1 - Retaining Ring 13 - Crush Ring / Shim Kit* 24 - Bearing

2 - Shaft Seal 14 - Bearing 25 - 'O'-Ring
3 - Pump Housing 15 - Bearing Swash Plate 26 - Pin
4 - Plug 16 - Screw 27 - Plug
5 - 'O'-Ring 17 - Spring 28 - Plug
6 - Pump Compensator 18 - Swash Plate 29 - End Cover
7 - Screw 19 - Key 30 - Plug
8 - Cover 20 - Drive Shaft 31 - Plug
9 - 'O'-Ring 21 - Rotating Group* 32 - Screw
10 - Shipping Plug 22 - Plug 33 - Retaining Ring
11 - Piston Control 23 - Valve Plate 34 - Spring
12 - Plug Assembly 35 - Spring Guide
36 - Piston
Fig. 6 - Exploded View Of Pump

4 SM 2356 01-05
 Steering System - Steering Pump
Section 220-0050
8. Wash the outside of steering pump (1) thoroughly Pump housing
with a suitable solvent and move to a clean work area
Numbers in parentheses refer to Figs 6 unless
for disassembly.
otherwise stated.

OVERHAUL 1. Remove 4-off screws (32) which secure end cover

(29) to main pump housing (3). Remove end cover (29).
In most cases, the pump will not require a complete
Remove and discard 'O'-ring (25).
overhaul as described within this section of the
manual. In general, pump disassembly is accomplished
2. Remove coupling if required from end of drive shaft
according to the item number sequence as shown in
(20).
Fig. 6. For pump assembly, reverse the item number in
sequence. The item number sequence can also be
3. Valve plate (23) should be removed at this time.
used as a guide for partial disassembly and assembly.
Remove bearing (24).
Repair of this unit is intricate and should not be
attempted without proper tools.
4. Carefully remove rotating group (21) from bore of
pump housing (3). (This group includes pistons,
DISASSEMBLY shoeplate and cylinder block housing).
Numbers in parentheses refer to Fig. 6.
5. Remove plug assembly (12) from top of pump
housing (3). With this removal of piston control
Note: Cleanliness is essential when working on a
assembly (11) should be possible.
hydraulic system or component. Always work in a
clean area, as contamination can cause serious
6. Using a suitable tool, remove retaining ring (1) from
damage to a hydraulic system.
internal groove on pump housing (3). Remove shaft
seal (2) from internal bore of pump housing (3), by
Pump Compensator tapping on the end of a brass rod or screwdriver.
Discard seals.
Numbers in parentheses refer to Fig. 7.
8. Remove drive shaft (20), with this the inner race of
1. Remove four screws (7) securing pump
shaft bearing (14) should also come out. If necessary
compensator (6) to housing (3) and remove pump
take a rubber hammer and gently chap shaft loose from
compensator (6) from the housing. Take care not to
bore. Now remove outer race of bearing (14) using a
lose or damage 'O' rings (5) when removing the pump
suitable tool.
compensator assembly.
Note: Crush ring (13) will be replaced after initial
Note: The pump compensator assembly (6) can only
overhaul of the pump with shim kit 15501799.
be replaced as an assembly. Therefore, no further
disassembly is required.
9. Remove crush ring (13) from inner face of pump
SM - 3343 housing (3).

10. Remove swash plate (18), bias spring (17) and

bearing swash plates (15) from the housing bore.
Remove screws (16) retaining bearing swash plates
(15) to swash plate (18).

Rotating Group
1. Remove piston assemblies and shoe plate from
cylinder block bores for inspection.

2. If removal of spring (34) is required, it is

recommended that caution be taken during this step.

Fig. 7 - Pump Compensator Removal

SM 2356 01-05 5
Steering System - Steering Pump
Section 220-0050
scratches with 500 grit paper. Remove burrs with an
India stone. Pistons should move freely over their
WARNING respective rods.
The spring located within the cylinder block is
under high tension and can cause bodily harm.
Ensure retaining ring is removed using the
Swash plate
manufacturers guidelines. 1. Inspect swash plate (18) face for wear, roughness or
scoring. Check the hubs and bearing surfaces for wear
and cracks. Replace if defective.
INSPECTION 2. Inspect bearing swash plates (15) for heavy wear
Numbers in parentheses refer to Fig. 6. and/or cracks. Replace if defective.

Note: Before inspection of parts, clean all parts with a

suitable solvent. Driveshaft and associated parts
1. Inspect driveshaft (20) for wear, chipped splines and
Note: Rotating group* (21) is made up of a cylinder burrs. Remove burrs with an India stone. Inspect
block, shoe plate and piston assemblies. contact area of tapered bearings (14 & 24) and shaft
seal (2). Replace driveshaft (20) if wear or scoring is
greater than 0.127 mm (0.005 in) total indicator reading
Rotating Group (T.I.R.).
1. Inspect cylinder block for wear, scratches and/or
erosion. If cylinder block condition is questionable, 2. Inspect inner and outer races of tapered bearings
replace the entire rotating group. (14 & 24) for roughness, pitting of rollers and
excessive end play. Make sure the inner race turns
2. Check each cylinder block bore for excessive wear. freely within the outer race. If the tapered bearing
Use piston and shoe assemblies for this purpose. The needs replacement, both the inner and outer races
pistons should be a very close fit and slide in and out must be replaced.
of the cylinder block bores. No binding can be
tolerated. If binding occurs, clean cylinder block and 3. Inspect pump housing (3) mounting flange for nicks
piston and shoe assemblies. Lubricate cylinder block and burrs. Remove minor nicks and burrs with an India
bores with clean hydraulic oil and try again. Even minor stone. Also check pump housing (3) for damaged or
contamination of the oil may cause a piston to seize up stripped threads. If any thread is damaged, replace the
in a cylinder block bore. pump housing.
3. Inspect shoe plate for heavy wear and/or cracks.
Replace if defective. 4. Check remaining pump parts for excessive wear,
damaged threads, burrs, cracks and/or erosion.
Replace any part that is in a questionable condition.
Pump Housing and Associated Parts
1. Inspect pump housing (3) for erosion, cracks and
burrs. Clean up minor burrs with an India stone. If ASSEMBLY
erosion or cracks are noted, replace pump housing (3). Numbers in parentheses refer to Fig. 6.

2. Inspect inner and outer races of tapered bearings (14 Note: Obtain a new shaft seal kit and a new bearing
& 24) for nicks and pitting. Make sure the inner race kit, if required. Refer to the vehicle Parts Book for kit
turns freely within the outer race. If either of the tapered part numbers. Apply a light film of clean hydraulic oil to
bearings need replaced, both the inner and outer races all new seals to make assembly easier and provide
must be replaced. To remove the outer races from initial lubrication of moving parts.
pump housing (3) or end cover (29) do so using tooling
in accordance with manufacturers guidelines. Assembly of the pump is largely the reverse numerical
sequence to disassembly, but note the following:
3. Inspect valve plate (23) for erosion, excessive wear,
heavy scratches and cracks. If any of the above 1. Lubricate new shaft seal (2) and pump housing (3)
conditions are found, replace the valve plate. bore with petroleum jelly. Using an arbor press and a
suitable shaft seal driver, install shaft seal (2) in pump
4. Inspect spring (17) and rotating group piston parts housing (3). Ensure correct orientation of seal.
for burrs, scratches and cracks. Clean up minor

6 SM 2356 01-05
 Steering System - Steering Pump
Section 220-0050

PUMP HOUSING Press outer race until it is fully seated on internal face
(3) of end cover (29).
INNER RACE
OUTER RACE OF TAPERED
6. Taking inner races of tapered bearings (14 & 24),
OF TAPERED BEARING (14) lubricate races and driveshaft (20) with clean hydraulic
BEARING (14)
oil. Fit bearing races to their respective ends of
driveshaft (20).
TEFLON
MATERIAL
SHAFT 7. Install driveshaft (20) in pump housing (3) as follows.
SEAL (2)

DRIVE SHAFT (20) Take a piece of shim stock or teflon material large
enough to roll into a funnel and protect the seal (2)
faces. Insert the teflon into shaft seal (2) as shown in
Fig. 8.
Fig. 8 - Driveshaft Installation
8. Pre-assemble bearing swash plate (15) to swash
plate (18) using screws (16). Taking spring and locating
2. Secure shaft seal (2) in pump housing with retaining
over domed locator on top of swash plate (18), insert
ring (1).
swash plate assembly and spring into bore of pump
housing (3). Spring should sit over stepped edge of
Note: Only install crush ring (13) if the following
bore.
parts; pump housing (3), drive shaft (20), shaft
bearings (14 & 24) and end cover (29) remain the
9. Fit 'O'-ring (9) over piston control end. Now locate
same and have not been needed to be replaced due
piston control (11) into bore of pump housing (3).
to wear or damage.
Torquing plug (12) to 15 - 25 Ibf ft (21-34 Nm).
3. Install crush ring (13) into bore of pump housing (3),
10. Pre-assemble the rotating group (21); apply a thin
ensure ring is seated against face of pump housing (3).
coat of clean hydraulic oil to the piston assemblies.
Lubricate the bores of the cylinder block with clean
4. Install a new outer race of tapered bearing (14) in
hydraulic oil and install pistons into cylinder bores.
pump housing with an arbor press. Make sure outer
race is orientated correctly to accommodate the inner
11. Align the rotating group with the bearing swash
race. Press the outer race in until it mates with the
plate (18) assembly. Install rotating group and valve
crush ring (13).
plate (23) into pump housing.
5. Install a new outer race of tapered bearing (24) in
12. Taking roll pin (26), press into end cover (29),
end cover , with an arbor and press. Make sure outer
ensure the split is orientated away from bearing (24),
race is orientated correctly to accommodate inner race.
within 5 degree of the centre line. Pin should protrude
from face of end cover (29) within the range stated.
Refer to Fig. 9. This will endure that the valve plate
(23) is located correctly.

13. Install a new 'O'-ring (25) on groove in pump

housing (3). Taking End cover (29), mate with housing
and secure together with 4-off screws (32). Torquing
screws to 87 - 107 Ibf ft (118 - 145 Nm)

Note:
If any of the following parts- pump housing (3), drive
shaft (20), shaft bearings (14 & 24) or end cover (29)
are replaced for any reason during servicing, the crush
ring (13) can no longer be used. To ensure correct
.173±.005 bearing location, shims (15501799) must be used in
Fig. 9 - Piston Assembly Tolerances place of the ring (13). This calls for the following steps
to be carried out:

SM 2356 01-05 7
Steering System - Steering Pump
Section 220-0050
Shim installation / Measurement: bolts (2) and lockwashers (3).

Note: For shim kit service Part No. refer to SERVICE 3. Remove caps and connect outlet and inlet lines to
TOOL section 300-0070 steering pump (1). Before connecting the case drain line,
fill steering pump (1) with clean hydraulic oil specified in
A. Measure the thickness of the existing crush Section 300-0020, LUBRICATION SYSTEM. Connect
ring (13). the case drain line to steering pump (1).

B. Stack a number of shims together, to a thickness a Note: It is very important that the pump cavity is
few thousands of an inch less than the measurement of completely filled with hydraulic oil. This will ensure
the existing ring (13). proper lubrication of the internal parts of the pump
when it is initially operated.
C. Insert shims (15501799) into pump housing (3) in
place of the ring (13). 4. Fill the steering and brake control tank with clean
hydraulic oil specified in Section 300-0020,
D. Assembly the pump housing (3), shaft bearings (14 LUBRICATION SYSTEM. Refer to Section 220-0040,
& 24), and end cover (29). Now install the end cover STEERING AND BRAKE CONTROL TANK for correct
screws (32) and torque to 87 - 107 Ibf ft (118 - 145 Nm) oil level.
E. Using a dial indicator, measure the drive shaft (20) 5. Refer to 'PUMP STARTING PROCEDURE' for
end play. Acceptable range is within 0.001" clearance proper pump priming and start-up procedure.
to 0.002" interference. Add shims (15501799) to
achieve desired result. Note: If no movement of the
shaft (20) is observed, the shims must be removed and PUMP STARTING PROCEDURE
repeat steps D & E. Numbers in parentheses refer to Fig. 6.

F. Finish pump assembly. 1. Make sure the reservoir and circuit are clean and
free of dirt and debris prior to filling with hydraulic fluid.
Fill the reservoir with filtered oil to a level sufficient to
INSTALLATION prevent vortexing at suction connection to pump inlet.
Numbers in parentheses refer to Fig. 5.
Note: It is good practice to clean the system by
Note: Tighten all fasteners to standard torques listed in flushing and filtering the system using an external
Section 300-0080, STANDARD BOLT AND NUT slave pump. Before starting the pump, fill with fluid
TORQUE SPECIFICATIONS. through one of the ports. This is particularly important
if the pump is above the fluid level of the reservoir.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 220-0000, 2. When initially starting the pump, remove all trapped
STEERING SYSTEM SCHEMATIC. Renew all air from the system. This can be done by loosening the
'O' rings where used. pump outlet fittings or connections before starting the
pump. or by using an air bleed valve. All inlet
connections must be tight to prevent air leaks.
WARNING
To prevent personal injury and property 3. Once the pump is started, it should prime within a
damage, be sure wheel blocks, blocking few seconds. If the pump does not prime, check to
materials and lifting equipment are properly make sure there are no air leaks in the inlet line and
secured and of adequate capacity to do the job connections. Also check to make sure that trapped air
safely. can escape at the pump outlet.

1. Coat steering pump (1) shaft splines with 4. After the pump is primed, tighten the loose outlet
molybdenum disulphide grease and place steering connections, then operate for five to ten minutes
pump (1) and gasket (5) on pump adaptor (4) mounting unloaded to remove all trapped air from the circuit. If
flange. the reservoir has a sight gauge, make sure the fluid is
clear- not milky. Add fluid to the reservoir up to the
2. Push steering pump (1) inward to engage pump proper fill level.
driveshaft with drive coupling (8) and PTO drive.
Secure steering pump (1) to pump adaptor (4) with two 5. The pump must be started with less than 40% of

8 SM 2356 01-05
 Steering System - Steering Pump
Section 220-0050
normal system pressure. This is done by backing off If it is, there is either excessive restriction in the case
the steering pressure relief valve so that the pump will drain line (obstructed or possibly a kinked line), or the
start under no-load conditions. leakage rate in the pump is too high. In either case, the
cause should be corrected.
2. Be sure the pump case drain line is free from
obstructions that restrict the pump case drain flow 5. The system pressure can then be set by screwing
back to tank and cause high case drain pressure which adjusting screw in until a system pressure of
can lead to an early pump failure. 159 bar (2 300 lbf/in²) is attained. The case tank
3. Before starting the engine after pump installation, pressure differential should still not exceed
remove the remaining case drain plug from the pump 0.07 - 0.14 bar (1 - 2 lbf/in²).
and an appropriate plug from the hydraulic tank and 6. Shut off the engine, bleed off hydraulic pressure and
install 0 - 3.5 bar (0 - 50 lbf/in²) gauges in both ports, remove the gauges.
as well as a gauge in the pressure circuit which can be
read for setting the steering system pressure. Be sure 7. Remove wheel blocks from all road wheels, start the
to back out adjusting screw in compensator assembly engine and check steering system for proper operation.
(1) until it is flush with the compensator body.
4. Start the engine and monitor the system pressure
gauge. Pressure should register within 30 seconds. If
not, re-check to assure that the system is properly SPECIAL TOOLS
filled with oil and that there is no restriction to the pump Details of recommended manufacturer tools to follow,
inlet. once confirmation and approval has been given from
pump manufacturer.
With the engine at Maximum No Load rev/min, read the
pressures on both the tank and the pump case. At no Refer to Section 300-0070, SERVICE TOOLS for part
time should the case pressure be more than numbers of special tools referenced in this section and
0.07 - 0.14 bar (1 - 2 lbf/in²) above the tank pressure. general service tools and adhesives required. These
tools and adhesives are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
6 4 Plug 5.5 - 6.8 4- 5
6 7 Screw 13.5 - 16.3 10 - 12
6 10 Plug 36.6 - 40.7 27 - 30
6 12 Plug 145 - 178 107 - 131
6 22 Plug 36.6 - 40.7 27 - 30
6 28 Plug 13.5 - 16.3 10 - 12
6 31 Plug 5.5 - 6.8 4- 5
6 32 Screw 118.4 - 144.7 87.3 - 106.7

* * * *

SM 2356 01-05 9
THIS PAGE IS INTENTIONALLY LEFT BLANK
 STEERING SYSTEM - Accumulator
Section 220-0080

SM - 171

1 - Charging Valve 1E - Body

1A - Cap 1F - ‘O’ Ring 5 - Backup Ring 9 - Hardened Washer
1B - Core 2 - Shield 6 - 'O’ Ring 10 - Piston
1C - ‘O’ Ring 3 - ‘O’ Ring 7 - Seal Rings 11 - Wear Ring
1D - Locknut 4 - End Cap 8 - Bolt 12 - Cylinder

Fig. 1 - Exploded View of Accumulator

DESCRIPTION TESTING
Numbers in parentheses refer to Fig. 1.

The Steering Accumulator can be identified as item 3 WARNING

in Section 220-0000, STEERING SYSTEM Accumulators are charged with Nitrogen. The
SCHEMATIC, in this manual. service pressure is 55 bar (800 lbf/in2) at 21° C
(70° F). Do not attempt to remove any valves
The accumulator is of the piston type and is pre- or fittings until all nitrogen pressure is
charged with nitrogen to 55 bar (800 lbf/in2). Mounted completely relieved to prevent personal injury
off the frame at the rear of the steering and brake and property damage.
control tank, the accumulator assembly consists of
charging valve (1), end cap (4), cylinder (12) and
piston (10). The charging valve (1) is equipped with a Testing Charging Valve For Leakage
locking feature. Loosening the locknut (1D) will open Numbers in parentheses refer to Fig. 1.
the valve so that the pre-charge can be checked or
the accumulator charged. The piston (10) acts as a Remove valve cap (1A) from charging valve (1) and
separator dividing the cylinder (12) into two sections. loosen locknut (1D). Coat open end of charging valve
The section nearest the charging valve (1) contains with soapy water. Bubbles indicate leaky valve core
the nitrogen pre-charge. The other section receives (1B). Attempt to reseat the valve core by depressing
the hydraulic oil from the steering pump.

SM 1205 2-98 1
Steering System - Accumulator
Section 220-0080
and releasing it quickly once or twice. Recheck for the body is completely lowered, apply the parking
leakage, if leakage continues then discharge the brake and switch off the engine.
accumulator as described under 'Discharging
Nitrogen' in this section, then replace the valve core. 2. Turn steering wheel in both directions several
Tighten locknut (1D) to 11 Nm (100 lbf in) and times to relieve pressure in accumulator and steering
replace the valve cap (1A) finger tight. system. Block all road wheels.

3. Check accumulator mountings to be sure the

Testing Pre-charge Pressure accumulator is held tightly in position.
Numbers in parentheses refer to Fig. 2, unless
otherwise specified. 4. Remove cap (1A, Fig. 1) from accumulator
charging valve (1, Fig. 1). Attach charging line (1) to
Note: The nitrogen pressure in a steering charging valve by rotating 'T' handle of valve chuck
accumulator is directly affected by changes in (2) counter-clockwise until it stops, then screw the
nitrogen temperature. The cylinder pressure will swivel nut down on valve. Loosen charging valve
increase or decrease proportionally with temperature locknut (1D, Fig. 1) by turning counter-clockwise one
changes. An accumulator pressure reading taken on to two turns.
a steering system can vary about 4.3 bar (62 lbf/in²)
with 22° C (72° F) temperature change. Such 5. Turn 'T' handle clockwise until charging valve core
temperature changes could easily occur between is depressed. Be sure bleeder valve (10) is tight and
noon and midnight of the same day. Refer to the table does not leak, and valves (4 & 6) are closed.
at the end of this section for Nitrogen pressures at
ambient temperatures of other than 21° C (70° F). 6. To read accumulator pre-charge pressure, slowly
open accumulator valve (4). Pressure gauge (5) will
To test accumulator pre-charge pressure or to charge register pre-charge pressure, it should be 55 bar
the accumulator, a charging assembly tool can be (800 lbf/in²) at 21° C (70° F) ambient temperature.
used. Refer to Fig. 2. Refer to the table at the end of this section for
Nitrogen pressures at ambient temperatures of other
1. Position the vehicle in a level work area, be sure than 21° C (70° F).

SM - 1273 7. Close accumulator valve (4) and open bleeder

valve (10) to dissipate gauge pressure. Close bleeder
valve (10) after pressure is relieved. If the
accumulator needs charged, leave line (1) and valve
chuck (2) attached to charging valve and charge the
accumulator as described under 'Charging The
Accumulator'.

8. If pre-charge is 55 bar (800 lbf/in²) at 21° C

(70° F), rotate 'T' handle counter-clockwise until it
stops, then tighten locknut (1D, Fig. 1) on charging
valve (1, Fig. 1) to 11 Nm (100 lbf in). Loosen the
swivel nut and remove gauging head.

9. Install valve cap (1A, Fig. 1) on charging valve

(1, Fig. 1) and tighten finger tight.

CHARGING THE ACCUMULATOR

Numbers in parentheses refer to Fig. 2, unless
1 - Line 6 - Tank Valve otherwise specified.
2 - Valve Chuck 7 - Gland Fitting
3 - Valve Extension 8 - Gland Nut
4 - Accumulator Valve 9 - Cylinder Adaptor
Either oil or water pumped nitrogen can be used to
5 - Pressure Gauge 10 - Bleeder Valve charge the accumulator. Both types are readily
available from a local compressed gas dealer.
Fig. 2 - Charging Assembly

2 SM 1205 2-98
 Steering System - Accumulator
Section 220-0080

DISCHARGING NITROGEN
WARNINGS Numbers in parentheses refer to Fig. 1.
Do not use Oxygen or any gas other than
Nitrogen to charge an accumulator. Oxygen Make sure charging valve (1) is closed internally by
under pressure coming into contact with oil or turning locknut (1D) clockwise. Remove valve cap
grease will cause a violent explosion. Always (1A) and valve core (1B) from charging valve
double check to make sure you are using assembly (1). Slowly turn locknut (1D) counter-
Nitrogen to prevent personal injury and clockwise to open charging valve assembly (1).
property damage.
DO NOT remove charging valve (1) until all the gas
A high pressure nitrogen pressure has been completely evacuated.
regulator must be used with the charging
assembly. Failure to use pressure regulator
could cause property damage, personal injury WARNING
or death. Do not try to discharge the accumulator by
depressing charging valve core (1B).
1. Attach line (1) and the swivel nut to charging valve
(1, Fig. 1) as described in Steps 1 through 4 under
the heading 'Testing Pre-Charge Pressure'. Be sure REMOVAL
valves (4 & 6) are closed. Numbers in parentheses refer to Fig. 3.

2. Attach gauging head to nitrogen bottle by screwing

down on gland nut (8). WARNINGS
To prevent personal injury and property
3. Open tank valve (6) slowly; pressure shown on damage, be sure wheel blocks, blocking
pressure gauge (5) is tank pressure. materials and lifting equipment are properly
secured and of adequate capacity to do the job
4. Open accumulator valve (4) slowly and charge safely.
accumulator to 55 bar (800 lbf/in²) at 21° C (70° F)
ambient temperature, closing valve occasionally. Accumulators are charged with Nitrogen.
Refer to the table at the end of this section for the Be sure all Nitrogen pressure has been
Nitrogen pressures at ambient temperatures of other relieved before removing accumulator from
than 21° C (70° F). machine. Sudden release of pressure may
cause personal injury.
5. To check accumulator charge, close tank valve
(6), relieve pressure between tank and pressure 1. Position the vehicle in a level work area, be sure
gauge (5) by opening bleeder valve (10) momentarily. the body is completely lowered, apply the parking
This will allow gauge needle to settle, thus giving brake and switch off the engine.
correct pressure reading of accumulator charge.
2. Turn steering wheel in both directions several
6. When the correct pressure for the ambient times to relieve pressure in accumulator and steering
temperature has been reached, close valves (4 & 6) system. Block all road wheels.
tightly. Bleed pressure off pressure gauge (5) by
opening bleeder valve (10). Close bleeder valve when 3. Discharge nitrogen from accumulator, as
oil pressure is bled from the gauge and unscrew described under 'Discharging Nitrogen' in this
gland nut (8) from nitrogen bottle. section.

7. Rotate 'T' handle of valve chuck (2) counter- 4. Disconnect hydraulic line from underside of
clockwise until it stops, tighten charging valve accumulator. Cap the line and accumulator port to
locknut (1D, Fig. 1) to 11 Nm (100 lbf in), loosen the prevent ingress of dirt.
swivel nut and remove gauging head.
5. Support the accumulator using an adequate sling
8. Check accumulator charging valve (1, Fig. 1) for and lifting device. Remove nuts (1), washers (2) and
leakage using soapy water. Reinstall valve cap mounting straps (3).
(1A, Fig. 1) and tighten finger tight.

SM 1205 2-98 3
Steering System - Accumulator
Section 220-0080

SM - 172 5. Insert a suitable wooden dowel through the port

end of cylinder (12) to push out piston (10). Remove
and discard seal rings (7) and wear rings (11) from
FRAME piston (10).

INSPECTION
Numbers in parentheses refer to Fig. 1

1. Wash metal components with a suitable solvent

and thoroughly air dry.

2. Inspect piston (10) for cracks or burrs. Replace

piston (10), if excessively scored or worn.

3. Use an inspection lamp to check the bore of

cylinder (12) for scratches or scoring. Minor nicks,
scratches or light scoring of the bore can be removed
by using crocus cloth. Dress the bore until all
apparent imperfections have been removed. Replace
complete accumulator assembly if inside of cylinder
(12) is excessively scored or worn.
1 - Nut 3 - Mounting Straps
2 - Washer 4 - Accumulator
4. Inspect end cap (4) for damage and replace if
Fig. 3 - Accumulator Installation necessary.

6. Remove accumulator (4) from it's mounting 5. Inspect threads of bolts (8) and threads in cylinder
bracket and move to a clean area for disassembly. (12) for damage. Replace all parts worn or damaged
beyond repair.

DISASSEMBLY
Numbers in parentheses refer to Fig. 1. ASSEMBLY
Numbers in parentheses refer to Fig. 1.

WARNING 1. Lubricate ‘O’ rings (3 & 6), backup ring (5), seal
Accumulators are charged with Nitrogen. The rings (7) and inside of cylinder (12) with hydraulic oil
service pressure is 55 bar (800 lbf/in²) at 21° C prior to assembly.
(70° F). Do not attempt to remove any valves
or fittings until all nitrogen pressure is 2. Install new seal rings (7) and wear rings (11) on
completely relieved to prevent personal injury piston (10). Insert piston (10) into cylinder (12) with
and property damage. seal rings (7) end toward open end of cylinder.

1. Make sure all nitrogen gas has been released 3. Place new backup ring (5) and ‘O’ ring (6) on end
before starting to disassemble the accumulator. cap (4). Oil outside diameter of end cap and insert
Refer to section on 'Discharging Nitrogen'. into cylinder (12).

2. Remove charging valve (1) from shield (2). 4. Align bolt holes in flange of cylinder (12) with those
of end cap (4) and insert bolts (8) and washers (9).
3. Remove shield (2) from end cap (4) by using the Tighten bolts (8) to a torque of 271 - 298 Nm
hex head to unscrew the shield. Remove and discard (200 - 220 lbf ft).
‘O’ ring (3) from end cap (4).
5. Place ‘O’ ring (3) on shield (2) and screw shield (2)
4. Remove bolts (8) and washers (9) from end cap into end cap (4). Tighten shield (2) to a torque of
(4). Remove end cap (4) from cylinder (12) and 102 - 135 Nm (75 - 100 lbf ft).
remove ‘O’ ring (6) and backup ring (5) from end cap
(4). Discard 'O' ring and backup ring. 6. Install charging valve (1). Tighten locknut (1D)

4 SM 1205 2-98
 Steering System - Accumulator
Section 220-0080
clockwise to 11 Nm (100 lbf in) to close charging 4. Install hydraulic line securely to the oil inlet port at
valve. Insert valve core (1B), replace valve cap (1A) bottom of accumulator.
and tighten finger tight.
5. Charge accumulator with Nitrogen gas as
7. Test accumulator hydraulically for leakage or described under the heading 'Charging the
failure at 255 - 276 bar (3 700 - 4 000 lbf/in²). Accumulator' in this section.
Discharge after testing.
6. Check oil level in the steering and brake control
tank and add oil if necessary. Refer to Section
INSTALLATION 220-0040, STEERING AND BRAKE CONTROL TANK
Numbers in parentheses refer to Fig. 3. for correct oil level and, Section 300-0020,
LUBRICATION SYSTEM for oil specification.
Note: Tighten all fasteners to torques listed in
Section 300-0080, STANDARD BOLT AND NUT 7. Remove wheel blocks from all road wheels and
TORQUE SPECIFICATIONS. start the engine. Operate the steering and check
hydraulic lines for leaks. Tighten lines and fittings as
Note: Tighten all hydraulic lines fitted with ORFS required.
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all 8. Recheck oil level in the steering and brake control
'O' rings where used. tank and add oil if necessary.

WARNINGS MAINTENANCE
To prevent personal injury and property Inspect the accumulator regularly for any signs of
damage, be sure wheel blocks, blocking leakage or damage.
materials and lifting equipment are properly
secured and of adequate capacity to do the job Every 500 hours
safely. Check the Nitrogen pre-charge pressure at the
accumulator, prior to checking steering system
1. Using an adequate sling and lifting device, position pressure. Refer to 'Testing Pre-charge Pressure', in
the accumulator on its mounting bracket with oil inlet this section.
port downward and install mounting straps (3).

2. Attach mounting straps (3) securely with washers SPECIAL TOOLS

(2) and nuts (1). Refer to Section 300-0070, SERVICE TOOLS, for
part numbers of special tools referenced in this
3. Remove caps installed at 'Removal' to prevent dirt section and general service tools required. These
entering the hydraulic line and accumulator port. tools are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft lbf in
1 1D Locknut 11 - 100
1 2 Shield 271 - 298 200 - 220 -
1 8 Bolt 102 - 135 75 - 100 -

SM 1205 2-98 5
Steering System - Accumulator
Section 220-0080

AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE

AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE
°C °F bar lbf/in²
-18 0 47.7 692
-12 10 48.8 708
-7 20 49.8 723
-1 30 50.9 738
5 40 52 754
10 50 53 769
16 60 54.1 785
21 70 55 800
27 80 56.2 815
32 90 57.3 831
38 100 58.3 846
43 110 59.4 862
49 120 60.5 877
54 130 61.5 892

WARNING
This truck is equipped with pre-charged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the truck 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.

* * * *

6 SM 1205 2-98
 STEERING SYSTEM - Steering Valve
Section 220-0090

SM - 1560

1 - Cap Screw 6 - Gerotor Gear 11 - Sleeve 16 - Retainer

2 - End Cap 7 - Wear Plate 12 - Spool 17 - 'O' Ring
3 - 'O' Ring 8 - 'O' Ring 13 - Centring Pin 18 - Seal
4 - Valve Housing 9 - Driveshaft 14 - Dust Seal 19 - Bearing Race
5 - Gerotor Housing 10 - Centring Springs 15 - Retaining Ring 20 - Needle Bearing

Fig. 1 - Sectional View of Steering Valve

DESCRIPTION housing (4), gerotor housing (5), gerotor gear (6),

Numbers in parentheses refer to Fig. 1. driveshaft (9), sleeve (11) and spool (12).

Note: The steering valve can be identified as item 5 in There are four ports on valve housing (4) as follows:
Section 220-0000, STEERING SYSTEM
SCHEMATIC. Port 'P' - Supply from accumulator valve
Port 'T' - Return to tank
The steering valve, mounted to the cab firewall and Port 'R' - Cylinder supply for right hand turn
connected to the steering column, controls hydraulic Port 'L' - Cylinder supply for left hand turn
flow in the steering system. The steering valve is of a
closed centre design, which means that the valve does Turning action of the steering wheel is transmitted
not have any flow through it when it is in the neutral or through the steering column to sleeve (11) and
no steering position. driveshaft (9), which is fastened to the sleeve with
centring pin (13). Rotation of driveshaft (9) causes
The main components of the steering valve are valve gerotor gear (6) to rotate in gerotor housing (5). When

SM 2027 7-00 1
Steering System - Steering Valve
Section 220-0090
gerotor gear (6) rotates, oil in gerotor housing (5) SM - 282
pockets (see Fig. 2) is forced out and flows through GEROTOR GEAR GEROTOR
spool (12) and sleeve (11) to the steering cylinder port. HOUSING

Spool (12) contains porting matched to sleeve (11)

and rotates within sleeve (11) to provide directional
control of the oil. See Fig. 3.

OPERATION
Numbers in parentheses refer to Fig. 1.

When the operator turns the steering wheel a certain POCKETS

number of degrees for either a left or right hand turn,
Fig. 2 - Gerotor Gear Set
the movement is transmitted through the steering
column to spool (12). After a minimum rotation of
2.5 degrees, the ports in spool (12) start to align with SM - 283

ports in sleeve (11). When the steering wheel is RIGHT LEFT

rotated to a maximum of 10 degrees the ports are fully SYSTEM TURN TURN
aligned allowing full oil flow. After 10 degrees of travel PRESSURE FEED FEED
in either direction the spool and sleeve rotate as an METER TO
PORTS TANK
assembly through centring pin (13).

Oil from the accumulator valve flows into valve

housing (4) at port 'P' and is channelled through
sleeve (11) and spool (12) to gerotor housing (5).
Porting in gerotor housing (5) permits oil to flow into
pockets formed by gerotor housing (5) and gerotor
gear (6). As spool (12) rotates, driveshaft (9) also
rotates which, in turn, rotates gerotor gear (6) to which
it is splined. When gerotor gear (6) rotates it
progressively forces oil out of the pockets (see Fig. 3 - Porting of Spool and Sleeve
Fig. 2) of gerotor housing (5). The oil is channelled
through sleeve (11) and spool (12) and exits valve the steering valve at port 'L' to the base port of the right
housing (4) through port 'R' for a right hand turn, or steering cylinder and rod port of the left steering cylinder.
port 'L' for a left hand turn. Oil then travels through Exhaust oil from the opposite ends of steering cylinders
steering lines to the steering cylinders. flows through port 'R' in the steering valve and exits
through port 'T' to tank.
As the steering cylinder pistons move, oil forced out of
the steering cylinders returns to valve housing (4). The Refer to Fig. 5, for right turn. As the steering column is
return oil passes through valve sleeve (11) and spool turned, oil from the accumulator valve is directed
(12) and exits through port 'T' to tank. through sleeve (11) and spool (12) to the metering
section of the steering valve. Discharge from the
When the steering effort is released, centring springs metering section exits the steering valve at port 'R' to
(10) which were put under tension by the rotation of the base port of the left steering cylinder and rod port
spool (12), force sleeve (11) to rotate back to its of the right steering cylinder. Exhaust oil from the
original position. This puts the ports out of alignment opposite ends of steering cylinders flows through
and stops pump oil flow to the steering cylinders. The port 'L' in the steering valve and exits through port 'T'
vehicle stops turning further but will hold the present to tank.
turning radius until spool (12) is rotated past the
2.5 degree minimum. Refer to Fig. 6 for steering valve operating in the
neutral position. In the neutral circuit, or non-steering
Refer to Fig. 4, for left turn. As the steering column is position of the steering valve, spool (12) and sleeve
turned, oil from the accumulator valve is directed through (11) are held in the proper relative position by centring
sleeve (11) and spool (12) to the metering section of the springs (10). These spring sets maintain a small
steering valve. Discharge from the metering section exits preload force just adequate to re-centre the valve at

2 SM 2027 7-00
 Steering System - Steering Valve
Section 220-0090

SM - 2532 REMOVAL
Numbers in parentheses refer to Fig. 7.
SUPPLY TO RETURN FROM
CYLINDERS CYLINDERS
WARNINGS
L R
5 Dangerous pressure. To prevent personal injury
and property damage, turn steering wheel
several times in each direction to relieve
pressure in the system.
T P To prevent personal injury and property
RETURN
TO TANK
SUPPLY FROM
damage, be sure wheel blocks, blocking
ACCUMULATOR VALVE materials and lifting equipment are properly
secured and of adequate capacity to do the job
Fig. 4 - Oil Flow for Powered Left Turn
safely.

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

SM - 2533 parking brake and switch off the engine.

RETURN FROM SUPPLY TO 2. Turn steering wheel in both directions several times
CYLINDERS CYLINDERS to relieve pressure in accumulator and steering
system. Block all road wheels.
L R
5
3. Remove bolts (2) and washers (3) securing cover
(1). Remove cover (1) from the truck.

4. Before removal of steering valve (9), clean the valve

T P and connecting lines around it to prevent entry of dirt.
RETURN
TO TANK
SUPPLY FROM
ACCUMULATOR VALVE
5. Ensure all hydraulic lines connected to steering
valve (9) are identified for ease of installation and, with
suitable containers available to catch spillage,
Fig. 5 - Oil Flow for Powered Right Turn
disconnect hydraulic lines. Cap all lines and plug all
ports to prevent entry of dirt.
SM - 2534
6. Support steering valve (9) and remove bolts (11)
and lockwashers (12) securing steering valve (9) to
cab firewall.
L R
5
7. Carefully remove steering valve (9) until steering
column shaft assembly (13) is free from steering valve
(9) and the cab firewall. Move steering valve (9) to a
clean area for disassembly and discard gasket (10).
T P

SUPPLY FROM DISASSEMBLY

ACCUMULATOR VALVE
Numbers in parentheses refer to Fig. 8, unless
otherwise specified.

Fig. 6 - Steering Valve In 'Neutral' Position Note: Although all illustrations do not show the
steering valve in a vice, it is recommended that you
any time it is brought against a travel limit and
released. In this way the system is protected from
becoming overheated when the truck is parked
temporarily with the power steering circuit loaded.

SM 2027 7-00 3
Steering System - Steering Valve
Section 220-0090

SM - 2535

31

2
3 7 30
1 8 29
28

26
27 20
19
16 18
6 14
27
17
26
25
24
24
5
15
23
21
14
22
9
10

13
4
3
2
12 11
1 - Cover 9 - Steering Valve 17 - Bushing
2 - Bolt 10 - Gasket 18 - Hardened Washer 25 - Nut
3 - Washer 11 - Bolt 19 - Washer 26 - Bolt
4 - Nut 12 - Lockwasher 20 - Circlip 27 - Bearing
5 - Bracket Assembly 13 - Shaft Assembly 21 - Gas Strut 28 - Bolt
6 - Bracket 14 - Bearing 22 - Bolt 29 - Washer
7 - Bolt 15 - Pivot Fork Assembly 23 - Bolt 30 - Nut
8 - Lockwasher 16 - Fork Assembly 24 - Washer 31 - Steering Wheel & Cap
Fig. 7 - Exploded View of Steering Valve Installation

keep it in a vice during disassembly. Follow the 7. Remove valve housing (4) from the vice and place
clamping procedures explained throughout the text. on a clean cloth to protect the surface finish. Using
suitable pliers remove retaining ring (15) from valve
1. Place steering valve assembly in a soft jawed vice, housing (4).
end cap (2) up.
8. Position 2 flat blade screwdrivers 180° apart in groove
2. Remove cap screws (1) securing end cap (2), of retainer (16) and pry retainer (16) assembly out of
gerotor housing (5) and wear plate (7) to valve housing valve housing (4). Push spool (12) down when removing
(4). Remove end cap (2) from valve retainer (16) from valve housing (4). Be careful not to
housing (4) and discard 'O' ring (3). damage groove of retaining ring (15).

3. Remove gerotor housing (5) and gerotor gear (6) 9. Remove and discard 'O' ring (17) and seal (18) from
from valve housing (4). Remove and discard 'O' ring retainer (16).
(8) from gerotor housing (5).
10. Using a thin blade screwdriver, pry dust seal (14)
4. Remove wear plate (7) from valve housing (4). from retainer (16). Discard dust seal (14).

5. Remove and discard 'O' ring (8) from valve 11. Remove bearing races (19) and needle bearing
housing (4). (20) from spool (12) and sleeve (11) assembly.

6. Remove driveshaft (9) from valve housing (4).

4 SM 2027 7-00
 Steering System - Steering Valve
Section 220-0090

SM - 1552

P
R
T
L

11
12
13
19
20
19 1
18 2
17
16 3
15 5
14 6
8
7
8
4
9

10

1 - Cap Screw 6 - Gerotor Gear 11 - Sleeve 16 - Retainer

2 - End Cap 7 - Wear Plate 12 - Spool 17 - 'O' Ring
3 - 'O' Ring 8 - 'O' Ring 13 - Centring Pin 18 - Seal
4 - Valve Housing 9 - Driveshaft 14 - Dust Seal 19 - Bearing Race
5 - Gerotor Housing 10 - Centring Springs 15 - Retaining Ring 20 - Needle Bearing

Fig. 8 - Exploded View of Steering Valve

SM - 614 12. Remove spool (12) and sleeve (11) assembly from
14 hole end of valve housing (4), as shown in Fig. 9.

Note: Avoid binding spool (12) and sleeve (11) in

valve housing (4). Rotate spool (12) and sleeve (11)
assembly slowly when removing from valve housing
(4). Keep centring pin (13) in a nearly horizontal
position when removing spool (12) and sleeve (11)
assembly. See Fig. 9. If centring pin (13) becomes
vertical during removal, it may drop from spool (12)
and sleeve (11) assembly into an oil passage within
valve housing (4).
4 - Valve Housing
11 - Sleeve
12 - Spool 13. Remove centring pin (13) from spool (12) and
13 - Centring Pin sleeve (11) assembly, as shown in Fig. 9.
Fig. 9 - Removing Spool and Sleeve Assembly

SM 2027 7-00 5
Steering System - Steering Valve
Section 220-0090
14. Remove spool (12) from sleeve (11) carefully. SM - 297
Remove centring springs (10) from spool (12) by
hand. See Fig. 10.

INSPECTION
1. Clean all metal parts in a suitable solvent and blow
dry with compressed air. Do not wipe dry with cloth or
paper towel as lint or other matter may get into the
hydraulic system and cause damage.

2. Check all mating surfaces and replace any parts that

have scratches or burrs that could cause leakage.
Fig. 10 - Separating Spool and Sleeve
3. Do not use course grit or try to file any metal parts.
SM - 615
Note: Replace all 'O' rings and seals with new 'O' rings
and seals at 'Assembly'. Lubricate all 'O' rings and
seals, except seal (18), with a petroleum jelly. SPRING SLOTS

ASSEMBLY
Numbers in parentheses refer to Fig. 8, unless
otherwise specified.

Note: Tighten all fasteners without special torques

specified to standard torques listed in Section 11 - Sleeve
300-0080, STANDARD BOLT AND NUT TORQUE 12 - Spool
SPECIFICATIONS.
Fig. 11 - Separating Spool and Sleeve

1. Insert control end of spool (12) in sleeve (11). Assemble

spool (12) and sleeve (11) carefully so that centring SM - 301

spring (10) slots line up at the same end. See Fig. 11.
Rotate spool (12) while sliding parts together.

Note: Because of close tolerance between spool (12)

and sleeve (11) do not use force when rotating parts
together. Be careful not to burr spool (12). Test for free
rotation. Spool (12) should rotate smoothly in sleeve (11)
with finger tip force applied at splined end.

2. Bring spring slots of spool (12) and sleeve (11) in

Fig. 12 - Installing Centring Springs
line and stand both parts on end of the bench. Insert
spring installation tool through spring slots of both
parts. push into spool (12) and sleeve (11) assembly. Keep
pressure on spring ends when withdrawing installation
Note: Spring installation tool can be fabricated as tool, push forward on centring springs (10) at the same
shown in Fig. 24. time.

3. Position two sets (three each) of centring springs (10) 5. Centre centring springs (10) in the parts so that they
on the bench so that the extended edge is down and push down evenly and are flush with upper surface of
arched centre section is together. In this position, spool (12) and sleeve (11).
enter one end of entire spring set into spring
installation tool, as shown in Fig. 12. Note: If centring springs (10) are to be installed
without the aid of an installation tool, the following
4. Compress extended end of centring springs (10) and procedure should be carried out:

6 SM 2027 7-00
 Steering System - Steering Valve
Section 220-0090

SM - 1559 a. Insert one centring spring, with extended edge

down, in spring slot of spool (12). Raise spool (12)
from sleeve (11) slightly for more clearance.

b. Insert 1 centring spring (10) opposite spring

located in slot of spool (12). Make sure centre
sections of both springs are together, and that the
13 extended edges of the springs are down.
13 - Centring Pin

Fig. 13 - Installing Centring Pin c. Push one set of two centring springs (10) between
the two springs in spool (12).

SM - 626 d. Push remaining set of two centring springs (10)

opposite the three springs in spool (12).

e. Push spool (12) in sleeve (11) until centring

springs seat flush with top and sides of sleeve (11).

6. Install centring pin (13) through spool (12) and

sleeve (11) assembly until centring pin (13) becomes
flush at both sides of sleeve (11). See Fig. 13.

7. Position spool (12) and sleeve (11) assembly so

that the splined end of spool (12) enters the 14 hole
end of valve housing (4) first. See Fig. 14.
Fig. 14 - Installing Spool and Sleeve Assembly
Note: Be extremely careful that the parts do not cock
SM - 1558 out of position while entering. Push parts gently into
place with slight rotating action. Bring spool (12) and
sleeve (11) assembly entirely within valve housing (4)
bore until the parts are flush at the meter end, or 14
hole end, of valve housing (4). Do not pull spool (12)
and sleeve (11) assembly beyond this point to prevent
centring pin (13) from dropping into the discharge
groove of valve housing (4). With spool (12) and
sleeve (11) assembly in this flush position, check for
free rotation within valve housing (4) by turning with
4 - Valve Housing light finger force at the splined end.
19 - Bearing Races
20 - Needle Bearing
8. Place valve housing (4) on a clean towel. Install two
Fig. 15 - Needle Bearing Installation bearing races (19) and needle bearing (20) in the
order shown in Fig. 15.
SM - 618
9. Install dust seal (14) in retainer (16), flat or smooth
side of dust seal (14) must face down toward retainer
(16), as shown in Fig. 17.

10. Install new seal (18) and 'O' ring (17) in retainer
(16), as shown in Fig. 17.

Note: Do not use any seal that falls freely into the
pocket of retainer (16).
4 - Valve Housing
15 - Retaining Ring
16 - Retainer 11. Install retainer (16) assembly over spool (12) end
with a twisting motion, as shown in Fig. 16. Tap
Fig. 16 - Retainer and Retaining Ring Installation retainer (16) in valve housing (4) with a rubber hammer

SM 2027 7-00 7
Steering System - Steering Valve
Section 220-0090

SM - 1554 SM - 621
PORT FACE

PIN PARALLEL
WITH PORT FACE
14 - Dust Seal
15 - Retaining Ring 17 - 'O' Ring 9 - Driveshaft
16 - Retainer 18 - Seal 13 - Centring Pin

Fig. 17 - Seal and 'O' Ring Locations Fig. 19 - Aligning Driveshaft With Centring Pin

SM - 620 GEROTOR SM - 622

STAR VALLEY

PORT FACE

4 - Valve Housing
8 - 'O' Ring 9 - Driveshaft
13 - Centring Pin
Fig. 18 - Valve housing Clamped in Vice Fig. 20 - Aligning Valve Housing and Gerotor Assembly

to seat. Make sure retainer (16) is flush against the SM - 623

face of bearing race (21).

12. Using suitable pliers install retaining ring (15) in

valve housing (4), as shown in Figs. 16 & 17. After
installing, tap on retaining ring (15) to seat properly in
its groove.
5 - Gerotor Housing
13. Clamp valve housing (4) in vice, as shown in 6 - Gerotor Gear
Fig. 18. Clamp lightly on edges of mounting area 8 - 'O' Ring
taking care not to overtighten. Install new 'O' ring (8) in
valve housing (4). Fig. 21 - 'O' Ring and Gerotor Gear Installation

Note: Check to ensure spool (12) and sleeve (11) are housing (4).
flush with, or slightly below, the 14 hole surface of
valve housing (4). Clean the upper surface of valve 15. Rotate spool (12) and sleeve (11) assembly until
housing (4) by wiping with the palm of clean hand. centring pin (13) is parallel with port face, see Fig. 19.
Clean each of the flat surfaces of the meter section Install driveshaft (9) in valve housing (4) making sure it
parts in a similar way when ready for re-assembly. Do engages with centring pin (13). To assure proper
not use cloth or paper to clean surfaces. alignment, mark driveshaft (9) as shown in Fig. 20.

14. Install wear plate (7) on valve housing (4). Align 16. Install new 'O' ring (8) and gerotor gear (6), in
bolt holes in wear plate (7) with tapped holes in valve gerotor housing (5). See Fig. 21.

8 SM 2027 7-00
 Steering System - Steering Valve
Section 220-0090

SM - 624

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

1. Make certain, area of installation is clean.

2. Install new gasket on steering valve (9) and

1 - Cap Screw
2 - End Cap 4 - Valve Housing carefully raise steering valve (9) until the splined shaft
3 - 'O' Ring 5 - Gerotor Housing of steering column shaft assembly (13) is engaged in
the steering valve through the cab firewall.
Fig. 22 - End Plate Installation
3. Secure steering valve (9) to cab firewall with bolts
SM - 313
(11) and lockwashers (12).

4. Remove plugs from steering valve ports and caps

from steering lines and install steering lines to steering
valve (9), as identified at removal.

5. Check oil level in the steering and brake control tank

and add oil if necessary. Refer to Section 220-0040,
STEERING AND BRAKE CONTROL TANK for correct
oil level and, Section 300-0020, LUBRICATION
Fig. 23 - Cap Screw Tightening Sequence
SYSTEM for oil specification.

17. With seal side of gerotor housing (5) toward wear 6. Remove wheel blocks from all road wheels and start
plate (7), align gerotor gear (6) valleys on driveshaft the engine. Operate the steering and check hydraulic
(9), as shown in Fig. 20. Note the parallel relationship lines for leaks. Tighten lines and fittings as required.
of reference lines A, B, C & D in Fig. 20. Align cap
screw (1) holes without disengaging gerotor gear (6) 7. Recheck oil level in the steering and brake control
from driveshaft (9). tank and add oil if necessary.

18. Install new 'O' ring (3) in end cap (2) and install 8. Secure cover (1) to the truck with bolts (2) and
end cap (2) on gerotor housing (5), as shown in Fig. 22. washers (3).

19. Align cap screw (1) holes and install seven dry cap
FILLING AND BLEEDING THE STEERING
screws (1) in end cap (2). Pre-tighten cap screws (1)
to 20 - 27 Nm (15 - 20 lbf ft) then tighten to a torque of SYSTEM
100 Nm (75 lbf ft), in the sequence shown in Fig. 23. 1. Fill steering and brake control 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
INSTALLATION prevent air entering the system.
Numbers in parentheses refer to Fig. 7.
2. Start engine and let it idle. Immediately add oil to the
Note: Tighten all fasteners to standard torques listed steering and brake control tank as required. When no
in Section 300-0080, STANDARD BOLT AND NUT more oil can be added and oil is clear, proceed as
TORQUE SPECIFICATIONS. follows:

Note: Tighten all hydraulic lines fitted with ORFS a. Turn the steering wheel from lock to lock to bleed
connections, as described in Section 220-0000, the air in the steering cylinders and lines.
STEERING SYSTEM SCHEMATIC. Renew all
'O' rings where used. Note: Immediately upon valve spool actuation oil must

SM 2027 7-00 9
Steering System - Steering Valve
Section 220-0090

be added to the steering and brake control tank to Hydraulic Oil

replenish the oil moving into the circuit. The steering system should be kept filled with
hydraulic oil as specified in Section 300-0020,
LUBRICATION SYSTEM.
WARNING
Do not operate the vehicle until all air is bled
from the oil. SPECIAL TOOLS
The special tool for installing the centring springs can
b. When the oil in the tank is clear (not cloudy or be fabricated as shown in Fig. 24. Refer to Section
creamy), the system is free of air. 300-0070, SERVICE TOOLS, for part numbers of
general service tools required. These tools are
Note: Slight creep or drift of the steering wheel is available from your dealer.
normal.
SM - 625

c. Fill steering and brake control tank with hydraulic oil

specified in Section 300-0020, LUBRICATION
SYSTEM. Refer to Section 220-0040, STEERING
AND BRAKE CONTROL TANK, for correct fill level.
Install filler cap on tank.

Note: Break all sharp corners 4 mm (0.015 in)

Fig. 24 - Centring Spring Installation Tool

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
8 1 Cap Screw 100 75

10 SM 2027 7-00
 Steering System - Steering Valve
Section 220-0090

STEERING CONTROL DIAGNOSIS

CONDITION REASON REMEDY
Steering wheel does not centre Binding in steering linkage to valve Align as required
Worn gerotor Replace parts
Broken centring springs Replace centring springs, drain
and flush system
Burrs on sleeve or spool Disassemble and repair or replace
parts
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

* * * *

SM 2027 7-00 11
 STEERING SYSTEM - Double Relief Valve
Section 220-0110

SM - 1326

1 - Valve Body 6 - Spring End 11 - Backup Ring 16 - Valve

2 - Valve 7 - Adjustment Screw 12 - Plug 17 - Valve Seat
3 - Valve Seat 8 - 'O' Ring 13 - Relief Body 18 - Spring
4 - Washer 9 - Backup Ring 14 - Jam Nut 19 - Spring End
5 - Spring 10 - 'O' Ring 15 - 'O' Ring 20 - Adjustment Screw

Fig. 1 - Cutaway View of Double Relief Valve

DESCRIPTION SM - 561

Numbers in parentheses refer to Fig. 1.

STEERING 6 STEERING
A A
The double relief valve can be identified as item 6 in CYLINDER
BASE END
CYLINDER
ROD END
Section 220-0000, STEERING SYSTEM
SCHEMATIC, in this manual. STEERING
B B
STEERING
CYLINDER CYLINDER
ROD END BASE END
Installed in the lines between the steering cylinders
and the steering valve, the double relief valve LEFT TURN RIGHT TURN
relieves shock loads on the steering cylinders by PORT ON PORT ON
STEERING VALVE STEERING VALVE
transferring the excessive pressure applied to the oil
by the road shock, to the opposite end of the Fig. 2 - Double Relief Valve - Valve (16) Activated
cylinders. This shock, if left unchecked, might
damage steering linkage components.
valves in the closed position.
Note: The relief valves are set to open at 172 bar
(2 500 lbf/in²). When oil flowing through valve body (1) at port 'A',
and out of the opposite side exceeds valve (16)
setting, valve (16) is moved off valve seat (17)
OPERATION against the pressure of spring (18). See Fig. 2. As
Numbers in parentheses refer to Fig. 1. Refer to valve (16) moves off valve seat (17), oil flows out of
Figs. 2, 3 and 4 for hydraulic schematics of double port 'B' to the opposite end of steering cylinders. After
relief valve. the road shock has been dissipated, pressure is
reduced and spring (18) seats valve (16) against valve
Note: Fig. 1 shows the double relief valve with both seat (17). See Fig. 3.

SM 1208 2-98 1
Steering System - Double Relief Valve
Section 220-0110
When oil flowing through valve body (1) at port 'B', and SM - 560
out of the opposite side exceeds valve (2) setting,
valve (2) is moved off valve seat (3) against the 6
STEERING A A STEERING
pressure of spring (5). See Fig. 4. As valve (2) moves CYLINDER CYLINDER
BASE END ROD END
off valve seat (3), oil flows out of port 'A' to the
opposite end of steering cylinders. After the road STEERING STEERING
B B
shock has been dissipated, pressure is reduced and CYLINDER CYLINDER
ROD END BASE END
spring (5) seats valve (2) against valve seat (3). See
Fig. 3.
LEFT TURN RIGHT TURN
PORT ON PORT ON
STEERING VALVE STEERING VALVE
REMOVAL
Fig. 3 - Double Relief Valve In Neutral Position

WARNINGS SM - 559
Hydraulic fluid pressure will remain within the
system after engine shutdown. To prevent 6
STEERING A A STEERING
personal injury and property damage, turn CYLINDER CYLINDER
steering wheel several times in each direction BASE END ROD END

to relieve pressure in the system.

STEERING STEERING
B B
CYLINDER CYLINDER
ROD END BASE END
To prevent personal injury and property
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job LEFT TURN RIGHT TURN
PORT ON
PORT ON
safely. STEERING VALVE STEERING VALVE

1. Position the vehicle in a level work area, raise the Fig. 4 - Double Relief Valve - Valve (2) Activated
body and secure in place with the body safety pins.
Apply the parking brake and switch off the engine. and carefully remove adjustment screw (7) from valve
body (1).
2. Turn steering wheel in both directions several times
to relieve any pressure in accumulator and steering
system. Block all road wheels. WARNING
Compressed springs. Use care when removing
3. Before removal of double relief valve from the truck, relief body (13). Springs (5 & 18) are under
clean exterior of the valve and hydraulic oil lines to compression and may spring out of valve body
prevent ingress of dirt. (1) bore, causing personal injury, if
compression is not released carefully.
4. Identify and tag all hydraulic oil lines to aid in
installation and disconnect from double relief valve. 3. Carefully remove relief body (13) assembly from
Cap all lines and plug all ports of the double relief valve body (1). Remove washer (4) and spring end
valve to prevent ingress of dirt. (6) assembly from relief body (13). Remove and
discard 'O' Ring (15) from spring end (6).
5. Remove mounting hardware securing double relief
valve to the truck and move to a clean area for 4. Remove spring (5) from valve body (1).
disassembly.
Note: To remove valve (2) assembly and valve
seat (3) assembly from valve body (1), it is necessary
DISASSEMBLY to turn valve body on its end and tap down on a work
Numbers in parentheses refer to Fig. 1. bench, or other suitable area, to release the parts.

1. If required, remove elbows and tees from double 5. Remove valve (2) assembly from valve body (1).
relief valve and identify to aid in assembly. Remove and discard 'O' Ring (10) and backup
ring (11) from valve (2).
2. Slacken jam nut (14) from adjustment screw (7)
6. Remove valve seat (3) assembly from valve

2 SM 1208 2-98
 Steering System - Double Relief Valve
Section 220-0110
body (1). Remove and discard 'O' ring (8) and backup 6. Repeat steps 1 through 5 to assemble remaining
rings (9) from valve seat (3). valve (16) assembly.

7. Follow steps 1 through 6 to disassemble the 7. If removed, install plugs (12) in valve body (1).
remaining valve (16) assembly.
8. Adjust valve as described under 'Adjustment'.
8. If necessary, remove plugs (12) from valve body (1).
9. If removed, install elbows and tees on double relief
valve as tagged at disassembly.
INSPECTION
Numbers in parentheses refer to Fig. 1.
ADJUSTMENT
Note: There is a seal kit available to replace all of the Numbers and letters in parentheses refer to Fig. 1.
seals in the valve. However, if any of the other items
are damaged the valve assembly should be replaced. SM - 165

Refer to the trucks Parts Book for part number of the NEEDLE
seal kit. VALVE

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

compressed air. PRESSURE
GAUGE
2. Inspect all threaded parts for stripped or damaged
threads.
PUMP
3. Inspect valve body (1) bores, valves (2 & 16) and
valve seats (3 & 17) for excessive wear, scratches DOUBLE
or deep grooves. If either valve body (1), valves (2 & 16) RELIEF
or valve seats (3 & 17) are damaged beyond repair, VALVE
the complete valve assembly must be replaced.
TANK TANK
4. Inspect springs (5 & 18) for breaks, lack of tension Fig. 5 - Setup for Adjusting Double Relief Valve
or other damage. Replace if required.

Note: Relief pressure setting is 172 bar (2 500 lbf/in²).

ASSEMBLY
Numbers in parentheses refer to Fig. 1. 1. Using adjusting setup as shown in Fig. 5, install a
0 - 207 bar (0 - 3 000 lbf/in2) pressure gauge in one
1. Install new 'O' ring (8) and backup rings (9) on valve side of port 'B' and a tee in the opposite side of port 'B'.
seat (3). Install new 'O' ring (10) and backup ring (11)
on valve (2). Refer to Fig. 1. 2. Attach a controllable oil source to one leg of the tee.

2. Install valve seat (3) assembly in valve body (1) and 3. Install a needle valve in the third leg of the tee,
lightly tap home with a pin punch. Install valve (2) with a line returning from needle valve to oil
assembly in valve body (1). reservoir.

3. Install new 'O' ring (15) on spring end (6) and install 4. Install a plug in one side of port 'A' and a line
spring end (6) assembly in relief body (13). Install returning to oil reservoir in the opposite side of port 'A'.
spring (5) in relief body (13).
5. Open the needle valve and start the pump.
4. Install washer (4) on relief body (13) and thread Gradually close the needle valve. If oil is discharged
relief body (13) assembly into valve body (1). Tighten through port 'A' before relief pressure is reached, turn
relief body (13) to a torque of 60 - 65 Nm (44 - 48 lbf/in2). adjustment screw (7) in until discharge stops.
Continue closing the needle valve and turning
5. Thread adjustment screw (7) into valve body (1). Do adjustment screw (7) until discharge through port 'A'
not secure with jam nut (14) until after pressure setting occurs at relief pressure.
adjustment is complete.

SM 1208 2-98 3
Steering System - Double Relief Valve
Section 220-0110
If oil is discharged through port 'A' only when relief secure in place with mounting hardware.
pressure is exceeded, turn adjustment screw (7) out
and open needle valve slightly. Continue opening 2. Remove blanking caps from hydraulic lines and
needle valve and turning adjustment screw (7) out install lines to double relief valve as identified during
until discharge through port 'A' occurs at relief pressure. removal.

6. Repeat Steps 1 through 5 on opposite end of 3. Check oil level in the steering and brake control tank
double relief valve. Adjust adjustment screw (20) so and add oil if required. Refer to Section 220-0040,
discharge through port 'B' occurs at relief pressure. STEERING AND BRAKE CONTROL TANK for
correct fill level, and, Section 300-0020,
7. Re-check both relief settings before securing LUBRICATION SYSTEM for oil specification.
adjustment screws (7 & 20) with jam nuts (14).
4. Start the engine and bring hydraulic oil to operating
8. Re-check both relief settings before installing temperature.
double relief valve assembly on the truck.
5. Check double relief valve and hydraulic line
connections for leaks and tighten as required.
INSTALLATION
Note: Tighten all fasteners to standard torques listed 6. Remove body safety pins and lower the body to the
in Section 300-0080, STANDARD BOLT AND NUT frame. Remove wheel blocks.
TORQUE SPECIFICATIONS.

Note: Tighten all hydraulic lines fitted with ORFS SPECIAL TOOLS
connections, as described in Section 220-0000, There are no special tools required for procedures
STEERING SYSTEM SCHEMATIC. Renew all outlined in this section. Refer to Section 300-0070,
'O' rings where used. SERVICE TOOLS, for part numbers of general
service tools required. These tools are available from
1. Make certain, area of installation is clean and your dealer.
position double relief valve on mounting bracket and

* * * *

4 SM 1208 2-98
 STEERING SYSTEM - Steering Cylinder and Linkage
Section 220-0120

SM - 2536

34
35 39
15
45
16 17 32
10 18 44
19 43
14
38 31

14 37
49
A
8 36
24 34
A
14 46
35
40 39
11 45
FRONT
26
10 33
25
14
11 41 27 38
42
13 37
47
30 28
9 12 36

15 48
40
A 22
47 29
23 7
5,6

1 - Spindle Assembly - LH
2 - Spacer 17 - Bolt 41 42
3 - Spindle Assembly - RH 18 - Lockwasher 1,3
4 - Spacer 19 - Plate
5 - Steering Arm - LH 20 - Cotter Pin 2,4 21 20
6 - Steering Arm - RH 21 - Castle Nut
7 - Bolt 22 - Seal
8 - Bellcrank 23 - Plug 32 - Rod End 41 - Castle Nut
9 - Pin 24 - Bolt 33 - Rod End 42 - Cotter Pin
10 - Bushing 25 - Retainer Ring 34 - Bolt 43 - Bolt
11 - Thrust Washer 26 - Plate 35 - Washer 44 - Nut
12 - Locking Pin 27 - Bushing 36 - Stud 45 - Plug
13 - Nut 28 - Ball Pin 37 - Bearing 46 - Lockwasher
14 - Lube Fitting 29 - Steering Cylinder 38 - Retainer Ring 47 - Spacer
15 - Expansion Plug 30 - Lube Fitting 39 - Plate 48 - Lube Fitting
16 - Anchor Pin 31 - Tie Rod 40 - Seal 49 - Mounting Bracket

Fig. 1 - Layout of Steering Cylinder and Linkage

DESCRIPTION chassis and piston rod ends are connected to steering

Numbers in parentheses refer to Fig. 1. arms (5 & 6). Cylinder mounting of the base end to the
chassis is by anchor pin (16) secured by plate (19),
The steering cylinders can be identified as item 7 in bolts (17) and lockwashers (18). Cylinder mounting of
Section 220-0000, STEERING SYSTEM SCHEMATIC. the piston rod end is by ball pin (28) secured in piston
rod eye and secured to steering arms (5 & 6) by castle
There are two single stage, double acting steering nuts (21) and cotter pins (20).
cylinders (29) installed on the machine. These exert
the necessary hydraulic force on the steering linkage The mechanical steering linkage is adjustable to
to pivot the front wheels. Single stage, double acting provide correct front end alignment and comprises of
means that the piston rod can have oil applied to either two tie rod assemblies (31) connected between
side, extending or retracting the piston rod. bellcrank (8) and steering arms (5 & 6). Rod end
assemblies (32 & 33) are secured to steering arms
Steering cylinder (29) base ends are connected to the (5 & 6) by castle nuts (41) and cotter pins (42).

SM 2028 R1 08-03 1
Steering System - Steering Cylinder and Linkage
Section 220-0120

REMOVAL Steering Linkage

Numbers in parentheses refer to Fig. 1. 1. Remove cotter pins (42) from studs (36) and
remove castle nuts (41).

WARNINGS 2. With suitable lifting equipment, remove tie rod (31)

To prevent personal injury and property assembly from steering arm (5) and bellcrank (8).
damage, turn steering wheel several times in Remove seals (40) and place tie rod (31) assembly in
each direction to relieve pressure in the a clean work area for disassembly.
steering accumulator.
3. Using suitable lifting equipment, support steering
To prevent personal injury and property arm (5) and remove bolts (7) securing steering arm (5)
damage, be sure wheel blocks, blocking to the spindle. Remove steering arm (5).
materials and lifting equipment are properly
secured and of adequate capacity to do the job 4. Repeat steps 1 through 3 to remove the opposite tie
safely. rod (31) assembly and steering arm (6).

1. Position the vehicle in a level work area, be sure the 5. Break tack welds around expansion plugs (15) and
body is completely lowered, apply the parking brake remove expansion plugs from bellcrank housing.
and switch off the engine.
6. Remove nut (13) from locking pin (12) and, using
2. Turn steering wheel in both directions several times a mild steel drift, tap locking pin (12) out from bellcrank
to relieve pressure in accumulator and steering (8).
system. Block all road wheels.
7. Using suitable lifting equipment, support bellcrank
(8) and, using a mild steel drift (slightly less than
Steering Cylinder 75 mm (3 in) in diameter), drive pin (9) from the
1. Support steering cylinder (29) with suitable blocks bellcrank housing and bellcrank (8).
or lifting device.
8. Remove bellcrank (8) and thrust washers (11) from
2. Ensure all hydraulic lines connected to steering the bellcrank housing.
cylinders (29) are identified for ease of installation and
with suitable containers available to catch spillage, 9. If bushings (10) are to be replaced, use a mild steel
disconnect hydraulic lines. Cap all lines and ports to drift (slightly more than 75 mm (3 in) in diameter) and
prevent entry of dirt. drive bushings out of the bellcrank housing.

3. Remove cotter pin (20) and castle nut (21) from ball Note: If removing welds using an air arc, follow the
pin (28) assembly at rod end of steering cylinder (29). procedures outlined for 'Welding' in Section 100-0010,
CHASSIS, HOOD AND FENDERS.
4. Remove bolts (17), lockwashers (18) and plate (19)
from anchor pin (16) at base end of steering cylinder 10. If one or both steering stops are damaged they
(29). Remove anchor pin (16) and carefully lift steering can be removed by using an air arc to break the
cylinder (29) from bellcrank (8) housing and steering welds.
arm (5). Spacers (47) will be removed with steering
cylinder (29). Remove seal (22) from steering arm (5)
ball joint bore. DISASSEMBLY

5. Drain hydraulic oil from steering cylinder (29) Tie Rod Assembly
assembly and place in a clean work area for disassembly. Numbers in parentheses refer to Fig. 1.

6. Repeat steps 3 through 5 to remove opposite Note: To aid in assembly and installation, record
steering cylinder (29) from bellcrank (8) and steering assembled length of tie rod (29) assembly for
arm (6). reference.

1. Remove lube fitting (14) and plug (45) from rod

end (32).

2 SM 2028 R1 08-03
 Steering System - Steering Cylinder and Linkage
Section 220-0120
2. Place tie rod (31) assembly in a vice, or similar 6. Remove and discard backup ring (5) and 'O' ring (6)
holding device, and remove bolts (34) and from outer groove of end cap (4).
lockwashers (35) securing plate (39) to rod end (32).
Remove plate (39). 7. Press piston rod (1) out of end cap (4).

3. Pry retainer ring (38) out of rod end (32). 8. Remove and discard wiper (2) and seal (3) from
inside groove of end cap (4).
4. Turn tie rod (31) in vice so that the threaded end of stud
(36) points upwards. Using a soft faced hammer, tap stud 9. If necessary, remove snap rings (12) and press
(36) out of rod end (32) and remove bearing (37). bushing (13) out of tube (11) eye.

5. Repeat steps 2 through 4 to disassemble rod end 10. Remove lube fitting (16) from base end of tube (11).
(33) of tie rod (31).

6. Loosen nuts (44) and bolts (43) and unscrew rod INSPECTION
ends (32 & 33) from tie rod (31). 1. Clean all metal parts of the steering cylinder in a
suitable solvent and dry with clean, lint-free cloths.
Make certain all cylinder ports are free of dirt or
Steering Cylinder - Piston Rod End contamination.
Numbers in parentheses refer to Fig. 1.
2. Check cylinder tube and outer diameter of piston for
1. Remove lube fitting (48) and plug (23) from piston scratches, cracks, or other signs of damage. Use a
rod end of steering cylinder (29). fine stone to remove scratches or ridges. Replace
these components, if defects cannot be corrected.
2. Place steering cylinder (29) assembly in a vice, or
similar holding device, and remove bolts (24) and 3. Inspect piston rod for distortion, cracks or other
lockwashers (46) securing plate (26) to piston rod end. defects. Replace piston rod if defective area is
Remove plate (26). irreparable.

3. Pry retainer ring (25) out of the piston rod eye. 4. Check bushings for wear and replace if required.

4. Turn steering cylinder (29) in vice so that the

threaded end of ball pin (28) points upwards. Using a ASSEMBLY
soft faced hammer, tap ball pin (28) out of piston rod Note: Tighten all fasteners without special torques
eye and remove bushing (27). specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
Steering Cylinder
Numbers in parentheses refer to Fig. 2.
Steering Cylinder
1. Clean outer surfaces of steering cylinder assembly Numbers in parentheses refer to Fig. 2.
with a suitable cleaning solvent to remove dirt and
grease. Note: To facilitate assembly procedure, apply a light
coating of hydraulic oil to all components as they are
2. Remove bolts (10) securing end cap (4) to tube (11). assembled. Make sure that all work is carried out in a
clean area.
3. Pull end cap (4), piston rod (1) and piston (7) out of
tube (11) as an assembly. 1. Insert a new seal (3) and wiper (2) to inner grooves
of end cap (4). Position a new backup ring (5) and 'O'
4. Position eye end of piston rod (1) in a soft-jawed ring (6) into outer groove of end cap (4).
vice and remove nut (9).
2. Press end cap (4) assembly into position on piston
5. Pull piston (7) assembly off piston rod (1). Remove rod (1).
and discard piston rings (8) from piston (7).
3. Position two new piston rings (8) on piston (7) and
slide the piston assembly onto piston rod (1) until it

SM 2028 R1 08-03 3
Steering System - Steering Cylinder and Linkage
Section 220-0120

SM - 2537

14
7
8

15

11
2
3 9

16

10 12

5
13
6
12

1 - Piston Rod 5 - Backup Ring 9 - Nut 13 - Bushing

2 - Wiper 6 - 'O' Ring 10 - Bolt 14 - Pipe Plug
3 - Seal 7 - Piston 11 - Tube 15 - Lube Fitting
4 - End Cap 8 - Piston Ring 12 - Snap Ring 16 - Lube Fitting

Fig. 2 - Exploded View of Steering Cylinder

bottoms against the shoulder. Screw nut (9) onto Steering Cylinder - Piston Rod End
threaded end of piston rod (1) and tighten to a torque Numbers in parentheses refer to Fig. 1.
of 540 - 610 Nm (400 - 450 lbf ft).
1. Place steering cylinder (29) assembly in a vice, or
Note: Nut (9) should not be used more than three similar holding device, with tapped holes in piston rod
times. Check nut locking collar condition and replace eye facing up.
the nut if it does not produce a firm locking action on
piston rod threads. 2. Lubricate bushing (27) and ball pin (28) with grease
and tap bushing and ball pin as an assembly into
4. If removed, press bushing (13) into tube (11) eye piston rod eye end of steering cylinder (29).
and secure with snap rings (12).
3. Secure ball pin (28) in place with retainer ring (25).
5. Slide tube (11) onto piston rod (1) assembly and Make sure retainer ring seats properly in piston rod eye.
press tightly into position to end cap (4). Secure end
cap (4) to tube (11) with bolts (10). Tighten bolts (10) 4. Position plate (26) on piston rod end and secure
to a torque of 150 - 165 Nm (110 - 120 lbf ft). with bolts (24) and lockwashers (46).

6. Install lube fitting (16) at base end of tube (11). 5. If removed, install lube fitting (48) and plug (23) in
piston rod end of steering cylinder (29).

4 SM 2028 R1 08-03
 Steering System - Steering Cylinder and Linkage
Section 220-0120

Tie Rod Assembly lube fittings (14) in bellcrank housing.

Numbers in parentheses refer to Fig. 1.
2. Using suitable lifting equipment, install bellcrank (8)
1. Place tie rod (31) in a vice, or similar holding device, between upper and lower bores of the bellcrank
and screw rod ends (32 & 33) onto tie rod (31) until housing with a thrust washer (11) on both sides of
assembled length recorded at disassembly is bellcrank hub. Align pin (9) bores of bellcrank (8) and
obtained. thrust washers (11) with those of the bellcrank
housing.
Note: The assembled length of tie rod (31) is for
reference only. Do not tighten bolts (43) and nuts (44) 3. Install pin (9) through bellcrank housing and
until front end alignment is checked and corrected, bellcrank (8), aligning the slot in pin (9) with locking pin
after installation is complete. (12) hole in bellcrank (8).

2. With tapped holes in rod end (32) facing up, 4. Drive locking pin (12) into bellcrank (8), making sure
lubricate bearing (37) and stud (36) with grease and it seats solidly in its bore. Secure locking pin (12) in
tap bearing and stud as an assembly into rod end (32). bellcrank (8) with nut (13). Tighten nut (13) to a torque
of 245 - 300 Nm (180 - 220 lbf ft).
3. Secure stud (36) in place with retainer ring (38). Make
sure retainer ring seats properly in rod end (32). Note: Prior to welding on the vehicle, follow the
procedures outlined for 'Welding' in Section 100-0010,
4. Position plate (39) on rod end (32) and secure with CHASSIS, HOOD AND FENDERS.
bolts (34) and lockwashers (35).
5. Place expansion plugs (15) into upper and lower
5. Repeat steps 1 through 4 to assemble rod end (33) bores of bellcrank (8) housing and tack weld each
assembly to opposite end of tie rod (31). expansion plug in three places.

6. Install lube fitting (14) and plug (45) in rod end (32). 6. Using suitable lifting equipment, position steering
arm (5) to spindle assembly (1) and secure with
bolts (7).
INSTALLATION
Numbers in parentheses refer to Fig. 1. 7. Install seals (40) on studs (36) and, using suitable
lifting equipment, install tie rod (31) assembly on
Note: Tighten all fasteners without special torques bellcrank (8) and steering arm (5) and secure with
specified to standard torques listed in Section castle nuts (41). Tighten castle nuts (41) to a torque of
300-0080, STANDARD BOLT AND NUT TORQUE 2 035 - 2 300 Nm (1 500 - 1 700 lbf ft).
SPECIFICATIONS.
8. Secure castle nuts (41) to studs (36) with new cotter
Note: Tighten all hydraulic lines fitted with ORFS pins (42).
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all 9. Repeat steps 6 through 8 to install steering arm (6)
'O' rings where used. and opposite tie rod (31) assembly.

10. Adjust tie rod (31) assembly length as described

WARNING under 'Adjustment', with bellcrank (8) centred and the
To prevent personal injury and property vehicle unladen.
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly Note: Prior to welding on the vehicle, follow the
secured and of adequate capacity to do the job procedures outlined for 'Welding' in Section 100-0010,
safely. CHASSIS, HOOD AND FENDERS.

11. If either steering stop was removed, position a new

Steering Linkage steering stop on the chassis and weld in place.
1. If removed, press or drive new bushings (10) into upper Use an E-70 welding rod and build 9 mm (3/8 in) fillet
and lower bores of the bellcrank housing. Be sure the all around steering stop.
13 mm (0.5 in) diameter hole in each bushing is in line with

SM 2028 R1 08-03 5
Steering System - Steering Cylinder and Linkage
Section 220-0120

Steering Cylinder SM - 154

FRONT
1. Position seal (22) on steering arm (5) ball joint bore. OF VEHICLE

2. Position spacers (47) to base end of steering

cylinder (29) and insert the base end of steering
cylinder (29) into the clevis on bellcrank housing.

3. Insert ball pin (28) in steering arm (5) bore and secure
ball pin (28) to steering arm (5) with castle nut (21).
Tighten castle nut (21) to a torque of 4 000 - 4 500 Nm
(3 000 - 3 300 lbf ft) and secure to ball pin (28) with
new cotter pin (20). OF VEHICLE

4. Install anchor pin (16) and plate (19) at base end of

steering cylinder (29) assembly and secure with bolts
(17) and lockwashers (18).
Wheel Alignment (Toe-in) Dimensions
Note: Plate (19) fits into the slot at the end of anchor
pin (16). TYRE TYPE DIMENSION 'Y'
Cross-ply 13 - 19 mm (0.5 - 0.75 in)
5. Repeat steps 1 through 4 to install the opposite
steering cylinder (29) to steering arm (6) and bellcrank Radial 10 - 16 mm (0.38 - 0.62 in)
housing.
Fig. 3 - Plan View of Wheel Alignment
6. Remove blanking caps from hydraulic lines and
cylinder ports and connect hydraulic lines to cylinder Note: Caster and camber are built into the vehicle and
ports, as identified at removal. are not adjustable.

7. Check oil level in the steering and brake control Check for toe-in only when the truck is empty and
tank and add oil if necessary. Refer to Section bellcrank (8) is centred. Use a slide bar attached to the
220-0040, STEERING AND BRAKE CONTROL TANK wheel rim edge to make this check.
for correct oil level and, Section 300-0020,
LUBRICATION SYSTEM for oil specification. If adjustment is necessary, loosen nuts (44) and
bolts (43) at each end of tie rod (31) assemblies. Turn
8. Remove wheel blocks from all road wheels and start tie rods (31) with a pipe wrench until correct toe-in
the engine. Operate the steering and check hydraulic dimension is obtained. Refer to Fig. 3.
lines for leaks. Tighten lines and fittings as required.
When tie rod (31) lengths have been established,
9. Re-check oil level in the steering and brake control secure rod ends (32 & 33) to tie rods (31) with bolts
tank and add oil if necessary. (43) and nuts (44).

ALIGNMENT MAINTENANCE
Numbers in parentheses refer to Fig. 1. Every 50 Hours - Lubricate steering cylinders and
steering pivot pin with grease specified in Section
Correct front end alignment is dependent on three 300-0020, LUBRICATION SYSTEM.
basic fundamentals:

a. Caster - Forward and rearward tilt of the axle SPECIAL TOOLS

assembly. There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
b. Camber - Outward tilt of the top of the front wheels. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
c. Toe-in - Inward turning of the front wheels. dealer.

6 SM 2028 R1 08-03
 Steering System - Steering Cylinder and Linkage
Section 220-0120

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 13 Nut 245 - 300 180 - 220
1 21 Castle Nut 4 000 - 4 500 3 000 - 3 300
1 41 Castle Nut 2 035 - 2 300 1 500 - 1 700
2 9 Nut 540 - 610 400 - 450
2 10 Bolt 150 - 165 110 - 120

* * * *

SM 2028 R1 08-03 7
 STEERING SYSTEM - Accumulator Valve
Section 220-0130

SM - 169

1 - Poppet 6 - Plug 11 - 'O' Ring 16 - Pin

2 - Spring 7 - Quad Ring 12 - Plug 17 - Piston
3 - 'O' Ring 8 - Relief Valve Cartridge 13 - Piston 18 - Spring
4 - Plug 9 - 'O' Ring 14 - 'O' Ring 19 - Filter
5 - 'O' Ring 10 - Backup Ring 15 - Spring 20 - Valve Body

Fig. 1 - Cutaway View of Accumulator Valve

DESCRIPTION Note: Relief valve cartridge (8) can be replaced only

Numbers in parentheses refer to Fig. 1. as an assembly.

The Accumulator Valve can be identified as item 4 in Incorporated in this assembly are three valves; a
Section 220-0000, STEERING SYSTEM check valve, accumulator two-way valve and a
SCHEMATIC, in this manual. system pressure protection valve.

SM 1209 2-98 1
Steering System - Accumulator Valve
Section 220-0130
An accumulator two-way valve (13 thru 17) is located and oil flows to the steering valve through port 'B' and
in the centre portion of the assembly. In the operating to the accumulator through port 'E'. Pressure is
position, engine running and two-way valve energized supplied to pressure switch (8, Figs. 2, 3 & 4) and
(refer to Fig. 2), this valve allows the accumulator to remote diagnostic test point through a tee piece in
retain its pressure. In its non-operating position, port 'G2'. Refer to Fig. 2.
engine shutdown and two-way valve de-energized
(refer to Fig. 3), a controlled bleed-down of the During operation of the machine, transmission pilot
accumulator pressure to the steering and brake pressure through port 'D' keeps the two-way valve
control tank occurs. This bleed-down takes 3 to 5 (13 thru 17) energized (closed). This traps a supply
minutes. of oil in the accumulator.

Relief valve cartridge (8), at the lower portion of the Return oil from the steering valve enters port 'C' and
assembly, is preset to 207 bar (3 000 lbf/in²) and exits through port 'R' to tank.
seated. This valve acts as a backup in the event of a
malfunction of the steering pump compensator valve. Port 'G1' is plugged.
Should the compensator valve allow steering system
pressure to exceed the preset pressure of relief valve Should pressure in any of these circuit lines exceed
cartridge (8), valve will open and relieve excess oil the preset pressure setting on relief valve cartridge
pressure to the steering and brake control tank. Refer (8), the relief valve will open and oil will exit through
to Fig. 4. port 'R' to tank. Refer to Fig. 4.

When engine is shut off, transmission pilot pressure

OPERATION dissipates, and spring (15) shifts the two-way valve
Numbers and letters in parentheses refer to Fig. 1, (13 thru 17) to the de-energised (open) position. This
unless otherwise specified. allows oil to flow back from the accumulator through
port 'E' into an internal passage, past piston (13) and
Oil from the steering pump enters the accumulator exits through port 'R' to tank. Refer to Fig. 3.
valve at port 'A'. This pressure unseats poppet (1)

SM - 1323

SUPPLY TO
RETURN FROM STEERING PRESSURE
STEERING VALVE VALVE TEST POINT

SUPPLY TO
ACCUMULATOR

BRAKE
CIRCUIT
RETURN SUPPLY
TO TANK FROM
PUMP

Fig. 2 - Two-way Valve Energized

2 SM 1209 2-98
 Steering System - Accumulator Valve
Section 220-0130

SM - 1324

PRESSURE
TEST POINT

RETURN FROM
ACCUMULATOR

RETURN
TO TANK

Fig. 3 - Two-way Valve De-energized

SM - 1325

SUPPLY TO
RETURN FROM STEERING PRESSURE
STEERING VALVE VALVE TEST POINT

SUPPLY TO
ACCUMULATOR

BRAKE
CIRCUIT
RETURN
SUPPLY
TO TANK
FROM
PUMP

Fig. 4 - Relief Valve Open

SM 1209 2-98 3
Steering System - Accumulator Valve
Section 220-0130

SM - 170

9 - Filter
10 - Breather
11 - 'O' Ring
12 - Spring
13 - Pin
1 - Relief Valve Cartridge 14 - Quad Ring
2 - 'O' Ring 15 - Piston
3 - 'O' Ring 16 - 'O' Ring
4 - Backup Rings 17 - Plug
5 - Valve Body 18 - Plug
6 - Filter 19 - 'O' Ring
7 - Spring 20 - Spring
8 - Plug 21 - Poppet

Fig. 5 - Exploded View of Accumulator Valve

REMOVAL 4. Disconnect all hydraulic lines from the

accumulator valve and drain oil into a suitable
container. Plug all hydraulic lines and ports of the
WARNINGS accumulator valve to prevent ingress of dirt.
Dangerous pressure. Turn steering wheel
several times in each direction to relieve 5. Remove mounting hardware securing accumulator
pressure in the system. Failure to release valve to the machine. Clean external surface of
pressure as stated can result in personal accumulator valve assembly with a suitable solvent
injury and property damage. and move to a clean area for 'Disassembly'.

To prevent personal injury and property

damage, be sure wheel chocks are properly DISASSEMBLY
secured and of adequate capacity to do the job Numbers in parentheses refer to Fig. 5.
safely.
1. Remove plug (17) and piston (15) from valve body
1. Position the vehicle in a level work area, apply the (5). Remove quad ring (14) from piston (15) and
parking brake and switch off the engine. 'O' ring (16) from plug (17). Discard quad ring (14)
and 'O' ring (16).
2. Turn steering wheel in both directions several
times to release any pressure in accumulator and 2. Remove pin (13), spring (12) and piston (10) from
steering system. Block all road wheels. valve body (5). Remove and discard 'O' ring (11)
from pin (13). Discard spring (12).
3. Clean the accumulator valve and surrounding area.
Identify and tag all hydraulic lines at accumulator valve. 3. Remove plug (18), spring (20) and poppet (21)
from valve body (5). Remove and discard 'O' ring

4 SM 1209 2-98
 Steering System - Accumulator Valve
Section 220-0130
(19) from plug (18). Discard spring (20). (13) assembly in valve body (5). Install new quad ring
(14) on piston (15) and install piston (15) assembly in
4. Clamp valve body (5) in a soft-jawed vice and valve body (5).
remove relief valve cartridge (1) from valve body (5).
Remove and discard backup rings (4), 'O' ring (3) and 5. Install new 'O' ring (16) on plug (17) and install
'O' ring (2) from relief valve cartridge (1). plug (17) in valve body (5).

Note: Do NOT disassemble relief valve cartridge (1) 6. Install new 'O' ring (19) on plug (18) and install
assembly; it is pressure set and sealed at assembly. poppet (21), new spring (20) and plug (18) in valve
If relief valve cartridge (1) is defective, it must be body (5).
replaced with a new one.

5. Remove plug (8), spring (7) and filter (6) from INSTALLATION
valve body (5). Remove breather (9) from valve body Note: Tighten all fasteners to standard torques listed
(5). Discard filter (6), breather (9) and spring (7). in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.

INSPECTION Note: Tighten all hydraulic lines fitted with ORFS

Numbers in parentheses refer to Fig. 5. connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all
1. Clean all parts with a suitable solvent and dry with 'O' rings where used.
compressed air.
1. Install accumulator valve assembly on its
2. Check port threads and make sure they are not mounting bracket and secure with mounting hardware
damaged or stripped. as removed at 'Removal'.

3. Check poppet (21) and seats in valve body (5). 2. Connect all hydraulic lines securely to accumulator
Ensure they are not worn, nicked, cracked or scored. valve as tagged at 'Removal'.

4. Check condition of relief valve cartridge (1). Insert 3. Check the level of oil in the steering and brake
a blunt-nosed drift or punch into relief valve cartridge control tank. Refer to Section 220-0040, STEERING
(1) end and depress the piston. If piston does not AND BRAKE CONTROL TANK. Add oil if low. Use
move freely, or hangs up, replace relief valve oils meeting the specifications outlined in Section
cartridge (1) assembly. Relief valve cartridge (1) 300-0020, LUBRICATION SYSTEM.
assembly should also be replaced if lead seal has
been removed, as the relief valve cartridge (1) 4. Remove wheel chocks, start the engine and slowly
adjustment may not be accurate. operate steering system. Check for correct steering
operation and leaks. Tighten lines and fittings if
necessary and re-check oil level.
ASSEMBLY
Numbers in parentheses refer to Fig. 5.
MAINTENANCE
1. Install new filter (6), new spring (7) and plug (8) in valve Numbers in parentheses refer to Fig. 5.
body (5). Install new breather (9) in valve body (5).
1. Check breather (9) regularly for plugging, due to
2. Place valve body (5) in a soft-jawed vice. Install accumulation of dirt, painting over or plugged with
new 'O' rings (2 & 3) and backup rings (4) on relief tape or other material. Check filter (6) for plugging.
valve cartridge (1). Install relief valve cartridge (1)
assembly in valve body (5). 2. Clean filter (6) and breather (9) with a suitable
cleaning solvent, or if required, replace.
3. Install new 'O' ring (11) on piston (10). Press
piston (10) into its bore in valve body (5). 3. If painting in the area of the accumulator valve is
necessary, be sure to mask breather (9). Be sure to
4. Install new spring (12) on pin (13) and install pin remove all masking tape from breather (9) after painting.

* * * *
SM 1209 2-98 5
 STEERING SYSTEM - Steering Filter
Section 220-0150

SM - 627

1 - Housing 4 - 'O' Ring 7 - Indicator Link

2 - Bowl 5 - Magnets 8 - Visual Indicator 'B' - Outlet Port
3 - Element 6 - Bypass Valve 'A' - Inlet Port 'C' - Bypass Port

Fig. 1 - Elevation and Sectional View of Steering Filter

DESCRIPTION element (3) is clean. Contaminants (dirt) build up

Numbers in parentheses refer to Fig. 1. across element (3) as hydraulic oil passes through the
filter. Pressure drop across the filter increases, as dirt
The steering filter is mounted off the rear left hand build up increases, and is felt across spring loaded
transmission mounting bracket. It is connected in the piston bypass valve (6). Bypass valve (6) is
steering line between the accumulator valve and the mechanically linked to visual indicator (8), see Fig. 2.
steering valve. Movement of the piston in bypass valve (6) is reflected
on visual indicator (8). As dirt build up increases,
The main components of the steering filter are; indicator link (7) will move from the green area into the
housing (1), bowl (2), element (3), magnets (5), yellow area on visual indicator (8). Element (3) should
bypass valve (6) and visual indicator (8). There are
two external ports 'A and 'B' and an internal bypass SM - 628

port 'C' in the steering filter assembly.

OPERATION
Numbers in parentheses refer to Fig. 1.

Hydraulic oil enters inlet port 'A' from the accumulator

valve and passes to the annular area of bowl (2)
outside element (3) and then through element (3) to
outlet port 'B'.
Fig. 2 - Steering Filter Visual Indicator
The pressure drop across the filter is minimal when

SM 1593 12-98 1
Steering System - Steering Filter
Section 220-0150
be changed immediately visual indicator registers in 2. Turn steering wheel in both directions several times
the yellow 'Needs Cleaning' area. to relieve any pressure in accumulator and steering
system. Block all road wheels.
Note: Bypass valve (6) is still not open at this point.
3. Remove hydraulic lines at inlet port 'A' and outlet
Bypass valve (6) starts to open when indicator link (7) port 'B' and drain oil into a suitable container.
passes from the yellow area into the red area on visual
indicator (8). If visual indicator (8) is in the red 'Bypass' 4. Drain hydraulic oil from filter assembly into a
area, bypass valve (6) is open and this allows a suitable container by unscrewing bowl (2) from
certain amount of hydraulic oil to bypass clogged housing (1). Lower bowl (2) vertically to clear element
element (3). (3), which will remain in housing (1), and discard 'O'
ring (4).

MAINTENANCE 5. Dislodge element (3) from its push fit in housing (1)
Numbers in parentheses refer to Fig. 1. and remove carefully.

The steering filter visual indicator (8) should be 6. Remove magnet (5) assembly from element (3) and
checked daily. Element (3) should be changed discard element (3). If necessary, remove hex nut
immediately visual indicator (8) registers in the yellow securing magnets (5) on the post. Clean magnets (5)
area, or every 1 000 hours, whichever comes first. and secure on post with hex nut.

7. Clean housing (1) and bowl (2) thoroughly with a

Changing Filter Element suitable solvent, for installation of new element (3).
Numbers in parentheses refer to Fig. 1.
8. Install magnet (5) assembly in new element (3) and
Note: Tighten all hydraulic lines fitted with ORFS push element (3) into housing (1).
connections, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC. Renew all 9. Install new 'O' ring (4) on bowl (2) and lubricate bowl
'O' rings where used. (2) and housing (1).

10. Screw bowl (2) into housing (1) and torque tighten
WARNINGS to 20 Nm (15 lbf ft).
Dangerous pressure. Turn steering wheel
several times in each direction to relieve 11. Connect inlet and outlet lines to steering filter and
pressure in the system. Failure to release fill hydraulic tank with oil as specified in Section
pressure as stated can result in personal injury 300-0020, LUBRICATION SYSTEM. Refer to Section
and property damage. 220-0040, STEERING AND BRAKE CONTROL
TANK, for correct fill level.
To prevent personal injury and property
damage, be sure wheel blocks are properly 12. Remove wheel blocks and disconnect shipping bar
secured and of adequate capacity to do the job and place in the stowed position. Start engine, check
safely. for correct steering operation and check for leaks.
Tighten lines and fittings, as required.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Note: If there is air in the steering system the system
must be bled, as described in Section 220-0000,
STEERING SYSTEM SCHEMATIC.

SPECIAL TORQUE SPECIFICATIONS TABLE184

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 2 Bowl 20 15

* * * *
2 SM 1593 12-98
 BODY SYSTEM - Body System Schematic
Section 230-0000

DESCRIPTION Body Control Valve (3)

Numbers in parentheses refer to Figs. 2 through 5. Refer to Section 230-0060, BODY CONTROL VALVE.
Also referenced in this section is Manifold Block (4)
The body system schematics primarily cover operation and Pressure Relief Valve (11).
of the body hoist system. However, as the body and
disc brake cooling tank is common to the body hoist Mounted off a bracket located on top of the
and the disc brake cooling circuit, several components transmission, the body control valve is used to direct
of the cooling system are also covered in the hydraulic oil to the body hoist cylinders for raising or
schematics. lowering the body, and, depending on the spool
position, directs oil through manifold block (4) to
A brief description of the individual components shown supplement the OCDB cooling oil flow.
in the body system schematics are listed below.
Detailed service and operating instructions for the Integral of the body control valve body is a four
individual components can be found in their relevant position spool. The four positions of spool (1) are;
component sections in this manual. 'Raise', 'Hold', 'Float' and 'Lower' (power down). The
spool is detented in the 'Hold' position.

Body and Disc Brake Cooling Tank (1) Note: The control lever should be kept in the 'Float'
Refer to Section 230-0040, BODY AND DISC BRAKE position at all times, except when raising or lowering
COOLING TANK. the body.

The body and disc brake cooling tank is the common A pressure relief valve, installed in port 'H', opens
reservoir for the body hoist system and oil cooled disc when pressure in the hydraulic system exceeds 190 bar
brakes (OCDB) cooling oil. It is mounted on the left (2 750 lbf/in2). This allows oil to flow through an
hand frame rail rearwards of the steering and brake internal passage in the valve body and exit at port 'E'
control tank. to manifold block (4). The oil flow is directed through
the manifold block to supplement the OCDB cooling oil.
Tandem Pump (2) The pressure relief valve works in parallel with
Refer to Section 230-0050, TANDEM PUMP. pressure relief valve (11) mounted off the valve body
at port 'F'. Should oil pressure exceed 190 bar
The tandem gear pump, mounted off the engine power (2 750 lbf/in2), the relief cartridge will open and oil will
takeoff, supplies hydraulic oil for operating the body flow through the relief cartridge and exit the relief valve
and cooling the rear disc brake assemblies. body to the body and disc brake cooling tank.

This is a multiple gear type pump consisting of two

separate sections connected together as one Body Cylinder (5)
assembly. Refer to Section 230-0130, BODY CYLINDER.

The front section draws oil from the body and disc There are two body hoist cylinders mounted between
brake cooling tank, then pumps the oil to body control the frame rails. The cylinders are two-stage with power
valve (3) where, depending on spool position, oil flows down in the second stage.
to the body hoist circuit or, with spool in the float
position, flows through manifold block (4) to
supplement the disc brake cooling oil. Manifold Relief Valve (6)
Refer to Section 230-0110, MANIFOLD RELIEF
The rear section draws oil from the body and disc VALVE.
brake cooling tank, then pumps the oil through
manifold block (4) to supply the disc brake cooling The manifold relief valve, mounted off a bracket
circuit. attached to the torque tube, is installed in the body
hoist system to prevent the body from pulling a void in
the body hoist cylinders when dumping unbalanced
loads. The manifold relief valve also provides a means
for return oil from the body lower circuit to return to the
body and disc brake cooling tank. The manifold relief
valve is set at 90 bar (1 300 lbf/in2).

SM 1929 Rev 1 11-00 1

Body System - Body System Schematic
Section 230-0000

Disc Brake Oil Filters (7) Tank Breather (12)

There are two full flow oil filters installed in the Located in the top of the body and disc brake cooling
hydraulic lines between manifold block (4) and disc tank, the breather is common to both the body and
brake oil cooler (8). Internal of the filter housing is a disc brake cooling tank and the steering and brake
relief valve which opens at 1 bar (15 lbf/in²) and allows control tank. The breather allows any air entering the
oil to bypass the filter element when it becomes tanks to be released to atmosphere, preventing a
blocked. The filter indicator should be checked daily, pressure build up in the tank assemblies.
and the element changed when the indicator shows oil
at the replace element level.
Disc Brake Oil Temperature Switch (13)
The disc brake oil temperature switch is installed in the
Disc Brake Oil Cooler (8) disc brake oil return tube to indicate if the disc brake
Refer to Section 210-0050, DISC BRAKE OIL COOLER. cooling oil is overheating. The oil temperature switch
sends a signal to illuminate the warning light on the
The disc brake oil cooler is connected in the hydraulic right hand dash panel when a temperature of 121° C
system between disc brake oil filters (7) and disc (250° F) is reached.
brake assemblies and is used to cool disc brake
cooling oil. The disc brake oil cooler is connected in
the cooling system between the transmission oil cooler Pilot Supply Valve (14)
and engine oil cooler and has a direct supply from the Refer to Section 230-0121, PILOT SUPPLY VALVE.
radiator bottom tank. Refer to Section 210-0000,
COOLING SYSTEM. The pilot supply valve, mounted off the accumulator
mounting bracket on the right hand platform, is located
Note: Oil flow must always flow in the opposite in the hydraulic lines between the steering pump and
direction to coolant flow through disc brake oil cooler. the body control joystick. Intregal of the pilot supply
valve is a restriction valve which steps down the
supply pressure of 159 bar (2 300 lbf/in²) from the
Body Control Joystick (9) steering pump to between 30 bar (435 lbf/in²) and
Refer to Section 230-0081, BODY CONTROL 35 bar (500 lbf/in²). The relief valve is set to open at
JOYSTICK. 40 bar (580 lbf/in²). The pilot supply valve is fitted with
an accumulator, pre-charged with nitrogen, to a
The body control joystick is located in the hydraulic pressure of 13 bar (188 lbf/in²).
lines between the pilot supply valve and the body
control valve. The body control joystick directs the oil
to either side of the body control valve to move the Pressure Test Points
control spool position. Body control joystick sequence, There are five diagnostic pressure test points in the
starting from the rear most position and working body hoist system, as shown in Figs. 2 through 5.
forward are; ‘Raise’, ‘Hold’, ‘Float’ and ‘Lower’ (Power
down). Note: When checking hydraulic pressures the vehicle
should be positioned on a level surface and all road
Note: The body control joystick should be kept in the wheels securely blocked.
‘Float’ position at all times, except when raising or
lowering the body. Test Point A
System Relief Pressure - Located at the diagnostic
test point mounted off the underside of the steering
Relief Valve (10) and brake control tank.
The relief valve is located in the body and disc brake
cooling tank and controls oil pressure in the disc brake The system relief pressure should be 190 bar
cooling circuit. The relief valve is set to open at 3 bar (2 750 lbf/in²), at maximum rev/min and with body
(45 lbf/in²). raised. Refer to Section 230-0060, BODY CONTROL
VALVE.

2 SM 1929 Rev 1 11-00

 Body System - Body System Schematic
Section 230-0000
Test Point B SM - 1335
Spool Actuation Pressure - Raise Side - Located at FITTING NUT
the diagnostic test point mounted off the underside of TUBE
the steering and brake control tank.

Spool in Raise position - Pressure should be

15.9 - 17.8 bar (230 - 258 lbf/in2).

Spool in Hold position - Pressure should be 0 bar

(0 lbf/in2). SLEEVE
'O' RING 'O' RING

Test Point C Fig. 1 - Assembly of Typical ORFS Connector

Spool Actuation Pressure - Lower Side - Located at
the diagnostic test point mounted off the underside of d. Where a tube is fitted, ensure that the connection
the steering and brake control tank. is aligned correctly.

Spool in Lower position - Pressure should be e. Tighten the nut a further 1/4 to 1/2 a turn using the
22.6 - 25.6 bar (328 - 371 lbf/in2). correct size spanner (wrench).

Spool in Float position - Pressure should be f. Check that a satisfactory routing has been achieved.
13 ± 0.5 bar (188 ± 7 lbf/in2).

Test Point D SERVICE TOOLS

Accumulator Pressure - Diagnostic test point located It is recommended that the following tools are used
in a tee installed in port 'PV' of the pilot supply valve. when carrying out pressure or temperature checks
The accumulator pressure should be 13 bar during maintenance procedures. These tools, along
(188 lbf/in²). with other general service tools, are available from
your dealer. Refer to Section 300-0070, SERVICE
Test Point E TOOLS, for part numbers of these tools.
Manifold Relief Valve - Taken from a connector
installed in port 'S' of the manifold relief valve. The
relief pressure should be 90 bar (1 300 lbf/in²), at Multi-gauge
maximum rev/min and with body cylinder extending The multi-gauge is basically four pressure gauges in
through second stage. Refer to Section 230-0110, one. Continuous system pressure readings are
MANIFOLD RELIEF VALVE. indicated on one of three simultaneously reading
gauges through a pressure range of 762 mm (30 in) of
vacuum to 345 bar (5 000 lbf/in2).
'O' RING FACE SEALS (ORFS)
Where hydraulic lines are fitted with ORFS
connections, the following procedure should be Non-contact Infrared Thermometer
carried out during 'Installation'. Refer to Fig. 1. The infrared thermometer can be used to spot heat
problems early in electrical, mechanical and hydraulic
a. Ensure 'O' ring/seal is in place and that joining systems. Hand held and easy to use, you simply aim,
surfaces are clean. If necessary, retain 'O' ring/seal pull the trigger, and read the temperature. Since there
in place with a light coating of grease or vaseline. is no need to touch what you are measuring,
temperatures of hard-to-reach or moving components
b. Initially, the nuts should be tightened by hand. can be taken without getting burned or shocked.

c. Where a hose is fitted, ensure that it is not twisted

or kinked when the nuts are tightened so that it is
allowed to adopt a natural position.

SM 1929 Rev 1 11-00 3

 4

Section 230-0000
Body System - Body System Schematic
SM - 2460A

5 5
D
9

7
6
8 TEST E 14

COMPONENTS
1 - Body and Disc Brake TO OCDB
Cooling Tank COOLING CIRCUIT
2 - Tandem Pump 7
3 - Body Control Valve
4 - Manifold Block STEERING
5 - Body Cylinder CIRCUIT B
6 - Manifold Relief Valve
7 - Disc Brake Oil Filter 3
8 - Disc Brake Oil Cooler HPCO C
9 - Body Control Joystick
10 - Relief Valve 4
11 - Pressure Relief Valve
12 - Tank Breather
13 - Disc Brake Oil Temp Switch
14 - Pilot Supply Valve

COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil 2
Orange - Pilot Pressure 13 A
Yellow - Static Oil 12
1
11

10
SM 1929 Rev 1 11-00

Fig. 2 - Body Hoist System Schematic - Body Control Valve in the 'Hold' Position
SM 1929 Rev 1 11-00
SM - 2460B

5 5
D
9

7
6
8 TEST E 14
COMPONENTS
1 - Body and Disc Brake
TO OCDB
Cooling Tank
COOLING CIRCUIT
2 - Tandem Pump
7
3 - Body Control Valve
4 - Manifold Block
5 - Body Cylinder STEERING
6 - Manifold Relief Valve CIRCUIT B
7 - Disc Brake Oil Filter
8 - Disc Brake Oil Cooler 3

Body System - Body System Schematic

HPCO
9 - Body Control Joystick C
10 - Relief Valve
11 - Pressure Relief Valve 4
12 - Tank Breather
13 - Disc Brake Oil Temp Switch
14 - Pilot Supply Valve

COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
Orange - Pilot Pressure 2
Yellow - Static Oil 13 A
12
1
11

10

Section 230-0000
Fig. 3 - Body Hoist System Schematic - Body Control Valve in the 'Raise' Position
5
 6

Section 230-0000
Body System - Body System Schematic
SM - 2460C

5 5
D
9

7
6
8 TEST E 14
COMPONENTS
1 - Body and Disc Brake TO OCDB
Cooling Tank COOLING CIRCUIT
2 - Tandem Pump 7
3 - Body Control Valve
4 - Manifold Block STEERING
5 - Body Cylinder CIRCUIT B
6 - Manifold Relief Valve
7 - Disc Brake Oil Filter 3
8 - Disc Brake Oil Cooler HPCO
C
9 - Body Control Joystick
10 - Relief Valve 4
11 - Pressure Relief Valve
12 - Tank Breather
13 - Disc Brake Oil Temp Switch
14 - Pilot Supply Valve

COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
Green - Intake Oil
2
Orange - Pilot Pressure 13 A
Yellow - Static Oil
12
1
11

10
SM 1929 Rev 1 11-00

Fig. 4 - Body Hoist System Schematic - Body Control Valve in the 'Float' Position
SM 1929 Rev 1 11-00
SM - 2460D

5 5
D
9

7
6
8 TEST E 14

COMPONENTS TO OCDB
1 - Body and Disc Brake COOLING CIRCUIT
Cooling Tank 7
2 - Tandem Pump
3 - Body Control Valve STEERING
4 - Manifold Block CIRCUIT B
5 - Body Cylinder
*

6 - Manifold Relief Valve

3
7 - Disc Brake Oil Filter

Body System - Body System Schematic

HPCO
*

C
8 - Disc Brake Oil Cooler
9 - Body Control Joystick
*

4
10 - Relief Valve
11 - Pressure Relief Valve
*

12 - Tank Breather
13 - Disc Brake Oil Temp Switch
14 - Pilot Supply Valve

COLOUR CODES
Red - Pressurized Oil
Blue - Exhaust or Return Oil
2
Green - Intake Oil
13 A
Orange - Pilot Pressure
Yellow - Static Oil 12
1
11

10

Section 230-0000
Fig. 5 - Body Hoist System Schematic - Body Control Valve in the 'Lower' Position
7
 BODY SYSTEM - Body and Disc Brake Cooling Tank
Section 230-0040

SM - 2438

24 26,27,28 28
5 1 26
6 27
28

16
11
10
15 30
12
78 9 29
14
13
14
13
26
14
28
4
25
17
2
21
23 19
22 28
31
20 27
32

33 8
7
34
18

3 15

1 - Hydraulic Tank 10 - Plate 19 - Relief Valve 28 - Hardened Washer

2 - Access Cover 11 - Rod 20 - Poppet 29 - Bolt
3 - Access Cover 12 - Wing Nut 21 - Cap 30 - Washer
4 - Plug 13 - Filter Element 22 - Spring 31 - Lockwire
5 - Filler Cap 14 - Gasket 23 - Shim *32 - Adaptor
6 - Gasket 15 - Gasket 24 - Mounting Bracket *33 - Valve
7 - Bolt 16 - Window Nut 25 - Mounting Bracket *34 - Drain Plug Kit
8 - Lockwasher 17 - Drain Plug 26 - Bolt
9 - Bypass Valve 18 - Suction Screen 27 - Nut * - Optional

Fig. 1 - Exploded View of Body and Disc Brake Cooling Tank

DESCRIPTION (OCDB) cooling oil. It is mounted off the LH frame rail

Numbers in parentheses refer to Fig. 1. rearwards of the steering and brake control tank.

The Body and Disc Brake Cooling Tank can be Integral with hydraulic tank (1) assembly are filter
identified as item 1 in Section 230-0000, BODY elements (13) with bypass valve (9), suction screens
SYSTEM SCHEMATIC, in this manual. (18) and window nuts (16). Access covers (2 & 3)
give easy access to replace filter elements (13) and
The hydraulic tank (1) is the common reservoir clean suction screens (18).
for the body hoist system and oil cooled disc brakes

SM 1928 R1 08-03 1
Body System - Body and Disc Brake Cooling Tank
Section 230-0040

SM - 2439 SM - 2440
J

13
2 G
12
J A B C D E F
1

10

1 - Hydraulic Tank A
2 - Tandem Pump 12 - Breather K B
10 - Relief Valve 13 - Oil Temperature Switch C E F
D

Fig. 2 - Hydraulic Schematic Fig. 3 - Port Locations

OPERATION An adaptor installed at port 'D' provides a line tapping for

Numbers in parentheses refer to Fig. 1, unless return oil from the manifold relief valve to return to
otherwise specified. Refer to Fig. 2 for hydraulic hydraulic tank (1).
schematic and Fig. 3 for port locations.
Return oil from the disc brake cooling circuit enters the
The body hoist oil flow is drawn from port 'B', through tank at ports 'E' & 'F'. A disc brake oil temperature
suction screen (18), by the front section of the switch (13, Fig. 2) is installed in return tube, at port 'E',
tandem gear pump mounted off the engine power to indicate if disc brake cooling oil is overheating. The
takeoff. Oil is then pumped to the body control valve oil temperature switch sends a signal to illuminate the
where, depending on spool position, oil flows to the warning light on the dash panel when a temperature of
body hoist circuit or, with spool in the float position, 121° C (250° F) is reached.
flows through the manifold block at the rear of the
control valve to supplement the disc brake cooling oil. Port 'H' is plugged.

The disc brake cooling oil flow is drawn from port 'C', A breather installed in a tee at port 'J' is the common
through suction screen (18), by the rear section of the breather to both the body and disc brake cooling tank
tandem gear pump. Oil is then pumped through the and the steering and brake control tank. This allows
manifold block at the rear of the body control valve to any air entering the tanks to be released to
the disc brake cooling circuit. atmosphere, preventing a pressure build up in the
tank assemblies. See Fig. 4.
Excess disc brake cooling oil at the manifold block,
returns to tank at port 'A' and flows through pressure Port 'K' is plugged and provides a tank drain port.
relief valve (19) to the tank body.
An inter-connecting hose assembly (3, Fig. 5) links
Return oil from the body hoist circuit enters the tank at the body and disc brake cooling tank and the steering
port 'D' from the body control valve. The oil enters filter and brake control tank. Refer to Section 220-0040,
element (13) chamber and flows through a centre tube STEERING AND BRAKE CONTROL TANK.
and filter elements (13) to the tank body, thus ensuring
return oil is filtered before entering the tank.

2 SM 1928 R1 03-08
 Body System - Body and Disc Brake Cooling Tank
Section 230-0040

SM - 1683

4
5
1
6
2
3

1 - Breather 4 - Bushing
2 - Nipple 5 - Elbow
3 - Tee 6 - Breather Line

Fig. 4 - Breather Line Installation

MAINTENANCE fully lowered, the oil level should show in top window
nut (16). Under all conditions bottom window nut (16)
Numbers in parentheses refer to Fig. 1, unless
should show full.
otherwise specified.
If oil is required, remove filler cap (5) and fill
Note: Tighten all fasteners to torques listed in
hydraulic tank (1) with hydraulic oil specified in
Section 300-0080, STANDARD BOLT AND NUT
Section 300-0020, LUBRICATION SYSTEM, until oil
TORQUE SPECIFICATIONS.
shows in top window nut (16). Fit filler cap (5).

Checking Oil Level

Replacing Hydraulic Oil
Cold Check: With the engine off and the body fully
Hydraulic tank (1) should be drained, cleaned, and
lowered, the bottom window nut (16) should show full.
hydraulic oil changed, at interval specified in Section
300-0020, LUBRICATION SYSTEM. Use only
If oil is required, remove filler cap (5) and fill
hydraulic oil as specified in Section 300-0020,
hydraulic tank (1) with hydraulic oil specified in
LUBRICATION SYSTEM.
Section 300-0020, LUBRICATION SYSTEM, until oil
shows in bottom window nut (16). Fit filler cap (5).
Note: When oil in hydraulic tank (1) is being replaced
due to overheated oil, hydraulic component failure, or
Hot Check: Operate the body hoist cylinders to their
at recommended change interval, filter elements (13)
fully extended positions to charge both cylinders and
should be replaced.
all hoist lines then lower the body. With the engine
running, oil at normal operating temperature and body

SM 1928 R1 08-03 3
Body System - Body and Disc Brake Cooling Tank
Section 230-0040

Changing Filter Elements SM - 1991

Change filter elements (13) at interval specified in

Section 300-0020, LUBRICATION SYSTEM.

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

1. Position the vehicle in a level work area, be sure

the body is fully lowered, apply the parking brake
and switch off the engine. 1 3 2
1 - Steering and Brake Control Tank
2. Block all road wheels. 2 - Body and Disc Brake Cooling Tank
3 - Inter-Connecting Hose Assembly
3. With suitable containers in position, remove drain
Fig. 5 - Layout View of Hydraulic Tanks
plug (17) from hydraulic tank (1) and drain the oil.
Reinstall drain plug (17) in hydraulic tank (1) and
tighten securely. Remove drain plug from steering Suction Screens and Relief Valve
and brake control tank and drain the oil. Refer to Remove and clean suction screens (18) at interval specified
Section 220-0040, STEERING AND BRAKE in Section 300-0020, LUBRICATION SYSTEM.
CONTROL TANK. Reinstall drain plug in hydraulic
tank and tighten securely. Note: Relief Valve (19) is set at 3 bar (45 lbf/in2).

4. Remove bolts (7), lockwashers (8), access cover

(2) and gasket (15) from hydraulic tank (1). Discard WARNING
gasket (15). To prevent personal injury and property
damage, be sure wheel blocks are properly
5. Remove wing nuts (12), bypass valve (9) and secured and of adequate capacity to do the job
plate (10) from rods (11). Remove and discard filter safely.
elements (13) and gaskets (14) from hydraulic tank (1).
1. Position the vehicle in a level work area, be sure
Note: Bypass valve (9) is set at 1.7 bar (25 lbf/in2). the body is fully lowered, apply the parking brake
and switch off the engine.
6. Install new gaskets (14) and filter elements (13) in
oil filter chamber in hydraulic tank (1). 2. Block all road wheels.

7. Install bypass valve (9) in plate (10) and secure 3. With suitable containers in position, remove drain
plate (10) assembly on rods (11) with wing nuts (12). plug (17) from hydraulic tank (1) and drain the oil.
Reinstall drain plug (17) in hydraulic tank (1) and
8. Install new gasket (15) and cover (2) on hydraulic tighten securely. Remove drain plug from steering and
tank (1) and secure with bolts (7) and lockwashers (8).
SM - 464
9. Fill hydraulic tank (1) and steering and brake
control tank to correct level with hydraulic oil as
specified in Section 300-0020, LUBRICATION
SYSTEM. Install filler cap (5).

10. Start the engine and raise and lower the body to
charge the system. Switch off the engine and check
oil level as described under 'Checking Oil Level'.
Remove wheel blocks.
Fig. 6 - Suction Screen Removal/Installation Tool

4 SM 1928 R1 03-08
 Body System - Body and Disc Brake Cooling Tank
Section 230-0040
brake control tank and drain the oil. Refer to Section 13. Fill hydraulic tank (1) and steering and brake control
220-0040, STEERING AND BRAKE CONTROL TANK. tank to correct level with hydraulic oil as specified in
Reinstall drain plug in hydraulic tank and tighten Section 300-0020, LUBRICATION SYSTEM. Install
securely. filler cap (5).

4. If required, remove inter-connecting hose 14. Start the engine and raise and lower the body to
assembly (3, Fig. 5) from access cover (3). Fit charge the system. Switch off the engine and check
blanking cap and plug to hydraulic line and tank port. oil level as described under 'Checking Oil Level'.
Remove bolts (7), lockwashers (8), access cover (3) Remove wheel blocks.
and gasket (15) from hydraulic tank (1). Discard
gasket (15).
Breather
5. Remove lockwire (31) securing suction screens Remove and clean breather (1, Fig. 4) at the interval
(18) in hydraulic tank (1). specified in Section 300-0020, LUBRICATION SYSTEM.
Replace breather if cleaning is not sufficient.
6. Using a suitable tool, as shown in Fig. 6, unscrew
suction screens (18) by turning hexagon head at
neck of each suction screen. TANK ASSEMBLY

7. Remove relief valve (19) assembly. Disassemble Removal

relief valve (19) assembly by removing, cap (21), Numbers in parentheses refer to Fig. 1, unless
shim (23), spring (22) and poppet (20). otherwise specified.

WARNING WARNING
Splashing liquid. Wear a suitable face shield To prevent personal injury and property
when using compressed air to dry tank and damage, be sure wheel blocks are properly
components. secured and of adequate capacity to do the job
safely.
8. Clean suction screens (18) and hydraulic tank (1)
with paraffin and dry with compressed air. Inspect for 1. Position the vehicle in a level work area, be sure
damage and renew if necessary. the body is fully lowered, apply the parking brake and
switch off the engine.
9. Assemble relief valve (19) in reverse order to
disassembly. Thoroughly clean and dry threads on 2. Block all road wheels.
relief valve (19) and tank port and apply Loctite
Activator 'T' to threads. Apply Loctite 243 to threads 3. With suitable containers in position, remove drain
of relief valve (19) and install relief valve assembly in plug (17) from hydraulic tank (1) and drain the oil.
hydraulic tank (1). Reinstall drain plug (17) in hydraulic tank (1) and
tighten securely. Remove drain plug from steering and
10. Insert lockwire (31) in suction screens (18) and brake control tank and drain the oil. Refer to Section
install suction screens in hydraulic tank (1). Secure 220-0040, STEERING AND BRAKE CONTROL TANK.
suction screens (18) in hydraulic tank (1) using a Reinstall drain plug in hydraulic tank and tighten
suitable tool, as shown in Fig. 6. securely.

11. Join ends of lockwire (31) and secure suction 4. Ensure all hydraulic lines connected to hydraulic
screens (18) together with lockwire (31). tank (1) assembly are identified for ease of installation
and, with suitable containers available to catch
Note: Do not grip the body of suction screens (18). leakage, disconnect all hydraulic lines. Fit blanking
Use a suitable tool, as shown in Fig. 6, to grip the caps and plugs to all hydraulic lines and tank ports.
hexagon head at the neck of each suction screen.
5. Disconnect breather line (6, Fig. 4) from elbow
12. Install new gasket (15) and access cover (3) on (5, Fig. 4). Fit blanking caps to line.
hydraulic tank (1) and secure with bolts (7) and
lockwashers (8). Remove blanking cap and plug from 6. Disconnect inter-connecting hose assembly
hydraulic line and tank port and install inter-connecting (3, Fig. 5) from access cover (3). Fit blanking caps to
hose assembly (3, Fig. 5) to access cover (3). line.
SM 1928 R1 08-03 5
Body System - Body and Disc Brake Cooling Tank
Section 230-0040
5. Check bypass valve (9) for damage or wear and
WARNING replace if required.
Heavy Tank. Ensure lifting device is of adequate
capacity and properly secured to avoid 6. Check breather (1, Fig. 4) for damage and replace
personal injury or property damage. if required.

7. Support hydraulic tank (1) assembly with suitable

lifting equipment. Assembly
Numbers in parentheses refer to Fig. 1, unless
8. Support transmission filler tube and remove nut otherwise specified.
(27) and hardened washer (28) from front right hand
side of the hydraulic tank (1). Secure transmission 1. Install all internal components as previously
filler tube away from hydraulic tank (1). Remove bolts described under 'MAINTENANCE'. Renew filter
(26), hardened washers (28) and nuts (27) securing elements (13) and gaskets (14 & 15).
hydraulic tank (1) assembly to mounting brackets (24
& 25). 2. If removed, install window nuts (16) and rods (11)
in hydraulic tank (1).
9. Remove hydraulic tank (1) assembly to a suitable
work area for disassembly. 3. If removed, install tee (3, Fig. 4), bushing (4, Fig. 4),
elbow (5, Fig. 4), nipple (2, Fig. 4) and breather (1, Fig.
4) on hydraulic tank (1).
Disassembly
Numbers in parentheses refer to Fig. 4, unless
otherwise specified. INSTALLATION
Numbers in parentheses refer to Fig. 1, unless
1. Remove internal components from hydraulic tank (1) otherwise specified.
as previously described under 'MAINTENANCE'.
Note: Tighten all fasteners to torques listed in
2. If required, remove rods (11, Fig. 1) and window Section 300-0080, STANDARD BOLT AND NUT
nuts (16, Fig. 1) from hydraulic tank (1, Fig. 1). TORQUE SPECIFICATIONS.

3. If required, remove breather (1), nipple (2), tee (3), Note: Tighten all hydraulic lines fitted with ORFS
bushing (4) and elbow (5) from hydraulic tank (1, Fig. 1). connections, as described in Section 230-0000,
BODY SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
Inspection
Numbers in parentheses refer to Fig. 1, unless
otherwise specified. WARNING
To prevent personal injury and property
damage, be sure wheel blocks, blocking
WARNING materials and lifting equipment are properly
Splashing liquid. Wear a suitable face shield secured and of adequate capacity to do the job
when using compressed air to dry tank and safely.
components.
1. Using suitable lifting equipment, position hydraulic
1. Clean hydraulic tank (1) and components with tank (1) assembly on mounting brackets (24 & 25).
paraffin and dry with compressed air. Secure transmission filler tube to underside of front
right hand mounting bracket and hydraulic tank (1)
2. Inspect tank for weld cracks and security of with bolt (26), hardened washers (28) and nut (27).
internal pipes and weld fitments. Secure hydraulic tank (1) assembly on mounting
brackets (24 & 25) with bolts (26), hardened washers
3. Check suction screens (18) for damage and renew if (28) and nuts (27).
required.
2. Remove blanking cap from breather line (6, Fig. 4)
4. Check pressure relief valve (19) assembly is free of and connect breather line to elbow (5, Fig. 4). Tighten
contaminants and that poppet (20) is free. breather line securely.

6 SM 1928 R1 03-08
 Body System - Body and Disc Brake Cooling Tank
Section 230-0040
3. Remove blanking cap from inter-connecting hose SPECIAL TOOLS
assembly (3, Fig. 5) and connect hose to access
There are no special tools required for procedures
cover (3). Tighten hose assembly securely.
outlined in this section. Refer to Section 300-0070,
SERVICE TOOLS, for part numbers of general
4. Remove blanking caps and plugs and install all
service tools and adhesives required. These tools
lines to hydraulic tank (1) , as tagged at removal.
and adhesives are available from your dealer.
5. Fill hydraulic tank (1) to correct level with
hydraulic oil as specified in Section 300-0020,
LUBRICATION SYSTEM. Install filler cap (5).

6. Start the engine and raise and lower the body to

charge the system. Switch off the engine and
check oil level as described under 'Checking Oil Level'.

7. Check all lines and fittings for leaks and tighten as

required. Remove wheel blocks.

* * * *

SM 1928 R1 08-03 7
 BODY SYSTEM - Tandem Pump
Section 230-0050

SM - 373

8 - Ring Seals 16 - Seals 24 - Name Plate *

1 - Snap Ring 9 - Bearings 17 - Connecting Shaft 25 - Drive Screws *
2 - Spacer 10 - Pocket Seals 18 - Bearing Carrier 26 - Washers *
3 - Seal Retainer 11 - Thrust Plates 19 - Plug * 27 - Studs *
4 - ‘O’ Ring * 12 - Driveshaft & Gear 20 - Drive Gear 28 - Nuts
5 - Seal * 13 - Driven Gear 21 - Driven Gear 29 - Pins (if used) *
6 - Shaft End Cover 14 - Seals 22 - Gear Housing 30 - Seals (if used)
7 - Plug * 15 - Gear Housing 23 - End Cover 31 - Anti-Vibration Rings

* Shown on Fig. 6.
Fig. 1 - Cutaway View of Tandem Pump

DESCRIPTION OPERATION
Numbers in parentheses refer to Figs. 1 & 6. Numbers in parentheses refer to Figs. 1 & 6. Refer to
Fig. 2 for the operation of a typical gear type
The Tandem Pump can be identified as item 2 in hydraulic pump. Refer to Fig. 3 for hydraulic
Section 230-0000, BODY SYSTEM SCHEMATIC, in schematic of the tandem pump operation.
this manual.
As the drive gear rotates, the driven gear rotates in
The tandem gear pump, mounted off the engine the opposite direction. The pockets between the gear
power takeoff, supplies hydraulic oil for operating the teeth carry oil from the inlet port around the gear
body and cooling the rear disc brake assemblies. housing ID to the pump outlet port. As the gear teeth
re-mesh, this oil is forced out of the outlet port of the
This is a multiple gear type pump consisting of two gear housing. The maximum oil delivery rate of each
separate sections connected together as one section of the tandem pump is fixed by the width of
assembly. The front section consists of driveshaft & its respective gear set and the speed at which
gear (12), driven gear (13) and gear housing (15). driveshaft (12) is turned.
Drive gear (20), driven gear (21) and gear housing
(22) make up the rear section. Connecting shaft (17) The front section of the tandem pump draws oil from
connects the rear section to driveshaft and gear (12). the body and disc brake cooling tank, then pumps the

SM 1213 2-98 1
Body System - Tandem Pump
Section 230-0050

SM - 338 SM - 575
DRIVE GEAR TO BODY
TO BRAKE CONTROL VALVE
COOLING
CIRCUIT

INLET OUTLET

DRIVEN GEAR FROM FROM

TANK TANK

Fig. 2 - Typical Pump Operation Fig. 3 - Hydraulic Schematic of Tandem Pump Operation

oil to the body control valve where, depending on DISASSEMBLY

spool position, oil flows to the body hoist circuit or, Numbers in parentheses refer to Figs. 1 & 6.
with spool in the float position, flows through the
manifold block at the rear of the control valve to 1. Place pump in a soft-jawed vice, driveshaft (12)
supplement the disc brake cooling oil. down. Match mark all pump sections with a punch to
aid assembly. See Fig. 4.
The rear section of the tandem pump draws oil from
the body and disc brake cooling tank, then pumps the Note: Do not clamp vice on pump machined surfaces
oil through the manifold block at the rear of the body at any time.
control valve to supply the disc brake cooling circuit.
2. Remove nuts (28) and washers (26) from studs (27).
See Fig. 5. Remove studs (27) from pump assembly.
REMOVAL
SM - 339

WARNING
To prevent personal injury and property
damage, make sure blocking or lifting
equipment is of adequate capacity and
properly secured to do the job safely.

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

the parking brake. Switch off the engine and block all
road wheels.
Fig. 4 - Marking Typical Pump Sections

2. Drain oil from hydraulic oil tank into a suitable

container. SM - 340

3. Clean pump housing and tag and disconnect inlet

and outlet lines from the pump. Drain oil in lines into
a suitable container. Cap lines and pump ports to
prevent ingress of dirt.

4. With suitable blocking or lifting equipment, support

pump before loosening attaching nuts. Remove nuts
and lockwashers from pump mounting studs. Move
pump to a suitable work area for 'Disassembly'.
Fig. 5 - Removing Nuts

2 SM 1213 2-98
 Body System - Tandem Pump
Section 230-0050

SM - 374

21 - Driven Gear
22 - Gear Housing
23 - End Cover
13 - Driven Gear 24 - Name Plate
14 - Seals 25 - Drive Screws
1 - Snap Ring 7 - Plug 15 - Gear Housing 26 - Washers
2 - Spacer 8 - Ring Seals 16 - Seals 27 - Studs
3 - Seal Retainer 9 - Bearings 17 - Connecting Shaft 28 - Nuts
4 - ‘O’ Ring 10 - Pocket Seals 18 - Bearing Carrier 29 - Pins (if used)
5 - Seal 11 - Thrust Plates 19 - Plug 30 - Seals (if used)
6 - Shaft End Cover 12 - Driveshaft & Gear 20 - Drive Gear 31 - Anti-Vibration Rings

Fig. 6 - Exploded View Of Tandem Pump

SM 1213 2-98 3
Body System - Tandem Pump
Section 230-0050
3. Tap end cover (23) with a soft hammer and SM - 344
separate from gear housing (22). If end cover (23)
must be pried off, use care to avoid damaging
machined surfaces of the cover and housing. See
Fig. 7. If thrust plate (11) stays with gear housing
(22), it can be tapped out later. Do not damage or
distort the thrust plate.

4. Separate gear housing (22) from bearing carrier

(18) and lift off. See Fig. 8. If it must be pried loose,
use care to prevent damage to machined surfaces.
Tap or pry out thrust plate (11) carefully, if it
remained with gear housing (22). Fig. 9 - Removing Gears

5. Mark three meshed gear teeth with a dab of

SM - 345
Prussian blue, or similar dye, and lift out matched
gears (20 & 21). See Fig. 9. Keep these gears
together. Do not interchange with other gear sets.

6. Loosen bearing carrier (18) with a plastic hammer

and lift or pry off with care to avoid damaging
machined surfaces. Separate thrust plate (11) from
bearing carrier (18) carefully to avoid distortion. See
Fig. 10.

7. Remove connecting shaft (17) from driveshaft and

gear (12). See Fig. 11. Fig. 10 - Removing Bearing Carrier

SM - 341 SM - 346

Fig. 7 - Removing End Cover Fig. 11 - Removing Connecting Shaft

SM - 342 SM - 347

Fig. 8 - Removing Gear Housing Fig. 12 - Removing Gear Housing

4 SM 1213 2-98
 Body System - Tandem Pump
Section 230-0050

SM - 348 8. Separate and lift off gear housing (15) with care.
See Fig. 12. Remove thrust plate (11) as in Step 4.

9. Mark three meshed gear teeth with a dab of

Prussian blue or similar dye and remove the matched
driveshaft and gear (12) and driven gear (13) set.
See Fig. 13.

10. Pry thrust plate (11) from shaft end cover (6)
carefully to avoid distortion. See Fig. 14.

11. Clamp shaft end cover (6) in vice, mounting face up.
Fig. 13 - Removing Driveshaft Remove snap ring (1) with snap ring pliers. See Fig. 15.

12. Pull spacer (2) from shaft end cover (6) with a
SM - 349
bearing puller. See Fig. 16.

13. Remove seal retainer (3) and seal (5) from shaft
end cover (6). See Fig. 17. The seal retainer removal
tool shown in Fig. 37 can be easily made for this
purpose. Remove and discard 'O' ring (4).

14. Tap seal (5) from seal retainer (3). See Fig. 18.
The tool shown in Fig. 37 can be fashioned to
separate these parts.

Fig. 14 - Removing Thrust Plate 15. If necessary, remove bearings (9) and ring seals
(8) from shaft end cover (6), bearing carrier (18) and

SM - 350 SM - 352

Fig. 15 - Removing Snap Ring Fig. 17 - Removing Seal Retainer

SM - 351 SM - 353

Fig. 16 - Removing Spacer Fig. 18 - Removing Seal From Retainer

SM 1213 2-98 5
Body System - Tandem Pump
Section 230-0050

SM - 354 Hydraulic pressure forces the gears against the low

pressure side of the housing. As the bearings and
gear hubs wear, the housing gear bores wear.
Excessive bore cutout, particularly in a short period,
indicates excessive pump loading or dirty oil. Place a
straight edge across the cutout area of the gear bore.
If a 0.13 mm (0.005 in) feeler gauge can be slipped
between the straight edge and the worn area of the
gear bore, replace the gear housing.

6. Check gears carefully for wear. Scoring, grooving

Fig. 19 - Removing Bearings
or burring of the gear teeth OD requires gear
replacement. Nicked, grooved or fretted gear tooth
SM - 355 mating surfaces also require gear replacement. Any
wear of gear hubs in excess of 0.05 mm (0.002 in), or
detectable by touch, requires gear replacement. Since
both drive and driven gears of a set are matched, both
gears must be replaced if one is worn or damaged.

7. Check the centre of thrust plates (11) at the point

of meshing of gears (12 & 13) and (20 & 21). Erosion
indicates contaminated oil. Pitted thrust plates indicate
cavitation or aeration of the oil supply. Discoloured
thrust plates are a sign of pump overheating.

Fig. 20 - Removing and Installing Seals Thrust plate side wear permits oil to bypass gears
and allows internal oil slippage and reduced pump
efficiency. Check thrust plate surface wear against
end cover (23). See Figs. 19 & 20.
the size of new thrust plates. If worn more than 0.05
mm (0.002 in), replace the thrust plates.
16. Remove and discard all seals (30), if used, and
pocket seals (10) from thrust plates (11), and seals
8. Bearings (9) should fit into their bores with a light
(14 & 16) from gear housings (15 & 22).
press fit. A tight hand fit is allowable. If the bearings
can fall out of their bores, the bores might be distorted
17. Remove plug (7) only if damaged.
or oversize. When gears are replaced, their bearings
must also be replaced.
18. Remove anti-vibration rings (31) from bearing
carrier (18) only if damaged.
9. Check driveshaft and gear (12) for wear or damage
to splines, and seal areas. Replace the driveshaft and
INSPECTION driven gear matched set if wear is detectable by touch
or measures in excess of 0.05 mm (0.002 in) at the
Numbers in parentheses refer to Figs. 1 & 6.
seal or drive areas. Excessive spline wear requires
driveshaft and matching gear replacement.
1. Clean all parts in suitable solvent and dry all but
bearings with compressed air.
SM - 356

2. Dry bearings with a clean, lint-free cloth.

3. Examine all bearings (9) carefully for scoring,

spalling or pitting. Lightly oil the bearings and spin by
hand to check for roughness of operation. Replace
bearings if necessary.

4. Check ring seals (8) for wear or damage and

replace if necessary.
Fig. 21 Cleaning Gear Housing
5. Check gear housings (15 & 22) carefully for wear.

6 SM 1213 2-98
 Body System - Tandem Pump
Section 230-0050

SM - 357 10. Smooth all machined surfaces with a medium-grit

stone. See Fig. 21. Deburr all bearing bores if required.

11. Clean parts in a suitable solvent and dry with

compressed air after smoothing surfaces.

ASSEMBLY
Numbers in parentheses refer to Figs. 1 & 6.

Note: Tighten all fasteners without special torques

specified to standard torques listed in Section
Fig. 22 - Installing Bearings 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
SM - 358
1. If removed, install new plug (7) in shaft end cover
(6). Be sure to install plug in the outlet side of shaft
end cover (6). The unplugged drain hole must be on
the inlet side of shaft end cover (6). Turn plug (7) in
until one thread of the hole is visible. Secure plug (7)
by staking around the hole with a punch.

2. If removed, install ring seals (8) into the bearing

bores in shaft end cover (6), bearing carrier (18) and
end cover (23). The notch in the ring seal must be
visible. See Fig. 20.
Fig. 23 - Installing Centre Pocket Seals
3. If removed, press new bearings (9) into the bearing
bores of shaft end cover (6), bearing carrier (18) and
SM - 359
end cover (23) with an arbor press. See Fig. 22. If
removed, install new anti-vibration rings (31) in
bearing carrier (18).

4. For each thrust plate (11) using pocket seals (10),

cut two pocket seals 9 mm (0.34 in) long from a new
seal strip. Coat with grease and insert seals into the
centre slots of thrust plates (11). See Fig. 23. Coat
new seals (30), if used, with grease and install in
remaining thrust plates (11).

5. Place thrust plate (11) over bearings (9) in shaft

Fig. 24 - Seating Thrust Plate
end cover (6), bearing carrier (18) and end cover
(23). With seals facing bearings, tap thrust plate with
SM - 360 a soft hammer to about 0.8 mm (0.031 in) from
machined surface. See Fig. 24.

6. For each thrust plate (11) using pocket seals (10),

cut four pocket seals 11 mm (0.44 in) long from a
new seal strip. Insert one pocket seal into each of the
outer slots in the thrust plates. Push each seal into
the thrust plate slot so that it touches bearing (9). Tap
thrust plate (11) down against the machined surface
with a soft hammer. Trim the exposed ends of pocket
seals (10) square and flush with thrust plate (11)
using a razor blade or sharp knife. See Fig. 25.
Fig. 25 - Trimming Pocket Seals

SM 1213 2-98 7
Body System - Tandem Pump
Section 230-0050
7. With shaft end cover (6) clamped in a soft-jawed SM - 362
vice, insert driveshaft and gear (12) into the shaft end
cover bore and push down until the gear is snug
against thrust plate (11). Install matched driven gear
(13) hub into its bearing (9) so that the three teeth
marked at 'Disassembly' will mesh. See Fig. 26.

8. Coat new seals (14 & 16) with grease and insert
them into their grooves in both sides of gear housings
(15 & 22). See Fig. 27.

9. Slide gear housing (15) over gears (12 & 13) and,
with match marks made at 'Disassembly' aligned, tap Fig. 27 - Installing Seals
gear housing (15) with a soft hammer until it rests
snugly against shaft end cover (6). See Fig. 28. If a SM - 363
new gear housing is used, make sure the large oil
port will be toward the inlet, and the small port toward
the outlet side of the pump assembly. Be sure seal
(14) is not pinched or dislodged. Coat gears (12 & 13)
with hydraulic fluid for initial lubrication when the
pump is started.

10. With match marks aligned, position bearing

carrier (18) on gear housing (15) so that bearings (9)
will receive the journals of the drive and driven gears
(12 & 13). Tap bearing carrier (18) down tight with a
soft hammer. See Fig. 29. Fig. 28 - Installing Gear Housing

Note: The drain hole plug (19) must be on the inlet

side of the pump. SM - 364

11. Insert connecting shaft (17) into the spline of

driveshaft and gear (12). See Fig. 30.

12. Insert the matched set of drive and driven gears

(20 & 21) into their respective bores of bearings (9) in
bearing carrier (18) so that the three teeth marked at
'Disassembly' will mesh. See Fig. 31. Push the gears
down tightly against thrust plate (11).

13. Slide gear housing (22) over gears (20 & 21) and,
Fig. 29 - Installing Bearing Carrier
with match marks made at 'Disassembly' aligned, tap

SM - 361 SM - 365

Fig. 26 - Installing Driveshaft and Gear Fig. 30 - Installing Connecting Shaft

8 SM 1213 2-98
 Body System - Tandem Pump
Section 230-0050

SM - 366 gear housing (22) with a soft hammer until it rests

snugly against bearing carrier (18). Refer to Fig. 28. If
a new housing is used, make sure the large oil port
will be toward the inlet, and the small port toward the
outlet side of the pump assembly. Be sure seal (14) is
not pinched or dislodged. Coat gears (20 & 21) with
hydraulic fluid for initial lubrication when pump is
started.

14. With match marks aligned, position end cover (23)

over gear (20 & 21) journals. Tap end cover (23)
lightly with a soft hammer to seat on gear housing
Fig. 31 - Installing Gears (22). See Fig. 32. Be careful not to pinch seal (16).

SM - 367
15. Insert eight studs (27) through the pump assembly
and thread into shaft end cover (6). Install washers
(26) and nuts (28). Tighten opposite nuts alternately
until snug. See Fig. 33. Rotate driveshaft (12) with a
150 mm (6 in) wrench and check carefully for pump
binding. If the pump rotates freely, torque tighten
alternate nuts (28) to 271 Nm (200 lbf ft). If the pump
binds, the cause should be determined and corrected
before completing the assembly. Check for burrs on
shafts, housings, bearings, etc., or similar causes.

16. Coat the OD of seal (5) with Loctite Seal retainer

Fig. 32 - Installing End Cover or equivalent. Press seal (5), metal side down, into
seal retainer (3) on an arbor press using a 70 mm
(2.75 in) diameter bar. See Fig. 34. Be careful not to
SM - 368 damage the lip of seal (5).

17. Clamp pump assembly in a soft-jawed vice,

driveshaft (12) up.

18. Coat a new 'O' ring (4) with grease and install on
seal retainer (3). Oil a seal installation sleeve and
twist into the seal ID carefully. Slide the sleeve and
seal over driveshaft (12) and seat seal (5) and seal
retainer (3) assembly firmly in shaft end cover (6)
bore. Remove seal installation sleeve. See Fig. 35.
Fig. 33 - Installing Stud Nuts
19. Insert spacer (2) over driveshaft (12) and install

SM - 369 SM - 370

Fig. 34 - Installing Seal In Retainer Fig. 35 - Installing Seal Retainer

SM 1213 2-98 9
Body System - Tandem Pump
Section 230-0050

SM - 371 4. Fill body and disc brake cooling tank to the proper
level. Refer to Section 230-0040, BODY AND DISC
BRAKE COOLING TANK. Refer to Section 300-0020,
LUBRICATION SYSTEM, for correct oil
specifications.

5. Operate the pump at least two minutes at zero

pressure at engine idle speed. During this break-in
period, it should run free and not develop excessive
heat. If the pump becomes hot to touch, it is binding
and might seize. The pump will then have to be
rebuilt with extra care to avoid binding. If the pump
runs properly, speed and pressure can be increased
Fig. 36 - Installing Spacer In Retainer
to normal operating values.

into shaft end cover (6) against seal retainer (3). See 6. Check pump mounting and line connections for leaks.
Fig. 36.

20. Install snap ring (1) in shaft end cover (6) snap LUBRICATION
ring groove. All pump parts are lubricated by the hydraulic oil. The
oil, therefore, must be kept clean to minimize pump
wear. Whenever there is a hydraulic system failure,
INSTALLATION AND RUN-IN the oil should be drained, the entire system flushed,
Note: Tighten all fasteners to standard torques listed oil filters replaced, oil screens thoroughly cleaned
in Section 300-0080, STANDARD BOLT AND NUT and fresh hydraulic oil installed to eliminate all metal
TORQUE SPECIFICATIONS. particles or foreign matter.

Note: Tighten all hydraulic lines fitted with ORFS Refer to Section 300-0020, LUBRICATION SYSTEM,
connections, as described in Section 230-0000, for recommended periodic oil drain periods and oil
BODY SYSTEM SCHEMATIC. Renew all 'O' rings specifications.
where used.

SPECIAL TOOLS
WARNING The special tools shown in use in Figs. 17 & 18 can
To prevent personal injury and property be fabricated as shown in Fig. 37.
damage, make sure blocking or lifting
equipment is of adequate capacity and SM - 372
properly secured to do the job safely.

1. Coat the pump driveshaft spline with high grade

plating-type molybdenum disulphide grease 15%
minimum (typical).

2. With suitable lifting equipment position pump on

mounting studs. Secure with lockwashers and nuts.

3. Fill all pump ports with clean hydraulic oil and

Fig. 37 - Special Tools
connect lines to pump, as tagged during 'Removal.

SPECIAL TORQUE SPECIFICATIONS TABLE047

TORQUE
FIG. NO. ITEM NO. NAME Nm lbf ft
1&6 33
28 Nut 271 200

* * * *
10 SM 1213 2-98
 BODY SYSTEM - Body Control Valve
Section 230-0060

SM - 2072

14 13
7 6
11 10 9 8 15
12

17

19 16

20
18 27
C
21
28
H
22
F
25
G 23 24
B A
J
D

5 4 2 3
E
1 26

1 - Valve Body 8 - Retainer - Inner Spring 15 - Plug 22 - Poppet

2 - Spool 9 - Inner Spring 16 - Plug 23 - Seal
3 - Seal 10 - Outer Spring 17 - 'O' Ring 24 - 'O' Ring
4 - 'O' Ring 11 - Retainer 18 - Relief Valve 25 - End Cap
5 - Retainer 12 - Spool Extension 19 - Spring 26 - Bolt
6 - 'O' Ring 13 - End Cap 20 - 'O' Ring 27 - Plug
7 - Retainer - Outer Spring 14 - Bolt 21 - Spring 28 - 'O' Ring

Fig. 1 - Exploded View of Body Control Valve

DESCRIPTION Note: Refer to Fig. 6 for port identification of the

Numbers letters in parentheses refer to Fig. 1. OCDB manifold block.

The body control valve can be identified as item 3, and Integral of body control valve body (1) is a four
the OCDB manifold block as item 4, in Section position spool (2). The four positions of control spool
230-0000, BODY SYSTEM SCHEMATIC. (2) are; 'Raise', 'Hold', 'Float' and 'Lower' (power
down). Spool (2) is detented in the 'Hold' position and
Mounted off the left hand frame rail to the rear of the contains an inner and outer spring (9 & 10) which
horse collar, the body control valve is used to direct returns spool (2) from the 'Raise' to 'Hold' position. The
hydraulic oil to the body hoist cylinders for raising or control lever should be kept in the 'Float' position at all
lowering the body, and, depending on spool (2) times, except when raising or lowering the body.
position, is directed through the OCDB manifold block
to supplement the OCDB cooling oil. Movement of spool (2) is by hydraulic pressure from
the pilot accumulator valve connected to the body
Hydraulic oil is pumped to the body control valve by control joystick at the left hand side of the drivers' seat.
the main hydraulic pump mounted on the engine Refer to Section 230-0081, BODY CONTROL
power takeoff. JOYSTICK.

SM 1659 Rev 3 06-07 1

Body System - Body Control Valve
Section 230-0060
The port identifications are as follows: SM - 2068

Port 'A' - Body cylinder 'Lower' circuit RAISE CIRCUIT LOWER CIRCUIT
Port 'B' - Body cylinder 'Raise' circuit TO HPCO &
Port 'C' - Inlet supply from main hydraulic pump MAN. BLOCK
A E B
Port 'D' - Return to tank
Port 'E' - Supply to OCDB manifold block
Port 'F' - Pressure relief valve assembly (12, Fig. 6)
Port 'G' - Check valve assembly
Port 'H' - Pressure relief valve (18)
Port 'J' - Plugged
D C F
TANK
Pressure Relief Valves SUPPLY
Numbers and letters in parentheses refer to Fig. 1. FROM PUMP

Relief valve (18) assembly, in port 'H' of valve body (1),

is set to relieve oil pressure in excess of 190 bar Fig. 2 - Body Control Valve - 'Raise' Position
(2 750 lbf/in2). Should oil pressure at inlet port 'C'
exceed 190 bar (2 750 lbf/in2), relief valve (18) will SM - 2069
open and oil will flow through an internal passage in
valve body (1) and exit at port 'E' to the OCDB manifold SUPPLY TO RETURN FROM
block. When excess oil pressure is relieved, relief valve RAISE CIRCUIT LOWER CIRCUIT
(18) will re-seat allowing normal oil flow through the MANIFOLD
BLOCK
body control valve. & HPCO A E B

Pressure relief valve (18) works in parallel with a

secondary pressure relief valve (12, Fig. 6) mounted off
valve body (1) at port 'F'. Should oil pressure exceed
190 bar (2 750 lbf/in2), relief cartridge (2, Fig. 7) will
open and oil will flow through the relief cartridge and
exit relief valve body (1, Fig. 7) to the body and disc
D C F
brake cooling tank. TANK
SUPPLY
FROM PUMP
The system relief pressure is tapped off from a
connector in pressure relief valve (12, Fig. 6) and can
be recorded at the diagnostic test point mounted off the Fig. 3 - Body Control Valve - 'Hold' Position
underside of the steering and brake control tank.
SM - 2070
The relief pressure is taken from port 'H' and can be
checked at the diagnostic test point on the rear left RETURN FROM SUPPLY TO
RAISE CIRCUIT LOWER CIRCUIT
hand cab support. MANIFOLD
BLOCK
& HPCO A E B
OPERATION
Body 'Raise' Position
Numbers and letters in parentheses refer to Fig. 1.
Refer to Fig. 2 for hydraulic schematic of the body
control valve operating in the 'Raise' position.
D C F
Moving the hydraulic control joystick to the 'Raise' TANK
SUPPLY
position moves spool (2) position within valve body (1). FROM PUMP
Hydraulic oil enters control valve body (1) at port 'C'.
Oil pressure opens poppet (22) and oil flows through
the passage opened by spool (2) and exits at port 'B' to Fig. 4 - Body Control Valve - 'Float' Position

2 SM 1659 Rev 3 06-07

 Body System - Body Control Valve
Section 230-0060

SM - 2071 position, moves the spool to a position within valve

body (1) which allows the body to lower by its own
RAISE CIRCUIT LOWER CIRCUIT weight.
TO HPCO &
MAN. BLOCK Hydraulic oil enters control valve body (1) at port 'C'.
A E B
Oil which is not required to replenish the oil in the hoist
cylinders, as the body is lowered, passes through
valve body (1) and exits at port 'E' to the OCDB
manifold block. The oil flow is directed through the
OCDB manifold block to supplement the OCDB
cooling oil.

D C F
TANK
Oil forced out of the hoist cylinders as the body lowers,
SUPPLY enters control valve body (1) at port 'B', flows through
FROM PUMP the passage opened by spool (2) and exits at port 'D'
to the body and disc brake cooling tank. Make-up oil
flows around spool (2) and exits at port 'A' to replenish
Fig. 5 - Body Control Valve - 'Raise' Position oil in the hoist cylinders as the body lowers.

the 'Raise' ports on the body hoist cylinders. Body 'Lower' (Power Down) Position
Return oil from the body hoist cylinders enters control Numbers and letters in parentheses refer to Fig. 1.
valve body (1) at port 'A', via the manifold relief valve, Refer to Fig. 5 for hydraulic schematic of the body
flows through the passage opened by spool (2) and control valve operating in the 'Lower' position.
exits at port 'D' to the body and disc brake cooling
tank. Refer to Section 230-0110, MANIFOLD RELIEF Moving the hydraulic control joystick to the 'LOWER'
VALVE. position moves spool (2) position within valve body (1).
Hydraulic oil enters control valve body (1) at port 'C'.
Oil pressure opens poppet (22) and oil flows through
Body 'Hold' Position the passage opened by spool (2) and exits at port 'A'
Numbers and letters in parentheses refer to Fig. 1. to the manifold relief valve.
Refer to Fig. 3 for hydraulic schematic of the body
control valve operating in the 'Hold' position. Oil travels through the manifold relief valve, to the
'Lower' ports on the body hoist cylinders. Refer to
With the hydraulic control joystick and spool (2) in the Section 230-0110, MANIFOLD RELIEF VALVE.
'Hold' position, oil enters control valve body (1) at port
'C', flows through the valve and exits at port 'E' to the Return oil from the body hoist cylinders enters control
OCDB manifold block. The oil flow is directed through valve body at port 'B', flows through the passage
the OCDB manifold block to supplement the OCDB opened by spool (2) and exits at port 'D' to the body
cooling oil. and disc brake cooling tank.

Spool (2) blocks the flow of oil to and from the body REMOVAL
hoist cylinders, holding the cylinder pistons in place.
Numbers in parentheses refer to Fig. 6, unless
otherwise specified.
Body 'Float' Position
Numbers and letters in parentheses refer to Fig. 1.
Refer to Fig. 4 for hydraulic schematic of the body WARNING
control valve operating in the 'Float' position. Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the
Note: The control joystick should be kept in the 'Float' body control joystick in both directions
position at all times, except when raising or lowering approximately 15 times to ensure the pressure
the body. has dissipated from the pilot supply valve
accumulator before carrying out any work on
Moving the hydraulic control joystick to the 'Float' the body control system or serious injury
could result.

SM 1659 Rev 3 06-07 3

Body System - Body Control Valve
Section 230-0060

SM - 2067

13 11 14,15,16 12

20
19
17
1
18

E
A
B
7,8 9,10

F
6,4,5 C

OCDB Manifold Block Ports

A - Supply from rear section of tandem pump
B - Supply to disc brake oil filter (rear)
C - Supply to disc brake oil filter (front)
D - Supply from front section of tandem pump
F - Return to body and disc brake cooling tank

3,4,5 2

1 - Body Control Valve 6 - Bolt 11 - Elbow 16 - Nut

2 - Mounting Bracket 7 - Adaptor Flange 12 - Pressure Relief Valve 17 - Manifold Block
3 - Bolt 8 - 'O' Ring 13 - Guard 18 - 'O' Ring
4 - Nut 9 - Bolt 14 - Bolt 19 - Lockwasher
5 - Lockwasher 10 - Washer 15 - Lockwasher 20 - Bolt

Fig. 6 - Body Control Valve and OCDB Manifold Block Installation

valve (1) and surrounding area with a suitable solvent.

WARNING Identify and tag all hydraulic lines connected to body
To prevent personal injury and property control valve (1), pressure relief valve (12) and
damage, be sure wheel blocks and lifting manifold block (17), to aid in 'Installation'.
equipment are properly secured and of
adequate capacity to do the job safely. 5. With suitable containers available to catch spillage,
disconnect all hydraulic lines from body control valve
1. Position the vehicle in a level work place, raise the (1), pressure relief valve (12) and manifold block (17).
body and secure in place with the body safety pins. Cap all hydraulic lines and ports to prevent ingress of
Apply the parking brake, switch off the engine. dirt.

2. Operate steering left and right several times to 6. Support body control valve (1), mounting bracket
discharge the steering accumulator. Block all road (2), pressure relief valve (12) and manifold block (17)
wheels. assembly with a suitable lifting device and remove
nuts (4), bolts (3) and lockwashers (5). Remove
3. Remove drain plug from body and disc brake assembly from mounting bracket and move clear of
cooling tank and drain oil into a suitable container. the vehicle.
Reinstall drain plug in the tank and secure.
7. Remove nuts (4), lockwashers (5) and bolts (6)
4. Remove mounting bolts and guard (13) to gain securing body control valve (1) to mounting bracket
access to body control valve (1). Clean body control (2). Remove mounting bracket (2).

4 SM 1659 Rev 3 06-07

 Body System - Body Control Valve
Section 230-0060
SM - 2429 Relief Valve
1. Carefully remove plug (15) and 'O' ring (17) from
1 port 'H' in valve body (1). Discard 'O' ring (17).

2. Remove relief valve (18) and spring (19) from port

'H' in valve body (1).
5

2 Check Valve
1. Carefully remove plug (16) and 'O' ring (20) from
8
port 'G' in valve body (1). Discard 'O' ring (20).
6
4
2. Remove spring (21) and poppet (22) from port 'G' in
valve body (1).
3
7
1 - Relief Valve Body Valve Spool
2 - Relief Cartridge
3 - 'O' Ring 6 - 'O' Ring 1. Carefully remove bolts (14) and end cap (13) from
4 - 'O' Ring 7 - Adjusting Screw valve body (1). If required, remove elbow from end cap
5 - Backup Ring 8 - Locknut
(13).
Fig. 7 - Exploded View of Pressure Relief Valve
2. Unscrew spool extension (12) and remove retainer
8. Remove bolts (20) and lockwashers (19) securing (11), outer spring (10) and inner spring (9) from valve
manifold block (17) to body control valve (1). Remove spool (2).
manifold block (17) from body control valve (1).
Discard 'O' ring (18) from manifold block (17). 3. Carefully remove inner and outer spring retainers
(8 &7) from valve spool (2).
9. Slacken elbow (11) and remove pressure relief
valve (12) from elbow (11). Remove bolts (9), washers 4. Carefully remove 'O' ring (6), retainer (5) and
(10) elbow (11) and adaptor flange (7) from body 'O' ring (4) from valve spool (2). Discard 'O' rings (4 & 6).
control valve (1). Remove and discard 'O' ring (8) from
adaptor flange (7). 5. Remove spool (2) and seal (3) from valve body (1).
Discard 'O' rings (4 & 6).

DISASSEMBLY 6. Remove bolts (26), end cap (25), seal (23) and 'O'
Numbers and letters in parentheses refer to Fig. 1. ring (24) from valve body (1). Discard 'O' ring (24). If
required, remove elbow from end cap (25).

WARNING
Valve Body
Spring loaded parts. Use care when removing
end cap, retainers and plugs to prevent sudden 1. If required, identify and remove adaptor blocks and
release of spring tension behind these parts. 'O' rings from ports 'D' and 'E' in valve body (1).
Personal injury or property damage could Discard 'O' rings.
result if care is not taken.

Note: Clean entire control valve assembly with a

suitable solvent and dry thoroughly prior to
disassembly.

SM 1659 Rev 3 06-07 5

Body System - Body Control Valve
Section 230-0060

INSPECTION 3. Assemble retainer (5), 'O' ring (6), outer spring

Numbers in parentheses refer to Fig. 1. retainer (7), inner spring retainer (8),inner spring (9),
outer spring (10) and retainer (11) and install in valve
1. Wash all parts thoroughly in a suitable solvent and body (1) as an assembly.
dry with compressed air.
4. Install spool extension (12) and tighten to a torque of
2. Inspect valve body (1) bores and spool (2) for 14 - 20 Nm (10 - 15 lbf ft).
grooves, deep scratches or excessive wear. Ensure
that spool (2) fits its respective valve body bore with a 5. Position end cap (13) on valve body (1) and secure
slight hand pressure and without perceptible side with bolts (14). Tighten bolts (14) to a torque of
clearance. 14 - 20 Nm (10 - 15 lbf ft). If removed, install elbow in
end cap (13).
Note: If condition of valve body (1) bores or spool (2)
indicates that they require to be replaced, the body
control valve should be replaced as an assembly. Check Valve
1. Install poppet (22) and spring (21) in port 'G' of valve
3. Inspect check valve poppet (22) for grooves or body (1).
defects which may cause leakage. Replace poppet
(22) if it appears to be damaged. Small nicks and 2. Install new 'O' ring (20) on plug (16) and secure in
grooves can be removed from poppet (22) seat by port 'G' of valve body (1). Tighten plug (16) to a torque
using a fine grain grinding compound and lapping seat. of 81 - 100 Nm (60 - 70 lbf ft).

4. Replace relief valve (18) assembly if defective.

Relief Valve
Note: If a new check valve poppet (22) or relief valve 1. Install spring (19) and relief valve (18) in port 'H' of
(18) is used, the respective seat should be lapped to valve body (1).
conform to the new part.
2. Install new 'O' ring (17) on plug (15) and secure in
port 'H' of valve body (1).
ASSEMBLY
Numbers and letters in parentheses refer to Fig. 1.
INSTALLATION
Note: Lubricate all components with hydraulic oil Numbers in parentheses refer to Fig. 6, unless
specified in Section 300-0020, LUBRICATION otherwise specified.
SYSTEM, prior to assembly.
Note: Tighten all fasteners to standard torques listed in
Section 300-0080, STANDARD BOLT AND NUT
Valve Body TORQUE SPECIFICATIONS.
1. If removed, install new 'O' rings on adaptor blocks
and secure in ports 'D' and 'E' of valve body (1) as Note: Tighten all hydraulic lines fitted with ORFS
identified at Dissassembly. connections, as described in Section 230-0000, BODY
SYSTEM SCHEMATIC. Renew all 'O' rings where
used.
Valve Spool
1. Install new 'O' ring (24) and seal (23) in valve body
(1). Position end cap (25) on valve body (1) and WARNING
secure with bolts (26). Tighten bolts (26) to a torque of To prevent personal injury and property
14 - 20 Nm (10 - 15 lbf ft). If removed, install elbow in damage, make sure lifting equipment is of
end cap (25). adequate capacity and properly secured to do
the job safely.
2. Install seal (3) and 'O' ring (4) over the eye end of
spool (2) and install in valve body (1). 1. Install new 'O' ring (8) in adaptor flange (7). Secure
adaptor flange (7) and adaptor (11) to port 'F' of body
control valve (1) with bolts (9) and washers (10).

6 SM 1659 Rev 3 06-07

 Body System - Body Control Valve
Section 230-0060

SM - 3509

Fig. 8 - Detail View of Relief Valve

2. Position pressure relief valve (12) to adaptor (11) pressure relief valve (12) and manifold block (17) and
and tighten adaptor (11) securely. Be sure pressure hydraulic lines for leaks. Correct as required. Check
relief valve (12) is correctly orientated. body control valve for correct operation in all four
positions.
3. Install new 'O' ring (18) in OCDB manifold block (17).
Secure OCDB manifold block (17) to port 'E' of body 11. Raise the body and secure in place with the body
control valve (1) with bolts (20) and lockwashers (19). safety pins. Install guard (13) over body control valve
(1). Remove body safety pins and all wheel blocks.
4. Position body control valve (1) assembly on
mounting bracket (2) and secure with bolts (6),
lockwashers (5) and nuts (4). MAINTENANCE
Numbers in parentheses refer to Fig. 1.
5. Using suitable lifting equipment, position body
control valve (1) and mounting bracket (2) assembly to Inspect the body control valve, manifold block,
mounting bracket on the chassis. pressure relief valve and hydraulic lines regularly for
any signs of leakage or damage. Limited repair of the
6. Secure mounting bracket (2) assembly to frame body control valve and pressure relief valve (18) is by
mounting bracket with bolts (3), lockwashers (5) and replacement of parts only. The manifold block should
nuts (4). Leave off bolt (3) which secures guard (13) to be replaced if damaged.
mounting bracket (2).

7. Reconnect hoses, as identified at removal, to Relief Valve Pressure Check

elbows located in end caps (13 & 25, Fig. 1). Relief valve (18) pressure should be checked at the
interval specified in Section 300-0020, LUBRICATION
8. Remove all blanking caps from hydraulic lines and SYSTEM, as follows:
install all hydraulic lines to body control valve (1),
pressure relief valve (12) and manifold block (17), as Note: Prior to any adjustment of relief valve (18),
tagged at 'Removal'. screw relief valve (12, Fig. 6) in, removing relief
pressure.
Note: Be sure to use new 'O' rings where used.
a. Connect a hydraulic gauge capable of reading
9. Fill body and disc brake cooling tank with hydraulic 0 - 207 bar (0 - 3 000 lbf/in2) to remote diagnostic test
oil as specified in Section 300-0020, LUBRICATION point mounted off the underside of the steering and
SYSTEM. Refer to Section 230-0040, BODY AND brake control tank.
DISC BRAKE COOLING TANK for fill level procedure.
b. Start the engine and raise the body completely.
10. Start the engine, remove body safety pins and
operate the body. Check body control valve (1), c. Increase engine speed to 1000rpm and check gauge

SM 1659 Rev 3 06-07 7

Body System - Body Control Valve
Section 230-0060
reading. Record pressure reading. a. Connect a hydraulic gauge capable of reading
0 - 207 bar (0 - 3 000 lbf/in2) into the diagnostic test
Proceed to 'Checking and adjusting Relief valve' point
steps. .
b. Start the engine and raise the body completely.
d. Finally check body relief pressure with body raised
completely at maximum engine rpm. Pressure should c. Increase engine speed to 1000rpm and check gauge
be 190-196bar (2750 - 2850 Ibf/in2). reading.

e. If pressure is too-high, a shim(1, Fig 8) should be d. Screw relief valve (12, Fig. 6) out until the pressure
removed from pressure relief valve (18, Fig. 1). starts to drop. Continue screwing relief valve (12, Fig.
6) out slightly until the pressure observed equals that
Note: Retain any shim removed in step 'e' for future recorded in "Relief Valve Pressure Check - Step C."
use if required.
e. Secure locking nut (8, Fig. 7) in place and operate
Checking and Adjusting Relief Valve body. Re-check relief valve pressure and adjust if
Relief valve (12, Fig. 6) pressure should be checked at required.
the interval specified in Section 300-0020,
LUBRICATION SYSTEM, as follows: f. Remove pressure gauge from diagnostic point

g. Proceed to step 'd' in "Relief Valve Pressure

Check".

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 3 Plug 81 - 100 60 - 70
1 20 Spool Extension 14 - 20 10 - 15
1 22 Bolt 14 - 20 10 - 15

* * * *

8 SM 1659 Rev 3 06-07

 BODY SYSTEM - Body Control Joystick
Section 230-0081

SM - 1795

2
3
1

5
6

8
7
9

10

8
9

7 - Mounting Bracket
1 - Body Control Joystick 4 - Connector 8 - Screw
2 - Bolt 5 - Elbow 9 - Lockwasher
3 - Lockwasher 6 - Elbow 10 - Cover Plate

Fig 1. - Body Control Joystick Installation

DESCRIPTION SM - 1798

The body control joystick can be identified as item 9 in T

Section 230-0000, BODY SYSTEM SCHEMATIC. P

Mounted on the left hand side of the operator's seat,

the body control joystick is located in the hydraulic
body circuit between the body control valve and the
pilot accumulator valve. See Fig. 2 for schematic
symbol.

OPERATION
The body control joystick controls the hydraulic valve 1 2
which operates the body hoist cylinders. The four
Fig. 2 - Body Control Joystick Schematic Symbol

SM 1597 12-98 1
Body System - Body Control Joystick
Section 230-0081
operating positions of the joystick from front to rear are 2. Operate the body control joystick (1) continuously to
as follows: discharge the pilot valve accumulator. Block all road
wheels.
'LOWER' - This position provides hydraulic force to
power-down the body. It is needed when the body
3. Remove screws (8) and lockwashers (9) securing
cannot be started downward from the fully raised
cover plate (10) to mounting bracket (7) on the
position by gravity. When the body starts lowering by
operator's seat. Remove cover plate (10).
gravity, the joystick should be moved to the 'FLOAT'
position.
4. Ensure all hydraulic lines connected to body control
'FLOAT' - The joystick should be moved to this joystick (1) are identified for ease of installation and, with
position while the body is lowering by gravity and suitable containers available to catch leakage, disconnect
should remain in this position until the body must be hydraulic lines. Fit blanking caps to all open lines.
operated again. The control joystick should always be
kept in 'FLOAT' while the machine is in motion. 5. Remove bolts (2) and lockwashers (3) securing
'HOLD' - Moving the joystick to this position while the body control joystick (1) to mounting bracket (7).
body is being raised or lowered traps the oil in the Remove body control joystick (1).
body hoists to stop and hold the body at any desired
height. The joystick will remain in the detented 'HOLD' 6. Note location of elbows (5 & 6) and connector (4)
position when released. and remove from body control joystick (1) for use on
the new joystick.
'RAISE' - This position directs oil to extend the body
hoists and raise the body. When released, the joystick 7. Install elbows (5 & 6) and connector (4) in new body
will be spring-returned to the 'HOLD' position. control joystick (1) ports as removed from the old joystick.

REMOVAL AND INSTALLATION 8. Secure body control joystick (1) to mounting bracket
Numbers in parentheses refer to Fig. 1. (7) on the operator's seat with bolts (2) and
lockwashers (3).
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT 9. Remove blanking caps from hydraulic lines and
TORQUE SPECIFICATIONS. install lines to body control joystick (1) as identified
during removal.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY 10. Check oil level in the body and disc brake cooling
SYSTEM SCHEMATIC. Renew all 'O' rings where used. tank and add oil if required. Refer to Section 230-0040,
BODY AND DISC BRAKE COOLING TANK for correct
fill level, and, Section 300-0020, LUBRICATION
WARNINGS SYSTEM for oil specification.
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the 11. Remove wheel blocks, start the engine and bring
body control joystick in both directions hydraulic oil to operating temperature. Operate body
approximately 15 times to ensure the pressure control joystick (1) and check hydraulic line
has dissipated from the pilot supply valve connections for leaks and tighten as required.
accumulator before carrying out any work on
the body control system or serious injury MAINTENANCE
could result. Limited repair of the body control joystick is by
replacement of parts only. Refer to vehicle Parts Book
To prevent personal injury and property for part numbers of kits.
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job SPECIAL TOOLS
safely.
There are no special tools required for procedures
1. Position the vehicle in a level work area, be sure the outlined in this section. Refer to Section 300-0020,
body is fully lowered, apply the parking brake and SERVICE TOOLS, for part numbers of general service
switch off the engine. tools required. These tools are available from your
dealer.
* * * *
2 SM 1597 12-98
 BODY SYSTEM - Manifold Relief Valve
Section 230-0110

SM - 586

7 - Seals
1 - Manifold Body 3 - Relief Cartridge 5 - 'O' Ring 8 - Connector
2 - Check Cartridge 4 - Plug 6 - Seals 9 - Cap

Fig. 1 - Exploded View Of Manifold relief valve

DESCRIPTION SM 2781

The manifold relief valve can be identified as item 6

in Section 230-0000, BODY SYSTEM SCHEMATIC. 5 5

The manifold relief valve, mounted off a bracket

attached to the torque tube, is installed in the body
hoist system to prevent the body from pulling a void
in the body hoist cylinders when dumping unbalanced
6
loads. The manifold relief valve also provides a TEST E

means for return oil from the body lower circuit to

return to the body and disc brake cooling tank.
FROM BODY
TO TANK CONTROL VALVE
OPERATION
TO BODY
Numbers in parentheses refer to Fig. 1. CONTROL VALVE

Refer to Fig. 2. As the body is raised, return oil from

the body cylinders enters the manifold relief valve at Fig. 2 - Body 'Raise' Position
port 'C'. Oil returns through the orifice and back to the
body and disc brake cooling tank. builds up to control the body. Relief cartridge (3) will open
at a pressure of 90 bar (1 300 lbf/in²) to allow a free flow
When the body runs ahead of pump supply, pressure of oil to the body and disc brake cooling tank.

SM 1645 R1 08-03 1
Body System - Manifold Relief Valve
Section 230-0110
Refer to Fig. 3. When the body control valve is used SM2782
to lower the body, oil enters the manifold relief valve
at port 'V'. Oil pressure opens check cartridge (2) to
port 'C' allowing oil to exit the manifold relief valve to 5 5
supply the lower ports on the body hoist cylinders.

Ports 'B' and 'G' are plugged with plugs (4) and
'O' rings (5). Connector (8) and cap (9) are installed
in port 'S' to provide a pressure check point.
6
TEST E

Return oil from the raise ports on the body cylinders

returns to the body and disc brake cooling tank, via
the body control valve. TO BODY
TO TANK CONTROL VALVE

FROM BODY
REMOVAL CONTROL VALVE
Numbers in parentheses refer to Fig. 4.

Fig. 3 - Body 'Lower' Position

WARNING
To prevent personal injury and property
SM - 589
damage, be sure wheel blocks and blocking
CHASSIS
materials are properly secured and of FRAME
adequate capacity to do the job safely.
TORQUE
TUBE
1. Position the vehicle in a level work place, raise the
body and secure in place with the body safety pins.
Apply the parking brake, switch off the engine and
operate steering left and right several times to
discharge the steering accumulator.

2. Block all road wheels.

3. Clean manifold relief valve (4) and surrounding

area with a suitable solvent. Identify and tag all
hydraulic lines connected to manifold relief valve (4),
to aid in installation. BODY CYLINDER
MOUNTING BRACKETS

4. With suitable containers available to catch 1 - Nut

spillage, disconnect all hydraulic lines from manifold 2 - Washer 4 - Manifold Relief Valve
3 - Bolt 5 - Bracket
relief valve (4). Cap all hydraulic lines and ports to
prevent entry of dirt. Fig. 4 - Exploded View Of Manifold Relief Valve Mounting

5. Remove mounting bolts (3), washers (2) and nuts (1)

securing manifold relief valve (4) to bracket (5). DISASSEMBLY
Move manifold relief valve (4) to a clean area for Numbers in parentheses refer to Fig. 1.
disassembly.
1. Remove plugs (4) from manifold body (1) and
6. If required, remove mounting hardware securing discard 'O' rings (5) from plugs (4).
bracket (5) to mounting bracket on the torque tube.
Remove mounting bracket (5). 2. Remove check cartridge (2) assembly from
manifold body (1).

3. Remove relief cartridge (3) assembly from

manifold body (1).

2 SM 1645 R1 08-03
 Body System - Manifold Relief Valve
Section 230-0110

4. If required, remove connector (8) and cap (9) from INSTALLATION

manifold body (1). Numbers in parentheses refer to Fig. 4, unless
otherwise specified.
INSPECTION Note: Tighten all fasteners to standard torques listed
Numbers in parentheses refer to Fig. 1. in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
1. Clean all parts thoroughly in a suitable solvent and
dry with compressed air. Inspect manifold body (1) Note: Tighten all hydraulic lines fitted with ORFS
bores and plugs (4) for grooves, deep scratches or connections, as described in Section 230-0000,
excessive wear. BODY SYSTEM SCHEMATIC. Renew all 'O' rings
where used.
2. Inspect check cartridge (2) and relief cartridge (3)
for signs of dirt contamination. If any contamination is
present carefully remove obvious particles and WARNING
proceed as follows: To prevent personal injury and property
damage, be sure wheel blocks and blocking
3. Through the nose of each cartridge, manually materials are properly secured and of
operate the inner working parts several times. Use a adequate capacity to do the job safely.
piece of plastic tubing to avoid damaging soft seats,
finished surfaces or screen protecting the pilot 1. If removed, install bracket (5) to mounting bracket
orifice. All parts should move freely. If possible do on the torque tube and secure with mounting
this with the cartridge submerged in mineral spirits. hardware removed at removal.

4. Dry both cartridges with compressed air. 2. Align manifold relief valve (4) with bracket (5) and
secure with bolts (3), washers (2) and nuts (1).
5. Examine cartridge seals (6 & 7) for signs of wear
or damage and replace if necessary. 3. Remove blanking caps and plugs and connect all
hydraulic lines to manifold relief valve (4) ports, as
Note: If cartridges (2 & 3) are damaged in any form tagged at removal.
they must be replaced with a new cartridge.
4. Start the engine, remove body safety pins and
operate the body to check manifold relief valve (4)
ASSEMBLY and hydraulic lines for leaks. Switch off the engine.
Numbers in parentheses refer to Fig. 1.
5. Remove cap (9, Fig. 1) and install a 0 - 207 bar
Note: Tighten all fasteners without special torques (0 - 3 000 lbf/in²) pressure gauge on connector
specified to torques listed in Section 300-0080, (8, Fig. 1).
STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS. 6. Start the engine and check manifold relief valve (4)
relief pressure is 90 bar (1 300 lbf/in²), at maximum
1. If removed, install connector (8) and cap (9) in rev/min and with body cylinder extending through
manifold body (1). second stage. If manifold relief valve (4) relief
pressure is not as above, it can be adjusted as
2. Install new 'O' rings (5) on plugs (4) and install follows:
plugs (4) in manifold body (1).
Note: Relief valve cartridge (3, Fig. 1) is factory
3. Install relief cartridge (3) in manifold body (1) and set at 90 bar (1 300 lbf/in²) and sealed.
torque tighten relief cartridge (3) to 60 - 65 Nm
(45 - 50 lbf ft). a. Break seal around relief cartridge (3, Fig. 1) and
unscrew the cap.
4. Install check cartridge (2) in manifold body (1) and
torque tighten check cartridge (2) to 60 - 65 Nm b. Slacken the lock nut on relief valve cartridge
(45 - 50 lbf ft). (3, Fig. 1) and adjust screw in, or out, until the
correct pressure reading is showing on the

SM 1645 R1 08-03 3
Body System - Manifold Relief Valve
Section 230-0110
pressure gauge. Tighten the lock nut and re-check of parts only.
the pressure setting. Install the cap on relief valve
cartridge (3, Fig. 1). When carrying out pressure checks on the machine,
follow the procedure described in 'Installation'. Refer
7. Switch off the engine, remove the pressure gauge to Section 300-0020, LUBRICATION SYSTEM, for
from connector (8, Fig. 1) and install cap (9, Fig. 1) recommended pressure check intervals.
on the connector.

8. Remove all wheel blocks. SPECIAL TOOLS

There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
MAINTENANCE SERVICE TOOLS, for part numbers of general
Inspect the manifold relief valve and hydraulic lines service tools required. These tools are available from
regularly for any signs of leakage or damage. Limited your dealer.
repair of the manifold relief valve is by replacement

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 2 Check Cartridge 60 - 65 45 - 50
1 3 Relief Cartridge 60 - 65 45 - 50

* * * *

4 SM 1645 R1 08-03
 BODY SYSTEM - Pilot Supply Valve
Section 230-0121

SM - 1799

13 2 4,5 3

12
11

PV
6,7,8
TO MANIFOLD
BRACKET IN
T P2
CAB FLOOR 9
10
1

TO STEERING TO MANIFOLD
TANK BRAKE VALVE

9 - Elbow - 90°
1 - Valve Body 5 - Seal 10 - Tee Piece
2 - Accumulator 6 - Bolt 11 - Diagnostic Fitting
3 - Mounting Bracket 7 - Lockwasher 12 - Cap
4 - Plug 8 - Washer 13 - Elbow - 45°

Fig 1. - Pilot Supply Valve Installation

DESCRIPTION SM - 2779

The pilot supply valve can be identified as item 14 in P1 P2

Section 230-0000, BODY SYSTEM SCHEMATIC.
30 - 35 bar (435 - 508 lbf/in²)
standard
Mounted off the accumulator mounting bracket on the
right hand platform, the pilot supply valve is located in
the hydraulic lines between the steering pump and the
body control joystick. See Fig. 2 for schematic symbol.
T

Intregal of the pilot supply valve is a restriction valve

which steps down the supply pressure of 159 bar
40 bar (580 lbf/in²)
(2 300 lbf/in²) from the steering pump to between standard
30 bar (435 lbf/in²) and 35 bar (500 lbf/in²). The pilot
PV
supply valve is fitted with an accumulator, pre-charged
with nitrogen, to a pressure of 13 bar (188 lbf/in²). Fig. 2 - Pilot Supply Valve Schematic Symbol

SM 1599 R1 08-03 1
Body System - Pilot Supply Valve
Section 230-0121

MAINTENANCE disconnect hydraulic lines. Fit blanking caps to all open

Numbers in parentheses refer to Fig. 1. lines.

The pilot supply valve is a non-serviceable item and 4. Remove bolts (6), lockwashers (7), washers (8) and
should be replaced completely, if damaged, as follows: pilot supply valve (1) from mounting bracket (3).

Note: Tighten all fasteners to standard torques listed in 5. Note location of elbows (9 & 13) and tee piece (10)
Section 300-0080, STANDARD BOLT AND NUT and remove from pilot supply valve (1) for use on the
TORQUE SPECIFICATIONS. new valve. If necessary, disconnect diagnostic fitting
(11) and cap (12) from elbow (13).
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 230-0000, BODY 6. Install elbows (9 & 13) and tee piece (10) in new pilot
SYSTEM SCHEMATIC. Renew all 'O' rings where supply valve (1) ports as removed from the old valve. If
used. necessary, install diagnostic fitting (11) and cap (12) to
elbow (13).

WARNINGS 7. Secure pilot supply valve (1) to mounting bracket

Hydraulic fluid pressure will remain within the (3) with bolts (6), washers (8) and lockwashers (7).
system after engine shut down. Operate the
body control joystick in both directions 8. Remove blanking caps from hydraulic lines and
approximately 15 times to ensure the pressure install lines to pilot supply valve (1) as identified during
has dissipated from the pilot supply valve removal.
accumulator before carrying out any work on
the body control system or serious injury could 9. Check oil level in the body and disc brake cooling
result. tank and add oil if required. Refer to Section 230-0040,
BODY AND DISC BRAKE COOLING TANK for correct
To prevent personal injury and property fill level, and, Section 300-0020, LUBRICATION
damage, be sure wheel blocks are properly SYSTEM for oil specification.
secured and of adequate capacity to do the job
safely. 10. Remove wheel blocks, start the engine and bring
hydraulic oil to operating temperature.
1. Position the vehicle in a level work area, be sure the
body is fully lowered, apply the parking brake and 11. Operate body control joystick (1) and check
switch off the engine. hydraulic line connections for leaks and tighten as
required.
2. Operate the body control joystick continuously to
discharge the pilot supply valve accumulator. Block all
road wheels. SPECIAL TOOLS
There are no special tools required for procedures
3. Ensure all hydraulic lines connected to pilot supply outlined in this section. Refer to Section 300-0020,
valve (1) are identified for ease of installation and, with SERVICE TOOLS, for part numbers of general service
suitable containers available to catch leakage, tools required. These tools are available from your
dealer.

* * * *

2 SM 1599 R1 08-03
 BODY SYSTEM - Body Cylinder
Section 230-0130

SM - 2462

BODY 4
3
2
1

FRAME
TORQUE
TUBE

6 5

6
1 6
2 5
3 1 - Pins
4 2 - Washer
6
3 - Lockwasher
4 - Bolt
5 - Cylinder
6 - Lube Fitting
Fig. 1 - Exploded View of Body Cylinder Mounting

DESCRIPTION
Numbers in parentheses refer to Fig. 1, unless WARNING
otherwise specified. Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the
The body cylinders can be identified as item 5 in body control joystick in both directions
Section 230-0000, BODY SYSTEM SCHEMATIC. approximately 15 times to ensure the pressure
has dissipated from the pilot supply valve
There are two body hoist cylinders mounted between accumulator before carrying out any work on
the frame rails. Cylinder base ends (3, Fig. 2) are the body control system or serious injury
connected to the body and retractable ends (26, Fig. 2) could result.
are connected to the frame. The cylinders are two-
stage with power down in the second stage. Cylinder 1. Position the vehicle in a level work area, raise the
mounting is by pins (1) secured by washers (2), body and install body prop pins at rear of unit. Apply
lockwashers (3) and bolts (4). the parking brake and switch off the engine.

2. Operate the body control joystick continuously to

REMOVAL discharge the pilot supply valve accumulator. Block all
Numbers in parentheses refer to Fig. 1. road wheels.

3. Install a suitable strap around the cylinder and

WARNING attach to a lifting device.
To prevent personal injury and property
damage, be sure wheel blocks and lifting 4. Ensure all hydraulic lines connected to body
equipment are properly secured and of cylinder (5) are identified for ease of installation and,
adequate capacity to do the job safely. with suitable containers available to catch leakage,
disconnect hydraulic lines. Fit blanking caps to all
open lines.

SM 1930 7-00 1
Body System - Body Cylinder
Section 230-0130

SM - 2463

25
26

18 15
24
22 10 23
21
20 9
8
17
16
14

19
27
15

12
11 28
13
29
30
7
31

6 28
2 5 29
4 32

3 33 25
1 34

1 - Bolt 10 - Wiper
2 - Bushing 11 - Wear Ring 19 - Tube 27 - Elbow - 45°
3 - Base 12 - Piston Ring 20 - Seal 28 - Bolt
4 - Backup Ring 13 - Tube 21 - Wear Ring 29 - Lockwasher
5 - 'O' Ring 14 - Set Screw 22 - Wiper 30 - P-clip
6 - Wear Ring 15 - Seal 23 - 'O' Ring 31 - Hose Assembly
7 - Tube 16 - Tube 24 - Backup Ring 32 - P-clip
8 - Seal 17 - Bushing 25 - Fitting 33 - Coupling
9 - Wear Ring 18 - Nut 26 - End 34 - Lube Fitting

Fig. 2 - Exploded View of Body Cylinder

4. Remove bolt (4), lockwasher (3), washer (2) and DISASSEMBLY

upper pin (1) from cylinder (5) connecting it to the Numbers in parentheses refer to Fig. 2.
body.

5. Collapse the cylinder. Wire cylinder to prevent it WARNING

from extending during removal. To prevent personal injury and property
damage, be sure lifting equipment is properly
6. Remove bolt (4), lockwasher (3), washer (2) and pin secured and of adequate capacity to do the job
(1) from lower end of cylinder. safely.

7. Remove cylinder to a clean area for 'Disassembly'. 1. Remove bolts (1) and nuts (18) securing base (3) to
cylinder tube (19). Remove base (3).

2 SM 1930 7-00
 Body System - Body Cylinder
Section 230-0130
2. Remove and discard backup ring (4) and 'O' ring (5) 7. Replace all seals, 'O' rings and wipers.
from base (3).

3. Extend end (26) assembly about 150 mm (6 in) and ASSEMBLY

remove set screw (14). Numbers in parentheses refer to Fig. 2.

4. Unscrew end (26) and remove.

WARNING
5. Remove and discard 'O' ring (23) and backup ring To prevent personal injury and property
(24) from end (26). damage, be sure lifting equipment is properly
secured and of adequate capacity to do the job
6. Push inner tube (7) from outer tube (19) and safely.
remove. Remove wear ring (6) from tube (7).
1. If removed, replace grease fitting (25) in end (26)
7. Remove and discard wiper (10), wear ring (9) and and replace bushings (2 & 17) in base (3) and end
seals (8) from tube (7). (26), respectively.

8. Push tube (13) from outer tube (19) and remove. 2. Install seal (20), wear ring (21) and wiper (22) into
Remove wear ring (11) and piston rings (12) from tube tube (19).
(13). Discard piston rings (12).
3. Replace seals (15) on tube (16) and place tube in
9. Remove tube (16) from tube (13). Remove and tube (13).
discard seals (15) from tube (16).
4. Place wear ring (11) and new piston rings (12) on
10. Remove and discard seal (20), wear ring (21) and tube (13), and install in tube (19).
wiper (22) from tube (19).
5. Install seals (8), wear ring (9) and wiper (10) in tube (7).
11. Press bushings (2 & 17) from base (3) and end
(26), respectively, if bushings show signs of excessive 6. Install wear ring (6) on tube (7) and place inner tube
wear. (7) in outer tube (19).

12. Remove grease fitting (25) from end (26), if damaged. 7. Place backup ring (24) and 'O' ring (23) on end (26).

8. Install end (26) assembly into tube (13) and tighten

INSPECTION to a torque of 1 900 - 2 300 Nm (1 400 - 1 700 lbf ft)
1. Wash all parts thoroughly in a suitable solvent and lubed.
dry with clean, lint-free cloths. Clean all grooves
carefully to remove any foreign material. 9. Install set screw (14) into tube (13).

2. Blow out the passages in the tubes and piston rod 10. Replace 'O' ring (5) and backup ring (4) on base (3).
with compressed air to remove any foreign material.
11. Align base (3) and tube (19) as shown in Fig. 3.
3. Inspect the tubes, for broken welds or deep
grooves. Shine a light through components to inspect SM - 181
for damage.

4. Remove ridges, nicks and scratches with a fine

stone and clean. Replace any components which
cannot be repaired.

5. Inspect all bolts and nuts for thread damage and

replace as necessary.

6. Inspect bushings and wear rings for excessive

wear, and replace as necessary.
Fig. 3 - Aligning Base

SM 1930 7-00 3
Body System - Body Cylinder
Section 230-0130
12. Secure base (3) to tube (19) with bolts (1) and 4. Check oil level in the body and disc brake cooling
nuts (18). Tighten bolts (1) to a torque of 156 - 176 Nm tank and add oil if required. Refer to Section 230-0040,
(115 - 130 lbf ft) lubed. BODY AND DISC BRAKE COOLING TANK for correct
fill level, and, Section 300-0020, LUBRICATION
SYSTEM for oil specification.
INSTALLATION
Numbers in parentheses refer to Fig. 1. 5. Start the engine and bring hydraulic oil to operating
temperature. Extend cylinder until top mounting hole is
Note: Tighten all fasteners to torques listed in aligned. Coat pin (1) shaft with anti-seize compound
Section 300-0080, STANDARD BOLT AND NUT and install in top mounting bore. Secure pin (1) in
TORQUE SPECIFICATIONS. place with washer (2), lockwasher (3) and bolt (4).

Note: Tighten all hydraulic lines fitted with ORFS 6. Lubricate pins at lube fittings (6) with lubricant as
connections, as described in Section 230-0000, BODY specified in Section 300-0020, LUBRICATION
SYSTEM SCHEMATIC. Renew all 'O' rings where SYSTEM. Check hydraulic oil tank level. Refer to
used. Section 230-0040, BODY AND DISC BRAKE
COOLING TANK.

WARNING 7. Remove body prop pins and operate body. Check

To prevent personal injury and property hydraulic line connections for leaks and tighten as
damage, be sure lifting equipment is properly required. Remove wheel blocks.
secured and of adequate capacity to do the job
safely.
MAINTENANCE
1. Install a suitable strap around the cylinder and Every 50 Hours:
position cylinder on unit so that bottom lube fitting (6) Lubricate body hinge pins and body hoist bushings
is toward the rear of the truck. with grease, as specified in Section 300-0020,
LUBRICATION SYSTEM.
2. Coat pin (1) shaft with anti-seize compound and
install in bottom mounting bore. Secure pin (1) in place
with washer (2), lockwasher (3) and bolt (4). SPECIAL TOOLS
There are no special tools required for procedures
3. Remove blanking caps from hydraulic lines and outlined in this section. Refer to Section 300-0020,
install lines to cylinder ports as identified during SERVICE TOOLS, for part numbers of general service
removal. tools required. These tools are available from your
dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
2 1 Bolt 156 - 176 115 - 130
2 26 End 1 900 - 2 300 1 400 - 1 700

* * * *

4 SM 1930 7-00
 BRAKING SYSTEM - Braking System Schematic
Section 250-0000

DESCRIPTION The accumulator is of the piston type and is

Numbers in parentheses refer to Figs. 2 through 7. precharged with nitrogen to 55 bar (800 lbf/in2). It
consists of a charging valve assembly, cylinder
The hydraulic braking system is of closed centre assembly and a piston. The charging valve is
design wherein constant pressure is stored in equipped with a locking feature which, when opened,
accumulators and is regulated, as required, to retard will allow the precharge to be checked or the
or stop the machine. accumulator charged. The piston acts as a separator
dividing the cylinder assembly into two sections. The
A brief description of the individual components used section nearest the charging valve contains the
in the braking system are listed below. Detailed nitrogen precharge. The other section receives the
service and operating instructions for the individual hydraulic oil from the pump, via the brake manifold
components can be found in their relative component valve.
sections in this manual.

Brake Manifold Valve (3)

Steering and Brake Control Tank Refer to Section 250-0050, BRAKE MANIFOLD
Refer to Section 220-0040, STEERING AND BRAKE VALVE.
CONTROL TANK.
The brake manifold valve is mounted off the cab
The steering and brake control tank is the common oil mounting crossmember and distributes hydraulic oil
reservoir for the steering system and the brake control flow from the pump, to the treadle valve, front and rear
system. It is mounted off the left hand frame rail beside brake circuit accumulators and parking brake at the
the body and disc brake cooling tank. rear wheels. It also provides appropriate returns to
tank for the hydraulic oil.
Steering Pump (1) Rear Brake Accumulator Pressure Switch (14) -
Refer to Section 220-0050, STEERING PUMP. The normally closed (NC) pressure switch, located in
port 'PS2', senses the pressure in the rear brake
The steering pump is an axial piston, variable accumulator. The pressure switch sends a signal to a
displacement (adjustable) pump, capable of high warning light on the dash panel when pressure drops
pressure operation. It is the common pressure supply below 82 bar (1 205 lbf/in²).
to both the steering and brake control systems. Output
is controlled to meet system requirements at any given Front Brake Accumulator Pressure Switch (15) -
time. The normally closed (NC) pressure switch, located in
port 'PS1', senses the pressure in the front brake
A compensator valve assembly regulates system accumulator, and sends a signal to a warning light on
pressure at 159 bar (2 300 lbf/in²). the dash panel when pressure drops below 90 bar
(1 323 lbf/in²).
The steering pump is assembled for right hand
(clockwise) rotation, as viewed from the driveshaft end. Parking Brake Pressure Switch (16) - The normally
closed (NC) pressure switch, located in port 'PS3',
Note: Never drive a pump in the wrong direction of senses pressure in the parking brake line, and sends a
rotation, as pump seizure may result. signal to a warning light on the dash panel when
pressure drops below 65 bar (940 lbf/in²).
Accumulator (2)
Refer to Section 220-0130, ACCUMULATOR. Treadle Valve (4)
Refer to Section 250-0070, TREADLE VALVE.
There are two brake accumulators mounted at the rear
of the cab. One for the rear brake circuit and the other The treadle valve controls the level of hydraulic oil
for the front brake circuit. The rear brake circuit pressure applied to front and rear brakes and the
accumulator also maintains a constant pressure in the maximum pressure available to these circuits. It is
parking brake circuit, to hold the parking brake off, operated by a foot pedal in the operators cab and, with
when the truck is operating. the engine running, is automatically applied by the
brake manifold valve.

SM 2039 Rev 1 11-00 1

Braking System - Braking System Schematic
Section 250-0000
The differing maximum operating pressures required for service brakes, or, the retarder control valve, to utilise
the front and rear brakes are achieved within the treadle the rear service brakes as a retarder.
valve. These can be adjusted, BUT, only together, i.e.
adjustments are made to both circuits simultaneously. The shuttle valve consists of a well fitting spool which
is pushed under pressure, depending on flow direction,
Stop Light Pressure Switch (13) - The normally open to one end position, where it seals against an 'O' ring
(NO) pressure switch is located in the front plate of the seal. The 'O' ring is protected by a metal housing.
treadle valve in the 'B1' circuit. As brake pressure
increases to 2.7 bar (39 lbf/in²) and above, the circuit
should close and send a signal to illuminate the brake Oil Cooled Disc Brakes (7)
lights. As pressure drops below 2.7 bar (39 lbf/in²) the Refer to Section 165-0030, BRAKE PARTS.
circuit should open and brake lights go out.
Service Brakes
Lockup Drop Out Pressure Switch (17) - The The service brakes are of 'Upright Design', i.e.
normally open (NO) pressure switch is located in the requiring pressure to hold the brakes on.
front plate of the treadle valve in the 'B2' circuit. As
brake pressure increases to 20 bar (290 lbf/in²) and The rear service brakes are hydraulically actuated to
above, the circuit should close and send a signal to the slow or stop drive wheel rotation. When the treadle
lockup drop out solenoid, which in turn drops the valve in the operators' compartment is depressed, or
transmission out of lockup. As pressure drops below when the retarder control lever on the centre console
20.5 bar (301 lbf/in²) the circuit should open and is actuated, with the retarder selection switch (if fitted)
lockup can be engaged. at the disc brake position, hydraulic pressure is
transmitted to the disc brake assembly. Hydraulic
pressure entering the disc brake assembly forces the
Front Brake Callipers (5) service piston against the brake disc pack consisting
Refer to Section 165-0020, BRAKE PARTS. of damper assemblies, rotating friction discs and
splined plates.
The service brakes are of the calliper disc type. The
calliper brake head is designed for use with hydraulic The rotating friction discs, which are driven by the
oils meeting the specifications outlined in Section wheel through wheel drivers and disc drivers, are
300-0020, LUBRICATION SYSTEM. DO NOT USE compressed between the splined plates. This slows
BRAKE FLUID (J1703). down and stops rotation of the driving wheels. The
force applied against the disc pack is directly
The calliper head is bolted to a mounting plate on the proportional to the degree of which the service brake
spindle and the disc is bolted to the wheel. There are treadle valve is depressed, or, retarder control lever is
two brake heads at each wheel. Each calliper brake moved.
head assembly consists of a torque plate, two brake
pads; one on each side of the disc, and six brake When the service brake treadle valve, or retarder
pistons; three on each side of the disc. control lever, is released, hydraulic pressure against
the service piston is relieved allowing the service
The brake is actuated by hydraulic oil entering the piston to return to its original position, thus, relieving
brake head through one of the bleeder ports. The the pressure against the brake disc pack.
piston bores on each side of the torque plate are
interconnected by internal passages. When the brake Parking Brakes
is actuated, the hydraulic pressure forces the pistons The parking brake is of 'Inverted Design', i.e. requiring
against the brake pads which are in turn forced pressure to hold the brakes off.
against each side of the brake disc, slowing or
stopping the disc and wheel rotation. The parking brakes are controlled by the park/
emergency brake control mounted on the right hand
side of the dash panel. The parking brakes are applied
Shuttle Valve (6) by spring tension and released by hydraulic pressure.
Refer to Section 250-0140, SHUTTLE VALVE. With the park/emergency control 'Out', the parking
brakes are held off. With the park/emergency control
The shuttle valve allows the distribution of pressure 'In' the parking brakes are held on.
from either the treadle valve, to activate the rear

2 SM 2039 Rev 1 11-00

 Braking System - Braking System Schematic
Section 250-0000

Monoblock Brake Valve (8) separate retarder selection switch on the dash panel.
Refer to Section 250-0100, MONOBLOCK BRAKE Pressing the switch at the top will select the OCDB
VALVE. retarder and pressing the bottom will select the
transmission retarder.
Mounted off the left hand frame rail, the monoblock
brake valve incorporates three valves; a pressure Note: The transmission retarder circuit is made up of
reducing valve, pressure relief valve and a shuttle valve. Directional Control Valve (11) and Transmission
Retarder Cylinder (12).
The pressure reducing valve reduces the available
hydraulic oil pressure from the rear brake accumulator
to a pressure of 83 bar (1 200 lbf/in2). Retarder Light Pressure Switch (18)
The retarder light pressure switch is a normally open
The pressure relief valve regulates pressure, after (NO) switch. As retarder pressure increases to 2.7 bar
pressure the reducing valve, to provide a residual (39 lbf/in²) and above, the circuit should close and
pressure of 3.1 ± 0.35 bar (45 ± 5 lbf/in2) in the rear send a signal to illuminate the retarder indicator light in
brake lines. A filter system, comprising of a disc filter the dash panel, and the retarder light at the rear of the
and a conical filter, helps protect an orifice plate at truck. As pressure drops below 2.7 bar (39 lbf/in²) the
the pressure relief valve. circuit should open and the retarder lights should go
out.
The shuttle valve, depending on spool position,
provides a residual pressure of 3.1 ± 0.35 bar
(45 ± 5 lbf/in2) in the rear brake lines, or, upon Pressure Reducing Valve (19)
actuation of the treadle or retarder valve, the brake Refer to Section 250-0110, PRESSURE REDUCING
actuation pressure overcomes the residual pressure VALVE.
to give a brake application at the rear brake packs.
Mounted on the inside of the left hand frame rail in
front of the body guide, the pressure reducing valve is
Directional Control Valve (9) located in the hydraulic brake circuit between the
Refer to Section 250-0090, DIRECTIONAL treadle valve and the front brake callipers.
CONTROL VALVE.
The pressure reducing valve, on application of the
The directional control valve is located in the 'Px' 50% brake reduction switch, mounted on the dash
hydraulic circuit between the brake manifold valve and panel in the cab, allows the operator to limit the
the treadle valve. The 'Px' circuit hydraulically actuates braking pressure to 50% at the front brakes.
the treadle valve when the park/emergency control
switch is activated. The directional control valve also
controls automatic service brake, applied pressure Pressure Test Points
bleed down, with engine shutdown. There are four diagnostic pressure test points in the
braking system, as shown in Figs. 2 through 7.

Retarder Control Valve (10) Note: When checking hydraulic pressures the vehicle
Refer to Section 250-0130, RETARDER CONTROL should be positioned on a level surface and all road
VALVE. wheels securely blocked.

The retarder control valve, mounted in the centre Test Point A

console to the right hand side of the operator, is a Park Brake Pressure - Taken from port 'TP1' on the
closed centre controller which is used to apply a monoblock brake valve, this pressure can be checked
continuous braking force to hold the vehicle at a safe at diagnostic test point (rear) mounted off rear
steady speed when descending grades. mounting bracket for the body and disc brake cooling
tank.
The valve applies reduced pressure to either the oil
cooled disc brakes (OCDB) or the optional Pressure reading should be 83 bar (1 200 lbf/in2) with
transmission retarder. Selection of either the OCDB the engine running and the parking emergency brake
retarder or transmission retarder is made by a control applied (pressed in).

SM 2039 Rev 1 11-00 3

Braking System - Braking System Schematic
Section 250-0000
Test Point B a. Ensure 'O' ring/seal is in place and that joining
Transmission Pilot Pressure - Taken from a tee in the surfaces are clean. If necessary, retain 'O' ring/seal in
transmission pilot pressure line to the directional place with a light coating of grease or vaseline.
control valve, this pressure can be checked at
diagnostic test point at the rear left hand cab support. b. Initially, the nuts should be tightened by hand.

Pressure should be 11.7 - 12.7 bar (170 - 180 lbf/in2) c. Where a hose is fitted, ensure that it is not twisted or
with the engine operating at 1 500 rev/min, output kinked when the nuts are tightened so that it is allowed
stalled, in all ranges and lockup. to adopt a natural position.

Test Point C d. Where a tube is fitted, ensure that the connection is

Front Service Brakes Pressure - Taken from a tee in aligned correctly.
the 'B1' line from the treadle valve to the front brake
callipers, this pressure can be checked at diagnostic e. Tighten the nut a further 1/4 to 1/2 a turn using the
test point at the rear left hand cab support. correct size spanner (wrench).

Pressure reading should be 110 bar (1 600 lbf/in2) with f. Check that a satisfactory hose or tube routing has
the engine running and the treadle valve applied. been achieved.

Test Point D
This test point is used to record the Rear Service RELIEVING PRESSURE
Brake Pressure, Residual Brake Pressure and the
Retarder Pressure - Taken from port 'TP2' on the
monoblock brake valve, these pressures can be WARNINGS
checked at diagnostic test point (front) mounted off The braking system is equipped with
rear mounting bracket for the body and disc brake accumulators which maintain pressure in the
cooling tank. Pressure readings should be as follows: system even after engine shutdown. Operate
the treadle valve continuously until the
Rear Service Brakes Pressure - 52 bar (750 lbf/in2), pressure has dissipated before carrying out
with the engine running and treadle valve applied. any work on the braking system or serious
injury could result.
Residual Brake Pressure - 3.1 ± 0.35 bar
(45 ± 5 lbf/in2), with the engine running and both the To prevent personal injury and property
service brakes and the parking brakes released. damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
Retarder Pressure - 33 bar (480 lbf/in2), with the safely.
engine running and the retarder control lever fully applied.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine.
'O' RING FACE SEALS (ORFS)
Where hydraulic lines are fitted with ORFS 2. Operate the treadle valve continuously to discharge
connections, the following procedure should be carried the brake accumulators (pressure in accumulator
out during installation. Refer to Fig. 1. hydraulic lines should be 0 bar (0 lbf/in2)). Block all
road wheels.

SM - 1335
FITTING NUT 3. Carefully loosen brake pipes at base of both the
front and rear accumulators to check that all pressure
TUBE
has been released. Tighten brake pipes.

BLEEDING THE BRAKES

If either the front or rear brake assemblies have been
serviced, the brakes must be bled to ensure that no air
SLEEVE remains in the braking system.
'O' RING 'O' RING
Fig. 1 - Assembly of Typical ORFS Connector

4 SM 2039 Rev 1 11-00

 Braking System - Braking System Schematic
Section 250-0000

In the interests of safety, it is important that the exact Multi-gauge

procedure for bleeding the brakes is carried out as The multi-gauge is basically four pressure gauges in
outlined in Section 165-0030, BRAKE PARTS (rear one. Continuous system pressure readings are
brakes) and Section 165-0020, BRAKE PARTS (front indicated on one of three simultaneously reading
brakes). gauges through a pressure range of 762 mm (30 in) of
vacuum to 345 bar (5 000 lbf/in2).

SERVICE TOOLS
It is recommended that the following tools are used Non-contact Infrared Thermometer
when carrying out pressure or temperature checks The infrared thermometer can be used to spot heat
during maintenance procedures. These tools, along problems early in electrical, mechanical and hydraulic
with other general service tools, are available from systems. Hand held and easy to use, you simply aim, pull
your dealer. Refer to Section 300-0070, SERVICE the trigger, and read the temperature. Since there
TOOLS, for part numbers of these tools. 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.

BRAKING SYSTEM DIAGNOSIS

CONDITION REASON REMEDY
Inadequate braking Low System Pressure Check oil level
Check oil condition
Check for leakage
Check system pressure and adjust as
required
Treadle valve delivery pressure below Check front and rear brake circuits
normal Check treadle valve operation
Check for leakage (modular assembly)
Brake surfaces inefficient Check brake linings and discs
Check callipers for leakage
Replace seals or components as required
Brakes do not release Defective treadle valve Repair or replace defective component.
Check adjustments (pedal return).
Loose or broken wire in the brake Repair circuit as required
manifold valve solenoid circuit
Faulty solenoid Replace defective component
Faulty park/emergency switch Repair or replace as required
Restriction in tank return line Clear restriction
Seal bypass condition - parking brake Replace seals or component as required
assembly
Emergency brakes do Faulty park/emergency switch Repair or replace as required
not apply Faulty solenoid Replace defective component
No transmission pilot pressure at Check transmission pressure
directional control valve Check for restriction in pilot line
Faulty directional control valve Check spool operation. Repair or replace
component.
Oil leakage - service brakes Check and repair
Faulty park brake assembly Replace seals or component as required
Faulty brake manifold solenoid cartridge Check valve operation. Replace solenoid
cartridge if required.

SM 2039 Rev 1 11-00 5

6

Section 250-0000
Braking System - Braking System Schematic
SM - 2296A

7 7 C OUTLET
COMPONENTS 19
1 - Steering Pump
TEST
2 - Accumulators
3 - Brake Manifold Valve
4 - Treadle Valve REF.
5 - Front Brake Callipers BODY
6 - Shuttle Valve HOIST
7 - Oil Cooled Disc Brakes CIRCUIT
RB2 RB1
8 - Monoblock Brake Valve TP2 INLET TANK
8
9 - Directional Control Valve D
10 - Retarder Control Valve
FB
11 - Directional Control Valve
9 B A
12 - Transmission Retarder Cylinder B
TP1 4
13 - Stop Light Pressure Switch 5
b
14 - Rear Brake Accumulator PX
A a
Pressure Switch
15 - Front Brake Accumulator T
Pressure Switch T P
16 - Parking Brake Pressure Switch
17 - Lockup Drop Out Pressure P1 P2
Switch 16 A
B1 B2 P1 P2
18 - Retarder Light Pressure Switch 1
2 2
*19 - Pressure Reducing Valve 3 6
13 17 12
* - Optional Components

PRESSURE TEST POINTS A P1

A - Park Brake Pressure
B - Transmission Pressure B T
18
C - Front Service Brake Pressure
10 11 A B
D - Rear Service Brake Pressure,
Residual Brake Pressure and
Retarder Pressure. T REG
P
COLOUR CODES PY
P P T
Red - Pressurized Oil ACC1
Blue - Exhaust or Return Oil
Green - Intake Oil ACC2
Orange - Pilot Pressure PS1 PS2
SM 2039 Rev 1 11-00

Yellow - Static Oil

15 14

Fig. 2 - Braking System Schematic - Engine Shutdown

SM 2039 Rev 1 11-00
SM - 2296B

7 7 C OUTLET
19
COMPONENTS
1 - Steering Pump TEST
2 - Accumulators
3 - Brake Manifold Valve REF.
4 - Treadle Valve BODY
5 - Front Brake Callipers HOIST
6 - Shuttle Valve CIRCUIT
7 - Oil Cooled Disc Brakes RB2 RB1
8 TP2 INLET TANK
8 - Monoblock Brake Valve D
9 - Directional Control Valve
10 - Retarder Control Valve FB
11 - Directional Control Valve 9 B A
B
12 - Transmission Retarder Cylinder TP1 4 5
13 - Stop Light Pressure Switch b
PX
14 - Rear Brake Accumulator A a

Braking System - Braking System Schematic

Pressure Switch
T
15 - Front Brake Accumulator
T P
Pressure Switch
16 - Parking Brake Pressure Switch P1 P2
17 - Lockup Drop Out Pressure 16 A
Switch B1 B2 P1 P2
1
18 - Retarder Light Pressure Switch 2 2
3 13 17 6
*19 - Pressure Reducing Valve 12

* - Optional Components
A P1
PRESSURE TEST POINTS
A - Park Brake Pressure B T
B - Transmission Pressure 18
C - Front Service Brake Pressure 10 11 A B
D - Rear Service Brake Pressure,
Residual Brake Pressure and
T REG
Retarder Pressure. P
PY P T
COLOUR CODES P
ACC1
Red - Pressurized Oil
Blue - Exhaust or Return Oil ACC2
Green - Intake Oil PS1 PS2

Section 250-0000
Orange - Pilot Pressure
Yellow - Static Oil 15 14

Fig. 3 - Braking System Schematic - Engine Running

7
8

Section 250-0000
Braking System - Braking System Schematic
SM - 2296C

COMPONENTS 7 7 C OUTLET
19
1 - Steering Pump
2 - Accumulators TEST
3 - Brake Manifold Valve
4 - Treadle Valve
REF.
5 - Front Brake Callipers
BODY
6 - Shuttle Valve HOIST
7 - Oil Cooled Disc Brakes CIRCUIT
8 - Monoblock Brake Valve RB2 RB1
TP2 INLET TANK
9 - Directional Control Valve 8
D
10 - Retarder Control Valve
11 - Directional Control Valve FB
12 - Transmission Retarder Cylinder 9 B A
B
13 - Stop Light Pressure Switch TP1 4 5
14 - Rear Brake Accumulator b
PX
Pressure Switch A a
15 - Front Brake Accumulator
Pressure Switch T
16 - Parking Brake Pressure Switch T P
17 - Lockup Drop Out Pressure P1 P2
Switch
16 A
18 - Retarder Light Pressure Switch B1 B2 P1 P2
1
*19 - Pressure Reducing Valve 2 2
3 13 17 6
12
* - Optional Components

PRESSURE TEST POINTS A P1

A - Park Brake Pressure
B - Transmission Pressure
B T
C - Front Service Brake Pressure 18
D - Rear Service Brake Pressure, 10 11 A B
Residual Brake Pressure and
Retarder Pressure.
T REG
P
COLOUR CODES
PY P T
Red - Pressurized Oil P
ACC1
Blue - Exhaust or Return Oil
Green - Intake Oil
ACC2
Orange - Pilot Pressure
PS1 PS2
Yellow - Static Oil
SM 2039 Rev 1 11-00

15 14

Fig. 4 - Braking System Schematic - Engine Running, Service Brake Applied

SM 2039 Rev 1 11-00
SM - 2296D

7 7 C OUTLET
COMPONENTS 19
1 - Steering Pump
2 - Accumulators TEST
3 - Brake Manifold Valve
4 - Treadle Valve
REF.
5 - Front Brake Callipers BODY
6 - Shuttle Valve HOIST
7 - Oil Cooled Disc Brakes CIRCUIT
8 - Monoblock Brake Valve RB2 RB1
8 TP2 INLET TANK
9 - Directional Control Valve D
10 - Retarder Control Valve
11 - Directional Control Valve FB
12 - Transmission Retarder Cylinder 9 B A
B
13 - Stop Light Pressure Switch TP1 4 5
14 - Rear Brake Accumulator b
PX
Pressure Switch A a
15 - Front Brake Accumulator

Braking System - Braking System Schematic

T
Pressure Switch
T P
16 - Parking Brake Pressure Switch
17 - Lockup Drop Out Pressure P1 P2
Switch 16 A
18 - Retarder Light Pressure Switch B1 B2 P1 P2
1
*19 - Pressure Reducing Valve 2 2
3 13 17 6
12
* - Optional Components

PRESSURE TEST POINTS A P1

A - Park Brake Pressure
B - Transmission Pressure
B T
C - Front Service Brake Pressure 18
D - Rear Service Brake Pressure, 10 11 A B
Residual Brake Pressure and
Retarder Pressure.
T REG
P
COLOUR CODES PY
Red - Pressurized Oil P P T
ACC1
Blue - Exhaust or Return Oil
Green - Intake Oil
ACC2
Orange - Pilot Pressure PS1 PS2
Yellow - Static Oil

Section 250-0000
15 14

Fig. 5 - Braking System Schematic - Engine Running, Park/Emergency Brake Applied

9
10

Section 250-0000
Braking System - Braking System Schematic
SM - 2296E

7 7 C OUTLET
COMPONENTS 19
1 - Steering Pump
2 - Accumulators TEST
3 - Brake Manifold Valve
4 - Treadle Valve REF.
5 - Front Brake Callipers BODY
6 - Shuttle Valve HOIST
7 - Oil Cooled Disc Brakes CIRCUIT
8 - Monoblock Brake Valve RB2 RB1
8 TP2 INLET TANK
9 - Directional Control Valve D
10 - Retarder Control Valve
11 - Directional Control Valve FB
12 - Transmission Retarder Cylinder 9 B A
B
13 - Stop Light Pressure Switch TP1 4 5
14 - Rear Brake Accumulator b
PX
Pressure Switch A a
15 - Front Brake Accumulator
T
Pressure Switch
T P
16 - Parking Brake Pressure Switch
17 - Lockup Drop Out Pressure P1 P2
Switch 16 A
18 - Retarder Light Pressure Switch B1 B2 P1 P2
1
*19 - Pressure Reducing Valve 2 2
3 13 17 6
12
* - Optional Components

PRESSURE TEST POINTS A P1

A - Park Brake Pressure
B - Transmission Pressure B T
C - Front Service Brake Pressure 18
D - Rear Service Brake Pressure, 10 11 A B
Residual Brake Pressure and
Retarder Pressure.
T REG
P
COLOUR CODES PY
P P T
Red - Pressurized Oil ACC1
Blue - Exhaust or Return Oil
Green - Intake Oil ACC2
Orange - Pilot Pressure PS1 PS2
Yellow - Static Oil
SM 2039 Rev 1 11-00

15 14

Fig. 6 - Braking System Schematic - Engine Running, OCDB Retarder Applied

SM 2039 Rev 1 11-00
SM - 2296F

COMPONENTS 7 7 C OUTLET
1 - Steering Pump 19
2 - Accumulators
TEST
3 - Brake Manifold Valve
4 - Treadle Valve
5 - Front Brake Callipers REF.
6 - Shuttle Valve BODY
HOIST
7 - Oil Cooled Disc Brakes
CIRCUIT
8 - Monoblock Brake Valve RB2 RB1
9 - Directional Control Valve 8 TP2 INLET TANK
D
10 - Retarder Control Valve
11 - Directional Control Valve FB
12 - Transmission Retarder Cylinder 9 B A
13 - Stop Light Pressure Switch B
TP1 4 5
14 - Rear Brake Accumulator b
PX
Pressure Switch A a

Braking System - Braking System Schematic

15 - Front Brake Accumulator
Pressure Switch T
16 - Parking Brake Pressure Switch T P
*

17 - Lockup Drop Out Pressure P1 P2

Switch
*

16 A
18 - Retarder Light Pressure Switch B1 B2 P1 P2
1
*19 - Pressure Reducing Valve 2 2
*

3 13 17 6
12
*

* - Optional Components

PRESSURE TEST POINTS A P1

A - Park Brake Pressure
B - Transmission Pressure
B T
C - Front Service Brake Pressure 18
D - Rear Service Brake Pressure, 10 11 A B
Residual Brake Pressure and
Retarder Pressure.
T REG
P
COLOUR CODES PY
Red - Pressurized Oil P P T
ACC1
Blue - Exhaust or Return Oil
Green - Intake Oil
ACC2
Orange - Pilot Pressure PS1 PS2

Section 250-0000
Yellow - Static Oil
15 14

Fig. 7 - Braking System Schematic - Engine Running, Transmission Retarder Applied

11
 BRAKING SYSTEM - Brake Manifold Valve
Section 250-0050
SM - 1505

6 PY ACC1

P ACC2

7 5,18

PS1 P2
P1
8 1
PS2
9 T PS3
A 20
P
10
B

16
14
12
11
2

17
15 3
19
13

1 - Valve Body 6 - Retainer 11 - 'O' Ring 16 - 'O' Ring

2 - Solenoid Cartridge 7 - 'O' Ring 12 - 'O' Ring 17 - Backup Rings
3 - Solenoid Coil 8 - Spring 13 - Backup Rings 18 - 'O' Ring
4 - Locknut 9 - Check Ball 14 - 'O' Ring 19 - Accumulator Pressure Switches
5 - Plug 10 - Seat 15 - Backup Rings 20 - Park Brake Pressure Switch

Fig. 1 - Exploded View of Brake Manifold Valve

DESCRIPTION Hydraulic oil from the steering pump enters the brake
The brake manifold valve can be identified as item 3 in manifold valve at port 'P'. Oil pressure moves check
Section 250-0000, BRAKING SYSTEM SCHEMATIC. balls (9) from their seats (10) and allows oil to flow
through port 'ACC1' to the front brake accumulator
Mounted off the cab mounting crossmember, the and through port 'ACC2' to the rear brake accumulator.
brake manifold valve distributes hydraulic oil flow from
the steering pump, to the treadle valve, front and rear Pressurised oil exits the brake manifold valve through
brake circuit accumulators and parking brake at the port 'PY' and flows to port 'P1' on the treadle valve,
rear wheels. The valve also provides appropriate and, through port 'P1' on the brake manifold valve to
returns to the steering and brake control tank for the port 'P2' on the treadle valve.
hydraulic oil.
Solenoid Cartridge - De-energized
When the park/emergency brake switch is activated
OPERATION (pushed in), the electrical signal between the switch
Numbers in parentheses refer to Fig. 1. Refer to Figs. and solenoid coil (3) is opened, de-energizing solenoid
2 and 3 for hydraulic schematics. cartridge (2). Oil flows through solenoid cartridge (2)
and exits the brake manifold valve through port 'A' to

SM 2040 R1 07-03 1
Braking System - Brake Manifold Valve
Section 250-0050

SM - 1660

16

PS3 3

TO DIRECTIONAL
A P1 TO PORT 'P2'
CONTROL VALVE
TREADLE VALVE
FROM MONOBLOCK
BRAKE VALVE B T

FROM
STEERING PUMP P
PY
TO PORT 'P1' TREADLE VALVE
ACC1
TO FRONT ACCUMULATOR
TO REAR ACCUMULATOR
ACC2
PS1 PS2

15 14

3 - Brake Manifold Valve 15 - Front Brake Accumulator Pressure Switch

14 - Rear Brake Accumulator Pressure Switch 16 - Parking Brake Pressure Switch
Fig. 2 - Park/Emergency Brake Switch Activated - Solenoid Cartridge De-energized

the directional control valve. The oil travels through the Pressure Switches
directional control valve and into the 'Px' port in the The normally closed (NC) pressure switch (19), located
treadle valve for an emergency brake application. in port 'PS1', senses the pressure in the front brake
accumulator, and sends a signal to a warning light on
Return oil from the parking brake circuit flows through the dash panel when pressure drops below 125 bar
the monoblock brake valve and enters the brake (1 812 lbf/in²). The normally closed (NC) pressure
manifold valve at port 'B'. The oil flows through switch (19), located in port 'PS2', senses the pressure
solenoid cartridge (2) and exits the brake manifold in the rear brake accumulator. The pressure switch
valve at port 'T' to the steering and brake control tank. sends a signal to a warning light on the dash panel
With no pressure in the parking brake circuit to hold when pressure drops below 82 bar (1 205 lbf/in²).
the parking brake off, the parking brake is applied.
The normally closed (NC) pressure switch (20), located
Solenoid Cartridge - Energized in port 'PS3', senses pressure in the parking brake line,
When the park/emergency brake switch is deactivated and sends a signal to a warning light on the dash panel
(pulled out), the electrical signal between the switch when pressure drops below 65 bar (940 lbf/in²).
and solenoid coil (3) is closed, energizing solenoid
cartridge (2). Oil flows through solenoid cartridge (2)
and exits the brake manifold valve at port 'B' to the REMOVAL
monoblock brake valve. The oil flows through the Numbers in parentheses refer to Fig. 1.
pressure reducing valve in the monoblock brake valve
and exits the valve to release the parking brakes.
Refer to Section 250-0100, MONOBLOCK BRAKE WARNING
VALVE. Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the
Return oil from the 'Px' port on the treadle valve flows treadle valve continuously until the pressure
through the directional control valve and into the brake has dissipated before carrying out any work on
manifold valve at port 'A'. The oil travels through the braking system or serious injury could
solenoid cartridge (2) and exits the brake manifold result.
valve at port 'T' to the steering and brake control tank.

2 SM 2040 R1 07-03
 Braking System - Brake Manifold Valve
Section 250-0050

SM - 1661

16

PS3 3

FROM DIRECTIONAL A P1
CONTROL VALVE TO PORT 'P2'
TREADLE VALVE
TO MONOBLOCK
B T
BRAKE VALVE

FROM
P
STEERING PUMP
PY
TO PORT 'P1' TREADLE VALVE
ACC1
TO FRONT ACCUMULATOR
TO REAR ACCUMULATOR
ACC2
PS1 PS2

15 14

3 - Brake Manifold Valve 15 - Front Brake Accumulator Pressure Switch

14 - Rear Brake Accumulator Pressure Switch 16 - Parking Brake Pressure Switch
Fig. 3 - Park/Emergency Brake Switch Deactivated - Solenoid Cartridge Energized

DISASSEMBLY
WARNING Numbers in parentheses refer to Fig. 1.
To prevent personal injury and property
damage, be sure wheel blocks are properly 1. Clamp valve body (1) lightly in a soft jawed vice,
secured and of adequate capacity to do the job retainers (6) face up. Do not overtighten jaws. Remove
safely. retainers (6) from valve body (1) and discard 'O' rings (7).

1. Position the vehicle in a level work area, apply the 2. Remove plug (5) from valve body (1) and discard 'O'
parking brake and switch off the engine. ring (18).

2. Operate the treadle valve continuously to discharge 3. Carefully remove valve body (1) assembly from the
the brake accumulators. Block all road wheels. vice and remove springs (8) and check balls (9) from
valve body (1).
3. Remove and tag electrical connections to solenoid
coil (3) and pressure switches (19 & 20). 4. If required, clamp valve body (1) lightly in soft jawed
vice and remove check ball seats (10).
4. Clean brake manifold valve assembly and
surrounding area with a suitable solvent. Ensure all 5. Rotate valve body (1) in vice until solenoid coil (3) is
hydraulic lines connected to the brake manifold valve facing up. Lightly clamp valve body (1) in vice and
are identified for ease of installation and, with suitable remove locknut (4) and solenoid coil (3) from solenoid
containers available to catch leakage, disconnect cartridge (2).
hydraulic lines. Fit blanking caps to all open lines.
6. Remove solenoid cartridge (2) assembly from valve
5. Release and remove mounting hardware securing body (1) and discard 'O' rings (11, 12, 14 & 16) and
brake manifold valve to the cab mounting backup rings (13, 15 & 17).
crossmember and remove assembly from the truck.
7. Mark valve body (1) port identification on each of

SM 2040 R1 07-03 3
Braking System - Brake Manifold Valve
Section 250-0050
the pressure switches (19 & 20) and remove from valve SM - 1508
body (1).
6
Note: It is important that the pressure switches are
clearly identified as the pressure settings between
pressure switches (19) and pressure switch (20) are 7
9
different.
8 10
8. If required, note orientation and remove hydraulic
line connectors from ports in valve body (1).

ASSEMBLY
6 - Retainer
Numbers in parentheses refer to Fig. 1. 7 - 'O' Ring 9 - Check Ball
8 - Spring 10 - Seat
1. Install new 'O' rings (11, 12, 14 & 16) and backup
Fig. 4 - Section Through Check Ball Assembly
rings (13, 15 & 17) on solenoid cartridge (2) as shown
in Fig. 1.
where used.
2. Install solenoid cartridge (2) assembly in valve body
(1) and tighten securely. Install solenoid coil (3) on 1. Position brake manifold valve assembly to the cab
solenoid cartridge (2) and secure with locknut (4). mounting crossmember and secure with mounting
hardware.
3. Rotate valve body (1) in vice until retainer (6) face is
up. Install new 'O' ring (18) on plug (5) and install plug 2. Remove blanking caps from hydraulic lines and
(5) assembly in valve body (1). connect to brake manifold valve as noted during
removal.
4. If removed, apply Loctite 603 to threads of seats
(10) and install seats (10) in valve body (1). Tighten 3. Connect electrical connections to solenoid coil (3)
seats (10) to a torque of 20 Nm (15 lbf ft). See Fig. 4. and pressure switches (19 & 20) as noted during
removal.
5. Install one check ball (9) on seat (10) and spring (8)
on check ball (9). Install new 'O' ring (7) on retainer (6) 4. Check oil level in the steering and brake control
and carefully place retainer (6) assembly over spring tank and add oil if required. Refer to Section
(8) in valve body (1). Tighten retainer (6) securely in 220-0040, STEERING AND BRAKE CONTROL TANK
valve body (1). See Fig. 4. for correct fill level, and, Section 300-0020,
LUBRICATION SYSTEM for oil specification.
6. Repeat step 5 for second check ball, spring and
retainer assembly. 5. Remove wheel blocks, start the engine and bring
hydraulic oil to operating temperature.
7. Install pressure switches (19 & 20) in valve body (1)
as noted during disassembly. 6. Check brake manifold valve and hydraulic line
connections for leaks and tighten as required.
8. If removed, install hydraulic line connectors in valve
body (1) as noted during disassembly. 7. Shut off engine and make sure a full service brake
application is made followed by a parking brake
application.
INSTALLATION
Note: Tighten all fasteners to torques listed in 8. Repeat all braking and engine shut down cycles
Section 300-0080, STANDARD BOLT AND NUT several times and check for appropriate application/
TORQUE SPECIFICATIONS. release cycle several times.

Note: Tighten all hydraulic lines fitted with ORFS 9. Check all connections again for leaks and tighten as
connections, as described in Section 250-0000, required.
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings

4 SM 2040 R1 07-03
 Braking System - Brake Manifold Valve
Section 250-0050
10. Remove body safety pins and lower the body to the replacement of parts only.
frame.

SPECIAL TOOLS
MAINTENANCE There are no special tools required for procedures
Inspect the brake manifold valve regularly for any signs outlined in this section. Refer to Section 300-0070,
of leakage or damage and repair/replace as required. SERVICE TOOLS, for part numbers of general service
tools and adhesives required. These tools, and
Note: Limited repair of the brake manifold valve is by adhesives are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 10 Seat 20 15

* * * *

SM 2040 R1 07-03 5
 BRAKING SYSTEM - Accumulator
Section 250-0060

SM - 277

1 - Charging Valve 8 - Wear Rings

1A - Cap 1E - Body 4 - Protector 9 - 'O' Ring
1B - Core 1F - 'O' Ring 5 - Piston 10 - End Cap
1C - 'O' Ring 2 - Screw 6 - Backup Rings 11 - Pad
1D - Locknut 3 - Lockwasher 7 - 'V' Section Ring 12 - Cylinder

Fig. 1 - Exploded View of Accumulator

DESCRIPTION the steering pump flows through accumulator check

Numbers in parentheses refer to Fig. 1. valves in the brake manifold valve and into the lower
section of the accumulators. Accumulator pressure is
The Brake Accumulators can be identified as items 2 in monitored by pressure switches in the brake manifold
Section 250-0000, BRAKING SYSTEM SCHEMATIC. valve. Refer to Section 250-0050, BRAKE
MANIFOLD VALVE.
There are two brake accumulators mounted off the
platform at the rear right hand side of the cab. One
for the rear brake circuit and the other for the front TESTING
brake circuit. The rear brake circuit accumulator also
maintains a constant pressure in the parking brake
circuit, to hold the parking brake off, when the truck WARNING
is operating. Accumulators are charged with Nitrogen. The
service pressure is 55 bar (800 lbf/in2) at
The accumulator is of the piston type and is 21o C (70o F). Do not attempt to remove any
precharged with nitrogen to 55 bar (800 lbf/in2). It valves or fittings until all nitrogen pressure is
consists of charging valve (1), end cap (10), cylinder completely relieved to prevent personal injury
(12) and piston (5). Charging valve (1) is equipped and property damage.
with a locking feature. Loosening locknut (1D) will
open the valve so that the precharge can be checked
or the accumulator charged.
Testing Charging Valve For Leakage
Numbers in parentheses refer to Fig. 1.

OPERATION 1. Remove screws (2), lockwashers (3), protector (4)

Numbers in parentheses refer to Fig. 1. and pads (11) from accumulator.

Piston (5) acts as a separator dividing cylinder (12) 2. Remove valve cap (1A) from charging valve (1)
into two sections. The section nearest charging valve (1) and loosen locknut (1D). Coat open end of charging
contains the nitrogen pre-charge. Hydraulic oil from valve with soapy water. Bubbles indicate leaky valve

SM 1600 12-98 1
Braking System - Accumulator
Section 250-0060
core (1B). Attempt to reseat the valve core by SM - 1273
depressing and releasing it quickly once or twice.
Recheck for leakage, if leakage continues then
discharge the accumulator as described under
'Discharging Nitrogen' in this section, then replace
the valve core. Torque tighten locknut (1D) to 11 Nm
(100 lbf in) and replace valve cap (1A) finger tight.

Testing Pre-charge Pressure

Numbers in parentheses refer to Fig. 2, unless
otherwise specified.

Note: The nitrogen pressure in an accumulator is

directly affected by changes in nitrogen temperature.
The cylinder pressure will increase or decrease
proportionally with temperature changes. An
accumulator pressure reading can vary about 4.3 bar
(62 lbf/in2) with 22o C (72o F) temperature change.
Such temperature changes could easily occur
between noon and midnight of the same day. Refer to
the table at the end of this section for Nitrogen pressures 1 - Line 6 - Tank Valve
at ambient temperatures of other than 21o C (70oF). 2 - Valve Chuck 7 - Gland Fitting
3 - Valve Extension 8 - Gland Nut
4 - Accumulator Valve 9 - Cylinder Adaptor
To test accumulator pre-charge pressure or to charge 5 - Pressure Gauge 10 - Bleeder Valve
the accumulator, a charging assembly tool can be
used. See Fig. 2. Fig. 2 - Charging Assembly

1. Position the vehicle in a level work area, apply the Nitrogen pressures at ambient temperatures of other
parking brake and switch off the engine. than 21o C (70o F).

2. Operate the treadle valve continuously to 7. Close accumulator valve (4) and open bleeder
discharge the brake accumulators. Block all road valve (10) to dissipate gauge pressure. Close bleeder
wheels. valve (10) after pressure is relieved. If accumulator
needs charged, leave line and chuck attached to
3. Check accumulator mountings to be sure the charging valve and charge the accumulator as
accumulator is held tightly in position. described under 'Charging The Accumulator'.

4. Remove cap (1A, Fig. 1) from accumulator 8. If precharge is 55 bar (800 lbf/in2) at 21o C (70o F),
charging valve (1, Fig. 1). Attach charging line (1) to rotate 'T' handle anticlockwise until it stops, then
charging valve by rotating 'T' handle of valve chuck torque tighten locknut (1D, Fig. 1) on charging valve
(2) anticlockwise until it stops. Screw the swivel nut (1, Fig. 1) to 11 Nm (100 lbf in). Loosen the swivel
down on the valve until it seats. Loosen charging nut and remove the gauging head.
valve locknut (1D, Fig. 1) by turning anticlockwise
one to two turns. 9. Install valve cap (1A, Fig. 1) on charging valve
(1, Fig. 1) and tighten finger tight.
5. Turn 'T' handle clockwise until charging valve core
is depressed. Be sure bleeder valve (10) is tight and
does not leak, and valves (4 & 6) are closed. CHARGING THE ACCUMULATOR
Numbers in parentheses refer to Fig. 2, unless
6. To read accumulator precharge pressure, slowly otherwise specified.
open accumulator valve (4). Pressure gauge (5) will
register pre-charge pressure, it should be 55 bar Either oil or water pumped nitrogen can be used to
(800 lbf/in2) at 21o C (70o F) ambient temperature. charge the accumulator. Both types are readily
Refer to the table at the end of this section for available from a local compressed gas dealer.

2 SM 1600 12-98
 Braking System - Accumulator
Section 250-0060
DISCHARGING NITROGEN
WARNINGS Numbers in parentheses refer to Fig. 1, unless
Do not use Oxygen or any gas other than otherwise specified.
Nitrogen to charge an accumulator. Oxygen
under pressure coming into contact with oil or Make sure charging valve (1) is closed internally by
grease will cause a violent explosion. Always turning locknut (1D) clockwise. Remove valve cap
double check to make sure you are using (1A) and valve core (1B) from charging valve
Nitrogen to prevent personal injury and assembly (1). Slowly turn the locknut (1D)
property damage. anticlockwise to open the charging valve assembly (1).

A high pressure nitrogen pressure DO NOT remove charging valve (1) until all the gas
regulator must be used with the charging has been completely evacuated.
assembly. Failure to use pressure regulator
could cause property damage, personal injury
or death. WARNING
Do not try to discharge the accumulator by
1. Attach line (1) and the swivel nut to charging valve depressing the charging valve core (1B, Fig. 1).
(1, Fig. 1) as described in Steps 1 through 4 under
the heading 'Testing Pre-charge Pressure'. Be sure
valves (4 & 6) are closed. REMOVAL
Numbers in parentheses refer to Fig. 3.
2. Attach gauging head to nitrogen bottle by screwing
down on gland nut (8).
WARNINGS
3. Open tank valve (6) slowly; pressure shown on Make sure that lifting equipment, blocking
gauge (5) is tank pressure. materials and wheel blocks are properly
secured and of adequate capacity to prevent
4. Open accumulator valve (4) slowly and charge personal injury and property damage.
accumulator to 55 bar (800 lbf/in2) at 21o C (70o F)
ambient temperature, closing valve occasionally. Accumulators are charged with Nitrogen.
Refer to the table at the end of this section for the The service pressure is 55 bar (800 lbf/in²) at
Nitrogen pressures at ambient temperatures of other 21o C (70o F). Be sure all Nitrogen pressure has
than 21o C (70o F). been relieved before removing accumulator
from the truck. Sudden release of pressure
5. To check accumulator charge, close tank valve may cause personal injury.
(6), relieve pressure between tank and gauge by
opening bleeder valve (10) momentarily. This will 1. Position the vehicle in a level work area, apply the
allow gauge needle to settle, thus giving correct parking brake and switch off the engine.
pressure reading of accumulator charge.
2. Operate the treadle valve continuously to discharge
6. When the correct pressure for the ambient the brake accumulators. Block all road wheels.
temperature has been reached, close valves (4 & 6)
tightly. Bleed pressure off pressure gauge (5) by 3. Remove screws (2, Fig. 1), lockwashers (3, Fig. 1)
opening bleeder valve (10). Close bleeder valve when and protector (4, Fig. 1).
all pressure is bled off the gauge.
4. Discharge nitrogen from accumulators. Refer to
7. Unscrew gland nut (8) from nitrogen bottle. previous section on 'Discharging Nitrogen' for correct
procedure.
8. Rotate 'T' handle of valve chuck (2) anticlockwise
until it stops, torque tighten charging valve locknut 5. Disconnect hydraulic lines from bottom of
(1D, Fig. 1) to 11 Nm (100 lbf in), loosen the swivel accumulators. Drain oil and cap the lines and
nut and remove gauging head. accumulator ports to prevent ingress of dirt.

9. Check accumulator charging valve (1, Fig. 1) for 6. Support the accumulators using an adequate sling
leakage using soapy water. Reinstall valve cap (1A, and lifting device. Remove bolts (1 & 2), washers (3)
Fig. 1) and tighten finger tight. and clamps (4). Remove accumulators.

SM 1600 12-98 3
Braking System - Accumulator
Section 250-0060
DISASSEMBLY SM - 278

Numbers in parentheses refer to Fig. 1.

WARNING
Accumulators are charged with Nitrogen. The
service pressure is 55 bar (800 lbf/in2) at
21o C (70o F). Do not attempt to remove any
valves or fittings until all nitrogen pressure is
completely relieved to prevent personal injury
and property damage.

1. Make sure all nitrogen gas has been released

before starting to disassemble the accumulator.
Refer to section on 'Discharging Nitrogen'.

2. Remove charging valve (1) from end cap (10).

3. With accumulator lying horizontal, hold

accumulator cylinder (12) with a strap wrench.
3 - Washer
1 - Bolt 4 - Clamp
4. Install pins in three equally spaced holes in end 2 - Bolt 5 - Accumulator
cap (10), then use a long bar working against the pins
to remove end cap from cylinder (12). Remove and Fig. 3 - Accumulator Installation
discard 'O' ring (9).
ASSEMBLY
5. Grip cast web of piston (5) with pliers and while
rotating, pull piston from cylinder (12). Remove and Numbers in parentheses refer to Fig. 1.
discard wear rings (8), backup rings (6) and 'V'
section ring (7). 1. Lubricate ‘O’ ring (9), wear rings (8), backup rings
(6), 'V' section ring (7) and inside of cylinder (12) with
hydraulic oil prior to assembly.
INSPECTION
Numbers in parentheses refer to Fig. 1. 2. Install new 'V' section ring (7), backup rings (6)
and wear rings (8) on piston (5).
1. Wash metal components with a suitable solvent
and thoroughly air dry. 3. Insert piston (5) into cylinder (12) with cupped end
facing the open end of the cylinder. Do not let
2. Inspect piston (5) for cracks or burrs. Replace 'V' section ring (7) drag on cylinder threads. Use a
piston (5) if excessively scored or worn. hammer and wood block to tap piston into place until
all of piston is 50 mm (2.0 in) below beginning of
3. Use an inspection lamp to check the bore of honed bore. Keep pressure against piston while
accumulator cylinder (12) for scratches or scoring. tapping 'V' section ring (7) through the bore chamfer,
Minor nicks, scratches or light scoring of the bore otherwise piston will bounce back, damaging the
can be removed by using crocus cloth. Dress the 'V' section ring.
bore until all apparent imperfections have been
removed. Replace complete accumulator assembly if 4. Install new 'O' ring (9) on end cap (10) and install
the inside of cylinder (12) is excessively scored or end cap (10) in cylinder (12). Tighten cap so that it is
worn. flush with the end of cylinder (12) within 1.6 - 2.4 mm
(0.062 - 0.094 in) above or below.
4. Inspect threads in end cap (10) and threads in
cylinder (12) for damage. Replace all parts worn or 5. Install charging valve (1). Torque tighten locknut
damaged beyond repair. (1D) clockwise to 11 Nm (100 lbf in) to close
charging valve, insert valve core (1B), replace valve
cap (1A) and tighten finger tight.

4 SM 1600 12-98
 Braking System - Accumulator
Section 250-0060
6. Test accumulator hydraulically for leakage or 5. Charge the accumulator with Nitrogen gas as
failure at 255 - 276 bar (3 700 - 4 000 lbf/in2). described under the heading 'Charging the
Discharge after testing. Accumulator' in this section.

6. Check oil level in steering and brake control tank

INSTALLATION and add oil if required. Refer to Section 220-0040,
Numbers in parentheses refer to Fig. 3. STEERING AND BRAKE CONTROL TANK for
correct fill level, and, use only oil as specified in
Note: Tighten all fasteners to standard torques listed Section 300-0020, LUBRICATION SYSTEM.
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. 7. Remove wheel chocks, start the engine and bring
hydraulic oil to operating temperature.
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000, 8. Check for oil leaks as the oil pressure increases.
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings Tighten line connections and fittings as necessary.
where used.

MAINTENANCE
WARNING Inspect the accumulators regularly for any signs of
Make sure that lifting equipment, blocking leakage or damage.
materials and wheel chocks are properly
secured and of adequate capacity to prevent Every 500 hours
personal injury and property damage. Check the Nitrogen precharge pressure at the
accumulators, prior to checking braking system
1. Position accumulators on mounting bracket with pressure. Refer to 'Testing Pre-charge Pressure', in
the oil inlet ports downward. this section.

2. Attach clamps (4) securely with washers (3) and

bolts (1 & 2). SPECIAL TOOLS
Refer to Section 300-0070, SERVICE TOOLS, for
3. Remove caps installed at 'Removal' to prevent dirt part numbers of special tools referenced in this
entering the hydraulic lines and accumulator ports. section and general service tools required. These
tools are available from your dealer.
4. Install hydraulic lines securely to the oil inlet port
at the bottom of the accumulators.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf in
1 1D Locknut 11 100

SM 1600 12-98 5
Braking System - Accumulator
Section 250-0060

AMBIENT TEMPERATURE - NITROGEN PRE-CHARGE PRESSURE

AMBIENT TEMPERATURE NITROGEN PRE-CHARGE PRESSURE
°C °F bar lbf/in²
-18 0 47.7 692
-12 10 48.8 708
-7 20 49.8 723
-1 30 50.9 738
5 40 52 754
10 50 53 769
16 60 54.1 785
21 70 55 800
27 80 56.2 815
32 90 57.3 831
38 100 58.3 846
43 110 59.4 862
49 120 60.5 877
54 130 61.5 892

WARNING
This truck is equipped with precharged nitrogen gas cylinders of more than 2.8 bar (40 lbf/in2).
Special permits may be required when transporting the truck 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.

* * * *

6 SM 1600 12-98
 BRAKING SYSTEM - Treadle Valve
Section 250-0070

SM - 1267

1 - Adjustment Collar
2 - Actuator Plunger 16 - Reaction Plunger
3 - Glyde Ring Assembly 17 - Wiper Seal 30 - Nut 43 - Screw
4 - Plunger Return Spring 18 - Backup Ring 31 - Washer 44 - Retainer Plate
5 - Regulator Spring 19 - Seal 32 - U Bolt 45 - Capscrew
6 - Regulator Spring 20 - Valve Body 33 - Screw 46 - Actuator Base
7 - Spring Seat 21 - Plate 34 - Nut 47 - Insert
8 - Regulator Spool 22 - 'O' Ring 35 - Adjustment Screw 48 - Nut
9 - Backup Ring 23 - Face Seal 36 - Actuator Cam 49 - Washer
10 - 'O' Ring 24 - Screw 37 - Insert 50 - Pedal
11 - Backup Ring 25 - 'O' Ring 38 - Pivot Pin 51 - Capscrew
12 - 'O' Ring 26 - Retaining Plug 39 - Return Spring 52 - Insert
13 - 'O' Ring 27 - Base Plate 40 - Return Spring 53 - Capscrew
14 - Regulator Sleeve 28 - Washer 41 - Cap 54 - Lockup Drop Out Pressure Switch
15 - Spool Return Spring 29 - Capscrew 42 - Boot 55 - Stop Light Pressure Switch

Fig. 1 - Exploded View of Treadle Valve Assembly

SM 1225 Rev 1 9-99 1

Braking System - Treadle Valve
Section 250-0070

SM - 1656 SM - 1657

FROM
TO FRONT FRONT
BRAKES BRAKES
4 4
Px FROM
TO REAR Px REAR
BRAKES BRAKES
T T

SUPPLY SUPPLY
FROM P1 P2 FROM P1 P2
BRAKE BRAKE
MANIFOLD B1 B2 MANIFOLD B1 B2

13 17 13 17

SUPPLY SUPPLY
FROM FROM
BRAKE BRAKE
MANIFOLD MANIFOLD

Fig. 2 - Normal Service Brake Application Fig. 3 - Normal Service Brake Release

DESCRIPTION actuation of the treadle valve.

Numbers in parentheses refer to Fig. 1.
Lockup drop out pressure switch (54) sends a signal
Note: The treadle valve can be identified as item 4 in to actuate the lockup drop out solenoid, which in turn
Section 250-0000, BRAKING SYSTEM SCHEMATIC. drops the transmission out of lockup on actuation of
the treadle valve.
The treadle valve is a closed centre controller which
controls the level of hydraulic oil pressure applied to
the front and rear brakes and the maximum pressure OPERATION
available to these circuits. It is operated by a foot Numbers in parentheses refer to Fig. 1.
pedal in the operators cab and with the engine
running, is automatically applied by the brake manifold Normal Service Brake Application
valve. Refer to Section 250-0050, BRAKE MANIFOLD Refer to Fig. 2. When the operator depresses pedal
VALVE. (50), actuator plungers (2) are moved down and push
on regulator springs (5 & 6) which in turn, push
The differing maximum operating pressures required regulator spools (8) down. As regulator spools (8)
for the front and rear brakes are achieved within the move down, the metering notches move out of the
treadle valve. These pressures can be adjusted as tank cavity and close outlet ports 'B1' and 'B2' off to
described under 'Testing and Adjustments'. tank port 'T'. Regulator spools (8) continue to move
downward until the lower edge of the metering notches
In the normal position, brake pedal (50) and regulator become exposed to the inlet pressure ports. This
spools (8) are in the up position. In this condition the movement opens inlet ports 'P1' and 'P2' to outlet
notched area near the top of regulator spools (8) is ports 'B1' and 'B2' respectively.
exposed to the tank cavity in valve body (20), the
lower portion of the notched area is exposed to the As hydraulic pressure builds in the brake, oil flows
regulated pressure outlet ports of the valve. This through the small orifice in the side of regulator spools
effects a direct link between the tank port 'T' and the (8) and into the cavities below the spools. As pressure
regulated outlet ports 'B1' and 'B2'. While regulator rises in the brake it also rises in the cavities below the
spools (8) are in this position the brakes are released. spools forcing regulator spools (8) upwards closing
outlet ports 'B1' and 'B2'. Regulator spools (8) are now
Stop light pressure switch (55) sends a signal to balanced between the brake pressure and the
illuminate the brake lights at the rear of the vehicle on pressure of regulator springs (5 & 6) generated by the

2 SM 1225 Rev 1 9-99

 Braking System - Treadle Valve
Section 250-0070

SM - 1658 SM - 1659

FROM
TO FRONT FRONT
BRAKES BRAKES
4 4
SUPPLY FROM
Px TO TANK Px
FROM TO REAR REAR
VIA
BRAKE BRAKES BRAKES
BRAKE
MANIFOLD T MANIFOLD T
SOLENOID SOLENOID

P1 P2 P1 P2
SUPPLY SUPPLY
FROM FROM
BRAKE B1 B2 BRAKE B1 B2
MANIFOLD MANIFOLD

13 17 13 17

SUPPLY SUPPLY
FROM FROM
BRAKE BRAKE
MANIFOLD MANIFOLD

Fig. 4 - Park/Emergency Brake Application Fig. 5 - Park/Emergency Brake Release

operators force on pedal (50). Regulator spools (8) oil in the 'B1' and 'B2' lines to return to tank, releasing
have closed off the inlet ports, outlet ports and the tank the brakes.
port and will remain in this position as long as pedal
(50) is not moved. If the operator further depresses Note: Outlet ports 'B1' and 'B2' will give output
pedal (50), regulator spools (8) will move down and pressure 5% higher when activated by an emergency
build more pressure in the brake until it balances the stop ('Px' circuit) than a brake pedal actuation.
pedal force.
REBUILD CRITERIA
Normal Service Brake Release Inspect the valve regularly for any signs of leakage or
Refer to Fig. 3. When the operator releases pedal (50), damage. Check the actuator for excessive cam rock
regulator spool (8) will become unbalanced and move and replace components if necessary.
upwards, opening outlet ports 'B1' and 'B2' to tank. At
this point, oil in the 'B1' and 'B2' lines is released to The controller should be rebuilt if one or more of the
tank through tank port 'T', releasing the brakes. following conditions exist:

1. Any sign of external leakage.

Emergency Stop Brake Application/
Release Note: Check all hydraulic lines and fittings to ensure
Refer to Fig. 4. Pressing/pushing of the emergency leakage is not coming from there.
control knob results in the de-energization of the brake
manifold valve solenoid. This allows full pressure to 2. Failure of the pedal to return to full upright position.
enter the 'Px' port in the treadle valve simulating a full
and immediate depression of pedal (50), i.e. pushing 3. Treadle valve holds pressure when in the neutral
regulator spools (8) downwards and thereby applying position.
maximum braking action.
4. Varying output pressure with the pedal fully
Refer to Fig. 5. Releasing the emergency control knob depressed.
will energize the brake manifold valve solenoid,
allowing the pressure in the 'Px' line to fall via the 5. Output pressure should remain constant between
return to tank port opened within the valve. Outlet circuits within ± 5.2 bar (± 75 lbf/in²).
ports 'B1' and 'B2' are opened to tank port 'T' allowing

SM 1225 Rev 1 9-99 3

Braking System - Treadle Valve
Section 250-0070

REMOVAL (32) securing actuator pivot pin (38).

Numbers in parentheses refer to Fig. 1.
5. Remove pivot pin (38) from actuator base (46) with
a punch and hammer. Remove actuator cam (36)
WARNINGS assembly and inspect for any abnormal wear or
To prevent personal injury and property cracks. Set aside for assembly.
damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job 6. Remove screws (43) securing retainer plate (44) to
safely. actuator base (46).

Hydraulic oil pressure will remain 7. Remove retainer plate (44), boot (42) and cap (41)
within the system after engine shut down. as an assembly by grasping boot (42) and gently lifting
Operate the treadle pedal continuously until from actuator base (46).
the pressure has dissipated before carrying
out any work on the braking system or serious 8. Loosen the socket head capscrews from adjustment
injury could result. collars (1) and unscrew adjustment collars (1).

1. Position the vehicle in a level work area, apply the 9. Remove capscrews (45) securing actuator base
parking brake and switch off the engine. (46) to valve body (20). Remove actuator base (46)
from valve body (20).
2. Operate the treadle valve continuously to discharge
the braking accumulators. Block all road wheels. 10. Remove stop light pressure switch (55) and lockup
drop out pressure switch (54) from plate (21).
3. Clean treadle valve assembly and surrounding area
with a suitable solvent. Ensure all hydraulic lines 11. Remove capscrews (53) securing plate (21) on
connected to the treadle valve are identified for ease valve body (20). Remove plate (21) and discard
of installation and, with suitable containers available to 'O' ring (22) and face seals (23).
catch leakage, disconnect hydraulic lines. Fit blanking
caps to all open lines and treadle valve ports. 12. Remove controller from the vice.

4. Remove and tag electrical connections to stop light 13. Remove capscrews (29) and washers (28) from
pressure switch (55) and lockup drop out pressure the base of valve body (20). Remove base plate (27).
switch (54).
14. With valve body (20) upright, retaining plug (26)
5. Release and remove mounting hardware securing should fall out. If retaining plug (26) does not fall out,
the treadle valve to the cab floor. Remove treadle lightly tap the plug to dislodge.
valve assembly to a clean area for 'Disassembly'.
15. Remove and discard 'O' ring (25) from counterbore
in the base of valve body (20).
DISASSEMBLY
Numbers in parentheses refer to Fig. 1. Note: Throughout the following steps it is important to
keep the circuits and circuit components identified as
1. Remove blanking caps from treadle valve ports and to which side of the unit they came from. For a given
drain oil from valve body (20) ports by rotating the circuit, all the components have a tolerance stack
valve over a suitable container. which could vary. Keep the 'B1' and 'B2' components
separate.
2. Secure the controller upright in a table vice.
16. With the controller upright on the work bench, hold
3. Remove pedal (50) from actuator cam (36) by valve body (20) with one hand and push the 'B1'
loosening two capscrews (51) at the pedal heel. Note actuator plunger (2) down with the other hand until
that capscrews (51) need not be removed. regulator sleeve (14) pops loose.

4. Loosen but do not remove nuts (30) from 'U' bolts 17. Repeat the above procedure to loosen the 'B2'
regulator sleeve (14).

4 SM 1225 Rev 1 9-99

 Braking System - Treadle Valve
Section 250-0070

18. Turn valve body (20) on its side on the work bench SUB-ASSEMBLY
and remove regulator sleeves (14) from valve body (20). Numbers in parentheses refer to Fig. 1.

19. Remove regulator spools (8), reaction plungers Note: All metal parts should be thoroughly cleaned
(16) and spool return springs (15) from regulator with a suitable solvent, dried, and lubricated with a
sleeves (14). light weight oil before assembly. This valve is built to
extremely close manufacturing tolerances. Great care
20. Remove plunger return springs (4), regulator should be taken to keep components protected from
springs (5 & 6) and spring seats (7) from valve body (20). contamination prior to and during assembly.

21. Remove actuator plungers (2) by pushing down by

hand (toward the bottom of valve body (20)) on the Boot and Cap
actuator plunger until actuator plunger (2) slides out. 1. Inspect boot (42) for any cracks, tears, or other
damage. If damage is evident, replace boot (42). To
22. Remove glyde ring assembly (3) from actuator replace boot (42), follow the procedure below.
plunger (2).
2. Remove and discard boot (42) from cap (41). Using
23. Remove 'O' rings (10, 12 & 13) and teflon backup a knife or suitable scraper, thoroughly clean the sides
rings (9 & 11) from regulator sleeves (14) and discard. of cap (41) by scraping the lip where the cap contacts
the boot. Clean thoroughly to remove all residual
24. Remove wiper seals (17), seals (19) and backup adhesive or particles of boot (42).
rings (18) from the actuator section of the valve and
discard. 3. Apply a thin bead of Loctite Prism 410 onto the
upper side of cap (41). Apply the bead to the two long
sides only. Do not apply it to the rounded ends, these
INSPECTION must not be sealed to allow the boot to 'breathe'.
Numbers in parentheses refer to Fig. 1.
4. Carefully position cap (41) into the groove of new
1. Clean all parts with a suitable cleaning solvent. boot (42) wiping off excess Loctite.

2. Inspect actuator plunger (2) for wear on the sides 5. Position boot (42) such that it conforms to the
where it moves through the seals. If axial grooves are contour of cap (41), then set aside. Loctite Prism 410
seen or if any wear is evident, replace actuator requires about 30 minutes to cure.
plunger (2). Actuator plungers (2) with diameter worn
below 18.97 mm (0.747 in) must be replaced.
Threaded Inserts
3. Place regulator spool (8) into regulator sleeve (14) 1. Position actuator base (46) upside down on the
and push the spool lightly through the sleeve. work bench and support directly under each of the four
Regulator spool (8) must be able to move freely and floor mounting holes. Install threaded inserts (47) into
smoothly the entire length of regulator sleeve (14). If it actuator base (46) by tapping lightly with a small
cannot, regulator spool (8) and regulator sleeve (14) hammer until insert (47) flanges become flush with
must be replaced as a matched set. actuator base (46). Be sure actuator base (46) is
supported to prevent braking. Thoroughly clean
Note: Never replace just the spool or sleeve. They actuator base (46) assembly and set aside.
must be replaced as a matched set.
2. Position actuator cam (36) upside down on the work
4. Inspect each spring carefully for cracks or breaks. bench and support it at the centre hole. Insert
Any spring with a crack or break must be replaced. threaded insert (37) by tapping lightly with a small
Also, if the treadle valve was not reaching proper hammer until its flange becomes flush with actuator
regulated pressure, replace all regulator springs. cam (36) surface. Be sure actuator cam (36) is
supported to prevent breaking. Thoroughly clean
5. Inspect threaded inserts (37, 47 & 52) in actuator actuator cam (36) assembly and set aside.
cam (36), actuator base (46) and pedal (50). If any of
the threads are damaged, the inserts must be replaced. 3. Position pedal (50) upside down on the work bench
and support it directly above the two holes near its

SM 1225 Rev 1 9-99 5

Braking System - Treadle Valve
Section 250-0070
centre. Install threaded inserts (52) by tapping lightly SM - 1235
with a small hammer until their flanges become flush
with pedal (50) surface. Be sure pedal (50) is
supported to prevent breaking.

4. Install oval point screws (33) into inserts (52) and

screw down until 12.7 mm (0.5 in) of screws (33)
protrude below insert (52) flanges. Make sure that
both screws (33) are adjusted to the same dimension.

5. If removed, install capscrews (51) into pedal (50)

INTERNAL
and install washers (49) and nuts (48) onto capscrews 'O' RING
(51). Screw nuts (48) on flush with the ends of
capscrews (51) and set the assembly aside.
Fig. 6 - Valve Body Seal Installation
Valve Body Seals
1. Install seal (19) in seal groove of valve body (20) SM - 1236

first. Position seal (19) in the groove so that internal

'O' ring is facing down toward the bottom of valve body
(20). See Fig. 6.

2. Make sure the internal 'O' ring is still seated inside

seal (19) and did not get dislodged during installation.
Position seal (19) to the bottom of the groove.

3. Install backup ring (18) on top of seal (19). Start by

hand and then continue to work into the groove either
by hand or by using an 'O' ring installation tool.

4. Install wiper seal (17) in the top counterbore.

Position wiper seal (17) in the groove so that the
register lip is facing up toward the actuator.

5. Repeat steps 1 through 4 for the second circuit.

Regulator Sleeve
1. Install 'O' ring (10) onto the smallest groove (on the
top) of regulator sleeve (14). Install 'O' ring (12) onto
the middle groove of regulator sleeve (14). Install
'O' ring (13) onto the largest groove (on the bottom) of Fig. 7 - Regulator Sleeve Seal Installation
regulator sleeve (14). See Fig. 7.
Actuator Plunger
2. Install backup ring (11) onto each side of 'O' ring
(12) located in the middle of regulator sleeve (14). See Note: Glyde ring (3) assembly consists of an 'O' ring
Fig. 7. and a split glyde ring.

3. Install backup ring (9) behind 'O' ring (10) located at 1. Install 'O' ring into the 'O' ring groove located at the
the top end of regulator sleeve (14). 'O' ring (10) is the large diameter end of actuator plunger (2).
smallest of the three 'O' rings. Position backup ring (9)
so that it is next to the top of regulator sleeve (14). The 2. Install split glyde ring over the 'O' ring. Twist and
top of regulator sleeve (14) is the end with the smallest squeeze the split glyde ring into a small circle before
OD. See Fig. 7. installing to ensure a tight fit over the 'O' ring.

4. Repeat steps 1 through 3 for the second circuit. 3. Repeat steps 1 and 2 for the second circuit.

6 SM 1225 Rev 1 9-99

 Braking System - Treadle Valve
Section 250-0070

ASSEMBLY SM - 1237

Numbers in parentheses refer to Fig. 1.

1. Lightly lubricate glyde ring assembly (3) and install

the 'B1' actuator plunger (2) into the 'B1' circuit. Be GLYDE RING
careful not to damage or cut the glyde ring during ASSEMBLY
installation. Observe glyde ring assembly (3) through
tank port 'T' as actuator plunger (2) is being installed.
AVOID
SHARP
Note: It may be necessary to work the glyde rings
EDGE
past the sharp edge in valve body (20) to prevent
damage to the seal. Make sure actuator plunger (2) is
completely seated and bottomed. See Fig. 8.

2. Repeat step 1 for the 'B2' actuator plunger.

Fig. 8 - Installation of Glyde Ring Assembly
Note: Start with either side (circuit) of the valve and
build that side up complete before starting on the other 9. Repeat steps 3 through 8 for the second circuit.
circuit. Be careful to assemble components into the
circuit from which they were removed. 10. Lightly lubricate 'O' ring (25) and install into the
counter bore in the bottom end of valve body (20).
3. Install plunger return spring (4), regulator springs
(5 & 6) and spring seat (7) into the appropriate circuit. 11. Install retaining plug (26) into the counter bore on
If spring seat (7) does not seat correctly on top of the bottom of valve body (20). Make sure steps on
regulator spring (6), lightly shake valve body (20) to retaining plug (26) are facing the counter bore (toward
correctly position spring seat (7). the top of valve body (20)).

4. Lightly lubricate regulator spool (8) assembly and 12. Install base plate (27) on top of retaining plug (26)
install into regulator sleeve (14). The spherical end of and secure with capscrews (29) and washers (28).
regulator spool (8) should be at the top of regulator Tighten capscrews (29) evenly to a torque of
sleeve (14). The top of regulator sleeve (14) is the end 16 - 17 Nm (140 - 150 lbf in), alternating diagonally to
with the smallest OD. evenly seat regulator sleeve (14) assembly.

Note: Check to ensure that regulator spool (8) will 13. Install actuator base (46) on top of valve body (20)
slide smoothly and freely in regulator sleeve (14). and secure with capscrews (45). Make sure to position
Replace the entire spool and sleeve assembly if the properly for correct port direction. Tighten capscrews
spool does not slide smoothly and freely. (45) to a torque of 20 - 21 Nm (180 - 190 lbf in).

5. Remove regulator spool (8) from regulator sleeve 14. Screw adjustment collars (1) onto the top of
(14) before installing sleeve into valve body (20). actuator plungers (2). Screw all the way down until
they bottom on the threads.
6. Lightly lubricate 'O' rings (10, 12 & 13) on regulator
sleeve (14). Note: It is extremely important to bottom-out
adjustment collars (1) to prevent over-stressing and
7. Install regulator sleeve (14) assembly into the breaking the springs during the adjustment process.
correct circuit of valve body (20). Make sure spring
seat (7) is correctly seated in regulator spring (6) 15. Lightly lubricate and install new 'O' ring (22) and
before installing regulator sleeve (14). Push regulator face seals (23) in grooves of plate (21).
sleeve (14) into bore until retaining flange at the base
contacts valve body (20). 16. Install valve body (20) in a vice with tank port 'T'
facing down. Carefully place plate (21) assembly on
8. Install spool return spring (15) into regulator spool (8). valve body (20) and secure with capscrews (53).
Install reaction plunger (16) into regulator spool (8). Tighten capscrews (53) to a torque of 16 - 17 Nm
Reinstall regulator spool (8) into regulator sleeve (14). (140 - 150 lbf in).

SM 1225 Rev 1 9-99 7

Braking System - Treadle Valve
Section 250-0070

SM - 499

PILOT

159 bar
(2 300 lbf/in²) RETURN

SUPPLY

SUPPLY

FRONT REAR
BRAKE BRAKE
PRESSURE PRESSURE

SIMULATED
BRAKE VOLUME

Fig. 9 - Typical Test Fixture

17. Install stop light pressure switch (55) and lockup SM - 1238
drop out pressure switch (54) in plate (21) and tighten SCREWDRIVER
OR PRY BAR
securely.

Note: The valve assembly must be connected to a

hydraulic supply and pressures set before further
assembly can be done.

TESTING AND ADJUSTMENTS

Numbers in parentheses refer to Fig. 1.
NORMAL POSITION
Note: A hydraulic test fixture with capabilities similar to
the one shown in Fig. 9 is required.

1. Position the valve in the test fixture to allow

plungers to be activated by hand using a lever. See
Fig. 10.

2. Attach pilot supply line to 'Px' port of valve body (20).

FULLY ACTUATED
3. Attach main supply lines to 'P1' and 'P2' ports of
Fig. 10 - Actuator Plunger Actuation
valve body (20).

8 SM 1225 Rev 1 9-99

 Braking System - Treadle Valve
Section 250-0070

4. Attach tank return line to 'T' port of valve body (20). FINAL ASSEMBLY
Numbers in parentheses refer to Fig. 1.
5. Attach output ports 'B1' and 'B2' to test lines. Check
that all ports are used. Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
6. Set supply line pressure to 159 bar (2 300 lbf/in²). 300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
7. Set pilot supply pressure to 159 bar (2 300 lbf/in²).
1. Remove pivot pin (38) from actuator base (46).
8. Return line pressure during this test is not to exceed
0.34 bar (5 lbf/in²). 2. Assemble actuator cap (41), boot (42) and retainer
plate (44) to actuator base (46) and secure with
9. Test valve with 10W hydraulic oil at 50° + 6° C screws (43).
(120° + 10° F).
3. Insert pivot pin (38) through the hole in actuator
base (46), through the holes in 'U' bolts (32), and
Setting Manual and Pilot Pressure through the pivot pin hole in the other side of actuator
1. Install pivot pin (38) in actuator base (46) by itself base (46). As pivot pin (38) is being inserted, install
without installing pedal (50) assembly. pedal return springs (39 & 40).

2. By taking a screw driver or pry bar and placing it 4. Centre pivot pin (38) and secure with nuts (30) and
under pivot pin (38) and on top of actuator plunger (2) washers (31) on 'U' bolts (32). Tighten nuts (30) to a
assembly, you will be able to actuate each circuit torque of 16 - 17 Nm (140 - 150 lbf in).
individually. See Fig. 10.
5. Install pedal (50) assembly on actuator cam (36)
3. Gradually apply pressure on each circuit to check and secure with capscrews (51), washers (49) and
for leaks. Make sure adjustment collar (1) is screwed nuts (48).
all the way down on the threads.

4. Adjust adjustment collar (1) up (anticlockwise) ADDITIONAL TESTING AND ADJUSTMENT

starting with one turn increments until the output Numbers in parentheses refer to Fig. 1.
pressure is 159 bar (2 300 lbf/in²) at port 'B1' with
adjustment collar (1) contacting actuator base (46) 1. Depress pedal (50) as quickly as possible. The
(fully actuated). See Fig. 10. Fine adjustment will output pressure on the circuits must reach 159 bar
require only turning the collar in 1/8 turn increments. (2 300 lbf/in²) at port 'B1' and 52 bar (750 lbf/in²) at
port 'B2' within 10 seconds. Measurement of time
5. Adjust adjustment collar (1) up (anticlockwise) begins the moment force is applied to move pedal (50).
starting with one turn increments until the output
pressure is 52 bar (750 lbf/in²) at port 'B2' with 2. Back-off deadband adjustment screw (35)
adjustment collar (1) contacting actuator base (46) (anticlockwise) so that adjustment screw (35) is not
(fully actuated). See Fig. 10. Fine adjustment will touching actuator cap (41). Apply Loctite 243 to
require only turning the collar in 1/8 turn increments. adjustment screw (35) prior to setting the deadband.

6. Cycle each circuit 50 times using pilot apply. 3. Set the deadband by placing a 0.64 mm (0.025 in)
shim between the pedal return stop and the boss on
7. Recheck pressures after cycling. If they have the actuator base return stop. See Fig. 11.
changed, readjust.
4. Turn adjustment screw (35) down (clockwise) until it
8. Tighten the capscrews in adjustment collars (1) to is touching actuator cap (41).
3 - 3.5 Nm (25 - 30 lbf in). You may have to rotate
entire actuator plunger (2) to get to the capscrews. 5. Continue turning adjustment screw (35) clockwise
until you start to see a pressure reading on the
9. Check pressures again after tightening the pressure gauge then back-off adjustment screw (35)
capscrews. If the pressures have altered, loosen the 1/8 turn (anticlockwise).
appropriate capscrew and readjust.

SM 1225 Rev 1 9-99 9

Braking System - Treadle Valve
Section 250-0070

SM - 1239 2. Remove blanking caps and connect hydraulic lines

to the treadle valve assembly as noted at removal.

3. Connect electrical connections to stop light pressure

switch (55) and lockup drop out pressure switch (54)
as noted at removal.
Shim Stock
0.64 mm 4. Check oil level in steering and brake control tank
(0.025 in) and add oil if required. Refer to Section 220-0040,
STEERING AND BRAKE CONTROL TANK for correct
fill level, and use only oil as specified in Section
300-0020, LUBRICATION SYSTEM.

Actuator Base 5. Remove wheel blocks, start the engine and bring
Return Stop
hydraulic oil to operating temperature.

6. Apply the brakes and check for oil leaks. Tighten

line connections and fittings as necessary.
Fig. 11 - Deadband Adjustment
Note: When performing Step 7, make sure that
6. Tighten nut (34) and remove the shim stock. Apply parking brake applies and releases appropriately.
a few drops of Loctite 243 to nut (34).
7. Check brake operations by actuating pedal and
park/emergency control.
Pedal Angle Adjustment
1. Loosen nuts (48) at the rear of actuator cam (36). 8. Switch off engine and check oil level in steering and
Do not loosen nuts (30) on 'U' bolts (32). brake control tank. See Step 4.

2. Adjust pedal (50) angle by turning screws (33)

located in the top face or ribbed side of pedal (50). SERVICE
Clockwise will raise the angle and anticlockwise will Numbers in parentheses refer to Fig. 1.
lower the angle.
Brake Actuating Pressure
3. Adjust the two screws (33) evenly. When the Note: Test front 'B1' and rear 'B2' brake circuit actuating
desired pedal angle is achieved, apply Loctite 243 on pressures at diagnostic test points and adjust if necessary.
screws (33). Refer to Section 250-0000, BRAKING SYSTEM
SCHEMATIC for location of test points.
4. While holding the pedal down, retighten the rear
capscrews (51) and nuts (48). 1. Connect a hydraulic gauge capable of recording a
pressure of 0 - 207 bar (0 - 3 000 lbf/in²) to diagnostic
pressure point for front 'B1' brake pressure.
INSTALLATION
Numbers in parentheses refer to Fig. 1. 2. Start engine and bring hydraulic oil temperature to
operating temperature.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT 3. Actuate treadle valve fully and check reading on
TORQUE SPECIFICATIONS. pressure gauge. Pressure reading should be 159 bar
(2 300 lbf/in²).
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000, 4. Repeat steps 1 through 3 at diagnostic pressure
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings point for rear 'B2' brake pressure. Pressure reading
where used. should be 52 bar (750 lbf/in²).

1. Position treadle valve assembly on cab floor and Note: If the pressures to the brake circuits have been
secure with mounting hardware. Remove blanking determined as low or high, the pressures can be
caps from ports. raised or lowered by an in service (in situ) adjustment.

10 SM 1225 Rev 1 9-99

 Braking System - Treadle Valve
Section 250-0070
5. Remove pedal (50) from actuator cam (36) by 18. Insert pivot pin (38) through the hole in actuator
loosening two capscrews (51) at the pedal heel. Note base (46), through the holes in 'U' bolts (32), and
that capscrews (51) need not be removed. through the pivot pin hole in the other side of actuator
base (46). As pivot pin (38) is being inserted, install
6. Loosen but do not remove nuts (30) from U bolts pedal return springs (39 & 40).
(32) securing actuator pivot pin (38).
19. Centre pivot pin (38) and secure with nuts (30) and
7. Remove pivot pin (38) from actuator base (46) with washers (31) on 'U' bolts (32). Tighten nuts (30) to a
a punch and hammer. Remove actuator cam (36) torque of 16 - 17 Nm (140 - 150 lbf in).
assembly.
20. Install pedal (50) assembly on actuator cam (36)
8. Remove screws (43) securing retainer plate (44) to and secure with capscrews (51), washers (49) and
actuator base (46). nuts (48).

9. Remove retainer plate (44), boot (42) and cap (41)

as an assembly by grasping boot (42) and gently lifting Stop Light Pressure Switch
from actuator base (46). Stop light pressure switch (55) is a normally open
switch. Attach a continuity tester to terminals on stop
10. Slacken capscrews in adjustment collars (1). light pressure switch (55). The circuit should be open.

11. Install pivot pin (38) in actuator base (46) and by As brake pressure increases to 2.7 bar (39 lbf/in²) and
taking a screw driver or pry bar and placing it under above, the circuit should close and send a signal to
pivot pin (38) and on top of actuator plunger (2), you illuminate the brake lights. As pressure drops below
will be able to actuate each circuit individually. 2.7 bar (39 lbf/in²) the circuit should open and brake
lights go out.
12. Start engine to ensure full hydraulic pressure.

13. Test front 'B1' and rear 'B2' brake circuit actuating Lockup Drop Out Pressure Switch
pressures at diagnostic test points and adjust if Lockup drop out pressure switch (54) is a normally
necessary. Pressures should be 159 bar (2 300 lbf/in²) open switch. Attach a continuity tester to terminals on
for front 'B1' circuit and, 52 bar (750 lbf/in²) for rear 'B2' lockup drop out pressure switch (54). The circuit
circuit. should be open.

Note: Turning adjustment collar (1) up (anticlockwise) As brake pressure increases to 20 bar (290 lbf/in²) and
will increase the pressure while turning it down above, the circuit should close and send a signal to
(clockwise) will decrease the pressure. Fine the lockup drop out solenoid, which in turn drops the
adjustment will require only turning the collar in 1/8 transmission out of lockup. As pressure drops below
turn increments. 20 bar (290 lbf/in²) the circuit should open and lockup
can be engaged.
14. When pressure is set correctly, tighten the
capscrews in adjustment collars (1) to 3 - 3.5 Nm
(25 - 30 lbf in).
MAINTENANCE

15. Check pressures again after tightening the

General
capscrews. If the pressures have altered, loosen the Check all hydraulic brake lines and fittings at treadle
appropriate capscrew and readjust. Shut down the valve for leaks and damage. Tighten/replace as
engine. required.

16. Remove pivot pin (38) from actuator base (46).

Every 1 000 Hours
17. Assemble actuator cap (41), boot (42) and retainer Check front and rear brake pressures at diagnostic
plate (44) to actuator base (46) and secure with test points. If the pressures are outwith the specified
capscrews (43). pressure range, inspect the valve and take relevant
action (adjust pressures, strip down and repair or
replace valve).

SM 1225 Rev 1 9-99 11

Braking System - Treadle Valve
Section 250-0070

SPECIAL TOOLS
There are no special tools required for procedures tools, sealants and adhesives required. These tools,
outlined in this section. Refer to Section 300-0070, sealants and adhesives are available from your dealer.
SERVICE TOOLS, for part numbers of general service

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf in
1 29 Capscrew 16 - 17 140 - 150
1 30 Nut 16 - 17 140 - 150
1 45 Capscrew 20 - 21 180 - 190
1 53 Capscrew 16 - 17 140 - 150
- - Adjustment Collar Capscrews 3 - 3.5 25 - 30

* * * *

12 SM 1225 Rev 1 9-99

 BRAKING SYSTEM - Directional Control Valve
Section 250-0090

SM - 1509

15

P
A
B

15

b
15 a

14

T
7 4 9 8 1 5 7 10

b a

6
6
3 11 12 11 3
2
13
B A

1 - Valve Body 5 - Spring End Cap 9 - Allen Bolt

2 - End Cover 6 - Slide Washer 10 - Allen Bolt 13 - Sub Plate
3 - Spool 7 - Spring 11 - 'O' Ring 14 - Connector
4 - Spring End Cap 8 - Spacer 12 - 'O' Ring 15 - Elbow

Fig. 1 - Directional Control Valve

DESCRIPTION are made as follows:

The directional control valve can be identified as
item 9 in Section 250-0000, BRAKING SYSTEM Valve Body Assembly
SCHEMATIC. Port 'a' - Transmission control pressure.
Port 'b' - Plugged.
Mounted off the underside of the cab floor, the
directional control valve is located in the 'Px' Note: Transmission control pressure is taken from a
hydraulic circuit between the brake manifold valve tee in the transmission control pressure line and can
and the treadle valve. The 'Px' circuit hydraulically be recorded at a remote diagnostic point on the rear
actuates the treadle valve when the park/emergency left hand cab support. Refer to Figs. 2 and 3.
brake switch is activated (pushed in). The directional
control valve also controls automatic service brake Sub Plate
applied pressure bleed down, with engine shutdown. Port 'A' - Plugged.
Port 'B' - 'Px' port on treadle valve.
The directional control valve assembly comprises of Port 'P' - Brake Manifold Valve.
a sub plate and valve body assembly. Hydraulic Port 'T' - Steering and Brake Control Tank.
connections to the directional control valve assembly

SM 1226 2-98 1
Braking System - Directional Control Valve
Section 250-0090

SM - 1510 SM - 1511

TO 'PX' PORT FROM 'PX' PORT

TREADLE VALVE TREADLE VALVE
9 B A 9 B A
B B
b b
a a

T P T P
BRAKE BRAKE
MANIFOLD MANIFOLD
VALVE VALVE

Fig. 2 - Directional Control Valve - Energized Fig. 3 - Directional Control Valve - De-energized

OPERATION A controlled bleed down of the applied service brakes

Numbers in parentheses refer to Fig. 1. to the steering and brake control tank occurs through
the directional control valve. This controlled bleed
Refer to Fig. 2. When the engine is running, down permits a synchronised service brake release/
transmission control pressure enters the directional mechanical park brake application. Refer to Section
control valve at port 'a'. Oil pressure forces spool (3) 250-0000, BRAKING SYSTEM SCHEMATIC.
against spring (7) pressure, at port 'b' side of valve
body (1), internally linking port 'P' to port 'B' in sub Note: On engine shutdown, brake accumulator
plate (13). This results in an open circuit between the pressure is dead headed at ports 'P' and 'A' in the
brake manifold valve and port 'Px' in the treadle directional control valve.
valve.

Depending on the condition of the park/emergency REMOVAL

brake switch, oil flows through the directional control Numbers in parentheses refer to Fig. 1.
valve to energise or exhaust the 'Px' port on the
treadle valve as follows:
WARNINGS
Park/emergency brake switch activated (pushed in) - Hydraulic fluid pressure will remain within the
Oil flows through the directional control valve to the system after engine shut down. Operate the
'Px' port in the treadle valve. treadle valve continuously until the pressure
has dissipated before carrying out any work
Park/emergency brake switch deactivated (pulled on the braking system or serious injury could
out) - Return oil from the 'Px' port in the treadle valve result.
flows through the directional control valve, through
manifold brake valve solenoid to the steering and To prevent personal injury and property
brake control tank. damage, be sure wheel blocks are properly
secured and of adequate capacity to do the job
Refer to Fig. 3. When the engine is shutdown, the safely.
park/emergency brake switch is automatically applied
and transmission control pressure is relieved from 1. Position the vehicle in a level work area, apply the
port 'a'. Spring (7) pressure, at port 'b' side of valve parking brake and switch off the engine.
body (1), forces spool (3) back, internally linking port
'B' to port 'T'. This results in an open circuit between 2. Operate the treadle valve continuously to
the brake manifold valve and port 'Px' in the treadle discharge the brake accumulators. Block all road
valve. wheels.

2 SM 1226 2-98
 Braking System - Directional Control Valve
Section 250-0090
3. Clean directional control valve assembly and a. Install hydraulic supply capable of 0 - 159 bar
surrounding area with a suitable solvent. Ensure all (0 - 2 300 lbf/in²) to port 'P'.
hydraulic lines connected to the directional control
valve are identified for ease of installation and, with b. Install hydraulic supply capable of 0 - 21 bar
suitable containers available to catch leakage, (0 - 300 lbf/in²) to port 'a'.
disconnect hydraulic lines. Fit blanking caps to all
open lines. c. Install a suitable return line to port 'T'.

4. Release and remove mounting hardware securing d. Install a pressure gauge suitable for 0 - 207 bar
directional control valve to the mounting plate on the (0 - 3 000 lbf/in²) to port 'B'.
underside of the cab floor and remove assembly from
the truck. 2. Make sure all control valves to supply lines are
closed.
DISASSEMBLY/ASSEMBLY 3. Turn on hydraulic power supplies and make sure
Numbers in parentheses refer to Fig. 1. hydraulic oil is at normal operating temperature.

Note: Tighten all fasteners to standard torques listed 4. Open control valve for port 'P' supply and adjust to
in Section 300-0080, STANDARD BOLT AND NUT give a supply reading of 159 bar (2 300 lbf/in²).
TORQUE SPECIFICATIONS. Reading on pressure gauge at port 'B' should be zero.

Note: With the exception of replacing 'O' rings (11 & 12), Note: The directional control valve starts to de-energise
the directional control valve is a non serviceable item (close) when transmission pilot pressure falls below
and should be replaced as a complete assembly. The 7 bar (100 lbf/in²) and is fully de-energised when
'O' rings can be replaced as follows: transmission pilot pressure falls to 5.5 bar (80 lbf/in²).

1. Note orientation of valve body (1) to sub plate (13) 5. Open control valve for port 'a' supply and slowly
to facilitate assembly. increase this supply pressure from 0 to 21 bar
(0 to 300 lbf/in²) thus energising (opening) the
2. Clamp sub plate (13) lightly in a soft jawed vice directional control valve. Pressure reading at port 'B'
and remove allen bolts (9) and spacers (8). should now read 159 ± 7 bar (2 300 ± 100 lbf/in²).
Reading on pressure gauge at port 'D' should begin to
3. Separate valve body (1) from sub plate (13) and fall when supply pressure at port 'a' drops to 7 bar
discard 'O' rings (12). (100 lbf/in²). This rate of fall should reach a maximum
rate when supply pressure at port 'a' drops to 5.5 bar
4. Install new 'O' rings (12) in valve body (1) and fit (80 lbf/in²) or below. With supply pressure at port 'a' at
valve body (1) to sub plate (13) as noted prior to 5.5 bar (80 lbf/in²) or less, pressure on gauge at port
disassembly. Install spacers (8) in valve body (1) 'B' should quickly drop to almost zero, by exhausting
and secure valve body (1) to sub plate (13) with allen to tank via port 'T'.
bolts (9).
6. Slowly energise (open) control valve for port 'a'
5. Remove allen bolts (10) and end covers (2) from supply. Pressure reading at port 'B' should start to rise
valve body (1) and discard 'O' rings (11). when pressure at port 'a' reaches 5.5 bar (80 lbf/in²).
Rate of pressure increase at port 'B', should reach a
6. Install new 'O' rings (11) in end covers (2) and maximum level, when supply pressure at port 'a'
secure to valve body (1) with allen bolts (10). reaches 7 bar (100 lbf/in²) or above.

7. Close all control valves and turn off hydraulic

BENCH TEST supply pressures. Bleed off hydraulic supply lines and
Letters in parentheses refer to Fig. 1. remove directional control valve from the test bed for
installation.
1. Install directional control valve on a test bench and
connect as follows:

SM 1226 2-98 3
Braking System - Directional Control Valve
Section 250-0090

INSTALLATION 5. Check directional control valve and hydraulic line

Note: Tighten all fasteners to torques listed in connections for leaks and tighten as required.
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. 6. Shut off engine and make sure a full service brake
application is made followed by a parking brake
Note: Tighten all hydraulic lines fitted with ORFS application.
connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings 7. Repeat all braking and engine shut down cycles
where used. several times and check for appropriate application/
release cycle several times.
1. Position the directional control valve assembly to
the mounting plate on the underside of the cab floor 8. Check all connections again for leaks and tighten
and secure with mounting hardware. as required.

2. Remove blanking caps from hydraulic lines and

connect to directional control valve as noted during MAINTENANCE
removal. Inspect the directional control valve regularly for any
signs of leakage or damage and replace 'O' rings or
3. Check oil level in the steering and brake control complete assembly as required.
tank and add oil if required. Refer to Section
220-0040, STEERING AND BRAKE CONTROL TANK
for correct fill level, and, Section 300-0020, SPECIAL TOOLS
LUBRICATION SYSTEM for oil specification. There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
4. Remove wheel blocks, start the engine and bring SERVICE TOOLS, for part numbers of general
hydraulic oil to operating temperature. service tools required. These tools are available from
your dealer.

* * * *

4 SM 1226 2-98
 BRAKING SYSTEM - Monoblock Brake Valve
Section 250-0100

SM - 1363

1 - Valve Body 4 - Retainer 7 - Bonded Washer 10 - Shuttle Valve

2 - Orifice Plate 5 - Disc Filter 8 - Blanking Plug 11 - Relief Valve
3 - Conical Filter 6 - Filter Retainer 9 - Pressure Reducing Valve 12 - Plug

Fig. 1 - Monoblock Brake Valve

DESCRIPTION Shuttle valve (10), depending on spool position,

Numbers in parentheses refer to Fig. 1. provides a residual pressure of 3.1 ± 0.35 bar
(45 ± 5 lbf/in2) in the rear brake lines, or, upon
The monoblock brake valve can be identified as item 8 in actuation of the treadle or retarder valve, the brake
Section 250-0000, BRAKING SYSTEM SCHEMATIC. actuation pressure overcomes the residual pressure to
give a brake application at the rear brake packs.
Mounted off the left hand frame rail, the monoblock
brake valve incorporates three valves; pressure
reducing valve (9), pressure relief valve (11) and OPERATION
shuttle valve (10). Numbers in parentheses refer to Fig. 1.

Pressure reducing valve (9) reduces the available Refer to Fig. 2. With the engine running and the brake
hydraulic oil pressure from the rear brake accumulator manifold valve energized, (park/emergency brake
to a pressure of 83 bar (1 200 lbf/in2). switch deactivated - pulled out) hydraulic oil from the
rear brake accumulator flows through the brake
Pressure relief valve (11) regulates pressure, after manifold valve and enters valve body (1) at port 'P'. Oil
pressure reducing valve (9), to provide a residual flows through pressure reducing valve (9) and exits
pressure of 3.1 ± 0.35 bar (45 ± 5 lbf/in2) in the rear valve body (1) at port 'RB2' to release the parking
brake lines. A filter system, comprising of disc filter (5) brake. Oil pressure is reduced to 83 bar (1 200 lbf/in2)
and conical filter (3), helps protect orifice plate (2) at before leaving valve body (1) at port 'RB2'. Excess oil
pressure relief valve (11). at pressure reducing valve (9) is diverted back to tank
through port 'T' in valve body (1).

SM 1227 Rev 2 11-00 1

Braking System - Monoblock Brake Valve
Section 250-0100
At the same time, oil enters pressure relief valve (11) SM - 1356
circuit, passing through conical filter (3), disc filter (5)
and orifice plate (2) to shuttle valve (10). Oil pressure
pushes shuttle valve (10) spool across and oil exits TO REAR
TO PARKING SERVICE BRAKES
valve body (1) from port 'RB1' to the rear brake lines.
BRAKE
Oil pressure is regulated to 3.1 ± 0.35 bar TEST
(45 ± 5 lbf/in2) before leaving valve body (1) at port POINT
'RB1'. Excess oil at pressure relief valve (11) is
diverted back to tank through port 'T' in valve body (1).
TEST
POINT
Brake Application
Refer to Fig. 3. On application of the treadle valve, oil
pressure, up to a maximum of 52 bar (750 lbf/in2),
flows through a shuttle valve in the front brake lines
and enters valve body (1) at port 'FB'. Oil pressure
acts on shuttle valve (10) spool, overcomes residual
pressure, and pushes shuttle valve (10) spool across SUPPLY FROM
BRAKE MANIFOLD VALVE
to open port 'FB' to port 'RB1'. Oil pressure then
leaves port 'RB1' to apply the rear brakes. Fig. 2 - Residual Pressure at Rear Service Brakes

Refer to Fig. 2. When the treadle valve is released and SM - 1357

the pressure in the rear brakes fall below
3.1 ± 0.35 bar (45 ± 5 lbf/in2), residual pressure TO REAR
pushes shuttle valve (10) spool back across to close TO PARKING SERVICE BRAKES
off port 'FB' to the rear brake lines. Residual pressure BRAKE
TEST
is present in the rear brake lines. POINT
FROM
TREADLE/
Retarder Application RETARDER
TEST
Refer to Fig. 3. On application of the retarder valve, oil VALVE
POINT
pressure, up to a maximum of 33 bar (480 lbf/in2),
flows through a shuttle valve in the front brake lines
and enters valve body (1) at port 'FB'. Oil pressure
acts on shuttle valve (10) spool, overcomes residual
pressure, and pushes shuttle valve (10) spool across
to open port 'FB' to port 'RB1'. Oil pressure then
leaves port 'RB1' to apply the rear brakes. SUPPLY FROM
BRAKE MANIFOLD VALVE
On application of the treadle valve during retarder
operation, treadle valve pressure takes priority at the Fig. 3 - Treadle/Retarder Valve Actuated
shuttle valve in the rear brake lines when it exceeds
retarder applied pressure. This operation cancels the
retarder input and the rear brakes are applied by the Pressure Test Points
treadle valve pressure. Port 'TP1' provides a tapping point for parking brake
pressure. This pressure can be checked at diagnostic
Refer to Fig. 2. In either condition (treadle/retarder test point (rear) mounted off rear mounting bracket for
valve application), when the pressure in the rear body and disc brake cooling tank.
brakes fall below 3.1 ± 0.35 bar (45 ± 5 lbf/in2),
residual pressure pushes shuttle valve (10) spool back Port 'TP2' provides a tapping point for rear brake/
across to close off port 'FB' to the rear brake lines. retarder application pressure. This pressure can be
Residual pressure is present in the rear brake lines. checked at diagnostic test point (front) mounted off
rear mounting bracket for body and disc brake cooling
tank.

2 SM 1227 Rev 2 11-00

 Braking System - Monoblock Brake Valve
Section 250-0100

REMOVAL SM - 1353

WARNINGS
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the
treadle valve continuously until the pressure
has dissipated before carrying out any work on
the braking system or serious injury could
result.
1 - 'O' Ring
To prevent personal injury and property 2 - 'O' Ring 4 - Backup Ring
damage, be sure wheel blocks are properly 3 - 'O' Ring 5 - Backup Ring
secured and of adequate capacity to do the job Fig. 4 - Pressure Reducing Cartridge Seals
safely.

SM - 1354
1. Position the vehicle in a level work area, raise the
body and secure in place with the body safety pins.
Apply the parking brake and switch off the engine.

2. Operate the treadle valve continuously to discharge

the brake accumulators. Block all road wheels.

3. Clean monoblock brake valve and surrounding area

with a suitable solvent. Ensure all hydraulic lines
connected to the valve are identified for ease of 1 - Valve Body
installation and, with suitable containers available to 2 - Shuttle Ball Retainer 5 - Backup Ring
catch leakage, disconnect hydraulic lines. Fit blanking 3 - 'O' Ring 6 - 'O' Ring
caps to all open line ends and valve ports. 4 - 'O' Ring 7 - Backup Ring

Fig. 5 - Shuttle Valve Cartridge Seals

4. Remove mounting hardware securing monoblock
brake valve to left hand frame rail and remove valve to
a clean work area for 'Disassembly'. SM - 1355

DISASSEMBLY
Numbers in parentheses refer to Fig. 1, unless
otherwise specified.

Note: Other than the outer seals on pressure reducing

valve (9), shuttle valve (10) and relief valve (11), it is
not recommended that anything else is changed.
1 - Body 6 - Nut
2 - Sleeve 7 - Spacer 11 - Backup Ring
1. Remove pressure reducing valve (9) assembly from 3 - Guide 8 - 'O' Ring 12 - Backup Ring
valve body (1). Remove and discard 'O' rings 4 - Spring 9 - 'O' Ring 13 - Ball
(1, 2 & 3, Fig. 4) and backup rings (4 & 5) from 5 - Adjustment Screw 10 - 'O' Ring 14 - Cap Nut
pressure reducing valve (9). Fig. 6 - Pressure Relief Cartridge

2. Remove shuttle valve (10) assembly from valve (1). Remove and discard 'O' rings (8 & 9, Fig. 6) and
body (1). Remove and discard 'O' rings (3, 4 & 6, Fig. 5) backup ring (11, Fig. 6) from relief valve (11).
and backup rings (5 & 7, Fig. 5) from shuttle valve (10).
4. If required, remove blanking plug (8) from valve
3. Remove relief valve (11) assembly from valve body body (1). Remove and discard 'O' ring (7) from
blanking plug (8).

SM 1227 Rev 2 11-00 3

Braking System - Monoblock Brake Valve
Section 250-0100

ASSEMBLY 3. Check oil level in steering and brake control tank

Numbers in parentheses refer to Fig. 1, unless and add oil if required. Refer to Section 220-0040,
otherwise specified. STEERING AND BRAKE CONTROL TANK for correct
fill level, and, use only oil as specified in Section
1. Install new 'O' ring (7) on blanking plug (8) and 300-0020, LUBRICATION SYSTEM.
install blanking plug in valve body (1). Tighten blanking
plug (8) securely. 4. Remove wheel chocks, start the engine and bring
hydraulic oil to operating temperature.
2. Install new 'O' rings (8 & 9, Fig. 6) and backup ring
(11, Fig. 6) on relief valve (11) as shown in Fig. 6. 5. Check monoblock brake valve for leaks and tighten
Install relief valve (11) assembly in valve body (1) and connections as required.
tighten securely.
6. Shut off engine and make sure a full service brake
3. Install new 'O' rings (3, 4 & 6, Fig. 5) and backup application is made followed by a parking brake
rings (5 & 7, Fig. 5) on shuttle valve (10) as shown in application.
Fig. 5. Install shuttle valve (10) assembly in valve body
(1) and tighten securely. 7. Repeat all braking and engine shut down cycles
several times and check for appropriate application/
4. Install new 'O' rings (1, 2 & 3, Fig. 4) and backup release cycle several times.
rings (4 & 5) on pressure reducing valve (0) as shown
in Fig. 4. Install pressure reducing valve (9) assembly 8. Check all connections again for leaks and tighten as
in valve body (1) and tighten securely. required.

9. Remove body safety pins and lower the body to the

INSTALLATION frame.
Note: Tighten all fasteners to torques listed in
Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS. MAINTENANCE
Inspect the monoblock brake valve regularly for any
Note: Tighten all hydraulic lines fitted with ORFS signs of leakage or damage.
connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings Note: Limited repair of the monoblock brake valve is
where used. by replacement of parts only.

1. Position monoblock brake valve assembly to

mounting brackets on the left hand frame rail and SPECIAL TOOLS
secure with mounting hardware. There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
2. Remove blanking caps from hydraulic lines and SERVICE TOOLS, for part numbers of general service
connect to monoblock brake valve as recorded at tools required. These tools are available from your
'Removal'. dealer.

* * * *

4 SM 1227 Rev 2 11-00

 BRAKING SYSTEM - Pressure Reducing Valve
Section 250-0110

DESCRIPTION SM - 2558

The pressure reducing valve can be identified as item 6

19 in Section 250-0000, BRAKING SYSTEM
SCHEMATIC. 2

Mounted on the inside of the left hand frame rail in

front of the body guide, the pressure reducing valve is 1
7
located in the hydraulic brake circuit between the
treadle valve and the front brake callipers.

The pressure reducing valve, on application of the

8,9,10
50% brake reduction switch, mounted on the dash
5
panel in the cab, allows the operator to limit the
braking pressure to 50% at the front brakes. 3,4

OPERATION
Numbers in parenthesis refer to Fig. 1. 6

Refer to Fig. 2. Pressing the 50% brake reduction 1 - Pressure Reducing Valve 6 - Elbow - 90°
switch to the 'On' position sends a signal to energize 2 - Solenoid 7 - Adapter
3 - Diagnostic Nipple 8 - Bolt
the solenoid in pressure reducing valve (1). Oil cannot 4 - Dust Cap 9 - Washer
pass through the check valve and is directed through 5 - Cartridge 10 - Pad
the relief valve. The relief valve limits the maximum
Fig. 1 - Pressure Reducing Valve Installation
braking pressure to the front brake callipers to 55 bar
(800 lbf/in²).
SM - 2298
Refer to Fig. 3. Pressing the 50% brake reduction TO FRONT BRAKE CALLIPERS
switch to the 'Off' position sends a signal to
OUTLET
de-energize the solenoid in pressure reducing valve 19
(1). In this condition full braking pressure 110 bar TEST
(1 600 lbf/in²) is applied to the front brake callipers
when the treadle valve is operated.

REMOVAL/INSTALLATION
INLET TANK
Numbers in parentheses refer to Fig. 1.
FROM BRAKE TREADLE VALVE
Note: Tighten all fasteners to standard torques listed
Fig. 2 - Pressure Reducing Valve - Solenoid Energized
in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
SM - 2299
TO FRONT BRAKE CALLIPERS
Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000, OUTLET
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings 19

where used. TEST

WARNING
Hydraulic fluid pressure will remain within the
system after engine shut down. Operate the INLET TANK
treadle valve continuously until the pressure
has dissipated before carrying out any work on FROM BRAKE TREADLE VALVE
the braking system or serious injury could
Fig. 3 - Pressure Reducing Valve - Solenoid De-Energized
result.

SM 2041 7-00 1
Braking System - Pressure Reducing Valve
Section 250-0110

7. Secure pressure reducing valve (1) to mounting with

WARNING bolts (8) and washers (9).
To prevent personal injury and property
damage, be sure wheel blocks are properly 8. Remove blanking caps from hydraulic lines and
secured and of adequate capacity to do the job install lines to pressure reducing valve (1) as identified
safely. during removal.

1. Position the vehicle in a level work area, raise the 9. Check oil level in the steering and brake control
body and secure in place with the body safety pins. tank and add oil if required. Refer to Section 220-0040,
Apply the parking brake and switch off the engine. STEERING AND BRAKE CONTROL TANK for correct
fill level, and, Section 300-0020, LUBRICATION
2. Operate the treadle valve continuously to discharge SYSTEM for oil specification.
the brake accumulators. Block all road wheels.
10. Remove wheel blocks, start the engine and bring
3. Clean pressure reducing valve (1) and surrounding hydraulic oil to operating temperature.
area with a suitable solvent. Ensure all hydraulic lines
connected to pressure reducing valve (1) are identified 11. Check pressure reducing valve (1) and hydraulic
for ease of installation and, with suitable containers line connections for leaks and tighten as required.
available to catch leakage, disconnect hydraulic lines.
Fit blanking caps to all open lines. 12. Remove body safety pins and lower the body to
the frame.
4. Support valve body and remove bolts (8) and
washers (9) securing pressure reducing valve (1) to its
mounting. Remove pressure reducing valve (1) from MAINTENANCE
vehicle. Limited repair of the pressure reducing valve is with
replacement of parts only. Refer to vehicle parts book
5. Note location and orientation of elbows (6) and for lists of kits available.
adaptor (7) and remove from pressure reducing valve
(1).
SPECIAL TOOLS
6. Replace all 'O' rings and install elbows (6) and There are no special tools required for procedures
adaptor (7) in pressure reducing brake valve (1) ports outlined in this section. Refer to Section 300-0070,
as identified. SERVICE TOOLS, for part numbers of general service
tools required. These tools are available from your
dealer.

* * * *

2 SM 2041 7-00
 BRAKING SYSTEM - Retarder Control Valve
Section 250-0130

SM - 1272

1 - Adjustment Collar
2 - Actuator Plunger 11 - 'O' Ring 20 - Washer 29 - Jam Nut
3 - Plunger Return Spring 12 - 'O' Ring 21 - Capscrew 30 - Set Screw
4 - Regulator Spring 13 - Regulator Sleeve 22 - Housing 31 - Spring
5 - Regulator Spring 14 - Spool Return Spring 23 - Cap 32 - Friction Puck
6 - Spring Seat 15 - Wiper Seal 24 - Cam 33 - Capscrew
7 - Regulator Spool 16 - Backup Ring 25 - Spring Pin 34 - Shaft
8 - Backup Ring 17 - Seal 26 - Plug 35 - Ring
9 - 'O' Ring 18 - Valve Body 27 - Set Screw 36 - Lever
10 - Backup Ring 19 - Retainer 28 - Jam Nut 37 - Knob

Fig. 1 - Exploded View of Retarder Control Valve

DESCRIPTION console to the right hand side of the operator, is a

Numbers in parentheses refer to Fig. 1. closed centre controller which is used to apply a
continuous braking force to hold the vehicle at a safe
The retarder control valve can be identified as item 10 steady speed when descending grades. The valve
in Section 250-0000, BRAKING SYSTEM SCHEMATIC. applies reduced pressure to either the oil cooled disc
brakes (OCDB) or the transmission retarder.
Also referenced in this section is a transmission Selection of either the OCDB retarder or transmission
retarder circuit consisting of a directional control retarder is made by a separate retarder selection
valve, transmission retarder cylinder and a pressure switch on the left hand switch panel. Pressing the
switch. Refer to Figs. 2 through 5. switch at the top will select the OCDB retarder and
pressing the bottom will select the transmission
The retarder control valve, mounted in the centre retarder.

SM 1601 Rev 1 11-00 1

Braking System - Retarder Control Valve
Section 250-0130

SM - 1662

REAR
SERVICE
BRAKES

'P2' PORT
TREADLE
VALVE

FROM
BRAKE
MANIFOLD
VALVE

10 - Retarder Control Valve 12 - Transmission Retarder Cylinder

11 - Directional Control Valve 18 - Pressure Switch
Fig. 2 - OCDB Retarder Applied

In the normal position, lever (36) is in the forward OCDB Retarder Application
position and regulator spool (7) is in the up position. Refer to Fig. 2. In this condition the directional control
In this condition the notched area near the top of valve (if fitted) is de-energized.
regulator spool (7) is exposed to the tank cavity in
valve body (18), the lower portion of the notched area When the operator activates lever (36), actuator
is exposed to the regulated pressure outlet port of the plunger (2) is moved down and pushes on regulator
valve. This effects a direct link between tank port 'T' springs (4 & 5) which in turn, push regulator spool (7)
and regulated outlet port 'R'. While regulator spool (7) down. As regulator spool (7) moves down, the
is in this position the retarder is released. metering notches move out of the tank cavity and
close outlet port 'R' off to tank port 'T'. Regulator spool
(7) continues to move downward until the lower edge
OPERATION of the metering notches become exposed to the inlet
Numbers in parentheses refer to Fig. 1, unless pressure port 'P'. This movement opens inlet port 'P'
otherwise specified. to outlet port 'R'.

Reduced pressure travels through directional control

WARNING valve (11, Fig. 2) to the shuttle valve in the rear brake
The retarder is used for slowing the vehicle, lines. A spool in the shuttle valve is moved under the
not for parking. When parking the vehicle, the influence of this pressure to close off the treadle valve
park/emergency control should be applied. circuit and open the retarder valve circuit to the
monoblock brake valve. When the pressure applied by
the retarder control valve is greater than the residual
pressure of 3.1 ± 0.35 bar (45 ± 5 lbf/in2) acting on the
shuttle valve in the monoblock brake valve, the spool
in the shuttle valve will move across, opening the
retarder circuit to the rear service brakes. The result

2 SM 1601 Rev 1 11-00

 Braking System - Retarder Control Valve
Section 250-0130

SM - 1663

REAR
SERVICE
BRAKES

'P2' PORT
TREADLE
VALVE

FROM
BRAKE
MANIFOLD
VALVE

10 - Retarder Control Valve 12 - Transmission Retarder Cylinder

11 - Directional Control Valve 18 - Pressure Switch
Fig. 3 - Transmission Retarder Applied

of this operation is a reduced pressure application of Note: Should the operator depress the treadle valve
the rear service brakes. to obtain a full service brake application, when the
retarder is applied, treadle valve pressure takes
As hydraulic pressure builds in the brake, oil flows priority at the shuttle valve in the brake lines when it
through the small orifice in the side of regulator spool exceeds retarder applied pressure. A full service
(7) and into the cavity below the spool. As pressure brake application occurs.
rises in the brake it also rises in the cavity below the
spool forcing regulator spool (7) upwards closing A retarder applied pressure switch (18, Fig. 2)
outlet port 'R'. Regulator spool (7) is now balanced (installed in a tee at port 'R') will close, sending a
between the brake pressure and the pressure of signal to illuminate an indicator light in the dash
regulator springs (4 & 5) generated by lever (36) panel, and a retarder light at the rear of the truck, to
position. Regulator spool (7) has closed off inlet port 'P', indicate that the retarder is applied.
outlet port 'R' and tank port 'T' and will remain in this
position until lever (36) is moved. This maintains the
applied pressure within the brake circuit and provides Transmission Retarder Application
infinitely variable application of the braking force. If Refer to Fig. 3. In this condition the directional control
the operator further actuates lever (36), regulator valve is energized.
spool (7) will move down and build more pressure in
the brake until it balances the lever force.
WARNING
The maximum pressure applied by the retarder Great care should be used if applying the
control valve is governed by the stroke of regulator retarder when road surfaces are slippery. The
spool (7) within the valve. This stroke can be retarder braking effect will occur only at the
adjusted during maintenance operations. driving axle and could make the truck difficult
to control.

SM 1601 Rev 1 11-00 3

Braking System - Retarder Control Valve
Section 250-0130

SM - 1664

REAR
SERVICE
BRAKES

'P2' PORT
TREADLE
VALVE

FROM
BRAKE
MANIFOLD
VALVE

10 - Retarder Control Valve 12 - Transmission Retarder Cylinder

11 - Directional Control Valve 18 - Pressure Switch
Fig. 4 - OCDB Retarder Released

When the operator activates lever (36), actuator outlet port 'R' and tank port 'T' and will remain in this
plunger (2) is moved down and pushes on regulator position until lever (36) is moved. This maintains the
springs (4 & 5) which in turn, push regulator spool (7) applied pressure within the transmission retarder
down. As regulator spool (7) moves down, the circuit and provides infinitely variable application of
metering notches move out of the tank cavity and the retarder. If the operator further actuates lever
close outlet port 'R' off to tank port 'T'. Regulator (36), regulator spool (7) will move down and build
spool (7) continues to move downward until the lower more pressure in the retarder until it balances the
edge of the metering notches become exposed to the lever force.
inlet pressure port 'P'. This movement opens inlet
port 'P' to outlet port 'R'. The maximum pressure applied by the retarder
control valve is governed by the stroke of regulator
This permits reduced pressure to travel through spool (7) within the valve. This stroke can be
directional control valve (11, Fig. 3) to transmission adjusted during maintenance operations.
retarder cylinder (12, Fig. 3) on the transmission. Oil
fills the cavity around the rotor within the retarder and Note: Should the operator depress the treadle valve
creates drag, which in turn, slows the truck down. to obtain a full service brake application, when the
When the cavity is emptied, the rotor is free of drag. retarder is applied, treadle valve pressure takes
priority at the shuttle valve in the brake lines when it
As hydraulic pressure builds in the retarder, oil flows exceeds retarder applied pressure. A full service
through the small orifice in the side of regulator spool brake application occurs.
(7) and into the cavity below the spool. As pressure
rises in the retarder it also rises in the cavity below A retarder applied pressure switch (18, Fig. 3)
the spool forcing regulator spool (7) upwards closing (installed in a tee at port 'R') will close, sending a
outlet port 'R'. Regulator spool (7) is now balanced signal to illuminate an indicator light in the dash
between the retarder pressure and the pressure of panel, and a retarder light at the rear of the truck, to
regulator springs (4 & 5) generated by lever (36) indicate that the retarder is applied.
position. Regulator spool (7) has closed off inlet port 'P',

4 SM 1601 Rev 1 11-00

 Braking System - Retarder Control Valve
Section 250-0130

SM - 1665

REAR
SERVICE
BRAKES

'P2' PORT
TREADLE
VALVE

FROM
BRAKE
MANIFOLD
VALVE

10 - Retarder Control Valve 12 - Transmission Retarder Cylinder

11 - Directional Control Valve 18 - Pressure Switch
Fig. 5 - Transmission Retarder Released

OCDB Retarder Release (18, Fig. 5) will open, switching off the retarder
Refer to Fig. 4. In this condition the directional control indicator light on the dash panel and retarder light at
valve (if fitted) is de-energized. rear of the truck.

When the operator releases lever (36), regulator

spool (7) will become unbalanced and move upwards REBUILD CRITERIA
under the influence of the rear brake circuit pressure Inspect the valve regularly for any signs of leakage or
and spool return spring (14). As a result, regulator damage. The controller should be rebuilt if one or
spool (7) moves to open outlet port 'R' to tank port 'T', more of the following conditions exist:
closing inlet pressure port 'P'. The pressure will fall
and retarder applied pressure switch (18, Fig. 4) will 1. Any sign of external leakage.
open, switching off the retarder indicator light on the
dash panel and retarder light at rear of the truck. Note: Check all hydraulic lines and fittings to ensure
leakage is not coming from there.

Transmission Retarder Release 2. Retarder valve holds pressure when in the neutral
Refer to Fig. 5. In this condition the directional control position.
valve is in energized.
3. Varying output pressure with the lever fully
When the operator releases lever (36), regulator actuated.
spool (7) will become unbalanced and move upwards
under the influence of the transmission retarder 4. Spring pin securing shaft to actuator cam has
circuit pressure and spool return spring (14). As a failed.
result, regulator spool (7) moves to open outlet port
'R' to tank port 'T', closing inlet pressure port 'P'. The 5. Excessively worn friction pucks. This will be evident
pressure will fall and retarder applied pressure switch through mechanical interference of actuator cam (24),

SM 1601 Rev 1 11-00 5

Braking System - Retarder Control Valve
Section 250-0130

or, the inability to compress spring (31) enough to Valve Body

hold lever (36) in the fully applied position during 1. Remove cap (23) from the top of valve body (18).
normal operation.
2. Loosen the socket head capscrew from
adjustment collar (1) and unscrew adjustment collar
REMOVAL (1). Remove controller from the vice.

3. Remove capscrews (21) and washers (20) securing

WARNINGS retainer (19) to valve body (18). Remove retainer (19).
To prevent personal injury and property
damage, be sure wheel blocks are properly 4. Remove and discard 'O' ring (9) from counterbore
secured and of adequate capacity to do the in the base of valve body (18).
job safely.
5. With the controller upright on the work bench, hold
Hydraulic oil pressure will remain valve body (18) with one hand and push actuator
within the braking system after engine shut plunger (2) down with the other hand until regulator
down. Operate the treadle pedal continuously sleeve (13) pops loose.
until the pressure has dissipated before
carrying out any work on the braking system 6. Turn valve body (18) on its side on the work bench
or serious injury could result. and remove regulator sleeve (13).

1. Position the vehicle in a level work area, apply the 7. Remove regulator spool (7) and spool return
parking brake and switch off the engine. spring (14) from regulator sleeve (13).

2. Operate the treadle valve continuously to 8. Remove plunger return spring (3), regulator springs
discharge the braking accumulators. Block all road (4 & 5) and spring seat (6) from valve body (18).
wheels.
9. Remove actuator plunger (2) by pushing down
3. Remove and tag electrical connections to retarder (toward the bottom of valve body (18)) on actuator
pressure switch. plunger (2) by hand, until the plunger slides out.

4. Ensure all hydraulic lines connected to the retarder 10. Remove and discard 'O' rings (9, 11 & 12) and
valve are identified for ease of installation and, with teflon backup rings (8 & 10) from regulator sleeve (13).
suitable containers available to catch leakage,
disconnect hydraulic lines. Fit blanking caps to all 11. Remove and discard wiper seal (15), seal (17)
open lines and retarder valve ports. and backup ring (16) from the actuator section of
valve body (18).
5. Release and remove mounting hardware securing
the retarder control valve in the centre console.
Remove retarder control valve assembly to a clean Actuator
area for 'Disassembly'. 1. Loosen jam nut (29) and remove set screw (30)
from housing (22).
DISASSEMBLY 2. Remove spring (31) from housing (22). Inspect
Numbers in parentheses refer to Fig. 1. spring (31) carefully for cracks or breaks and replace
if required.
1. Remove blanking caps from valve body (18) ports
and drain oil by rotating the valve over a suitable 3. Remove plug (26) from housing (22). Spring pin
container. (25) may have already sheared off. If not, use a
2.3 mm (0.09 in) pin punch to press spring pin (25)
2. Secure the valve upright in a table vice. past shaft (34).

3. Remove capscrews (33) securing housing (22) 4. Rotate lever (36) and shaft (34) sub-assembly to
assembly to valve body (18). Remove housing assembly. release it from cam (24). Pull lever (36) and shaft
(34) sub-assembly from housing (22).

6 SM 1601 Rev 1 11-00

 Braking System - Retarder Control Valve
Section 250-0130
Note: Do not try to disassemble lever (36) from shaft proceed as follows:
(34). If shaft (34) or lever (36) are damaged, replace
shaft (34), lever (36), ring (35) and spring pin (25). a. Attach lever (36) to shaft (34) and compress ring (35)
into the groove on lever (36).
5. Remove cam (24) from housing (22). Inspect cam
(24) surfaces and replace if worn. b. Slide lever (36) and ring (35) into shaft (34) while
maintaining ring (35) in a compressed state. As lever
6. Remove spring pin (25) from cam (24), and also (36) and shaft (34) are assembled, ring (35) will
from shaft (34) if it has sheared off during operation. disappear and spring into shaft (34) as it passes the
shaft groove.
7. Remove friction pucks (32) from housing (22).
c. Move lever (36) back and forth to ensure ring (35)
8. Loosen jam nut (28) and set screw (27). was allowed to spring out completely. Attach knob
(37) to lever (36) and secure.

INSPECTION 2. Place friction puck (32) located furthest from

Numbers in parentheses refer to Fig. 1. spring (31) into cavity in housing (22). Tap puck (32)
lightly with a rod and mallet to ensure puck (32)
1. Clean all parts with a suitable cleaning solvent. protrudes from housing (22).

2. Inspect actuator plunger (2) for wear on the sides 3. Measure the distance friction puck (32) protrudes
where it moves through the seals. If axial grooves from housing (22). This distance should be
are seen or if any wear is evident, replace actuator approximately 2.3 mm (0.09 in). If this distance
plunger (2). Actuator plunger (2) must be replaced if varies more than 0.5 mm (0.02 in), replace the
the diameter is worn below 18.97 mm (0.747 in). actuator assembly.

3. Place regulator spool (7) into regulator sleeve (13) 4. Insert cam (24) in housing (22).
and push the spool lightly through the sleeve.
Regulator spool (7) must be able to move freely and 5. Align shaft (34) and lever (36) assembly with
smoothly the entire length of regulator sleeve (13). If housing (22) and cam (24) bore. Insert shaft (34) into
it cannot, regulator spool (7) and regulator sleeve housing (22) and cam (24) bore.
(13) must be replaced as a matched set.
6. Align 3 mm (0.12 in) diameter holes in shaft (34)
Note: Never replace just the spool or sleeve. They and cam (24). Install spring pin (25) until pin is
must be replaced as a matched set. recessed approximately 2.3 mm (0.09 in) below
cam (24) surface.
4. Inspect each spring carefully for cracks or breaks.
Any spring with a crack or break must be replaced. 7. Place second friction puck (32) in housing (22) and
Also, if the retarder valve was not reaching proper place spring (31) behind friction puck (32).
regulated pressure, replace all regulator springs.
8. Install set screw (30) in housing (22).
SUB-ASSEMBLY Note: Set screw (30) will be adjusted later to provide
Numbers in parentheses refer to Fig. 1. the proper spring compression.

Note: All metal parts should be thoroughly cleaned 9. Install jam nut (29) on set screw (30) and tighten
with a suitable solvent, dried, and lubricated with a finger tight.
light weight oil before assembly. This valve is built to
extremely close manufacturing tolerances. Great 10. Install set screw (27) in housing (22) and jam nut
care should be taken to keep components protected (28) on set screw (27). Finger tighten jam nut (28).
from contamination prior to and during assembly.
11. Turn sub-assembly with the bottom side up and
fill the actuation cavity with EP, NLGI grease until
Actuator cam (24) is covered. Refer to Section 300-0020,
1. If new lever (36) and shaft (34) are being fitted LUBRICATION SYSTEM for grease specification.

SM 1601 Rev 1 11-00 7

Braking System - Retarder Control Valve
Section 250-0130

Valve Body Seals SM - 1347

1. Install seal (17) in seal groove of valve body (18)

first. Position seal (17) in the groove so that 'O' ring
inside the seal is facing down toward the bottom of
valve body (18). See Fig. 6.

2. Make sure the internal 'O' ring is still seated inside

seal (17) and did not get dislodged during installation.
Position seal (17) to the bottom of the groove.

3. Install backup ring (16) on top of seal (17). Start by INTERNAL

'O' RING
hand and then continue to work into the groove either
by hand or by using an 'O' ring installation tool.

4. Install wiper seal (15) in the top counterbore. Fig. 6 - Valve Body Seal Installation
Position wiper seal (15) in the groove so that the
register lip is facing up toward the actuator. SM - 1348

Regulator Sleeve
1. Install 'O' ring (9) onto the smallest groove (on the
top) of regulator sleeve (13). Install 'O' ring (11) onto
the middle groove of regulator sleeve (13). Install
'O' ring (12) onto the largest groove (on the bottom)
of regulator sleeve (13). See Fig. 7.

2. Install backup ring (10) onto each side of 'O' ring

(11) located in the middle of regulator sleeve (13).
See Fig. 7.

3. Install backup ring (8) behind 'O' ring (9) located at

the top end of regulator sleeve (13). 'O' ring (9) is the
smallest of the three 'O' rings. Position backup ring
(8) so that it is next to the top of regulator sleeve
(13). The top of regulator sleeve (13) is the end with
the smallest OD. See Fig. 7.

Valve Body Assembly

Numbers in parentheses refer to Fig. 1.
Fig. 7 - Regulator Sleeve Seal Installation
1. Install actuator plunger (2) in valve body (18).
Note: Check to ensure that regulator spool (7) will
2. Install plunger return spring (3), regulator springs slide smoothly and freely in regulator sleeve (13).
(4 & 5) and spring seat (6) in valve body (18). If Replace the entire spool and sleeve assembly if the
spring seat (6) does not seat correctly on top of spool does not slide smoothly and freely.
regulator spring (5), lightly shake valve body (18) to
correctly position spring seat (6). 4. Remove regulator spool (7) from regulator sleeve
(13) before installing sleeve into valve body (18).
3. Lightly lubricate regulator spool (7) assembly and
install into regulator sleeve (13). The spherical end of 5. Lightly lubricate 'O' rings (9, 11 & 12) on regulator
regulator spool (7) should be at the top of regulator sleeve (13).
sleeve (13). The top of regulator sleeve (13) is the
end with the smallest OD. 6. Install regulator sleeve (13) assembly in valve
body (18). Make sure spring seat (6) is correctly

8 SM 1601 Rev 1 11-00

 Braking System - Retarder Control Valve
Section 250-0130

SM - 1349

207 bar RETURN

(3 000 lbf/in2)
SUPPLY

BRAKE
PRESSURE

Fig. 8 - Typical Retarder Control Valve Test Circuit

seated in regulator spring (5) before installing TESTING AND ADJUSTMENTS

regulator sleeve (13). Push regulator sleeve (13) into Numbers in parentheses refer to Fig. 1.
bore until retaining flange at the base contacts valve
body (18). Note: A hydraulic test fixture with capabilities similar
to the one shown in Fig. 8 is required.
7. Install spool return spring (14) into regulator
spool (7). Reinstall regulator spool (7) into regulator 1. Position the valve in the test fixture to allow actuator
sleeve (13). plunger (2) to be activated by hand using a lever.

8. Lightly lubricate 'O' ring (9) and install into counter 2. Attach main supply input pressure line to port 'P'.
bore in the bottom end of valve body (18).
3. Attach tank return line to port 'T'.
9. Install retainer (19) to valve body (18) and secure
with capscrews (21) and washers (20). Tighten 4. Attach regulated output test line to port 'R'. Check
capscrews (21) evenly to a torque of 20 - 21 Nm that all ports are used.
(180 - 190 lbf in), alternating diagonally to evenly seat
regulator sleeve (13) assembly. 5. Set supply line pressure to 159 bar (2 300 lbf/in2).

10. Screw adjustment collars (1) onto the top of 6. Return line pressure during this test is not to
actuator plunger (2). Screw all the way down until it exceed 0.34 bar (5 lbf/in2).
bottoms on the thread.
7. Test valve with 10W hydraulic oil at 50° + 6° C
Note: It is extremely important to bottom-out (120° + 10° F).
adjustment collar (1) to prevent over-stressing and
breaking the springs during the adjustment process.

SM 1601 Rev 1 11-00 9

Braking System - Retarder Control Valve
Section 250-0130

Setting Apply Pressure 4. Adjust set screw (27) on top of housing (22) inward
Note: Before actuating the valve, be sure adjustment until the pressure begins to rise. Measure lever (36)
collar (1) is bottomed to prevent excessive pressure angle and back set screw (27) out until a lever angle
from damaging regulator springs (4 & 5). of 6° is achieved.

1. Gradually increase pressure in order to check for Note: Failure to comply with this specification may
leaks. Make sure adjustment collar (1) is screwed all result in the regulated pressure not being released to
the way down on the threads and cap (23) is installed tank.
on valve body (18).
5. Secure jam nut (28) on set screw (27) to lock the
2. Actuate plunger (2) until cap (23) contacts valve initial lever angle.
body (18). The pressure reading should be below
regulated pressure of 33 ± 1.7 bar (480 ± 25 lbf/in2). 6. Fully apply lever (36) to check the maximum
regulated output pressure and readjust if required.
3. To raise the regulated pressure, back adjustment
collar (1) up (anticlockwise) in small increments until Note: The approximate total lever (36) travel is 60°
the output pressure is 33 ± 1.7 bar (480 ± 25 lbf/in2) at and this value may be used for reference purposes
port 'R'. Fine adjustment will require only turning the only.
collar in 1/8 turn increments.
7. Apply and hold lever (36) to maintain maximum
Note: Adjust adjustment collar (1) in small increments regulated output pressure. Adjust set screw (30) until
to prevent the valve from being over pressurised sufficient spring (31) force is generated to hold lever
during the adjustment procedure. Excessive pressure (36) in the full apply position.
could cause premature regulator spring failure.
8. Turn set screw inward until friction pucks (32) hold
4. Once regulated pressure has been set, tighten the lever (36) while generating the maximum regulated
capscrew on adjustment collar (1). Check the pressure (approximately 1.5 turns).
pressure again after tightening the capscrew. If the
pressure has moved out of the specified range, loosen 9. Secure set screw (30) in position with jam nut (29)
the capscrew and readjust. to lock spring (31) compression.

5. Cycle the valve for a minimum of 50 times, then

recheck the pressure. If the pressure setting has INSTALLATION
moved out of the specified range, repeat the Note: Tighten all fasteners to torques listed in
adjustment procedure. Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATION.
6. Apply Loctite 290, or equivalent, to actuator plunger
(2) threads and adjustment collar (1) locking screw. Note: Tighten all hydraulic lines fitted with ORFS
connections, as described in Section 250-0000,
BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
Final Assembly and Adjustments where used.
Numbers in parentheses refer to Fig. 1.
1. Position retarder control valve assembly in the
1. Apply a small bead of Loctite 518 gasket centre console and secure with mounting hardware.
compound, or equivalent, to the top of valve body (18)
sub-assembly. 2. Remove blanking caps from hydraulic lines and
connect to retarder valve assembly as noted on
2. Install actuator sub-assembly on top of valve body removal.
(18) sub-assembly with the valve porting facing as
shown in Fig. 1. 3. Connect electrical connections to retarder
pressure switch as noted at 'Removal'.
3. Secure actuator sub-assembly to valve body sub-
assembly with capscrews (33). Tighten capscrews 4. Check the level of oil in the steering and brake
(33) to a torque of 20 - 21 Nm (180 - 190 lbf in). control tank. Refer to Section 220-0040, STEERING

10 SM 1601 Rev 1 11-00

 Braking System - Retarder Control Valve
Section 250-0130
AND BRAKE CONTROL TANK. Add oil if low. Use b. Start engine and bring hydraulic oil temperature to
oils meeting the specifications outlined in Section operating temperature.
300-0020, LUBRICATION SYSTEM.
c. Actuate retarder control valve fully and check
5. Start engine and bring hydraulic fluid to operating reading on pressure gauge. Pressure reading should
temperature and apply all brakes in sequence. be 33 ± 1.7 bar (480 ± 25 lbf/in2).

6. Check for oil leaks and tighten connections as If the pressure is outwith the specified pressure
necessary. range, inspect the valve and take relevant action
(adjust pressures, strip down and repair or replace
7. Engage retarder. Make sure of a full service brake valve).
application and that retarder light illuminates. Release
retarder.
Retarder Light Pressure Switch
8. Check all connections again for leaks and tighten The retarder light pressure switch is a normally open
as necessary. switch. Attach a continuity tester to terminals on the
pressure switch. The circuit should be open.

MAINTENANCE As retarder pressure increases to 2.7 bar (39 lbf/in²)

and above, the circuit should close and send a signal
General to illuminate the retarder indicator light in the dash
Check all hydraulic brake lines and fittings at retarder panel, and the retarder light at the rear of the truck.
control valve for leaks and damage. Tighten/replace As pressure drops below 2.7 bar (39 lbf/in²) the
as required. circuit should open and the retarder lights should go
out.

Every 1 000 Hours

Check retarder pressure at diagnostic test point as SPECIAL TOOLS
follows: There are no special tools required for procedures
outlined in this section. Refer to Section 300-0070,
a. Connect a hydraulic gauge capable of recording a SERVICE TOOLS, for part numbers of general
pressure of 0 - 70 bar (0 - 1 000 lbf/in2) to diagnostic service tools and adhesives required. These tools,
pressure point for rear brake/retarder pressure. and adhesives are available from your dealer.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf in
1 21 Capscrew 20 - 21 180 - 190
1 33 Capscrew 20 - 21 180 - 190

* * * *

SM 1601 Rev 1 11-00 11

 BRAKING SYSTEM - Shuttle Valve
Section 250-0140

DESCRIPTION SM - 1350
TO MONOBLOCK
Letters in parentheses refer to Fig. 1. BRAKE VALVE

The Shuttle Valve can be identified as item 6 in

Section 250-0000, BRAKING SYSTEM SCHEMATIC.
FROM 'B2' PORT
The shuttle valve allows the distribution of pressure TREADLE VALVE
from either the treadle valve, to activate the rear
service brakes, or, the retarder control valve, to
utilise the rear service brakes as a retarder. RETARDER
CONTROL VALVE
The shuttle valve consists of a well fitting spool Fig. 1 - Treadle Valve Activated
which is pushed under pressure, depending on flow
direction ('P1' to 'A' or 'P2' to 'A') to one end position,
where it seals against an 'O' ring seal. The 'O' ring is SM - 1351
TO MONOBLOCK
protected by a metal housing. Flow from 'P1' to 'A', or BRAKE VALVE
'P2' to 'A' can only occur with the valve open.

OPERATION FROM 'B2' PORT

Refer to Fig. 1. On application of the treadle valve, TREADLE VALVE
hydraulic oil, up to a maximum pressure of 52 bar
(750 lbf/in²), acts on port 'P1'. This pressure pushes
the spool across to close port 'P2'. Oil pressure flows
RETARDER
through port 'A' to the monoblock brake valve CONTROL VALVE
mounted off the left hand frame rail. Refer to
Fig. 2 - Retarder Control Valve Activated
Section 250-0100, MONOBLOCK BRAKE VALVE.

Refer to Fig. 2. On application of the retarder control

valve, hydraulic oil, up to a maximum pressure of MAINTENANCE
33 bar (480 lbf/in²), acts on port 'P2'. This pressure The shuttle valve is a non-serviceable item and
pushes the spool across to close port 'P1'. Oil should be replaced completely, if damaged, as
pressure flows through port 'A' to the monoblock follows:
brake valve mounted off the left hand frame rail.
Refer to Section 250-0100, MONOBLOCK BRAKE Note: Tighten all fasteners to standard torques listed
VALVE. in Section 300-0080, STANDARD BOLT AND NUT
TORQUE SPECIFICATIONS.
On application of the treadle valve during retarder
operation, treadle valve pressure takes priority at the Note: Tighten all hydraulic lines fitted with ORFS
shuttle valve when it exceeds retarder applied connections, as described in Section 250-0000,
pressure. This operation cancels the retarder input BRAKING SYSTEM SCHEMATIC. Renew all 'O' rings
and the rear brakes are applied by the treadle valve. where used.

TESTING WARNINGS
Letters in parentheses refer to Fig. 1. To prevent personal injury and property
damage, ensure wheel blocks are of sufficient
Remove shuttle valve from the truck (as described capacity and properly secured to do the job
under 'Maintenance') and plug outlet port 'A'. Apply safely.
hydraulic oil pressure of 110 bar (1 600 lbf/in²)
through inlet port 'P1' and visually inspect inlet port To prevent personal injury, relieve the
'P2' for leaks. Repeat this test for inlet port 'P2'. If pressure in the braking system. The exact
any leakage of hydraulic oil occurs, replace shuttle procedure must be followed as described in
valve. Section 250-0000, BRAKING SYSTEM
SCHEMATIC.

SM 1229 2-98 1
Braking System - Shuttle Valve
Section 250-0140
1. Position the vehicle in a level work area, apply the install lines to shuttle valve as identified during removal.
parking brake and switch off the engine.
7. Check oil level in steering and brake control tank
2. Operate the treadle valve continuously to discharge and add oil if required. Refer to Section 220-0040,
the brake accumulators. Block all road wheels. STEERING AND BRAKE CONTROL TANK for
correct fill level, and, use only oil as specified in
3. Clean shuttle valve assembly and surrounding Section 300-0020, LUBRICATION SYSTEM.
area with a suitable solvent. Ensure all hydraulic
lines connected to the shuttle valve are identified for 8. Remove wheel blocks, start the engine and bring
ease of installation and, with suitable containers hydraulic oil to operating temperature.
available to catch leakage, disconnect hydraulic
lines. Fit blanking caps to all open lines. 9. Apply the brakes and check for oil leaks and
correct operation of the shuttle valve. Tighten line
4. Remove mounting hardware securing the shuttle connections and fittings as necessary.
valve to mounting bracket on the underside of the
cab. Remove shuttle valve and disconnect all fittings
for use on the new valve. SPECIAL TOOLS
There are no special tools required for procedures
5. Install all fittings on the new shuttle valve and outlined in this section. Refer to Section 300-0070,
secure shuttle valve assembly to mounting bracket SERVICE TOOLS, for part numbers of general
with mounting hardware. service tools required. These tools are available from
your dealer.
6. Remove blanking caps from hydraulic lines and

* * * *

2 SM 1229 2-98
 OPERATORS COMPARTMENT - Cab and Mounting
Section 260-0010

SM - 2391

9
2 1

16
5
7 17
18 19

15

20

10

13 11
4 6
11 12
8
12

11
14 *21
3

1 - Cab Assembly 9 - Rear Glass 17 - Screw

2 - RH Door Assembly 10 - Bolt 18 - Washer
3 - LH Door Assembly 11 - Snubbing Washer 19 - Nut
4 - Front Glass 12 - Rubber Mount 20 - Cap
5 - RH Side Glass 13 - Bolt *21 - Locknut
6 - LH Side Glass 14 - Locknut
7 - RH Cover 15 - Insert * - From January 2000
8 - LH Cover 16 - Catch Assembly Production

Fig. 1 - Exploded View of Cab Assembly

DESCRIPTION
Numbers in parentheses refer to Fig. 1. WARNING
The protection offered by the FOPS protective
Cab assembly (1) is mounted through rubber mounts structure may be impaired if it has been
(12) which damp structure borne noise and vibration. subjected to any modification or damage.
The cab conforms with ISO/SAE, FOPS (Falling Unauthorized modification will void
Object Protective Structure) safety legislation, with certification.
ROPS (Roll Over Protective Structure provided by
the cab guard. Access to cab assembly (1) is from either side and
visibility is unrestricted through tinted glass. A
FOPS - ISO 3449, SAE J231 heater/filter/pressurizer and demisting unit in front of

SM 1602 Rev 1 1-00 1

Operators Compartment - Cab and Mounting
Section 260-0010
the passengers seat keeps the cab interior air fresh order to prevent damage to the electrical
and dust free. A sliding window in RH door assembly components.
(2) and an electric window in LH door assembly (3)
provide additional ventilation. An air conditioner is a. Disconnect battery equalizer ground cables.
also fitted to cab assembly (1) as standard. Refer to b. Disconnect battery cables from terminal posts
Section 260-0130, AIR CONDITIONING. (ground cables first).
c. Disconnect battery equalizer positive cables.
d. Disconnect electrical connections at the ECU.
REMOVAL
Numbers in parentheses refer to Fig. 1. 5. Disconnect all remaining electrical connections
attached to cab assembly (1).
Note: Identify and tag all cables, harnesses, lines
and pipes disconnected from cab assembly (1) during 6. Carefully loosen brake pipes at the base of both
removal to aid in installation. brake accumulators to check that brake pressure has
been discharged. Re-tighten brake pipes.

WARNINGS 7. Ensure all steering and braking lines connected to

To prevent personal injury and property the cab are identified for ease of installation, and with
damage, be sure wheel chocks, blocking suitable containers available to catch leakage,
materials and lifting equipment are properly disconnect all lines. Fit blanking caps to all open
secured and of adequate capacity to do the job lines and fittings.
safely.

Hydraulic oil pressure will remain within WARNING

the braking system after engine shutdown. Before disconnecting any air conditioner lines,
Operate the treadle valve continuously until refer to Section 260-0130, AIR CONDITIONING.
the pressure has dissipated before removing Refrigerant will rapidly freeze all objects with
any brake lines or serious injury could result. which it comes into contact. It can cause
serious and permanent damage to the eyes
Hydraulic oil pressure will remain within and skin.
the body control system after engine
shutdown. Operate the body control joystick 8. Evacuate the air conditioning system and
in both directions approximately 15 times to disconnect air conditioning lines. Refer to Section
discharge the pilot valve accumulator before 260-0130, AIR CONDITIONING. Fit blanking caps to
disconnecting any hoses. all open lines and fittings.

High electrical current. Turn the ignition 9. Ensure heater lines are identified for ease of
key switch 'Off' before disconnecting any installation, and with suitable containers available to
electrical components. Disconnect electrical catch leakage, disconnect heater lines. Fit blanking
connections in the correct order given to caps to open lines and fittings.
prevent damage to the electrical components.
10. Ensure body control joystick lines are identified
1. Position the vehicle in a level work area, raise the for ease of installation, and with suitable containers
body and install the body safety pins. Refer to available to catch leakage, disconnect hoses at
Section 270-0010, BODY AND MOUNTING. manifold plate in cab floor. Fit blanking caps to open
lines and fittings.
2. Apply the parking brake and switch off the engine.
11. Ensure all connections to cab assembly (1) have
3. Turn the steering wheel in both directions several been removed, prior to removal.
times to relieve any pressure in the steering system.
Operate the treadle valve continuously to discharge 12. Attach suitable lifting equipment to cab assembly
the braking accumulators. Operate the body control (1) and take up the slack. Remove cap (20) from bolt
joystick continuously to discharge the pilot valve head. Remove locknut (14) securing bolt (13) to front
accumulator. Block all road wheels. cab support. Remove locknut (21), if fitted and
slacken off bolts (10) from rear cab supports.
4. Disconnect the electrical cables in the following

2 SM 1602 Rev 1 1-00

 Operators Compartment - Cab and Mounting
Section 260-0010
Note: Use padded spreader bars when removing cab 5. Remove blanking caps from all braking and
assembly (1) with overhead lifting equipment to steering lines and connect lines as identified at
prevent damage from concentrated loads at cab removal. Tighten all lines securely.
lifting points with hooks, chains, cables etc..
6. Connect all electrical connections with the
13. Lift cab assembly (1) carefully from the cab exception of battery cables, battery equalizer cables
supports and remove to suitable stands. Remove and CEC connections, as identified at removal.
bolts (13 & 10), snubbing washers (11) and rubber
mounts (12) from cab assembly (1). 7. Remove blanking caps from heater lines and
fittings and connect lines as identified at removal.
Tighten heater lines securely.
INSTALLATION
Numbers in parentheses refer to Fig. 1.
WARNING
Note: Tighten all fasteners to standard torques listed Before connecting any air conditioner lines,
in Section 300-0080, STANDARD BOLT AND NUT refer to Section 260-0130, AIR CONDITIONING.
TORQUE SPECIFICATIONS. Refrigerant will rapidly freeze all objects with
which it comes into contact. It can cause
Note: Tighten all hydraulic lines fitted with ORFS serious and permanent damage to the eyes
connections, as described in Section 250-0000, and skin.
BRAKING SYSTEM. Renew all 'O' rings where used.
8. Connect the air conditioning lines to the evaporator
and charge the system. Refer to Section 260-0130,
WARNING AIR CONDITIONING.
To prevent personal injury and property
damage, be sure wheel chocks, blocking 9. Connect electrical cables in the following order.
materials and lifting equipment are properly
secured and of adequate capacity to do the job a. Connect all electrical connections removed at the
safely. ECU.
b. Connect battery equalizer positive connections.
1. Inspect rubber mounts (12) for damage and c. Connect battery cables to terminal posts (positive
replace if necessary. If installing new rubber mounts cables first).
(12), lubricate them with water or a suitable rubber d. Connect battery equalizer ground cables.
lubricant and install in cab assembly (1). Use a driver
of the same diameter as the internal metal sleeve in 10. Check cab assembly (1) and be sure that all
rubber mount (12) to drive the mounts fully home. lines, cables and harnesses removed at removal
have been reconnected.
2. Attach suitable lifting equipment (with padded
spreader bars) and position cab assembly (1) to cab 11. Fill both hydraulic tanks with hydraulic oil
supports. Take care when positioning cab assembly specified in Section 300-0020, LUBRICATION
(1) to prevent snagging of lines and components on SYSTEM. Check coolant level at radiator header tank
the underside of cab assembly (1). and add coolant if low. Refer to Section 300-0020,
LUBRICATION SYSTEM.
3. Secure cab assembly (1) to front cab support with
bolt (13), snubbing washer (11) and locknut (14) and, 12. Start the engine and check for leaks. Tighten
to rear cab support with bolts (10), snubbing washers lines and fittings as required. Allow the vehicle to
(11) and locknuts (21), if fitted. Fit cap (20) over head warm to normal operating temperatures and check all
of rear mounting bolts (10). connections for leaks.

4. Remove blanking caps from all body control 13. Check all instruments and controls for proper
joystick lines and connect lines as identified at operation. Remove body safety pins and lower the
removal. Tighten all lines securely. body to the frame.

SM 1602 Rev 1 1-00 3

Operators Compartment - Cab and Mounting
Section 260-0010

SM - 2394

3
2

33

32
8
9

13
14
7 21
17

12
6 18
5

10 19 20
11

28

23 26
24 25 27
23 22 1 15 16
31
30
29
28
25 - Hinge
1 - Gasket 9 - Screw 17 - Fixing Plate 26 - Pin
2 - RH Door Frame 10 - Screw 18 - Lock Cover 27 - Split Pin
3 - Sliding Frame 11 - Grommet 19 - Washer 28 - Clip
4 - Seal 12 - Lock 20 - Screw 29 - Washer
5 - Gasket 13 - Locking Plate 21 - Cover 30 - Nut
6 - Spacer 14 - Screw 22 - Nut 31 - Cap
7 - Door Handle 15 - Screw 23 - Retainer 32 - Catch - LH
8 - Screw 16 - Nut 24 - Screw 33 - Catch - RH
Fig. 2 - Exploded View of Right Hand Door Assembly

RIGHT HAND DOOR Removal and Installation

Numbers in parentheses refer to Fig. 2.
Description
The right hand door assembly is of welded steel
construction, hinged at the rear. It has a two section WARNING
glass window. The lower section is stationary while To prevent personal injury and property
the upper section slides up and down, with a multi- damage, be sure lifting equipment is properly
position lock and stop rack arrangement on each side secured and of adequate capacity to do the job
to hold the window in the selected position. A retainer safely.
assembly mounted on the platform prevents the door
from swinging all the way open, and holds the door in 1. Open RH door assembly (2, Fig. 1) and attach a
the open position. suitable lifting device. Remove caps (28) and splitpins
(27) from hinges (25). Using a suitable driver, chap pin
The door assembly can be removed from the cab as (26) out from hinge (25). Remove RH door assembly
a complete assembly, however, components such as (2, Fig. 1) from cab assembly (1, Fig. 1).
the lock, handle and glass assembly can be removed
with the door attached to the cab.

4 SM 1602 Rev 1 1-00

 Operators Compartment - Cab and Mounting
Section 260-0010

SM - 1994
64

65

63
3 58 59 60
61
62

34 7 8
33 55
56
32 11
57
48 2
19 18
15
6
46

31 9
4
10
54

30 14
12 13 20 45
27 49
24 66 67 21 68 43
69
29 28 35 44
16 17
47 21 1
50
39
45 40 41
26 22 42
36
23 37 38
25 37
52 53
51

1 - Grommet 15 - Cover 42 - Cap 56 - Washer

2 - LH Door 16 - Spacer 29 - Inner Door 43 - Pin 57 - Nut
3 - Window assembly 17 - Door Handle 30 - Screw 44 - Split Pin 58 - Spacer
4 - Screw 18 - Screw 31 - Grommet 45 - Clip 59 - Mirror Support
5 - Seal 19 - Screw 32 - Switch Support 46 - Handle 60 - Washer
6 - Glass Support 20 - Screw 33 - Screw 47 - Screw 61 - Nut
7 - Screw 21 - Slide 34 - Switch 48 - Screw 62 - Cap
8 - Washer 22 - Screw 35 - Seal 49 - Grommet 63 - Mirror Arm
9 - Lock Assembly 23 - Screw 36 - Nut 50 - Spacer 64 - Bolt
10 - Latch Bracket 24 - Support 37 - Door Retainer 51 - Motor 65 - Mirror
11 - Screw 25 - Screw 38 - Screw 52 - Screw 66 - Screw
12 - Screw 26 - Electric Cable 39 - Hinge 53 - Washer 67 - Washer
13 - Washer 27 - Clip 40 - Washer 54 - Spacer 68 - Nylon Roller
14 - Nut 28 - Grommet 41 - Locknut 55 - Screw 69 - Bush
Fig. 3 - Exploded View of Left Hand Door Assembly

LEFT HAND DOOR

2. If required, fit new inserts (15, Fig. 1) to hinges.
Description
3. Attach a suitable lifting device to RH door The left hand door assembly is of welded steel
assembly (2, Fig. 1) and align the door assembly to construction, hinged at the rear. It has an electric roll
hinges on cab. Install pin (26), aligning holes and down glass window which provides the operator with
secure using split pin (27). Replace caps (28). additional ventilation. A retainer assembly mounted
on the platform prevents the door from swinging all
4. Check RH door assembly (2, Fig. 1) for correct the way open, and holds the door in the open
operation and also that the locks are operating position.
correctly.

SM 1602 Rev 1 1-00 5

Operators Compartment - Cab and Mounting
Section 260-0010
The door assembly can be removed from the cab as feed the wire through the opening. Pierce a second
a complete assembly, however, components such as hole in the adhesive on the side directly opposite the
the lock, handle and glass assembly can be removed first.
with the door attached to the cab.
3. From inside the cab pull the wire through and feed
it back out through the second hole.
Removal and Installation
Numbers in parentheses refer to Fig. 3. 4. Re-fit the handle on the special tool. Pull both
handles outwards until wire is taut.

WARNING 5. Manouver the special tool around the edge of the

To prevent personal injury and property glass, keeping the wire taut, to cut the adhesive seal.
damage, be sure lifting equipment is properly Ensure the glass is supported adequately before
secured and of adequate capacity to do the job completing the cut. Remove glass from window aperture.
safely.
6. Clean the remains of the adhesive from the edge of
1. Open LH door assembly (3, Fig.1) fully and attach a the panel opening using a suitable solvent.
suitable lifting device. Remove caps (45) and splitpins
(44) from hinges (39). Using a suitable driver, chap pin 7. Coat the edge of the replacement glass with primer
(43) out from hinge (39). Remove LH door assembly and apply adhesive around the lip of the window aperture,
(3, Fig. 1) from cab assembly (1, Fig. 1). as per the manufacturers recommendations.

2. If required, fit new inserts (15, Fig. 1) to hinges. 8. Position glass onto panel opening, pressing firmly
so that adhesive bonds sufficiently to allow the glass
3. Attach a suitable lifting device to LH door to be moved or straightened up as required.
assembly (3, Fig. 1) and align the door assembly to
hinges on cab. Install pin (43), aligning holes and 9. Ensuring the glass is adequately supported, allow
secure using split pin (44). Replace caps (45). the sealing adhesive to set properly.

4. Check LH door assembly (3, Fig. 1) for correct 10. Clean off any excess adhesive using a suitable
operation and also that the locks are operating correctly. solvent.

11. If removed, re-fit corner covers (7 & 8).

REPLACING GLASS
Numbers in parentheses refer to Fig. 1.
Water Leaks
Note: When replacing broken glass, it is the user’s Test for leaks by directing a stream of water along
responsibility to ensure that replacement glass meets the adhesive seal, while an assistant marks the spot
the required specifications. of leakage inside the cab. Care should be taken to
note whether the leak is between adhesive and glass.
Front glass (4), side glasses (5 & 6) and rear glass Then apply a sealing compound from the outside.
(9) panels are held in place by a bonding adhesive. Start from a point near the leak and continue applying
The front and side glasses (4, 5 & 6) also have the sealer until well beyond the suspected point of
corner covers (7 & 8). entry.

To replace a glass assembly, proceed as follows: This should stop the leak immediately, but since
some sealing compounds should be allowed to set
Note: Ensure the glass is supported adequately before getting wet, wait a few minutes before testing.
before starting to cut the adhesive seal.

1. If necessary, remove corner covers (7 & 8). SPECIAL TOOLS

Refer to Section 300-0070, SERVICE TOOLS, for
2. Using a pointed tool, pierce a hole in the adhesive part numbers of special tools referenced in this
seal, it is advisable to start at the top edge of the section and general service tools required. These
glass. Unscrew one handle of the special tool and tools are available from your dealer.
* * * *
6 SM 1602 Rev 1 1-00
 OPERATORS COMPARTMENT - Driver Seat and Mounting
Section 260-0090

SM - 3267
21
31

4 2

1 21
10

3
5

16 11
9
10

8
7

14 12

23 15
22
13
32
17 20

24 30

C 19

A
D 18
B
25
F 26
27 28
29
E

1 - Seat Assembly 12 - Damper 22 - Tether

2 - Seat Frame 13 - Suspension Assembly 23 - air Pipes
3 - Reel Cover 14 - Upstop/Bumpstop 24 - Bolt
4 - Lumbar Support 15 - Air Spring 25 - Washer
5 - Back Cushion 16 - Suspension Cover 26 - Lockwasher
6 - Back Cover 17 - Manual Valve 27 - Nut
7 - Seat Cushion 18 - Bearing 28 - Bolt
8 - Seat Cover 19 - Lever 29 - Lockwasher
9 - Height Riser Assembly 20 - Slide Adjuster 30 - Seat Base
10 - Handles 21 - Seat Belt 31 - Headrest (optional)
11 - Height Riser Spring 32 - Switch / valve
Fig. 1 - Exploded View of Driver Seat

DESCRIPTION The driver seat is secured to the cab floor with bolts
Numbers in parentheses refer to Fig. 1. (28) and lockwashers (29). The seat assembly (1)
consists of a seat cushion (7) and back cushion (5)
mounted to seat frame (2). Seat frame (2) is attached
WARNING to seat base (30) by means of a suspension
By Law, seat belts must be provided. Always assembly. The air seat only reacts when the driver
wear seat belts when travelling in the vehicle. sits on the seat. When unoccupied, the seat sinks to

SM 1901 Rev 1 07-04 1

Operator's Compartment - Driver Seat and Mounting
Section 260-0090
the lowest position to allow easier access. The 6. Remove bolts and lockwashers securing belt (21) to
incorporated block out maintains the seat in position seat assembly. Remove lap belt (21).
for driving.
7. Remove bolts (24), washers (25), lockwashers
An adjustable '4-point harness' seat belt (21) is secured (26) and nuts (27) securing seat base (30) to seat
to the seat assembly using bolts and lockwashers. A assembly. Remove seat base (30) from seat
push button buckle allows quick release of the belt (21). assembly.

The following is the list of controls to adjust the seat: 8. If required, remove pop-out button and pull back
A. Height and slope adjustment, front. suspension cover (16) to allow access to suspension
B. Height and slope adjustment, rear. assembly (13).
C. Backrest angle adjustment.
D. Weight adjustment. 9. If required, remove mounting hardware securing
E. Horizontal adjustment (sliderails). dampers (12) to suspension assembly (13). Remove
F. Lumber support adjustment. dampers (12).

WARNING INSPECTION
Do not attempt to adjust the seat or seat belt Numbers in parentheses refer to Fig. 1.
while the machine is moving. Loss of control
may result. Stop the machine; apply the 1. Inspect air lines, control valve (D), dampers (12)
brakes; then adjust. and air spring (15) for leaks and damage and replace if
required.

REMOVAL AND DISASSEMBLY 2. Check all brackets and frame for cracks and/or
Numbers in parentheses refer to Fig. 1. damage. Repair or replace as necessary.

3. Check springs (11) for fatigue or damage and

WARNINGS replace as required.
To prevent personal injury and property
damage, be sure wheel chocks, blocking
materials and lifting equipment are properly ASSEMBLY AND 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, apply the specified to torques listed in Section 300-0080,
parking brake and switch off the engine. STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
2. Operate the steering in both directions several
times to relieve any pressure in the steering system. 1. If removed, secure dampers (12) to suspension
Block all road wheels. assembly (13) using mounting hardware as removed
at Removal.
3. Disconnect compressor connector at the rear of
the seat. 2. If required, install suspension cover (16) over
suspension assembly (13) and refit pop-out button.
4. Push the control valve button (D) in to release the
air from the seat air suspension system. 3. Install seat base (30) to seat assembly and secure
using bolts (24), washers (25), lockwashers (26) and
5. Using suitable lifting equipment, support seat and nuts (27).
remove bolts (28) and lockwashers (29) securing
complete seat assembly to the cab floor. Remove
seat assembly from vehicle.

2 SM 1901 Rev1 07-04

 Operator's Compartment - Driver Seat and Mounting
Section 260-0090

4. Position seat belt (21) to seat assembly and secure MAINTENANCE

using bolts and lockwashers as removed at Removal. Numbers in parentheses refer to Fig. 1.

5. Using suitable lifting equipment, position seat The care of the upholstery on seat cover (8) and
assembly on the cab floor and secure with bolts (28) back cover (6) is a relatively simple, but important
and lockwashers (29). matter. Accumulation of dirt on the surface eventually
turns into a hard gritty substance which cuts into the
6. Reconnect compressor connector at the rear of the surface of the upholstery.
seat.
To clean seat cover (8) and back cover (6), use warm
7. Start the engine and charge the air system. Pull water and a mild soap, such as Castile. Work up thin
out control valve button (D) to allow air into seat soap suds on a piece of soft cloth and rub the
suspension system and check seat for proper upholstery briskly. Remove the suds with a damp
operation. cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.
8. Remove wheel chocks from road wheels.
Seat belt (21) assembly should be inspected by the
user on a regular basis. Replace Seat belt (21)
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, Seat belt (21) must

be removed and replaced at least once every three
years.

* * * *

SM 1901 Rev 1 07-04 3

 OPERATORS COMPARTMENT - Passenger Seat and Mounting
Section 260-0110

SM - 2392

A
27 A 31 32
28 B 24
29 30 5
A
4 23
A
22
30 24
29 B A 7
6
B 26 17
25 12 18
28 14
27
18 33 12
9 17 18 19
A 3318 11

A 10
8
13
16

B
15
6
26

20 20
21
21

1 - Seat Cushion
2 - Seat Frame 10 - Spring 18 - Lockwasher 26 - Bolt
3 - Back Cushion 11 - Latch 19 - Washer 27 - Bolt
4 - Bolt 12 - Pad 20 - Bolt 28 - Washer
5 - Lockwasher 13 - Pivot Pin 21 - Lockwasher 29 - Lockwasher
6 - Bracket 14 - Latch Pin 22 - Spacer 30 - Nut
7 - Bolt 15 - Locknut 23 - Bracket 31 - Bolt
8 - Seat Base 16 - Hardened Washer 24 - Washer 32 - Spacer
9 - Hinge 17 - Nut 25 - Lap Belt 33 - Nut

Fig. 1 - Exploded View of Passenger Seat

DESCRIPTION The passenger seat is located to the right of the

Numbers in parentheses refer to Fig. 1. control console and secured to the cab floor with bolts
(20) and lockwashers (21). The seat assembly
consists of a seat cushion (1) and back cushion (3)
WARNING mounted to seat frame (2). Seat frame (2) is attached
By Law, seat belts must be provided. Always to seat base (8) by means of a hinge (9) at the front
wear seat belts when travelling in the vehicle. end and locked at the rear by a spring loaded latch

SM 1902 1-00 1
Operator's Compartment - Passenger Seat and Mounting
Section 260-0110
arrangement. Located within seat base (8) are the 8. Remove bolts (27), washers (28), lockwashers (29)
major CEC components; battery equalizer box, and nuts (30) securing lap belt (25) to seat base (8)
electronic control unit (ECU) and CEC interface box. and remove lap belt (25). Remove bolts (26),
lockwashers (18), nuts (33) and brackets (6) from seat
A retractable lap belt (25) is secured to seat base (8) base (8).
using bolts (27), washers (28), lockwashers (29) and
nuts (30). A release button allows quick release of lap 9. If seat base (8) requires to be removed, disconnect
belt (25). the electrical cables in the following order to prevent
damage to the electrical components.

REMOVAL AND DISASSEMBLY a. Disconnect battery equalizer ground cables.

Numbers in parentheses refer to Fig. 1. b. Disconnect battery cables from terminal posts
(ground cables first).
c. Disconnect battery equalizer positive cables.
WARNINGS d. Disconnect electrical connections at the ECU.
To prevent personal injury and property
damage, be sure wheel chocks, blocking 10. Disconnect electrical connections from switch
materials and lifting equipment are properly breakers. If required, remove switch breakers from
secured and of adequate capacity to do the job seat base (8).
safely.
11. Remove mounting hardware securing the CEC
WARNINGS components to seat base (8). Remove bolts (20) and
High electrical current. Turn the ignition key lockwashers (21) securing seat base (8) to the cab
switch 'Off' before disconnecting any electrical floor. Remove seat base (8) from the cab.
components. Disconnect electrical connections
in the correct order given to prevent damage to
the electrical components. ASSEMBLY AND INSTALLATION
Numbers in parentheses refer to Fig. 1.
1. Position the vehicle in a level work area, apply the
parking brake and shutdown the engine. Note: Tighten all fasteners without special torques
specified to torques listed in Section 300-0080,
2. Turn the steering wheel in both directions several STANDARD BOLT AND NUT TORQUE
times to relieve any pressure in the steering system. SPECIFICATIONS.
Block all road wheels.
1. If removed, position seat base (8) on cab floor and
3. Move seat latch (11) to the release position and tilt secure with bolts (20) and lockwashers (21).
seat assembly forward. Support or block the seat
assembly and remove bolts (4) and lockwashers (5). 2. If removed, install switch breakers on seat base (8)
Remove seat assembly from seat base (8). and connect electrical cables to switch breakers.

4. Remove mounting hardware, back and seat 3. Connect the electrical cables in the following order
cushions (1 & 3) from seat frame (2). to prevent damage to the electrical components.

5. Remove bolts (7 & 31), washers (24) and spacers a. Connect electrical connections at the ECU.
(22 & 32) securing bracket (23) to seat frame (2). b. Connect battery equalizer positive connections.
Remove bracket (23). c. Connect battery cables to terminal posts (positive
cables first).
6. Remove nut (17), lockwasher (18) and latch pin (14) d. Connect battery equalizer ground cables.
from bracket (23).
4. Position brackets (6) on seat base (8) and secure
7. Remove spring (10) from latch (11) and seat with bolts (26), lockwashers (18) and nuts (33).
base (8). Remove locknut (15), hardened washer (16) Position lap belt (25) on mounting brackets (6) and
and latch (11) from pivot pin (13). Remove nut (17), secure with bolts (27), washers (28), lockwashers (29)
lockwasher (18), washer (19) and pivot pin (13) from and nuts (30).
seat base (8).

2 SM 1902 1-00
 Operator's Compartment - Passenger Seat and Mounting
Section 260-0110

5. Install pivot pin (13) through mounting hole in seat MAINTENANCE

base (8) and secure with washer (19), lockwasher (18) Numbers in parentheses refer to Fig. 1.
and nut (17).
The care of the upholstery on seat cushion (1) and
6. Install latch (11) on pivot pin (13) and secure with back cushion (3) is a relatively simple, but important
hardened washer (16) and locknut (15). Tighten matter. Accumulation of dirt on the surface eventually
locknut (15) enough to allow latch (11) to pivot freely. turns into a hard gritty substance which cuts into the
Install spring (10) to latch (11) and seat base (8). surface of the upholstery.

7. Install latch pin (14) in bracket (23) and secure with To clean seat cushion (1) and back cushion (3), use
lockwasher (18) and nut (17). warm water and a mild soap, such as Castile. Work up
thin soap suds on a piece of soft cloth and rub the
8. Position bracket (23) on seat frame (2) and secure with upholstery briskly. Remove the suds with a damp
bolts (7 & 31), washers (24) and spacers (22 & 32). cloth, using no soap, and finish by wiping the
upholstery dry with a soft, dry cloth.
9. Position back and seat cushions (1 & 3) on seat
frame (2) and secure with mounting hardware. Lap belt (25) assembly should be inspected by the
user on a regular basis. Replace lap belt (25)
10. Position the seat assembly to hinge (9) of seat immediately if hardware is worn or damage, straps are
base (8) and secure with bolts (4) and lockwashers nicked or frayed, release mechanism is not functioning
(5). Tighten bolts (4) to a torque of 18 Nm (13 lbf ft) correctly, loose stitching is found, or if the strap
lubed. Lower seat assembly on seat base (8) and material has lost strength due to the effects of
ensure latch arrangement is operating correctly. ultraviolet rays.

11. Remove wheel chocks from road wheels. Note: Regardless of appearance, lap belt (25) must be
removed and replaced at least once every three years.

SPECIAL TORQUE SPECIFICATIONS

TORQUE
FIG. NO. ITEM NO. ITEM NAME Nm lbf ft
1 4 Bolt 18 13
1 15 Nut To allow latch to pivot

* * * *

SM 1902 1-00 3
 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 'V' 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.
located in the cab. The 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
Compressor the coil winding is grounded to the compressor and
The compressor is designed to compress vapour and equipment frame. Energizing the coil creates a magnetic
can be damaged by non-compressibles such as dirt, force that 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
condensation. The high pressure vapour then moves heat energy from the compressed high pressure
into the condenser where heat can be radiated to vaporized R-134a so that the R-134a changes from
change the R-134a back to liquid. vapour to liquid. During normal operation all the high
pressure section of the system will be warm or hot, but
Note: R-134a designates the type of refrigerant used large quantities of heat should be radiating from the
in heavy duty vehicle air conditioning systems. condenser. Nothing should be permitted to stop or

SM 2043 R1 08-03 1
Operators Compartment - Air Conditioning
Section 260-0130
slow down this radiation of heat. Cooling fins are Blockage of the filter will result in a drop in pressure
located on the condenser tubes and fans are used to that will be indicated by a drop in system performance.
circulate cool air around the condenser tubes. Keep all Connections of the new receiver drier should be
leaves, paper, dirt, etc. clear from the condenser and securely capped before installation to prevent the
condenser filter. The cooling fins should be straight to entrance of moisture (air) while in storage.
permit free flow of air. The condenser is sometimes
located ahead of the engine radiator and blockage of
air flow through the radiator also affects the Thermostatic Expansion Valve
condenser. Bent fan blades, slipping fan drive, An expansion valve is installed in the system to lower
inoperable condenser fan motors, or any other fault the pressure before the R-134a enters the evaporator.
that lessens the amount of cool air circulated through The reduction in pressure is done by passing the
the condenser, should be corrected. The oil, dirt, or R-134a through a small hole (orifice). The size of the
antifreeze will act as an insulator that will inhibit the orifice must be controlled to compensate for changes
radiation of heat. in pressure and temperature. The temperature of
R-134a leaving the evaporator is sensed by a
Since the purpose of the condenser is to radiate heat thermostatic sensor that moves the valve seat via a
energy, anything that prevents or inhibits this action diaphragm and actuating pin.
may affect cooling, but the temperature and pressure
of the R-134a raise and lower together. Heat energy
that has not been radiated will remain in the R-134a Evaporator - Heat/Cool
and the result will be pressure that is too high. The The evaporator is the low pressure, low temperature
condenser, hoses, connections and seals can be component where liquid R-134a absorbs heat from
damaged by the high pressure. Pressure sensing surrounding air. The expansion valve bleeds high
safety switches may be activated by the high pressure pressure R-134a into the low pressure evaporator.
caused by the condenser not radiating enough heat. The R-134a expands rapidly in the evaporator and its
temperature is quickly reduced. The R-134a absorbs
heat from the air when the blower fan circulates air
Receiver Drier over the evaporator coil fins. The exchange of heat
The high pressure liquid R-134a moves from the from the air to the R-134a depends upon the
condenser to the receiver drier, where the R-134a is difference in temperature. During high heat load, such
stored and filtered. Moisture is the major enemy of the air as usually encountered when the system is first turned
conditioning system and the desiccant inside the receiver on, the temperature difference is great and the R-134a
drier will absorb only a small amount. The container of will absorb heat quickly. The blower fan can be set at
desiccant inside the receiver drier may break open and its highest setting to circulate large quantities of warm
contaminate the system if any attempt is made to dry the air around the evaporator. After the cab has cooled,
desiccant, or, if more moisture is inside the system than the fan speed should be reduced so that the already
the desiccant can absorb. cool air will have a longer time to yield heat to the
R-134a as it passes the evaporator coils. The heater
Every effort should be made to remove all moisture circuits utilize engine coolant at approximately 82° C
from the system and install a new receiver drier if its (180° F).
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 High Pressure and Low Pressure Switches
are observed in the sight glass on top of the receiver The pressure switches are electric switches that
drier during the charging procedure. monitor air conditioner operation. The high pressure
and low pressure switches are activated at preset
A filter screen is located in the receiver drier to stop pressures and engage and disengage the compressor
solid contaminates circulating round the system. clutch.

2 SM 2043 R1 08-03
 Operators Compartment - Air Conditioning
Section 260-0130

REMOVAL 5. When satisfied that the system is completely

Numbers in parentheses refer to Fig. 2, unless discharged, tag refrigerant hoses (1 & 2) to aid in
otherwise stated. installation and carefully disconnect hoses from
adaptors at cab firewall. Cap adaptor fittings and
refrigerant hoses (1 & 2) to prevent foreign matter from
WARNINGS entering the system. Discard 'O' rings.
Always wear goggles or glasses to protect
your eyes when working around R-134a. 6. If necessary to gain access to components inside
R-134a boils at sea level temperatures of air conditioning unit (33, Fig. 3) (located in the right
-29.8° C (-21.6° F), which means that direct hand side of the cab), disengage quarter-turn screws
contact with your skin will produce frostbite. securing front cover (34, Fig. 3) and filter element
Exercise extreme care when handling R-134a. (36, Fig. 3) on air conditioning unit (33, Fig. 3).
Remove front cover (34, Fig. 3).
If you get the slightest trace of R-134a in
your eye, flood the eye immediately with cool 7. Tag and disconnect harness connector at the right
water; then treat with mineral oil or clear hand side of air conditioner.
petroleum jelly followed by boric acid rinse.
Report to a hospital or doctor as soon as 8. Tag refrigerant hoses (2 & 4) to aid in installation
possible. and carefully disconnect hoses from receiver/drier (6).
Cap receiver/drier (6) fittings and refrigerant hoses
The chemicals of R-134a change when (2 & 4) to prevent foreign matter from entering the
burned and become a poison phosgene gas system. Disconnect switch (7) from receiver/drier (6).
that will damage the respiratory system if Discard 'O' rings.
inhaled. NEVER SMOKE in an area where
R-134a is used or stored. Use hot water or an 9. Support receiver/drier (6) and slacken clamps (8)
approved heated charge cylinder as a heat securing receiver/drier (6) to mounting bracket (9).
source if required to force R-134a into the Remove receiver/drier (6) from vehicle. If necessary,
system. If using water, do not exceed 52° C remove mounting hardware and bracket (9) from
(125° F). Never use direct flame or electric vehicle.
heaters in direct contact with the R-134a
container. High temperatures may result in 10. Tag refrigerant hoses (3 & 4) to aid in installation
raising the pressure to a dangerous level. and carefully disconnect hoses at condenser (5). Cap
condenser (5) fittings and refrigerant hoses (3 & 4) to
NEVER discharge or vent refrigerant prevent ingress of foreign matter. Discard 'O' rings.
gases into the atmoshere. All possible steps
should be taken to ensure refrigerant gases 11. If required, support air conditioner condenser (5)
are recovered under strict control. and remove mounting hardware and condenser (5)
from vehicle.
To prevent personal injury and property
damage, be sure wheel blocks, blocking 12. Tag refrigerant hoses (1 & 3) to aid in installation
materials and lifting equipment are properly and carefully disconnect hoses from compressor (10).
secured and of adequate capacity to do the job Cap compressor (10) fittings and refrigerant hoses
safely. (1 & 3) to prevent foreign matter from entering the
system. Discard 'O' rings.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. 13. Disconnect electrical connection from compressor
(10) clutch.
2. Operate steering right and left several times to
relieve pressure in the steering system. Block all road 14. Remove mounting hardware and drive belt guard
wheels. (13) from vehicle.

3. If required, remove mounting hardware securing 15. Slacken nuts (26) and washers (27 & 28) on
hoodsides to vehicle. Remove hoodsides. adjuster rod (21) to release tension on drive belt (11).

4. Discharge the air conditioning system as described 16. Slacken bolts (14 & 17), lockwashers (15 & 18),
under 'Discharging The System'. washers (16 & 19), spacer (20) and fixing block (22).

SM 2043 R1 08-03 3
Operators Compartment - Air Conditioning
Section 260-0130

SM - 2560A

11

4 7

2
8
9

8 1

14
17
12 16 15
3
2

32
31
1
30 19 18 10

20 23

26 27 24 13

21
22

25 24
28
29 27
26

1 - Refrigerant Hose 9 - Bracket 17 - Bolt 25 - Nut

2 - Refrigerant Hose 10 - Compressor 18 - Lockwasher 26 - Nut
3 - Refrigerant Hose 11 - Drive Belt 19 - Washer 27 - Washer
4 - Refrigerant Hose 12 - Mounting Bracket 20 - Spacer 28 - Washer
5 - Condenser 13 - Belt Guard Cover 21 - Adjuster Rod 29 - Bracket
6 - Receiver/Drier 14 - Bolt 22 - Fixing Block 30 - Bolt
7 - Switch - Trinery 15 - Lockwasher 23 - Bolt 31 - Washer
8 - Clamp 16 - Washer 24 - Washer 32 - Lockwasher

Fig. 2 - Air Conditioner Lines and Mounting

4 SM 2043 R1 08-03
 Operators Compartment - Air Conditioning
Section 260-0130

SM - 2560B

42

33

41

37

40

39

38
35

35

36

34

33 - Air Conditioning Unit 37 - Expansion Valve

34 - Cover 39 - Adaptor
35 - Grille 40 - Adaptor
36 - Filter Element 41 - Relay
37 - Evaporator Matrix 42 - Thermostat

Fig. 3 - Air Conditioner Lines and Mounting

SM 2043 R1 08-03 5
Operators Compartment - Air Conditioning
Section 260-0130
Drive belt (11) should now be free to slide off of groove 4. Install receiver/drier (6) to mounting bracket (9) and
in compressor (10). secure with clamps (8). If removed, secure mounting
bracket (9) assembly to vehicle with mounting
17. Support compressor (10) and remove bolts (14, 17 hardware removed during Removal.
& 23), lockwashers (15 & 18), washers (16, 19, 24, 27
& 28), nuts (25 & 26), spacer (20), adjuster rod (21), 5. Remove caps from end of refrigerant hoses (2 & 4)
fixing block (22) and mounting bracket (29) securing and ports on receiver/drier (6), renew 'O' rings and
compressor (10) to mounting bracket (12). Remove connect hoses to ports as tagged at Removal. Renew
compressor (10) from the vehicle. 'O' ring and connect switch (7) to receiver/drier (6).

Note: If drive belt (11) does not require replacement 6. If removed, install condenser unit (5) to vehicle and
do not remove from engine fan pulley. If drive belt (11) secure with mounting hardware removed during
requires replacement, proceed with step 18. Removal.

18. Release tension on Poly 'V' fan belt and remove 7. Remove caps from end of refrigerant hoses (3 & 4)
from fan pulley. Remove compressor drive belt (11) and ports on condenser unit (5), renew 'O' rings and
from the rear groove of the fan pulley. Refer to Section connect refrigerant hoses (3 & 4) to condenser unit (5)
110-0030, ENGINE AND MOUNTING. ports as tagged at Removal.

19. If required, remove bolts (30), washers (31), 8. If removed, install mounting bracket (12) to vehicle
lockwashers (32) and mounting bracket (12) from and secure with bolts (30), washers (31) and
vehicle. lockwashers (32).

20. If required, disconnect all clamps and clips 9. Fit compressor (10) to mounting bracket (12) and
securing refrigerant hoses and harnesses to the secure with bolts (14, 17 & 23), lockwashers (15 & 18),
vehicle. Remove hoses and harnesses from the washers (16, 19, 24, 27 & 28), nuts (25 & 26), spacer
vehicle. (20), adjuster rod (21), fixing block (22) and mounting
bracket (29). Do not fully tighten at this stage.

INSTALLATION Note: If Poly 'V' fan belt and compressor drive belt
Numbers in parentheses refer to Fig. 2, unless (11) were removed, proceed with steps 10 & 11.
otherwise stated.
10. Install new drive belt (11) onto rear groove on
Note: Tighten all fasteners to standard torques engine fan pulley and fit to rear groove on compressor
specified in Section 300-0080, STANDARD BOLT (10).
AND NUT TORQUE SPECIFICATIONS.
11. Refit Poly 'V' fan belt and adjust tension. Refer to
Section 110-0030, ENGINE AND MOUNTING.
WARNING
To prevent personal injury and property 12. Adjust tension of compressor drive belt (11) with
damage, be sure wheel blocks, blocking nuts (26) on adjuster rod (21) until there is
materials and lifting equipment are properly approximately an inward deflection of 10 mm (0.4 in)
secured and of adequate capacity to do the job at the centre of drive belt (11). Fully tighten all
safely. mounting hardware.

1. If removed, position front cover (34, Fig. 3) and filter 13. Install drive belt guard (13) and secure using
assembly (36, Fig. 3) on air conditioner unit mounting hardware as removed at Removal.
(33, Fig. 3) and secure using quarter-turn screws.
14. Remove caps from end of refrigerant hoses (1 & 3)
2. Remove caps from end of refrigerant hoses (1 & 2) and ports on compressor (10), renew 'O' rings and
and adaptors on cab firewall, renew 'O' rings and connect hoses to ports as tagged at Removal.
connect hoses to ports as tagged at Removal.
15. Connect electrical connection to compressor (10)
3. Route refrigerant hoses (1 & 2) and secure with clutch.
clamps removed during Removal.

6 SM 2043 R1 08-03
 Operators Compartment - Air Conditioning
Section 260-0130
16. Secure all lines with clips and clamps as removed 3. To check the refrigerant level, run the engine at
during removal. Ensure no lines are chaffing on sharp 1 200 rev/min with fans on high speed and thermostat
edges or resting against areas where heat will be fully open for a minimum of five minutes. If the clutch is
evident. engaged in this situation, there should be very few
bubbles visible in the receiver-drier sight glass.
17. Charge the air conditioning system as described
under 'Charging Procedure'. Note: Unit can operate with occasional bubbles
visible, but not milky looking.
18. Start up the engine and check for correct operation
of the air conditioning system. 4. Ensure all hoses and hose clamps are free from
contact with sharp metal, moving parts or near to
19. Secure hood sides to vehicle and remove wheel manifolds.
blocks.
5. Inspect condensation drain lines for debris, sharp
bends or breaks.
MAINTENANCE
6. Inspect the clutch wire from the thermostat for bare
spots.
WARNING
Always wear goggles or glasses to protect 7. Inspect bolts and nuts on the compressor and
your eyes when working around R-134a. mounting bracket for proper tightness.
R-134a boils at sea level temperatures of
-29.8° C (-21.6° F), which means that direct 8. Inspect and clean outside and inside cab air filters
contact with your skin will produce frostbite. periodically, depending on dust conditions. Replace
Exercise extreme care when handling R-134a. the outside filter when it becomes saturated to the
point it won't come clean.
If you get the slightest trace of R-134a in
your eye, flood the eye immediately with cool
water; then treat with mineral oil or clear Maintenance of 'V' belt Drives
petroleum jelly followed by boric acid rinse. 1. Listen for 'ticking' sound - they mean interference
Report to a hospital or doctor as soon as with the belts. Visually inspect for bent or damaged
possible. belt guards.

The chemicals of R-134a change when 2. Replace all belts in a mismatched set at one time to
burned and become a poison phosgene gas ensure even load distribution.
that will damage the respiratory system if
inhaled. NEVER SMOKE in an area where 3. Periodically check tension and keep belts tight.
R-134a is used or stored. Use hot water or an
approved heated charge cylinder as a heat - The ideal tension is the lowest tension at which the
source if required to force R-134a into the belt will not slip under peak load conditions.
system. If using water, do not exceed 52° C - Check belt tension frequently during the first 24 - 48
(125° F). Never use direct flame or electric hours of run-in operation.
heaters in direct contact with the R-134a - Initial belt tension should be 445 N (100 lbf)
container. High temperatures may result in dropping to 334 N (75 lbf) after the first 48 hours.
raising the pressure to a dangerous level. - There should be a freeplay of 10 mm in the 'V' belt.
- Do not over tension belts.
1. Periodically clean the condenser coil of debris and - Keep belts free from foreign material that may
dirt using water or air pressure. A partially blocked cause slippage.
condenser coil can reduce the life of the compressor - Inspect the V-drive periodically. Re-tension belts if
belt and/or clutch. they are slipping.
- Maintain sheave alignment with a strong straight
2. If the system has a heater in the same location as edge tool while tensioning belts.
the air conditioning evaporator core, heater valves
should be closed. 4. Never attempt to correct belt slippage by using a

SM 2043 R1 08-03 7
Operators Compartment - Air Conditioning
Section 260-0130
belt dressing. The dressing may cause softening and or by using an oil injector when the system is being
deterioration. charged, observing the following good practises:

5. If belt slips, even when properly tensioned, check a. Only pour the amount required from the container
for overload, worn sheave grooves or oil or grease on straight into a CLEAN measuring jug and
the belts. immediately pour the oil into the compressor.
b. Re-cap container tightly as soon as the required
6. Never pry a 'V' belt or force it into the sheave amount has been taken (never leave an oil container
groove. Loosen the 'V' belt tightener prior to open).
installation. c. Do not mix different oils.

7. A belt that has operated while rolled over in the Only new oil should be used, because oil that has
sheave groove may be damaged - replace it. been exposed to the air will have absorbed water
(hygroscopic).
8. Store belts in a cool, dry place. If stored on a
machine, relieve all belt tension by loosening the Use only refrigerant oil as specified in Section
'V' belt tightener. 300-0020, LUBRICATION SYSTEM.

9. Never attempt to check or adjust belts while they

are running. System Leak Testing
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
WARNINGS have an oily or greasy appearance. The refrigerant
To prevent personal injury always wear rubber carries compressor oil with it and deposits it around
gloves when handling refrigerant oils. the leak area. Check all such points for loose
connections and tighten.
Too much refrigerant oil will dampen the
cooling effect and too little refrigerant oil may Using a suitable leak detector, search for leaks around
lead to compressor failure. If in doubt flush all joints, connections, seals and control devices. If a
the system. leak is located, recover the refrigerant from the system
and repair. Fully evacuate and charge the system to
Oil is required to lubricate the compressor. The oil make it operational.
mixes with the refrigerant and is carried around the
system. The compressor and receiver drier are
supplied with an oil charge. DISCHARGING THE SYSTEM
Note: Refer to all WARNINGS listed under
Compressor 4.75 fl oz (135 ml) 'Maintenance' prior to discharging the system.
Receiver Drier 2 fl oz (60 ml)
Recommended Equipment Required:
However, if any component is replaced the following Portable High Vacuum Charging Station
amount of oil should be added to the system; Suitable Canister
or Standard Service Manifold (Refer to Fig. 4)
Condenser add 1 fl oz (30 ml)
Evaporator add 1.5 fl oz (40 ml) To eliminate system contaminants from an air
conditioning system requires discharging the entire
The oil should be added to the oil filling port of the system. This means recovering all of the refrigerant
compressor before the recovery procedure is started and cleansing all contamination (air and moisture)

8 SM 2043 R1 08-03
 Operators Compartment - Air Conditioning
Section 260-0130

SM - 2424 3. If required, remove mounting hardware securing

B C D
hoodsides to vehicle. Remove hoodsides.

4. Connect the service hose (yellow) to the centre

access port on the manifold gauge and to the vacuum
2 3 4 connection (6) on vacuum pump. Ensure that the
system is empty before connecting the vacuum so that
SUC DIS R refrigerant does not enter the pump.
ACCESS E
F
PORT R 5. Tighten down (turn clockwise) both high and low
I
G side valves on the gauge manifold to the closed
E position. Remove protective caps from the service
A R
A ports on the compressor.
N
T
6. Connect both service hoses from the two fittings (2
& 3) in the bottom of the manifold to the two service
VACUUM PUMP ports on the compressor. High side (red) to
compressor discharge valve, low side (blue) to
compressor suction valve.
6
1 5
7. Switch vacuum pump on, open vacuum pressure
Gauges: Valves: valve (1) until less than 6 mb is reached on vacuum
A - Vacuum Gauge 1 - Vacuum Pressure
B - Low Pressure Gauge 2 - Suction Line gauge (A). The vacuum gauge (A) should remain at
C - High Pressure Gauge 3 - Discharge Line this value when vacuum pressure valve (1) is closed to
D - Charging Cylinder 4 - Refrigerant Gas indicate that there are no leaks.
Pressure Gauge 5 - Refrigerant Liquid
Port:
6 - Vacuum Connection Note: Minimum evacuation time = 1 hour.

Fig. 4 - Standard Service Manifold 8. Open the low side hand valve on the manifold and
vacuum pressure valve (1) and watch that the gauges
from the system components. If any of the major start to register that a vacuum is being drawn. If the
system components are to be repaired or replaced, gauges do not register the vacuum then a blockage or
the system must also be completely discharged. leak is present. Open the high side and pump down
until a vacuum of 10 mb is achieved.

WARNINGS 9. After 10 - 15 minutes close vacuum pressure valve

The vehicle must not be running during this (1) and allow the system to settle, vacuum gauge (A)
procedure. Be sure to have adequate should not alter. If the vacuum is held, no leaks or
ventilation during this operation. Do not refrigerant contaminated oil is present. If not, open the
discharge refrigerant near an open flame. vacuum pressure valve (1) and continue pumping,
checking at regular intervals. If there is a leak, check
NEVER discharge or vent refrigerant all fittings and tighten if necessary.
gases into the atmoshere. All possible steps
should be taken to ensure refrigerant gases 10. Tighten down (turn clockwise) both high and low
are recovered under strict control. side valves on the gauge manifold to the closed
position, remove the service hose (yellow) from the
Numbers and letters in parentheses refer to Fig. 4. vacuum connection (6) on vacuum pump and switch
the pump 'Off'.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. 11. Connect the service hose (yellow) to the R-134a
cylinder. Open the cylinder valve and then purge air
2. Operate steering right and left several times to from the hose at the manifold connection.
relieve pressure in the steering system. Block all road
wheels. 12. Open the low side hand valve on the manifold
slowly, until low pressure gauge (B) is at bottle

SM 2043 R1 08-03 9
Operators Compartment - Air Conditioning
Section 260-0130
pressure. Watch the high side manifold gauge (C) rise 5. Connect the high pressure gauge hose (red hose
to ensure that no blockage is present. Close the and gauge) to discharge or high side fitting on
manifold valve and cylinder, then disconnect the hose compressor.
from the cylinder.
6. Connect yellow supply hose to suction port on
13. Connect the service hose (yellow) to the Nitrogen vacuum pump.
cylinder. Open the neck valve on the cylinder and set
the regulator pressure such that it is higher than the 7. Open both sides of gauges, low and high, completely.
system pressure then purge the hose. Open the low
side hand valve on the manifold, as the pressure rises 8. Start vacuum pump to evacuate the complete air
open the high side hand valve on the manifold and conditioning system.
allow a system pressure of 10 bar (150 psig) to be
reached. Close all the valves. Using a suitable 9. Run vacuum pump for approximately 30 minutes.
electronic leak detector, check all joints in the air Ideal gauge readings should be 29.92 inches of
conditioning system for leaks. Tighten any loose joints mercury. The pressure will vary with altitude; it will be
and re-test if necessary. approximately 0.03 bar (0.5 lbf/in²) less for each 305 m
(1 000 ft) of elevation.
14. If removed, secure hood sides to vehicle and
remove wheel blocks. 10. Before disconnecting power supply from vacuum
pump, close both high and low side gauges. Remove
yellow hose from vacuum pump and connect to
CHARGING THE SYSTEM R-134a source.
Note: Refer to all WARNINGS listed under
'Maintenance' prior to charging the system. 11. Open R-134a source. Loosen, but do not remove,
yellow supply hose at manifold on gauges to remove
Recommended Equipment Required: all air in the yellow supply hose, replacing the air with
Portable High Vacuum Charging Station R-134a. This is done in a few seconds. Tighten yellow
Electronic Leak Detector supply hose.
or Standard Service Manifold (Refer to Fig. 4)
12. Open low side of R-134a gauges slowly. When
gauge reads zero open both sides completely.
For New Or Completely Empty System Vacuum in the system will draw R-134a gas into the
Note: The charging procedure must be done in system. Hold until both gauge readings equalize.
ambient temperatures above 15.5° C (60° F) with the
R-134a canister temperature equal to the outside Note: Never charge with liquid R-134a. Charge on the
ambient temperature. low pressure side only.

1. Shut off engine and block all road wheels.

Final Charging Of The System
2. If required, remove mounting hardware securing 1. Start the engine and run at engine idle speed.
hoodsides to vehicle. Remove hoodsides.
2. Turn the air conditioning system on with the
3. Remove protective caps from 'quick coupler' valves thermostat set on maximum cooling and fan on high
on rear of compressor. speed.

4. Connect low pressure gauge hose (blue hose and 3. At this point a visual inspection must be made of the
gauge) to suction side or low side fitting on sight glass on top of the receiver-drier. As charging
compressor. The suction side can be identified by the continues, the sight glass will appear milky coloured
size of the hose connected to the fitting. This will be as the bubbles in the system circulate. As the system
the largest diameter hose of the system. continues the charging process, the regularity of the

10 SM 2043 R1 08-03
 Operators Compartment - Air Conditioning
Section 260-0130
bubbles in the sight glass will gradually diminish. The system is completely charged when;
When no bubbles are seen in the sight glass, close the
low pressure valve (blue side) completely. a. the sight glass is free from bubbles.
b. the suction pressure on the gauge is approx.
4. Increase the engine idle speed while observing the 20 - 30 psig at 25° C ambient.
sight glass. If many bubbles are seen resulting from c. the correct weight of refrigerant has been added
the increased engine speed, open the low pressure (typically 1.4 kg (3 lb)).
side valve. Allow the system to continue the charging d. the correct superheat can be measured at the
procedure until the sight glass is clear. If the sight evaporator, approx. 3 - 6° C.
glass remains clear, with the increased engine speed, e. the correct sub-cooling can be measured at the
do not add any more R-134a. condenser, approx. 5 - 7° C.

Note: Occasionally bubbles are noticed during clutch 6. Replace protective caps on hoses and valve fittings.
cycling or system start-up. This is a normal condition.
7. Secure hood sides to vehicle and remove wheel
5. With the system completely charged, shut off the blocks.
engine. Close the valve on the R-134a canister and
remove the yellow supply hose. Remove both the low
pressure (blue) hose and high pressure (red) hose SPECIAL TOOLS
from the filling ports on the compressor. Refer to Section 300-0070, SERVICE TOOLS, for part
numbers of special tools referenced in this section and
Note: Some R-134a will escape as the hoses are general service tools and sealants required. These
being removed. Replace protective caps on hoses. tools and sealants are available from your dealer.

SM 2043 R1 08-03 11
Operators Compartment - Air Conditioning
Section 260-0130

AIR CONDITIONING DIAGNOSIS TABLE158

CONDITION PROBLEM REMEDY

1. Belt Trouble
Slipping Loose Adjust belt to 12 mm (0.5 in)
depression

Overcharge Correct the charge

Air in system Evacuate and re-charge

Excessive wear Pulley not aligned Align Pulley

Belt too tight Adjust or replace

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
disengaged
Clutch loose Tighten
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

12 SM 2043 R1 08-03
 Operators Compartment - Air Conditioning
Section 260-0130

AIR CONDITIONING DIAGNOSIS (CONT.)

CONDITION PROBLEM REMEDY
3. Noise - Evaporator
Rubbing/scraping Fan blade or blower Repair or replace
Hissing Low charge/leak Correct charge/repair leak
Chatter/knocking Expansion valve Replace
Noisy case Loose brackets/screws Tighten
Motor squeal Dry bearings Replace
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
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 circuit breaker Replace
Loose connection Clean and tighten connection
Broken wire - ground Repair wire
Shorted or open field Replace field

SM 2043 R1 08-03 13
Operators Compartment - Air Conditioning
Section 260-0130

AIR CONDITIONING DIAGNOSIS (CONT.)

CONDITION PROBLEM REMEDY
6. Air Conditioning System
Trouble - Gauges must be
connected
High head pressure Air conditioning fan not operating Repair or replace fan
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 2043 R1 08-03
 BODY - Body and Mounting
Section 270-0010

SM - 2423

1 5
6
2

38
37 37
36

35 39

34
3,4
40 25 27 22 24
41
43 17
42
44
18
19 16
14,15 23
11 21
BODY
12
20
FRAME 9,28,29 7
26
30,31 9
8 10 13
32,33

1 - Body Assembly 12 - Washer 23 - Hardened Washer 34 - Body Down Indicator

2 - Cab Guard Assembly 13 - Locknut 24 - Body Safety Pin 35 - Plate
3 - Shedder Plate - LH 14 - Shim 25 - Screw 36 - Bolt
4 - Shedder Plate - RH 15 - Shim 26 - Hardened Washer 37 - Washer
5 - Bolt 16 - Cover Plate 27 - ROPS/FOPS Decal 38 - Locknut
6 - Washer 17 - Bolt 28 - Bolt 39 - Reflector
7 - Guard 18 - Lockwasher 29 - Nut 40 - Screw
8 - Bolt 19 - Nut 30 - Shim 41 - Washer
9 - Washer 20 - Shim 31 - Shim 42 - Washer
10 - Body Pad 21 - Body Hinge Pin 32 - Shim 43 - Locknut
11 - Bolt 22 - Bolt 33 - Shim 44 - Cap

Fig. 1 - Exploded View of Body and Mounting

DESCRIPTION of high yield abrasion-resistant steel reinforced by wide

Numbers in parentheses refer to Fig. 1. channel-section stiffeners. A long 15° sloping tail chute
gives good load retention and permits controlled
Note: Refer to Section 000-0000, GENERAL dumping into hoppers or crushers.
INFORMATION, for body volumes, plate thicknesses,
material specifications and dimensions. The body is pivoted at body hinge pins (21) at the rear
of the frame and is operated by two, two stage hoist
Body assembly (1) is constructed from a one piece, cylinders mounted between the frame rails. The hoist
longitudinal 'V' floor which gives the body rigidity and a cylinders raise the body to a tipping angle of 58° in
low centre of gravity. Bottom, side and front plates are 13 seconds and power down the body in 11.5 seconds.

SM 1917 7-00 1
Body - Body and Mounting
Section 270-0010

OPERATION
The body control joystick, mounted at the left hand WARNING
side of the drivers' seat, controls the body control To prevent personal injury and property
valve which supplies hydraulic oil to operate the body damage, be sure wheel chocks and lifting
hoist cylinders. equipment are properly secured and of
adequate capacity to do the job safely.
The four operating positions of the body control
joystick from front to rear are; Lower, Float, Hold and 1. Position the vehicle in a level work area, apply the
Raise. Refer to Section 230-0060, BODY CONTROL parking brake and block all road wheels.
VALVE and, Section 230-0081, BODY CONTROL
JOYSTICK. 2. Raise body assembly (1) and install body safety
pins (24).

Raising the Body 3. Remove mounting hardware securing hoist cylinder

Before raising the body, allow the engine to slow to mounting pins to body assembly (1). Do not remove
idle, make sure the rear wheels are on firm level cylinder mounting pins at this stage.
ground, shift the transmission to Neutral and hold the
vehicle stationary by applying the brakes with the 4. Remove body safety pins (24) and lower body
Parking-Emergency brake control. assembly (1) to rest on the frame rails.

Move the body control joystick all the way back to the 5. Support body hoist cylinders from the rear of the
'Raise' position and accelerate the engine. The body vehicle to prevent them swinging back on removal of
can be stopped at any point by moving the joystick to cylinder mounting pins. Remove cylinder mounting
'Hold'. Decelerate the engine as the last stages of the pins and allow body hoist cylinders to rest against the
body hoists begin to extend to slow the raising speed chassis.
as the hoists approach their maximum extensions.
6. Remove bolts (22) and hardened washers (23)
When the body has been raised to the desired height, securing body hinge pins (21) through body
move the control joystick to the 'Hold' position until the assembly (1) and pin mounting bores.
body is to be lowered.
7. Remove body hinge pins (21) and shims (20) from
body assembly (1) and pin mounting bores. Using
Lowering the Body suitable lifting equipment, sling body assembly (1) and
To lower the body, move the control joystick to the remove from the vehicle.
'Float' position to allow the body's weight to lower it to
the frame. Body descent can be stopped at any Note: Do not remove body pads (10) and shims (14 & 15)
position by moving the joystick back to the 'Hold' unless body pads (10) are being replaced.
position. If the body does not begin to lower by its own
weight, such as after dumping downgrade, move the 8. If required, remove locknuts (13), hardened
control joystick all the way forward to the 'Lower' washers (26), washers (12) and bolts (11) securing
position and power the body downward until it begins body pads (10) and shims (14 & 15) to body
lowering by gravity. Then move the joystick to 'Float' to assembly (1). Remove and discard body pads (10)
allow the body to lower the rest of the way to the and shims (14 & 15).
chassis.

Make sure that the body is completely lowered and the INSTALLATION
control lever is in 'Float' before releasing the brakes Numbers in parentheses refer to Fig. 1.
and moving the vehicle.
Note: Tighten all fasteners to standard torques listed
in Section 300-0080, STANDARD BOLT AND NUT
REMOVAL TORQUE SPECIFICATIONS.
Numbers in parentheses refer to Fig. 1.
Note: Approximate weight of body assembly (1) is
Note: Approximate weight of body assembly (1) is 11 500 kg (25 350 lb).
11 500 kg (25 350 lb).

2 SM 1917 7-00
 Body - Body and Mounting
Section 270-0010

Body Shimming Procedure

WARNING Numbers in parentheses refer to Fig. 1.
To prevent personal injury and property
damage, be sure wheel chocks and lifting Note: Tighten all fasteners to standard torques listed
equipment are properly secured and of in Section 300-0080, STANDARD BOLT AND NUT
adequate capacity to do the job safely. TORQUE SPECIFICATIONS.

1. Ensure body hinge pins (21) and bores in body Note: When it becomes necessary, body pads (10)
assembly (1) are thoroughly cleaned with a suitable should be replaced as a set to maintain load
solvent. Coat body hinge pins (21) and bores in body distribution along the chassis. Existing body pads will
assembly (1) with a suitable anti-seize compound. have taken a compression 'set' and a new pad
shimmed to match existing pads will not carry its share
2. Using suitable lifting equipment, sling body of the load, resulting in uneven load distribution along
assembly (1) and centralise over the frame. the chassis.

3. Align body hinge pin (21) bores in body assembly Note: The body guides should also be inspected and
(1) with mounting bores in the frame. Install body hinge rebuilt with shims (29, 30, 31 or 32) as necessary at
pins (21) and secure with bolts (22) and hardened this time.
washers (23).
1. Raise body assembly (1) clear of the frame and
4. Remove lifting equipment from rear lifting points on position body pads (10) roughly in position on the
body assembly (1) and raise the front end of body frame rails. Lower body assembly (1) onto body
assembly (1) to provide access to install body hoist pads (10).
cylinders. Position wooden blocks (or suitable stands)
on the frame rails and lower body assembly (1) to rest 2. Shim the two rear body pads (10) with shims
on the blocks. Remove lifting equipment from body (14 & 15) until body hinge pins (21) are just touching at
assembly (1). the top of body assembly (1) bores.

5. Start the engine and using the body control lever, 3. Shim remaining body pads (10) with shims (14 & 15)
extend the body hoist cylinders until mounting holes to ensure body assembly (1) is resting parallel on the
are aligned with mounting bores on body assembly (1). frame.
Secure both body hoist cylinders to body assembly (1).
Refer to Section 230-0130, BODY CYLINDER. 4. Secure body pads (10) and shims (14 & 15) to body
assembly (1) with bolts (11), washers (12), hardened
6. Raise body assembly (1), remove blocks and lower washers (26) and locknuts (13).
body assembly (1).
5. Centralise body assembly (1) on the frame rails,
7. If removed, install body pads (10) and shims (14 & 15) remove body hinge pins (21) and reinstall with shims
as described under 'Body Shimming Procedure'. (20) to obtain a maximum gap of 1.5 mm (0.060 in)
between inner leg and body pivot. Secure body hinge
8. Centralise body assembly (1) on the frame rails, pins (21) with bolts (22) and hardened washers (23).
remove body hinge pins (21) and shim body hinge pins
(21) with shims (20) as described under 'Body 6. Ensure body assembly (1) is centralised on the
Shimming Procedure'. frame rails and measure gap between body guides on
the frame and the body guides. Secure shims (30, 31,
9. If removed, shim the body guides with shims (30, 32 or 33) to body guides on body assembly (1) using
31, 32 or 33) as described under 'Body Shimming bolts (28), washers (9) and nuts (29) as shown in
Procedure'. Figure 1. Leave a gap of 3.3 mm (0.13 in) between
body and frame guides.
10. Raise and lower body assembly (1) and check for
correct clearance at body hinge pins (21) and body Note: Only one shim (30, 31, 32 or 33) to be used on
guides. each side.

SM 1917 7-00 3
Body - Body and Mounting
Section 270-0010
7. Raise and lower body assembly (1) and check for gases. The resulting fire in the heating passages is
correct clearance at body hinge pins (21) and body helpful in that it burns away some of the carbon and
guides. helps keep the body passages open. However, the fire
should be allowed to burn itself out and should not be
encouraged by pouring fuel into the passages.
CLEANING HEATED BODY
Note: Optional exhaust heating of the body is If excessive exhaust back pressure develops, another
available for dumping of sticky or frozen materials. method of cleaning out the body passages is to
remove the heat channel plates and scrape the carbon
from the heating passages.
WARNINGS
To prevent personal injury and property To remove the heat channel plates, burn out the weld
damage, be sure lifting equipment is properly around them and lift out from the body assembly with
secured and of adequate capacity to do the job suitable lifting equipment.
safely.
Note: Prior to welding on the vehicle, follow the
Oxygen and oil should never be blown procedures outlined for 'Welding' in Section 100-0010,
into the body passages in an attempt to burn CHASSIS, HOOD AND FENDERS.
out the carbon deposits, as the combination of
oxygen and oil forms a highly explosive After the heating passages are thoroughly cleaned,
mixture. replace the heat channel plates and weld to sides and
bottom of the body assembly.
It is necessary to periodically clean out the carbon
deposits in the body heating passages which restrict
the flow of exhaust gases. This reduces the engine MAINTENANCE
efficiency and prevents the body from being heated. Lubricate body hinge pins and body hoist cylinder pins
at the intervals stated and with lubricant specified in
Occasionally the carbon deposits are ignited by Section 300-0020, LUBRICATION SYSTEM.
spontaneous combustion or by heat from the exhaust

* * * *

4 SM 1917 7-00
 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
safety precautions detailed throughout this manual. at maximum gradeability as designated in the
'Performance Data' section of the relevent
Always attach a 'DO NOT OPERATE' or similar Sales Specification Sheet.
warning sign to the ignition switch or a prominent
control before cleaning, lubricating or servicing the Lubrication is an essential part of preventive
vehicle. maintenance. It is important that the instructions,
regarding types of lubricants and the frequency of
Never allow anyone to work on the vehicle while it is their application, be followed to prolong the useful life
moving. Make sure there is no one on the vehicle of the vehicle. Periodic lubrication of moving parts
before working on it. reduces to a minimum the possibility of mechanical
failures.
Do not work under or near an unblocked or
unsupported body. Always use the body safety pins. All change and service periods are recommendations
based on average operating conditions. Lubricants
Do not work under or near any unblocked or showing evidence of excessive heat, oxidation or dirt
unsupported linkage, part or vehicle. should be changed more frequently to prevent these
conditions.
Always relieve pressure before servicing any
pressurized system. Follow the procedures and Lubricant change and service periods must be
safety precautions detailed in the relevant established on the basis of individual job conditions
Maintenance Manual section. utilizing oil sampling and recommendations from
lubricant suppliers.
Always deflate the tyre before attempting to remove
any embedded objects or removing the tyre and rim Thoroughly clean all fittings, caps, plugs etc., to
assembly from the vehicle. prevent dirt from entering any system while carrying
out servicing procedures. Lubricants must be at
Always use a self-attaching chuck with a long airline, operating temperature when draining.
and, stand to one side while the tyre is inflating.
Refer to Section 160-0050, WHEEL RIM AND TYRE. Note: Do not operate any system unless oil level is
within the recommended operating levels as indicated
on oil level dipstick, sight gauge or level plug.

Lubrication and Service Chart

Small circles on the following illustration represent
points at which lubrication and/or servicing must take
place, at the intervals indicated on the left hand side
of the lubrication and service chart. The numbered
circles on the illustration contain reference numbers
which correspond to the reference numbers in the
'Ref. Points' column of the lubrication and service chart.

Note: At each scheduled maintenance interval, perform

all previous checks in addition to the ones specified.

SM 2030 Rev3 03-06 1

Miscellaneous - Lubrication System
Section 300-0020

SM - 2543

7 1 16 21 5 8 26 10 20 24 21 22 19 12 21 25 13 18 9 14

27 6 23 22 26 8 10 24 11 24 4 20 2 3 15 25 18 17 9 14

Fig. 1 - Lubrication and Service 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 HTF As Required
3 Main Hydraulic Tank Check oil level. Add if low. 1 HO As Required
4 Steering Hydraulic Tank Check oil level. Add if low. 1 HO As Required
5 Radiator Header Tank Check coolant level. Add if low. 1 Antifreeze See Page 4
- Steering Filter Check W/Light. Replace element if reqd. 1 - See Page 4
6 Rear Disc Brake Filter(s) Check indicator. Replace element if reqd. - - See Page 4
- Fuel Filter/Water Separator Drain water and sediment. 2 - -
10 7 Cooling Fan Visually inspect for debris and damage. 1 - -
8&9 Front and Rear Ride Cylinders Visually inspect heights. 4 - Ref. Sec. 180-0030/
180-0050
- Air Cleaner Restriction W/Light Check. Replace element if reqd. 1 - -
- Air Cleaner Vacuator Valve(s) Check for proper operation. - - -
- Tyres Check condition. Check pressures when 6 - Ref. Sec. 140-0040/
tyres are cold. 160-0050
- Controls, Instruments and W/Lights Check for proper operation. - - -
- General Inspection Check for leaks and worn/damaged parts. - - -
Repair/replace as required.

2 SM 2030 Rev3 03-06

 Miscellaneous - Lubrication System
Section 300-0020

LUBRICATION AND SERVICE CHART

Interval Ref. No. of
Hours Points Identification Service Instructions Points Lubricant Service/Quantities
8 Front Ride Cylinders Lube 2 EP, NLGI 20 Strokes
9 Rear Ride Cylinder Spherical Bushing Lube 4 EP, NLGI See Note
10 Steering Cylinders Lube 4 EP, NLGI See Note
24 Steering Linkage Lube 4 EP, NLGI See Note
50 11 Steering Pivot Pin Lube 2 EP, NLGI See Note
12 A-Frame Nose Spherical Bushing Lube 1 EP, NLGI See Note
13 Banjo Stabilizer Spherical Bushing Lube 2 EP, NLGI See Note
14 Body Hinge Pins Lube 2 EP, NLGI See Note
15 Body Hoist Bushings Lube 4 EP, NLGI See Note
100 - Drive Belts Visually inspect all belts. - - See Page 5
- Battery Electrolyte Check level. Add if low. 2 - As Required
16 Engine Power Takeoff Check oil level. Add if low. 1 EPL -
17 Differential Check oil level. Add if low. 1 EPL -
18 Wheel Planetaries Check oil level. Add if low. 2 EPL -
- Differential Breather Clean. 1 - -
250 - Transmission Breather Clean. 1 - -
- Alternator Drive Belt Check belt tension. Adjust if required. 1 - Ref. Sec. 110-0030
- Accessory Drive Belts (if fitted) Check belt tension. Adjust if required. - - Ref. sec. 110-0030
- Front Brake Pads Check wear. Replace as required. 2 - See Page 5
- Fuel Tank Drain water and sediment. 1 - -
1 Engine Drain and refill. 1 EO See Page 6
- Engine Oil Filters Replace filters. 3 - Ref. Sec. 110-0030
- Engine Fuel Filters Replace filters. 4 - Ref. Sec. 110-0030
- Engine Coolant Additive Check inhibitor concentration & replenish. - Power Cool See Page 5
- Engine Crankcase Pressure Check and record. 1 - Ref Engine Manual
- Engine Mounting Bolts Check torques. - - Ref. Sec. 110-0030
- Alternator Check terminals and wiring. - - -
- Transmission Mounting Bolts Check torques. - - Ref. Sec. 120-0010
500 19 Fuel Tank Clean filler neck screen and cap. - - -
- Fuel Tank Mounting Bolts Check torque. - - Ref. Sec. 200-0010
- Air Cleaner(s) Clean primary tubes and inlet screens. - - -
20 Accumulators Check nitrogen pressures. 3 - -
21 Driveline Universal Joints Lube (if grease nipple fitted). - *EP, NLGI See Note
22 Driveline Slip Joints Lube (if grease nipple fitted). - *EP, NLGI See Note
23 Steering Column Universal Joints Lube. 3 *EP, NLGI See Note
27 Radiator Clean and inspect radiator fins. 1 - See Note 1
- Hydraulic & Steering Tank Breather Clean. 1 - -
- Exhaust System Check for leaks. Repair if damaged. - - -
- Engine Crankcase Breather Clean/Replace if required 1 - Ref Engine Manual
- Fan Hub Lube. 1 EP, NLGI Ref Engine Manual
2 Transmission Drain and refill. 1 HTF See Page 6
1 000 - Transmission Oil Filter Replace element. 1 - -
- Hydraulic System Pressure Checks Check pressures at check points. - - See Page 5
- Main Hydraulic Filter Replace elements. 2 - See Page 5
6 Rear Disc Brake Filter(s) Replace element(s). - - See Page 5
16 Engine Power Takeoff Drain and refill. 1 EPL See Page 6
1 500 17 Differential Drain and refill. 1 EPL See Page 6
18 Wheel Planetaries Drain and refill. 2 EPL See Page 6

1 Engine Steam Clean. - - -

3 Main Hydraulic Tank Drain and refill. 1 HO See Page 6
- Main Hydraulic Tank Suction Screens Remove and clean. 2 - -
2 000 4 Steering Tank Drain and refill. 1 HO See Page 6
- Steering Filter Replace element. 1 - See Page 5
- Steering Tank Suction Screen Remove and clean. 1 - -
25 Rear Brake Packs Drain and refill. 2 HO -
- Engine Thermostats and Seals Replace. - - Ref Engine Manual
4 000 27 Cooling System Drain, flush and refill. 1 Antifreeze See Page 6
- Air Conditioning Compressor Drain, flush and refill. 1 PAG Oil See Page 6
5 000 26 Front Wheel Bearings Repack. 2 *EP, NLGI *
6 000 - Engine Coolant Level Sensor Replace. 1 - Ref Engine Manual

SM 2030 Rev3 03-06 3

Miscellaneous - Lubrication System
Section 300-0020
*- Fill compartment one half full. Engine Air Cleaner(s) - Check air cleaner piping,
Note - Lubricate slowly until excess lube is seen. hoses and clamps. Change air cleaner element only
when air cleaner flow restriction warning light
Note 1 - Clean more often when operating under illuminates. Service vacuator valve daily. Inspect
extremely dusty conditions. and remove any obstructions from the vacuator
EO - Engine Oil. Refer to chart under valve lips. Valve lips should be open and pliable
'Recommended Lubricants'. with engine stopped.
Note: Service air cleaner(s) more often under
EPL - Extreme Pressure Gear Lubricant meeting extremely dusty operating conditions.
specification MIL-L-2105C.
HTF - Hydraulic Transmission Oil Type C-4. Radiator Header Tank - Check coolant level and
Refer to chart under 'Recommended add if low. Fill radiator header tank with coolant
Lubricants'. until coolant reaches the bottom of the filler neck
and holds at that level.
HO - Hydraulic Transmission Oil meeting Note: Any time a significant amount of coolant is
Specification EMS19058 Refer to chart added, the inhibitor concentration MUST be
under 'Recommended Lubricants'. checked. If the concentration is low, engine
EP, NLGI -Extreme Pressure Lithium No. 2 Grease. damage will result. Conversely, over-inhibiting
Refer to chart under 'Recommended antifreeze solutions can cause silicate dropout.
Lubricants'. Refer to Section 210-0000, COOLING SYSTEM.
*EP, NLGI - Extreme Pressure Lithium No. 2 Grease
Steering, Braking and Body Hoist Systems -
(without 'Molybdenum'). Refer to chart
Check for correct operation of all systems before
Under 'Recommended Lubricants'.
operating the truck.
PAG Oil - Polyalklene Glycol (PAG) Compressor
Lubricating Oil - Low Viscosity (ISO46). Steering Filter - Check steering filter restriction
warning light with the truck empty, brakes released,
oil at normal operating temperature, engine
operating at 1 500 rev/min and while turning the
MISCELLANEOUS SERVICING steering wheel at one turn/sec. If the warning light
illuminates, the filter element should be replaced.
WHEN REQUIRED
Seat Belts - Inspect seat belts and replace if Rear Disc Brake Oil Filter(s) -
damaged. Replace element(s) when indicator shows oil at the
Note: Replace seat belts at least once every three replace element level.
years, regardless of appearance.
AFTER FIRST 100 HOURS OF OPERATING NEW
Windscreen Wipers and Washers - Inspect wiper OR REBUILT COMPONENTS
blades and replace if damaged. Top up washer Fuel Tank - After first 100 hours of operation re-
reservoir. torque all mounting fasteners. Refer to Section
200-0010, FUEL TANK AND MOUNTING.
Wheel Rim Nuts - After first 10 hours of operation
re-torque nuts to 690 Nm (510 lbf ft). Check torque
every 50 hours (weekly) thereafter.
AFTER FIRST 150 HOURS OF OPERATING NEW OR
REBUILT COMPONENTS
EVERY 10 HOURS OF OPERATION Engine - Drain oil, replace oil filters and refill.
Replace fuel filters.
Walk Around Inspection - Inspect the machine as
described in Section 4 of the Operators Handbook. Transmission - Drain oil, replace filters and refill.
Differential - Drain oil and refill.
Engine - Visually check engine for damage, loose
or frayed belts and listen for any unusual noises. Planetaries - Drain oil and refill.

4 SM 2030 Rev3 03-06

 Miscellaneous - Lubrication System
Section 300-0020
AFTER FIRST 200 HOURS OF OPERATING NEW OR EVERY 1 000 HOURS OF OPERATION
REBUILT COMPONENTS Hydraulic System Pressure Checks - Check all
Coolant System - Check coolant level. Check and steering, body and braking system pressures.
replenish inhibitor concentration as described in Note: Instructions for checking pressure, and
Section 210-0000, COOLING SYSTEM. locations of pressure check points, are contained in
the relevant maintenance manual section. If the
pressures are outwith the specified settings then
EVERY 100 HOURS OF OPERATION components in the relevant system should be
Drive Belts - Visually check the belts and replace inspected, repaired or replaced to ensure the
if they are cracked or frayed. Adjust belts that have correct operation of the system. All safety
a glazed or shiny surface which indicates belt instructions in the relevant sections should be
slippage. Correctly installed and tensioned belts will strictly adhered to.
show even pulley and belt wear. Refer to Section
110-0030, ENGINE AND MOUNTING, for drive belt Main Hydraulic Tank Filter - Clean filter housing
tension and adjustment of new and used drive and install new element.
belts.
Rear Disc Brake Filter(s) - Replace filter
element(s) when indicator sight gauge shows
EVERY 250 HOURS OF OPERATION replacement is necessary, or after 1 000 hours of
operation, whichever comes first.
Oil Can Points - Oil accelerator linkage, hinges,
and other working parts with engine oil.
Front Brakes - Check pads and discs for wear and EVERY 2 000 HOURS OF OPERATION
replace where necessary. Steering Filter - Clean filter housing and install
Note: This service interval applies to normal new element when indicated, or after 2 000 hours of
driving. Check more frequently under more severe operation, whichever comes first.
conditions. Thickness of pad friction material
should never be allowed to wear below 3 mm
(0.12 in). ENGINES AND TRANSMISSIONS
All information contained in the 'Lubrication and
Service Chart' was extracted from the relevant
EVERY 500 HOURS OF OPERATION manufacturers 'Operation and Maintenance
Coolant Additive - Check and replenish inhibitor Manual', and was correct at time of publication.
concentration as described in Section 210-0000,
COOLING SYSTEM. User should ensure that information contained in
Cooling Fan - Visually check the fan for cracks, loose this chart reflects the information shown in the
rivets, and bent or loose blades. Check fan mounting relevant manufacturers 'Operation and Maintenance
and tighten if required. Replace any fan that is damaged. Manual' supplied with the Truck.
Note: The fan belt is maintained to the correct belt
tension by a spring loaded idler arm, therefore, Maintenance procedures should be carried out in
there is no need to check or adjust belt tension. conjunction with any additional procedures
contained in the relevant manufacturers 'Operation
and Maintenance Manual', at the intervals specified.

SM 2030 Rev3 03-06 5

Miscellaneous - Lubrication System
Section 300-0020

SERVICE CAPACITIES
Ref. Service Capacities
Points Identification Lubricant litres US gal
1 Engine Crankcase and Filters EO 94 25
2 Transmission and Filters HTF 85 22.5
3 Main Hydraulic Tank HO 258 68
- Main Hydraulic System HO 432 114
4 Steering Hydraulic Tank HO 61 16
- Steering Hydraulic System HO 92 24.3
27 Cooling System Coolant 236 62.3
19 Fuel Tank Diesel 938 248
8 Front Ride Cylinders (Each) HO 25 6.6
9 Rear Ride Cylinders (Each) HO 21 5.5
16 Engine Power Takeoff EPL 2 0.53
17 Differential EPL 52 13.7
18 Wheel Planetaries (Total) EPL 43 11.4
- Air Conditioning Compressor PAG Oil 0.135 0.036

Note: Capacities given are approximate. Work to dipstick, sight gauges or level plugs. Use table in
conjunction with 'Recommended Lubricants' table.

6 SM 2030 Rev3 03-06

 Miscellaneous - Lubrication System
Section 300-0020

RECOMMENDED LUBRICANTS
COMPONENT LUBRICANT VISCOSITY (See Note 1)
Transmission Allison C-4 Type Specification; Refer to Ambient Temp Recommendation
www.allisontransmission.com for a complete -35° C SAE 0W-30 or Transynd RD
list of C-4 approved oils. See note 3* -30° C SAE 0W-20 (Arctic)
-28° C DEXRON-III
-20° C SAE 10W
-15° C SAE 15W-40
0° C SAE 30
10° C SAE 40
Engine Engine oil with 1.00 % sulphated ash is SAE 15W-40
recommended. Sulphated ash must not exceed
1.85 % limit. Meeting MIL-2104F specifications.
API code CG-4. See Note 2.
Hydraulic System Hydraulic Transmission Oil meeting SAE 10W
Specification EMS19058. See Note 4. at ambient temperatures of -18° to 32° C
SAE 30W
at ambient temps of 32° C and above
Cooling System Heavy Duty Coolant. Refer to Section
210-0000, COOLING SYSTEM.
Fuel Tank Diesel Fuel Oil with maximum Sulphur 0.5%. DIN EN590
Differential Multipurpose Extreme Pressure type gear oil SAE 80W-90
Planetary Gears meeting MIL-L-2105C Specifications (No Zinc at ambient temperatures of -18° to 32° C
Power Takeoff Additive). See Note 5.
Grease Fittings Multipurpose Extreme Pressure Lithium No. 2 Consistency
Grease (which may, or may not contain
'Molybdenum'), with a typical melting point of
190° C.
Drivelines Multipurpose Extreme Pressure Lithium No. 2 Consistency
Steering Column Grease (without 'Molybdenum'), with a typical
Wheel Bearings melting point of 190° C.
Ride Cylinders Hydraulic oil meeting MIL-L-2104C SAE 10W
(Nitrogen/Oil) Specifications or API Service code CC or at ambient temperatures of -18° to 32° C
CD/SC.
Air Conditioning Polyalklene Glycol (PAG) ISO46
Compressor Compressor Lubricating Oil - Low Viscosity SP 10

Temperature Conversions
° Celsius -32 -30 -27 -25 -20 -18 -15 -10 0 10 15 25 32 35 38 45 93 190
° Fahrenheit -26 -22 -17 -13 -4 0 5 14 32 50 59 77 90 95 100 113 200 375

SM 2030 Rev3 03-06 7

Miscellaneous - Lubrication System
Section 300-0020
Note 1 - Consult your lubricant supplier for the Note 4 - Typical SAE 10W oils complying with
correct viscosity of lubricant to use when ambient Specification EMS19058 are:
temperatures are consistently above or below those
listed. KUWAIT TO4
SHELL DONAX TC
Note 2 - Detroit Diesel do not recommend any ESSO TORQUE FLUID
specific brand of engine oil but the use of oils that TEXACO TEXTRAN
meet API categories. Detroit Diesel recommend use TOTAL TRANSMISSION AC
of only the multi-graded viscosity oils shown for the MOBILTRANS HD
various ambient temperatures listed. CASTROL TFC
BP AUTRAN 4
Note 3 - Operation below the minimum temperatures
listed for the oil used without proper preheat or warm- Other lubricant suppliers may have comparable
up results in greatly reduced transmission life. If products and should be consulted for confirmation.
auxiliary heating is available, preheat the oil to the
minimum temperature limit. If not available, run the Note 5 - If rear axle has limited slip differential, use of
engine at part throttle with the transmission in neutral standard SAE 90 oil may result in very loud noise and
to raise the fluid temperature. jerking of the wheels when driving slowly round sharp
corners and an EP oil with limited slip additives should
Hydraulic Transmission Oil meeting Specification be used.
EMS19058 may also conform to the Allison C-4
requirements. Consult your lubricant supplier for
confirmation.

* * * *

8 SM 2030 Rev3 03-06

 MISCELLANEOUS - Service Tools
Section 300-0070

INTRODUCTION Series 2000 Engine

Contained in this section are recommended service DDEC IV Electronic Diagnostic
tools and equipment required for maintenance, 15275098 - DDR Multikit (Reader, Cartridge, Cables)
overhaul and troubleshooting. In certain instances, 15275096 - DDEC III/IV Diagnostic Card (For Above)
both Metric and Imperial equivalents of the same tools 15268974 - PRO-LINK 9000 DDEC MPC and PC
are listed. These tools are available from your dealer. Card Kit
15273793 - Detroit Diesel Diagnostic Link (Diskette)
Note: The Company reserves the right to make 15273794 - Detroit Diesel Diagnostic Link (CD)
changes in the design or construction of tools and 15269239 - High Impedance Digital Multimeter Kit
equipment without obligation to incorporate such 15270271 - Diagnostic Jumper Wire Kit
changes in tools and equipment previously sold. 15273795 - DDEC Repair Kit
15270310 - DDR Adaptor Cable
Note: A tool may be of one piece construction or 15269038 - Portable Printer for use with DDR,
consist of a number of parts. complete with 110 V AC Adaptor
15269039 - Portable Printer for use with DDR,
complete with 220 V AC Adaptor
General 15269040 - Printer Paper for use in above
*15269784 - Multi-Gauge - Pressure range of 30 in of printers - 5 rolls
vacuum to 5 000 lbf/in²
15269785 - Non-contact Infrared Thermometer The following tools are recommended for Engine
15268968 - Strap Type Filter Wrench Maintenance Procedures. These tools should be used
15268969 - Socket Type Filter Wrench in conjunction with procedures outlined in the Series
15268970 - Universal Belt Tension Gauge 2000 Engine service manual.
15269858 - Digital Tachometer
15269859 - Multimeter 15270275 - Liner Remover
15269813 - Water Manometer 15273984 - Bridge Pin Installer
15269802 - Dial Indicator Gauge - Metric 15273999 - Cam Follower Installer/Remover
15269803 - Dial Indicator Gauge - Imperial 15274000 - Camshhaft Pilot 17" Long
15269804 - Magnetic Base for Dial Indicator Gauge 15274001 - Compression Tester
15269805 - Micrometer - 0 to 25 mm 15274002 - Crankshaft Position Timing Tool
15269806 - Micrometer - 0 to 1 in 15274003 - Cylinder Head Pressure Test Kit
15269807 - Micrometer - 400 to 500 mm 15274004 - Cylinder Liner Installer & Hold Down
15269808 - Micrometer - 16 to 20 in 15274005 - Engine Barring Tools
15269809 - Internal Micrometer - 50 to 210 mm 15274007 - Flywheel Guide Studs
15269810 - Internal Micrometer - 2 to 8 in 15274008 - Front Seal Installer
15269860 - 92 Piece Heavy Equipment Tool Kit 15274009 - Front Wear Sleeve Installer
15269861 - Torque Wrench - 3/8 in drive, 15274010 - Front/Rear Crank Hub Installer/Remover
20 - 100 Nm (15 - 80 lbf ft) range 15274011 - Gearcase Alignment Tool
15269862 - Torque Wrench - 1/2 in drive, 15274012 - Injector Adaptor Assembly
60 - 330 Nm (45 - 250 lbf ft) range 15274013 - Injector Nozzle Puller Adaptor
15269863 - Torque Wrench - 3/8 in drive, 15274014 - Main Bearing Guide Studs
4 - 20 Nm (40 - 180 lbf in) range 15274015 - Nozzle Tube Socket
15269864 - Torque Wrench - 3/4 in drive, 15274016 - Piston Ring Compressor
300 - 1 000 Nm (200 - 750 lbf ft) range 15274017 - Piston Ring Pliers
15269865 - Torque Wrench - 3/4 in drive,
700 - 1 500 Nm (500 - 1 000 lbf ft) range
15269866 - Torque Multiplier - 1/2 in to 1 in drive, Transmission
25:1 Ratio, 3 000 Nm (2 200 lbf ft) range CEC Electronic Diagnostic
15275098 - DDR Multikit (Reader, Cartridge, Cables)
* - The following items should be added to the 15275180 - CEC 1 & 2 Diagnostic Card (For Above)
multi-gauge to enable the gauge to be used on 15268971 - PRO-LINK Diagnostic Data Reader (DDR)
diagnostic test points: 15268973 - CEC I and II Cartridge For DDR
15018226 - Diagnostic Coupling 15268975 - DDR and CEC I and II Cartridge
00118748 - Connector (2 off) Assembly
15004085 - Hose Assembly (-4 HP, 84 in long) 15269231 - CEC Off-Highway Diagnostic Service Kit

SM 2037 Rev 2 08-03 1

Miscellaneous - Service Tools
Section 300-0070
15269241 - Crimper (Alternate) - Throttle Position
15270344 - LPS NoFlash Electro Contact Cleaner
Sensor
15269038 - Portable Printer for use with DDR,
complete with 110 V AC Adaptor 15275731 - Remover - ECU Connectors, Shift Selector
15269039 - Portable Printer for use with DDR, Connection
complete with 220 V AC Adaptor 15275732 - Connector Repair Kit - Transmission
15269040 - Printer Paper for use in above printers - Harness Bulkhead Connector
5 rolls
15275733 - Guide Pin - Transmission Harness
The following tools are contained in CEC Bulkhead Connector
Off-Highway Diagnostic Service Kit - 15269231: 15275734 - Insertion Tool - Transmission Harness
15269232 - Wire Cutter, Stripper and Terminal Bulkhead Connector
Crimper 15275735 - Terminal Remover - Transmission Harness
15269233 - Jumper Wire Set Bulkhead Connector
15269234 - Terminal Crimper
15269235 - Terminal Remover - Metri Pack (J1A, 15275736 - Crimper - ECU Connectors, Shift Selector
J1B, J3 and Shift Selector Connector Connection
Terminals)
15269236 - Terminal Remover - Speed Sensor and
Throttle Position Sensor Terminals The following tools are recommended for Transmission
15269237 - Terminal Remover - Depress holding Maintenance Procedures and should be used in
prong on ECU and DDL Connector conjunction with procedures outlined in the
Terminals transmission manufacturers service manual.
15269238 - PROM Remover
15269239 - High Impedance Digital Multimeter Kit 15270422 - Stator Assembly Installing Tool
15269240 - AMP Pin Remover - Remove terminal 15270423 - Support Legs
pins from interface and shift selector 15270424 - Switch Sequence Gauge
Terminals 15270425 - Shift Inhibitor Clutch Drilling Feature
15269241 - Terminal Crimper - Weatherpac 15270426 - Harness Adaptor
15270427 - Torque Converter Spanner Wrench
The following tools are required for CEC 2 harness 15270428 - Belville Assembly Spring Compressor
wiring repairs;
15275719 - Sealed Splice (14-16 AWG)
Wheel, Rim and Tyre
15275720 - Sealed Splice (18-22 AWG)
09202013 - Fishtail Wrench
15275721 - Crimper - Deutsch Connector, 15251192 - Tyre Inflation Kit (Air)
Trans. Harness Bulkhead, J1939 Conector 15269121 - Tyre Inflation Kit (Nitrogen)
15269234 - Crimper (Alternate) - Delphi Packard (DDL 15270392 - Hydraulic Bead Breaking Kit
connector)
15275722 - Crimper (Alternate) - Throttle Position Accumulators/Ride Cylinder Charging
Sensor
09359489 - Charging Assembly
15275723 - Wire Stripper
15275724 - Remover - Delphi Packard (DDL The following parts can be assembled for
Connector), Sump Temperature Sensor simultaneously charging the rear ride cylinders:
09359489 - Charging Assembly
15275725 - Remover - Throttle Position Sensor
00454145 - Tee Piece
15275726 - Remover - Deutsch Connector 15269788 - Hose
15275727 - Crimper - Throttle Position Sensor, Delphi 15269789 - Chuck Valve
Packard (DDL Connector) 15269790 - Valve Extension
15275728 - Crimper - Speed Sensors, Throttle Position
The following parts can be assembled for
Sensor,
simultaneously charging the front ride cylinders:
15275729 - Crimper - Repair of broken cable using
appropriate Sealed Splice
15275730 - Remover - Deutsch Connector(Optional
DDL)
2 SM 2037 Rev 2 08-03
 Miscellaneous - Service Tools
Section 300-0070
09359489 - Charging Assembly 15023696 - Loctite 635
00454145 - Tee Piece 09371048 - Loctite 648
00444355 - Coupling 15269107 - Loctite 641
15269788 - Hose - 2 required 15304830 - Loctite 5205 (Ref. Sec. 160-0020)
15269789 - Chuck Valve 15305445 - Loctite 7063 Cleaning Agent
15269790 - Valve Extension 15269108 - Loctite Superclean Safety Solvent 706
15229541 - Loctite Activator 'N'
09243825 - Loctite Activator 'T'
Steering Valve 09175039 - General Adhesive
15270489 - Spring Installation Tool 15269114 - Tectyl 280 Wax Based Rust Preventive
09380475 - Hylosil RTV Silicone Compound
15270516 - Wynn's STP
Cooling and Air Conditioning 15303808 - Silicon Grease (Dielectric)
15000000 - Coolant Test Strips - Bottles of 50 strips
(Cases of 12) Fabricated Tools
15500001 - Coolant Test Strips - Bottles of 10 strips The service tools shown in Figs. 1 through 8 can be
(Cases of 6) fabricated as shown.
15500002 - Coolant Test Strips - Individual foil packed
15269816 - Refractometer - °C Scale
15269817 - Refractometer - °F Scale
15269844 - Portable High Vacuum Charging
Station - R-134a Gas
15269845 - Halogen Leak Tester

Cab
15271016 - Glass Removal Tool
15271017 - Bonding Kit (Quick Dry)

OCDB Brake Packs

15267573 - Seal Installation Kit
15265300 - Seal Installation Tool
15265301 - Seal Installation Tool

Lubrication
09122784 - Grease Gun Assembly
09175662 - High Pressure Bucket Pump Lube Kit

Adhesives and Sealants

15269103 - Loctite 221
09362529 - Loctite 225
09029849 - Loctite 243
09244598 - Loctite 270
09985300 - Loctite 271
15269104 - Loctite 275
15269245 - Loctite 277
15233715 - Loctite Prism 406
15269111 - Loctite Prism 410
15269105 - Loctite 515
09007209 - Loctite 574 (50 ml)
09379518 - Loctite 574 (160 ml)
15269106 - Loctite 577 (Superflex)
15270244 - Loctite 592 Pipe Sealer with Teflon
SM 2037 Rev 2 08-03 3
Miscellaneous - Service Tools
Section 300-0070

SM - 112

in mm
1/8 3.2
ONE-4340 STL. OR EQUIV.-HDN.-GRIND
1/4 6.4
3/8 9.5
7/16 11.1
1/2 12.7
5/8 15.9
3/4 19.1
29/32 23.0
1 25.4
1 1/8 28.6
ACME THD.

1 1/4 31.8
1 3/8 34.9
1 1/2 38.1
APPROX ONE-4340
STL.-HDN.-GRIND 1 7/8 47.6
2 50.8
2 1/32 51.6
2 1/8 54.0
2 15/32 62.7
2 3/4 69.9
4 3/4 120.7
4 7/8 123.8
5 1/2 139.7
5 3/4 146.0
5 31/32 151.6
6 7/8 174.6
7 1/2 190.5
9 1/2 241.3

Fig. 1 - Spider Bearing Spreader Tool Dimensions (Section 160-0020, DIFFERENTIAL)

4 SM 2037 Rev 2 08-03

 Section 300-0070

SM - 126

0.56 - 3 HOLES
in mm
EQUALLY SPACED
0.12 3.0
0.50 12.7
0.56 14.22
0.62 15.7
1.00 25.4
1.62 41.1
2.00 50.8
2.50 63.5
MATERIAL: 3.25 82.5
PLAIN CARBON STEEL 3.31 84.0
9.38 238
15.88 403
26.25 668

Fig. 2 - Fabrication of Lifting Tool (Section 165-0030, BRAKE PARTS)

SM - 1487 SM - 1488

117 16 108 16
77.8 4.45 77.8 4.45
+- 0.13 +- 0.13
R51.6 R51.6
14 7.1 14 7.1
+- 0.13 +- 0.13
66.7 +- 0.25

66.7 +- 0.25
28.4
42.9

42.9
57

42.9

R0.50 R0.50
/0.76 /0.76
½in NPT R15
R15 R0.13/0.25
R0.13/0.25

Fig. 3 - Fabrication of Blanking Plate for Port 'B' Fig. 4 - Fabrication of Blanking Plate for Port 'C'
(Section 165-0030, BRAKE PARTS) (Section 165-0030, BRAKE PARTS)

SM 2037 Rev 2 08-03 5

 6
0.62
0.50
0.47
0.38
0.26
0.25
0.22
0.19
0.18
0.12
0.06
0.03

0.177
0.139
0.130
INCHES

9.6
6.6
6.3
5.6
4.8
4.6
4.5
3.5
3.3
3.0
mm

15.7
12.7
11.9
1.52
0.76
Section 300-0070

6.00
5.50
4.00
3.00
2.56
2.50
2.00
1.68
1.12
1.00
0.81
0.75
0.72

20.00
INCHES

SPRING COMPRESSOR TOOL

mm

508
152
140
101
76.2
65.0
63.5
50.8
42.7
28.4
25.4
20.5
19.0
18.2

MATERIAL: PLAIN CARBON STEEL

ITEM #2 - BASE
(WELDMENT)

100 SQ.
STOCK
ITEM #1 -
HANDLE
Miscellaneous - Service Tools

.250 DIA.
HOLE THRU.

KNURL

DIA. HOLE
ITEM #5 - 'T' HANDLE
(WELDMENT)

.19 SQ.
8-32 UNC 2B X .38 MIN. FULL STOCK
THD. MINOR DIA. .130/.139 X .72 ITEM #3 - PIVOT BLOCK
DEEP

1 - Handles ITEM #4 - RETAINER .22 DIA. HOLE

2 - Base

Fig. 5 - Fabrication of Spring Compressor Tool (Section 165-0030, BRAKE PARTS)

3 - Pivot Block
4 - Retainer (2 Req’d)
5 - ”T” Handle
6 - Capscrew # 8-32 x .38 in long (4 Req’d.)
7 - Plain Washer # 10 (2 Req’d.) ROUND HD.
8 - Nut # 10-24 (4 Req’d.) MACHINE SC.
9 - Roll Pin .25 in Dia x 1.12 in long #16 DRILL (.1770) 10-24 X 3.00 LG.
2-HOLES FULL THD.
SM - 134

SM 2037 Rev 2 08-03

 Miscellaneous - Service Tools
Section 300-0070

SM - 403

HEAVY WALL TUBING

ALUMINIUM RING

PRESS RING ON END OF TUBING

Fig. 6 - Shaft Seal Driver (Section 220-0050, STEERING PUMP)

SM - 404

ALUMINIUM ROUND STOCK

BRG. RACE 'A' 'B' 'C'

ITEM NO. mm (in) mm (in) mm (in)
38 100 (4.0) 25 (1.00) 50 (2.00)
56 100 (4.0) 40 (1.55) 70 (2.75)

Fig. 7 - Bearing Inner Race Installation Tool (Section 220-0050, STEERING PUMP)

SM - 625

Note: Break all sharp

corners 4 mm (0.015 in)

Fig. 8 - Centring Spring Installation Tool (Section 220-0090, STEERING VALVE)

* * * *

SM 2037 Rev 2 08-03 7

Miscellaneous - Service Tools
Section 300-0070

8 SM 2037 Rev 2 08-03

 MISCELLANEOUS - Standard Bolt and Nut Torque Specifications
Section 300-0080

and to establish a uniform value to which these

WARNING fasteners can be safely tightened, the following torque
Some fasteners are important attaching parts tables have been compiled.
which could affect the performance of vital
components and systems, and/or, could result The torque values listed in the tables have been
in major repair expense. Fasteners should be established over a period of years and cover all
replaced with parts of the same part number, conditions of assembly. The maximum torque values
or with equivalent parts, if replacement for standard bolts and nuts are based on 75% of the
becomes necessary. Do not use replacement specified minimum proof strength of the bolt steel in
parts of lesser quality or substitute design. order to provide a safety factor to compensate for the
The torque values shown in the following variation in the accuracy of torque wrenches, skill of
tables should be used in all cases, unless the assembler, and variance in fractional conditions.
otherwise specified elsewhere in this manual, All torque values are for lubricated threads. The
in order to avoid possible personal injury or term 'lubricated' includes the application of thread
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 or
classifications, or, prevailing torque specifications for nut, compare the bolt head markings to those in the
self-locking fasteners. appropriate tables, then locate the maximum torque
value for that bolt size in the column under that
To prevent the threaded bolts and nuts used on this marking.
equipment from being overstressed during assembly,

RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ± 10% TABLE144

SAE Symbol SAE Symbol SAE Symbol SAE Symbol

GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel 12 Point Cap
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8) Screws
Size 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 1 021 753
1.00 - 12 285 210 719 530 881 650 1 003 740 1 119 825
1.00 - 14 285 210 732 540 902 665 1 030 760 1 148 847

SM 1238 2-98 1
Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080

RECOMMENDED MAXIMUM TORQUES (IMPERIAL) ± 10% TABLE145

SAE Symbol SAE Symbol SAE Symbol SAE Symbol

GM 260-M Steel GM 280-M Steel GM 290-M Steel GM 300-M Steel 12 Point Cap
(SAE GR 2) (SAE GR 5) (SAE GR 7) (SAE GR 8) Screws
Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
1.12 - 7 366 270 800 590 1 132 835 1 302 960 1 447 1 067
1.12 - 12 407 300 902 665 1 274 940 1 451 1 075 1 624 1 198
1.25 - 7 515 380 1 132 835 1 600 1 180 1 830 1 350 2 043 1 507
1.25 - 12 569 420 1 254 925 1 776 1 310 2 034 1 500 2 267 1 672
1.38 - 6 664 490 1 478 1 090 2 095 1 545 2 400 1 770 2 676 1 974
1.38 - 12 759 560 1 688 1 245 2 393 1 765 2 739 2 020 3 056 2 254
1.50 - 6 881 650 1 966 1 450 2 786 2 055 3 186 2 350 3 556 2 623
1.50 - 8 936 690 2 088 1 540 2 962 2 185 3 390 2 500 3 781 2 789
1.50 - 12 990 730 2 217 1 635 3 145 2 320 3 593 2 650 4 010 2 958
1.75 - 5 - - - - 4 393 3 240 5 016 3 700 5 604 4 133
1.75 - 12 - - - - 5 091 3 755 5 830 4 300 6 497 4 792
1.88 - 8 - - - - 6 006 4 430 6 874 5 070 7 664 5 653
1.88 - 12 - - - - 6 304 4 650 7 213 5 320 8 048 5 936
2.00 - 4.5 - - - - 6 623 4 885 7 565 5 580 8 448 6 231
2.00 - 8 - - - - 7 342 5 415 8 406 6 200 9 367 6 909
2.00 - 12 - - - - 7 687 5 670 8 786 6 480 9 811 7 236
2.25 - 4.5 - - - - 9 701 7 155 11 090 8 180 12 377 9 129
2.25 - 8 - - - - 10 629 7 840 12 148 8 960 13 566 10 006
2.25 - 12 - - - - 11 050 8 150 12 636 9 320 14 102 10 401
2.50 - 12 - - - - 15 280 11 270 17 463 12 880 19 500 14 383

Note: Where materials other than GM Standards are used, refer to the conversion table below.

Types of Steel Rockwell Hardness Range Applicable Torque Values SAE Bolt Head Symbols

Plain Low Carbon

(eg. SAE 1018 or 1020) Rockwell "B" 85-100 GM 260-M
Plain Medium Carbon
(eg. SAE 1035, 1038 & 1045) Rockwell "C" 19-30 GM 280-M
Medium Carbon Alloy
(eg. SAE 4140, 8642 & 5157) Rockwell "C" 28-34 GM 290-M
Medium Carbon Alloy
(eg. SAE 4140, 8642 & 5147) Rockwell "C" 32-38 GM 300-M

2 SM 1238 2-98
 Miscellaneous - Standard Bolt and Nut Torque Specifications
Section 300-0080

RECOMMENDED MAXIMUM TORQUES (METRIC) ± 10% TABLE146

Class 8.8 Class 9.8 Class 10.9 Class 12.9

Size Nm lbf ft Nm lbf ft Nm lbf ft Nm lbf ft
M 1.6 - 0.35 - - 0.20 0.15 - - 0.20 0.15
M 1.6 - 0.20 - - 0.25 0.20 - - 0.40 0.30
M 2.0 - 0.40 - - 0.25 0.20 - - 0.45 0.30
M 2.0 - 0.25 - - 0.45 0.30 - - 0.45 0.30
M 2.0 - 0.45 - - 0.25 0.20 - - 0.45 0.30
M 2.5 - 0.35 - - 1 0.75 - - 1 0.75
M 3.0 - 0.50 - - 1 0.75 - - 2 1.5
M 3.0 - 0.35 - - 1 0.75 - - 2 1.5
M 3.5 - 0.60 - - 2 1.5 - - 3 2
M 4.0 - 0.70 - - 3 2 - - 4 3
M 4.0 - 0.35 - - 3 2 - - 5 3
M 5.0 - 0.80 - - 5 4 - - 8 6
M 5.0 - 0.50 - - 6 4 - - 9 6
M 6.0 - 1.00 - - 9 6 - - 13 10
M 6.3 - 1.00 - - 10 8 13 10 16 11
M 6.0 - 0.75 - - 10 7 12 9 14 10
M 8.0 - 1.25 - - 21 15 27 20 32 23
M 8.0 - 1.00 - - 23 17 29 21 34 25
M 10.0 - 1.50 - - 42 31 54 39 63 46
M 10.0 - 1.25 - - 45 32 57 41 67 48
M 12.0 - 1.75 - - 74 53 94 68 110 80
M 12.0 - 1.25 - - 81 58 103 74 121 87
M 14.0 - 2.00 - - 118 85 151 109 176 127
M 14.0 - 1.50 - - 128 92 163 118 190 137
M 16.0 - 2.00 169 122 - - 234 169 274 197
M 16.0 - 1.50 181 130 - - 250 180 292 211
M 18.0 - 2.50 234 169 - - 323 234 378 273
M 18.0 - 1.50 263 190 - - 363 262 425 307
M 20.0 - 2.50 330 239 - - 457 330 531 386
M 20.0 - 1.50 367 265 - - 507 366 593 423
M 22.0 - 2.50 451 325 - - 623 450 728 526
M 22.0 - 1.50 495 357 - - 684 494 800 577
M 24.0 - 3.00 571 412 - - 790 570 923 667
M 24.0 - 2.00 623 450 - - 861 622 1 007 727
M 27.0 - 3.00 837 605 - - 1 158 836 1 354 977
M 27.0 - 2.00 903 652 - - 1 250 902 1 461 1 055
M 30.0 - 3.00 1 135 820 - - 1 570 1 134 1 835 1 325
M 30.0 - 2.00 1 258 908 - - 1 740 1 256 2 034 1 468
M 30.0 - 1.50 1 300 939 - - 1 799 1 299 2 102 1 516
M 36.0 - 4.00 1 985 1 433 - - 2 745 1 982 3 208 2 317
M 36.0 - 3.00 2 102 1 517 - - 2 907 2 099 3 398 2 453

SM 1238 2-98 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 TABLE537

Lockscrews Locknuts
SAE Grade 5 & 8
and ASTM A-574 SAE Grade 5 SAE Grade 8
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 2-98
 MISCELLANEOUS - Unit Storage
Section 300-0090

GENERAL 8. ENGINE - Consult the relevant Engine Maintenance

The storage of machines for short periods of time or Manual for complete information on storing the engine
during the off-season is an important item if major for periods shorter than 30 days.
damage to components is to be avoided. Failure to
take the necessary steps to protect the various 9. TRANSMISSION - Fill transmission sumps to the
assemblies while the machine is being stored can proper level.
result in an expensive overhaul job and delay in
returning the machine to work.
EXTENDED STORAGE - Under Six Months
When storing a machine for periods of longer than 30
TEMPORARY STORAGE days, but under six months, the following procedure
When storing a machine for a period of 30 days or must be followed:
less, the following precautions must be taken:
1. INSPECTION AND REPAIR - Same as Step 1
1. INSPECTION AND REPAIR - Thoroughly inspect given under 'Temporary Storage'.
and test the machine and make any necessary repairs
or adjustments which may be necessary to prepare 2. LUBRICATION - Same as Step 2 given under
the machine for service. This will enable you to put the 'Temporary Storage'.
machine back into use immediately at the end of the
storage period. 3. PARKING - Same as Step 3 given under
'Temporary Storage'. Machines should be blocked up
2. LUBRICATION - Lubricate the machine completely so the tyres are off the ground or floor.
according to the instructions given in Section
300-0020, LUBRICATION SYSTEM of this manual. 4. BATTERIES - Remove batteries from the machine
and store them in a suitable place where they can be
3. PARKING - After thoroughly cleaning the entire inspected and charged at least every 30 days or
machine, park it on a hard, dry, level surface that is placed on a trickle charger.
free from grease and oil. The oil and grease would
cause tyre deterioration. Apply the parking brake. 5. RUST PREVENTION - Same as Step 5 given under
'Temporary Storage'.
4. BATTERIES - Where moderate temperatures are
expected, the batteries may be left in the machine. Up 6. SUPPLY TANKS - Same as Step 6 given under
to 30 days, the batteries may require a boost at the 'Temporary Storage'.
end of the storage period. Preferably place the
batteries in the shop where they can be inspected, 7. TYRES - With the machine on blocks, as called for
brought up to full charge and placed on a trickle in Step 3, deflate the tyres to 0.7 bar (10 lbf/in²)
charge to keep them at full charge. In very cold or hot pressure. Remove all traces of grease and oil and
climates, store the batteries where they will be protect the tyres from direct sunlight and water with a
protected from temperature extremes. suitable cover.

5. RUST PREVENTION - Remove all evidence of rust 8. TRANSMISSION - Consult the relevant
from the machine and repaint. In addition, cover all Transmission Maintenance Manual for storage data
exposed machine surfaces with a good rust involving periods longer than 30 days.
preventive.
9. ENGINE - Consult the relevant Engine Maintenance
6. SUPPLY TANKS - Fill fuel and hydraulic tanks to Manual for storage data involving periods longer than
prevent moisture condensation within the tanks. 30 days.

7. TYRES - Inflate all tyres to correct pressure. During 10. VENTS AND BREATHERS - Remove all vents
storage, check inflation pressure approximately once and breathers and plug openings with pipe plugs. If it
every two weeks. is not possible to do this, seal vents and breathers with
waterproof tape.

SM 1239 2-98 1
Miscellaneous - Unit Storage
Section 300-0090

EXTENDED STORAGE - Over Six Months 2. BATTERIES - Install batteries and check for a full
When a machine is to be stored for a period over SIX charge. Charge batteries as required.
MONTHS, the following procedure must be followed:
3. TYRES - Inflate tyres to the proper pressures. Refer
Note: These steps are in addition to those given to Section 140-0040, WHEEL RIM AND TYRE, of this
previously under 'Extended Storage - Under Six manual.
Months'.
4. FUEL AND HYDRAULIC TANKS - Drain off
1. LUBRICATION - Completely lubricate the machine condensation and fill tanks to proper level, remove
according to the instructions contained in Section breather covers and install air breathers. Be sure
300-0020, LUBRICATION SYSTEM of this manual. breathers are clean before installation.

2. WHEEL BEARING - Remove, clean, inspect and 5. VENTS AND BREATHERS - Remove seals and
repack all wheel bearings. plugs from all breather openings, then install all
breathers and vents.
Note: The above steps must be repeated for every Six
Month period the machine is in storage. 6. ENGINES - Consult the relevant Engine
Maintenance Manual for instructions on removing an
engine from storage.
REMOVAL FROM EXTENDED STORAGE
7. PAINT - Check machine for rust. Remove all rust
General spots and repaint rusted areas.
1. LUBRICATION - Completely lubricate the machine
according to the instructions in Section 300-0020, 8. TRANSMISSION - Consult the relevant
LUBRICATION SYSTEM of this manual. Transmission Maintenance Manual for instructions on
removing from storage.

* * * *

2 SM 1239 2-98